Bacharach GDC-150 Operation Manual
Bacharach GDC-150 is a versatile gas detection controller designed for continuous monitoring of various gases in commercial and industrial applications. Its customizable configuration allows for the detection of specific gases, making it ideal for ensuring safety and compliance in a range of environments, including warehouses, laboratories, and production facilities. With its advanced sensor technology and flexible enclosure options, the GDC-150 provides reliable and accurate gas detection to safeguard personnel, equipment, and processes.
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Instruction 5209-9000
Operation Manual
Rev. 0 - May 2011
Product Leadership • Training • Service • Reliability
GDC-150 Operation Manual
IMPORTANT NOTE
READ AND UNDERSTAND THIS MANUAL PRIOR TO USING THIS INSTRUMENT.
THIS INSTRUMENT SHOULD BE INSPECTED AND PROGRAMMED BY
QUALIFIED AND TRAINED PERSONNEL.
THIS INSTRUMENT HAS NOT BEEN DESIGNED TO BE INTRINSICALLY SAFE IN
HAZARDOUS OR EXPLOSION-RATED ENVIRONMENTS. FOR YOUR SAFETY,
DO NOT USE OR INSTALL IT IN AREAS CLASSIFIED AS HAZARDOUS AREAS
(E.G., EXPLOSION-RATED ENVIRONMENTS). ii 5209-9000 Rev 0
GDC-150 Operation Manual
DISCLAIMER
UNDER NO CIRCUMSTANCES WILL BACHARACH, INC. BE LIABLE FOR ANY
CLAIMS, LOSSES OR DAMAGES RESULTING FROM OR ARISING OUT OF THE
REPAIR OR MODIFICATION OF THIS EQUIPMENT BY A PARTY OTHER THAN
BACHARACH, INC. OR ITS AUTHORIZED SERVICE REPRESENTATIVES, OR BY
OPERATION OR USE OF THE EQUIPMENT OTHER THAN IN ACCORDANCE
WITH THE PRINTED INSTRUCTIONS CONTAINED WITHIN THIS MANUAL OR IF
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BACHARACH, INC. WARRANTS THIS INSTRUMENT TO BE FREE FROM
DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF TWO (2)
YEARS FROM THE DATE OF PURCHASE. THIS INCLUDES ALL ELECTRONICS,
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CARBON MONOXIDE (CO) SENSORS. OTHER ELECTROCHEMICAL SENSORS
ARE WARRANTED FOR ONE YEAR.
THE WARRANTY STATUS WILL BE AFFECTED (VOIDED) IF THE INSTRUMENT
HAS NOT BEEN INSTALLED AND MAINTAINED ACCORDING TO THE
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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.
ALL GOODS MUST BE SHIPPED TO THE MANUFACTURER BY PREPAID
FREIGHT. ALL RETURNED GOODS MUST BE ACCOMPANIED BY AN RMA
NUMBER.
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GDC-150 Operation Manual
SERVICE POLICY
BACHARACH, INC. MAINTAINS AN INSTRUMENT SERVICE FACILITY AT THE
FACTORY. SOME BACHARACH DISTRIBUTORS / AGENTS MAY ALSO HAVE
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WARRANTIES). SHOULD YOUR INSTRUMENT REQUIRE NON-WARRANTY
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PURCHASED OR YOU MAY CONTACT BACHARACH DIRECTLY.
IF BACHARACH IS TO DO THE REPAIR WORK, SEND THE INSTRUMENT,
PREPAID, TO BACHARACH, INC. AT THE FOLLOWING ADDRESS.
BACHARACH, INC.
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
PERFORMING ALL NEEDED REPAIRS TO RESTORE THE INSTRUMENT TO
FULL OPERATING CONDITION.
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WHOLE OR IN PART, IN ANY MANNER OR FORMAT, WITHOUT THE WRITTEN
PERMISSION OF BACHARACH, INC. iv 5209-9000 Rev 0
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REVISIONS
BACHARACH, INC. MAKES NO WARRANTY OR REPRESENTATION,
EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR PURPOSE, WITH RESPECT TO THIS MANUAL. ALL
INFORMATION CONTAINED IN THIS MANUAL IS BELIEVED TO BE TRUE AND
ACCURATE AT THE TIME OF PRINTING. HOWEVER, BACHARACH RESERVES
THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE. REVISED
COPIES OF THIS MANUAL CAN BE OBTAINED BY CONTACTING BACHARACH,
INC.
SHOULD YOU DETECT ANY ERRORS OR OMISSIONS IN THIS MANUAL,
PLEASE CONTACT THE COMPANY AT THE FOLLOWING ADDRESS.
BACHARACH, INC.
621 HUNT VALLEY CIRCLE
NEW KENSINGTON, PA 15068-7074
USA
TOLL FREE: 1-800-736-4666
FAX: 724-334-5001
E-MAIL: [email protected]
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IN NO EVENT WILL BACHARACH, INC., OR ITS OFFICERS OR EMPLOYEES BE
LIABLE FOR ANY DIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES RESULTING FROM ANY DEFECT IN ANY MANUAL, EVEN IF ADVISED
OF THE POSSIBILITY OF SUCH DAMAGES.
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GDC-150 Operation Manual
TABLE OF CONTENTS
1.
OVERVIEW ................................................................................................................ 1
1.1. General Description ............................................................................................ 1
1.2. Enclosures .......................................................................................................... 1
1.3. Key Components ................................................................................................ 3
2.
SPECIFICATIONS ..................................................................................................... 4
2.1. General ............................................................................................................... 4
2.2. Standard Enclosures .......................................................................................... 4
2.3. Optional Enclosures ............................................................................................ 4
2.4. Sensors (Solid-State and Catalytic) .................................................................... 5
2.5. Sensors (Electrochemical) .................................................................................. 6
2.6. Sensor Cross Sensitivity (Electrochemical) ......................................................... 7
3.
INSTALLATION ......................................................................................................... 8
3.1. Mounting Holes and Conduit Ports ...................................................................... 8
3.2. Enclosure Door ................................................................................................... 9
3.3. Sensor Mounting Height Recommendations ......................................................10
3.4. Wiring the GDC-150 for Power ..........................................................................10
4.
OPERATION ............................................................................................................ 13
4.1. General ..............................................................................................................13
4.2. Detecting Gas ....................................................................................................14
4.3. System Failure ...................................................................................................14
4.4. Sensor Notes .....................................................................................................14
4.5. Open Loop Diagnostic .......................................................................................15
4.6. Jumper Functions ...............................................................................................15
4.7. Adjusting the Alarm Set Point (For Relay Option Only) ......................................15
4.7.1. Calculating the Alarm Set Point Value .................................................... 15
4.7.2. Adjusting the Alarm Set Point ................................................................. 16
5.
CALIBRATION ......................................................................................................... 16
5.1. Frequency Recommendations ...........................................................................16
5.2. Calibration Specifications – Gases .....................................................................17
5.3. Regulators and Flow – Solid-State and Catalytic Sensors ..................................17
5.4. Regulators and Flow – Electrochemical Sensors ...............................................17
5.5. Calculating the Span Gas Value ........................................................................18
5.6. Setting the Span Gas Value ...............................................................................19
5.7. Calibrating the Null (Zero) Value ........................................................................19
5.8. Calibrating the Span Value ................................................................................20
6.
ACCESSORIES AND REPLACEMENT PARTS ...................................................... 21
6.1. Metal Protective Guards ....................................................................................21
6.2. Accessory and Replacement Part Numbers .......................................................21
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1. OVERVIEW
1.1. General Description
GDC-150 transmitters are rugged, user-friendly, configurable analog transmitter gas detectors for use in non-hazardous (non-explosion rated) environments for commercial HVAC and light industrial use. It can be configured for either electrochemical toxic gas sensors, solid-state sensors, or catalytic sensors.
A standard transmitter provides a bi-color LED indicating light for power, fault condition, and alarm (option with one dry contact relay). An optional LED digital display is available as well as other enclosure options.
The electrochemical sensors utilized in this device are accurate enough to measure to
Occupational Health and Safety hazardous levels for toxic gases and oxygen levels.
NOTE: The GDC-150 analog transmitters operate by diffusion. If a sample draw system is desired, consult a Bacharach authorized distributor or the factory for details.
1.2. Enclosures
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Figure 1-1. Standard (NEMA 1X) Enclosures
1
GDC-150 Operation Manual
Figure 1-2. Optional Water-Tight (NEMA 4X) Enclosure
Figure 1-3. Water-Tight Enclosure (Side View) Showing Optional Splash Guard
NOTE: GDC-150 transmitters utilizing catalytic combustible or electrochemical H
2
S/SO
2
sensors are supplied with the water- and dusttight NEMA 4X enclosure standard.
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1.3. Key Components
GDC-150 Operation Manual
Figure 1-4. Key Components on GDC-150 Circuit Board
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2. SPECIFICATIONS
2.1. General
Power
Current
All Sensor Types
12 VAC to 30 VAC or 16 VDC to 30 VDC
80 to 120 mA
Indicators
One bi-color LED:
• Green = Power
• Flash Green = Warm-up
• Red = Alarm
• Flash Red = Fail
One amber LED (internal relay coil status indicator)
One red LED (4-20 mA open-loop indicator for remote transmitter)
Options
• LED digital display (3.5 digits)
• Relay (one SPDT dry contact relay rated 2A @ 30 VAC)
• Water/dust tight enclosure
• Splash guard (water-tight enclosure only)
2.2. Standard Enclosures
Solid-State Catalytic Electrochemical
Type
Dims
(HxWxD)
Weight
PVC
6.5 x 4.4 x 2.5 in
165 x 113 x 65 mm
20 ounces
Construction
Drip-proof overlap with hinged door
2.3. Optional Enclosures
Solid-State
Polycarbonate
4.9 x 4.9 x 2.9 in
125 x 125 x 75 mm
16 ounces
Water- & dust-tight with hinged door
Catalytic
Type
Dims
(HxWxD)
Weight
Polycarbonate
4.9 x 4.9 x 2.9 in
125 x125 x 75 mm
16 ounces
PVC
6.5 x 4.4 x 2.5 in
165 x 113 x 65 mm
20 ounces
Drip proof overlap with hinged door
Electrochemical
Polycarbonate
4.9 x 4.9 x 2.9 in
125 x125 x 75 mm
16 ounces
Construction
Water- & dust-tight with hinged door
Water- & dust-tight with hinged door
1
Non ground referenced supply only
2
For electro-chemical sensors, this depends on the options that are selected.
3
Only supplied if relay option has been selected
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2.4. Sensors (Solid-State and Catalytic)
Solid-State
Type Solid-state MOS
Range
Life Span
Combustible: 0-50% LEL
Refrigerant: 0-2000 ppm
Combustible: Approximately 5 to 8 years in clean, ambient conditions
Refrigerant: Approximately 5+ years in clean, ambient conditions
Resolution
Temperature
Humidity
Combustible: 1% LEL
Refrigerant: 2 ppm
-20°C to +40°C
(-4°F to +104°F)
0-90% non-condensing
Response
Combustible: T
90
= <60 seconds
Refrigerant: T
90
= <120 seconds for most refrigerants
Warm-up
2 minute delay
24 hours for best performance
(maximum accuracy)
4
MOS: Metal Oxide Semiconductor
GDC-150 Operation Manual
Catalytic
Catalytic pellistor
0-100% LEL of target combustible gas or vapor
Approximately 5 years in clean, ambient conditions
1% LEL
-20°C to +40°C
(-4°F to +104°F)
0-90% non-condensing
T
90
from air to 50% LEL = <12 seconds
2 minute delay
1 hour for best performance
(maximum accuracy)
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2.5. Sensors (Electrochemical)
Sensor Range
Life
Span
Resolution
Temp RH
Ammonia (NH
3
)
0-500 ppm
2
1-2 ppm
-40 TO
+50°C
15-90%
Response
Time (T
90
)
Warm
Up
<90 sec
2-6 hrs
Carbon Monoxide
(CO)
Hydrogen Sulfide
(H
2
S)
Nitrogen Dioxide
(NO
2
)
Nitric Oxide (NO)
0-200 ppm
0-50 ppm
0-5.0 ppm
0-100 ppm
5-8
3
3
1 ppm,
3 ppm
-20 to
+50°C
10-95%
0.5 ppm
0.1 ppm
-30 to
+50°C
-30 to
+50°C
15-90%
15-90%
<2 min
<35 sec
(0-20 ppm)
<60 sec
(0-10 ppm)
3 1 ppm
-30 to
+50°C
15-90%
<20 sec
(0-50 ppm)
1 hr
1 hr 9
1-2 hrs
1-2 hrs
Oxygen (O
2
)
Sulfur Dioxide
(SO
2
)
0-25.0
% vol
0-20 ppm
2
0.1% vol
-30 to
+50°C
5-95%
<15 sec
(20.9%-0%)
2 1 ppm
-30 to
+50°C
15-90%
<30 sec
(0-20 ppm)
1 hr 9
2 hrs
Formaldehyde
(HCHO)
0-10 ppm
2
5
Approximate, in years
6
Non-condensing
7
Temperature drift occurs
8
Without regular calibration
9
Minimum warm-up time
0.2 ppm
-20 to
+50°C
15-90% <80 sec 1 hr
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2.6. Sensor Cross Sensitivity (Electrochemical)
Sensor Cross Sensitivity – Electrochemical Sensors Only
Ammonia
0-500 ppm
300 ppm CO = 8
15 ppm H
2
S = 30
5 ppm SO
2
= -0.5
10% vol CO
2
= -15 35 ppm NO = 6
1 ppm Cl
2
= -1
200 ppm H
2
= 4
5 ppm HCl = -3
5 ppm NO
2
= -1
Carbon
Monoxide
Conforms to UL 2034 performance specification.
Hydrogen
Sulfide
Nitrogen
Dioxide
Nitric Oxide
Oxygen
20 ppm SO
2
≤18
10 ppm Cl
2
≤ -25
400 ppm CO
≤ 4
50 ppm NO
≤ 6
400 ppm H
2
≤ 1
400 ppm NH
3
≤ 0.1
10 ppm NO
400 ppm C
2
2
H
≤ -30
4
≤ 0.8
50 ppm NO
≤ 0.5
400 ppm H
2
≤ 0.1
20 ppm SO
2
≤ -2
10 PPM Cl
2
= 100
20 ppm H
2
S = -100 400 ppm CO
≤ 0.1
400 ppm C
2
H
4
≤ 0.1 20 ppm NH
3
≤ 0.1
10 ppm NO
2
≤ 5
400 ppm H
2
≤ 0.1
20 ppm NH
3
≤ 0.1
20 ppm SO
20 ppm H
2
2
S
≤ 4
≤ 60
10 ppm Cl
5% volume CO
2
= 0.1 0% to 95% RH @ 40°C
≤ 0.7
2
≤ 5
400 ppm CO
≤ 0.1
Sulfur Dioxide 50 ppm NO
≤ -3
400 ppm H
2
≤ 0.1
20 ppm NH
3
≤ 0.1
10 ppm NO
2
400 ppm CO
≤ -100 10 ppm Cl
2
≤ 1
400 ppm C
Formaldehyde
(HCHO)
100 ppm CO <18 100 ppm H
2
≤ 3
Other reducing gases such as alcohol (Note: Formalin – commercial grade formaldehyde – contains alcohol.)
2
≤ -70
H
4
≤ 40
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3. INSTALLATION
3.1. Mounting Holes and Conduit Ports
The GDC-150 should be installed on a flat vertical surface with the sensor pointing outwards in a clean, dry environment. If the GDC-150 is to be installed in a potentially wet environment, the optional water-tight enclosure should have been selected. This reference refers to the standard, general purpose PVC enclosure. Four mounting holes are provided in the enclosure base for securing the GDC-150 to the wall. Do not block the front of the enclosure as this is where the sensor is situated and where it monitors the air for the target gas.
NOTE: Four mounting holes are provided in the enclosure base for securing the GDC-150 to the wall. The mounting holes are 3/16
″ (4.8 mm) in diameter.
Conduit entry points are provided for the PVC enclosure.
Figure 3-1. Standard Enclosure Showing Mounting Holes
The water-tight enclosure must be installed with the mounting screws passing through the same openings that accommodate the four door securing screws. This ensures the mounting screws are outside of the door gasket and confirms a water-tight installation.
NOTE: No conduit entry points are provided for the water-tight enclosure. The reason is the installer may not want one where we would place it and this would result in unnecessary openings into this enclosure.
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GDC-150 Operation Manual
Figure 3-2. Water-Tight Enclosure Showing Mounting Holes
WARNING: Do not drill holes in the back of the base of the enclosure for the purpose of mounting the sensor/transmitter. Leak paths can occur. Corrosion damage will not be covered under warranty.
NOTE: Use caution when drilling holes in the water-tight enclosure for conduit entry so as not to damage the circuit board inside. Use liquid tight conduit hubs wherever conduit enters the water-tight enclosure.
Failure to do so creates a leak path. Water running down the conduit enters the interior of the enclosure and could corrode the circuit board.
This is not covered under warranty.
NOTE: When mounting either enclosure, allow enough room to enable the end user to open the door fully to access the internal adjustments.
3.2. Enclosure Door
The standard enclosure has one screw securing the door to the base for electrical safety and provides an opening to allow the user to apply a zip tie if they desire the
transmitter to be locked more securely. Refer to Figure 1-1 on page 1.
The door of the standard enclosure can be easily removed to facilitate installation of the base. Simply grasp the lid with one hand, being careful not to make contact with any of the internal components (circuit board), and grasp the base with your other hand. Tug on the base, pulling it towards you. The section of the hinges located on the base should “snap” apart from the part of the hinges located on the door.
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After installation, simply locate the lid hinges over the installed base hinges and pull toward you. The hinges should easily “snap” back into place.
By design, the overlapping door of the PVC enclosure makes it inherently drip proof, although it is not water tight or dust tight. The optional water-tight enclosure has four
screws for sealing the door to the base. Refer to Figure 1-2 on page 2.
3.3. Sensor Mounting Height Recommendations
Some toxic gases such as ammonia (NH
3
) and combustible gases such as methane
(CH
4
) are lighter than air, therefore the sensor/transmitter should be installed on or near the ceiling.
Some toxic gases such as carbon monoxide are only slightly lighter than air, therefore the sensor/transmitter should be installed at approximately 4’ to 6’ from the floor.
Oxygen sensors should be installed at approximately 4’ to 6’ from the floor.
For toxic gases, combustible gases, and vapors that are heavier than air, the sensor/transmitter should be installed with the sensor opening at 6” from the floor.
Although most refrigerants (e.g., Freons) are heavier than air, some applications may be better suited to a slightly higher mounting height for refrigerant sensors.
NOTE: If the area to be monitored is a wet environment, water-tight enclosures should be used. The water-tight enclosure must be installed using the indicated holes or it may leak. Damage caused by leaking because of improperly installed enclosures is not covered under warranty. If the area to be monitored has the potential for water spray, a splash guard should be used to protect the sensor.
3.4. Wiring the GDC-150 for Power
If powering the GDC-150 with 24 VAC, use terminals 1 and 2. If powering the
GDC-150 with 24 VDC, the positive (red) wire should be connected to terminal 2 and the negative (black) wire should be connected to terminal 3. The signal wire is always
connected to terminal 4. See Figure 3-4 for proper wiring examples and Figure 3-5
for improper wiring examples.
Terminals 5, 6, and 7 are used only if the relay option has been supplied. Double check the relay ratings in the specifications section of this manual before operation.
For normal operation, the relay control wiring should be connected to N/C and COM
(fail-safe operation is used).
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GDC-150 Operation Manual
Figure 3-3. Power and Optional Relay Wiring
NOTE: The main wiring terminal strip on the GDC-150 circuit board can be unplugged for easier wiring installation. Grasp the two sides of the terminal strip and lift upward with a slight side to side rocking motion.
NOTE: DO NOT use solid-core wire for connection to wiring terminal strip. Any damage caused by using solid-core wire will void warranty.
Use stranded wire ONLY.
IMPORTANT: The GDC-150 is a low voltage powered device. Any application of operating voltages higher than indicated in the manual may result in damage. Double check wiring connections prior to powering the transmitter. Damage from incorrect wiring connections or from too much voltage are not covered under warranty.
IMPORTANT: When providing power to the GDC-150, use non-
grounded reference supplies only. Refer to Figure 3-4 for proper wiring
examples and Figure 3-5 for improper wiring examples.
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12
Figure 3-4. Proper Wiring Examples
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GDC-150 Operation Manual
Figure 3-4. Proper Wiring Examples (Continued)
Figure 3-5. Improper Wiring Example
4. OPERATION
4.1. General
After installation, double check wiring prior to applying power to the GDC-150 transmitter. Remember, these are low voltage devices. After power up, the outer
LED will flash green indicating the system is in a warm-up period. During the warmup period, the signal output from the GDC-150 is fixed at 4.0 mA. If the digital display option has been fitted, the LED display will indicate a scrolling decimal “…..” until the warm-up is completed. If the relay option has been selected, the relay is not activated during warm-up. The GDC-150 has been programmed with a 5-minute warm-up period. After the warm-up is completed, the signal output and digital display (if this option has been supplied) will indicate current gas readings (if any).
If the relay option has been supplied, it will have a factory preset alarm set point (this can easily be changed in the field). In a non-alarm state, the outer LED will be illuminated green and the amber relay coil inner LED will be illuminated. The illuminated relay coil LED indicates to the user that the relay coil is energized. The relay option on the GDC-150 has been designed to operate in a fail-safe manner, meaning that the relay coil is energized in non-gas-alarm state and de-energize when a gas alarm is indicated. The device to be controlled should be connected to the N/C
(normally closed) and COM (common) terminals. In the event of a sensor failure, anything controlled by the relay is activated continuously until the fail condition has been corrected.
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4.2. Detecting Gas
Upon detection of the presence of target gas, the signal output increases to a value equal to the amount of gas being detected by the sensor. If the LED display option has been supplied, this value will be displayed. If the concentration of gas is above the preset alarm threshold, the outer LED changes to red, the alarm relay deenergizes and the amber relay coil LED goes out.
As the detected gas level subsides, the output signal will decrease again to a value equal to anything being detected by the sensor and this will be indicated on the LED display (if this option has been selected). The relay will automatically reset after the signal drops below the set point value.
4.3. System Failure
In the event of a system failure, the outer LED will flash red, the relay will de-energize, the relay coil LED will go out and the output signal will drop below 4.0 mA. A failure can consist of a burned out sensor element (solid-state or catalytic), a failed or damaged component on the circuit board, or a wiring-related problem.
4.4. Sensor Notes
Sensor Type
Operation Notes
Solid-State
(Refrigerant)
Solid-State
(Combustible)
• Not gas specific
• Respond to a fairly wide range of interfering gases and vapors
• Temperature and humidity compensated to reduce drift in environments where these values change regularly
• Not gas specific, but are less likely to suffer from false alarms from interfering gases (due to the extremely high measuring range for which they have been calibrated)
Catalytic
(Combustible)
• Specific to combustible gases and vapors
• Temperature compensated
Electrochemical
(E.g., Oxygen)
• These sensors are quite gas specific
• Will respond to some other gases (see cross sensitive
gases table on page 7 for more information)
• Temperature compensation to reduce drift in environments where the temperature changes regularly
10
Sensors require lengthy warm up and stabilization time after installation. Do not perform any calibration functions until the sensors have been operating for at least 24 hours.
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4.5. Open Loop Diagnostic
The GDC-150 circuit board has been fitted with a red LED located near the bottom center of the circuit board. This is an “open loop” indicator and has been designed as a quick trouble shooting device. If the 4-20 mA signal loop has not been connected properly or has been damaged in some manner between the analog transmitter and the device to which it is sending its signal output, this LED illuminates. At this point, the wiring should be inspected for potential problems.
4.6. Jumper Functions
Figure 4-1. Jumper Functions
4.7. Adjusting the Alarm Set Point (For Relay Option Only)
If the optional relay has been supplied, the alarm set point on the GDC-150 can be adjusted. The alarm set point value is converted to a voltage in the range of 0-4 VDC.
This voltage range correlates to the full measurement range of the installed sensor.
4.7.1. Calculating the Alarm Set Point Value
Prior to adjusting the alarm set point, calculate the voltage value required using the following formula.
Example: Catalytic combustible sensors have a standard measurement range of
0-100% LEL. Therefore 4.0 VDC = 100% LEL. Using the values below, 10% of
4.0 VDC = 0.4 VDC. Therefore, the required voltage setting to achieve an alarm set point of 10% LEL is 0.4 VDC.
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Figure 4-2. Calculating the Alarm Set Point
4.7.2. Adjusting the Alarm Set Point
Step Description
1.
2.
3.
Move the jumper to position P5. The green outer LED will flash once within 2 seconds for confirmation. The system is now waiting for the user to set the desired value.
read the value indicated on the display.
Use the UP or DOWN push buttons until the calculated voltage is displayed on the volt meter (or on the optional LED digital display).
4.
Move the jumper back to its resting position (P1). At this time the new value is saved and the green LED flashes once for confirmation.
5. CALIBRATION
5.1. Frequency Recommendations
Sensor Types / Applications Calibration Frequency
Parking garage detectors Once every 12 months
OHS (Occupational Health and Safety) applications Once every 6 months
For the purposes of safety in OHS applications, sensors should be gas tested (bump tested) once every month to confirm response.
Required Equipment:
•
Volt meter
•
Calibration kit
•
Calibration gases.
Users can order the calibration kit, calibration accessories and/or gases from any
Bacharach authorized distributor or they can supply their own gas and equipment as long as the gas meets the minimum specifications indicated in this manual.
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NOTE: It is recommended that a calibration label should be applied after every calibration to confirm work performed and the date it was confirmed. If a controller is involved, the alarm set points should be indicated on a label on the front door of the enclosure so anyone working in the environment will be aware.
NOTE: For best performance and to ensure the sensor meets the indicated specifications, all electrochemical sensors should be calibrated every six months. The sensors may not perform to the listed specifications if they are not maintained regularly.
5.2. Calibration Specifications – Gases
Calibration span gases should be at least ±5% accuracy and have a current date stamp. Gas generators should have a current dated cell installed. Service personnel should flow zero emissions air or oxygen before attempting to null adjust toxic gas sensors.
NOTE: For most electrolytic sensors, nitrogen (N
2
) can be substituted for zero air. However, for solid-state and catalytic sensors, nitrogen (N
2
)
should not be substituted for zero air because all solid-state and catalytic sensors require at least a small volume of Oxygen to operate.
Calibration will be inaccurate.
5.3. Regulators and Flow – Solid-State and Catalytic Sensors
Calibration gases that are lighter than or the same weight as air (CH
4
, H
2
, etc.) should be flowed at 0.5 LPM. Gases heavier than air (C
3
H
8
, etc.) should be flowed between
0.5 and 1.0 LPM. Fixed flow regulators provide more accuracy. Gases should be flowed over the sensor for at least 3 minutes.
The proper calibration adapter should be utilized to allow the gas to properly diffuse
around the sensor. They are available from Bacharach (see table on page 21).
A humidification chamber must be utilized for all solid-state sensors. This is also
available from Bacharach (see table on page 21).
5.4. Regulators and Flow – Electrochemical Sensors
Calibration gases should be flowed at 0.5 LPM. Fixed flow regulators provide more accuracy. Zero air and span gases should be flowed over the sensor for at least
3 minutes.
The proper calibration adapter should be utilized to allow the gas to properly diffuse
around the sensor. They are available from Bacharach (see table on page 21).
For best performance and to ensure the sensor meets the indicated specifications, all electrochemical sensors should be calibrated every six months. The sensors may not perform to the listed specifications if they are not maintained regularly.
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5.5. Calculating the Span Gas Value
To achieve calibration the user must first tell the GDC-150 what concentration of span he is going to flow over the sensor. Within the transmitter, this is a voltage setting.
The range of 0-4 VDC is equal to the full measurement range of the sensor. Prior to attempting to calibrate, determine the voltage value required.
Use the following formula to calculate the voltage required.
Therefore, in this example, the required voltage setting to calibrate a 0-2000 ppm sensor with 1000 ppm is 2.0 VDC.
NOTE: When calibrating solid-state sensors for combustibles or refrigerants, the span gas must be humidified. The use of a humidification chamber is required. The humidification chamber sits in line between the cylinder of span gas and the calibration adapter.
Remove the sponge inside the chamber and wet it under the tap.
Squeeze out the excess water so it is not dripping wet and place it back inside the chamber. As gas flows through the chamber, it absorbs water which acts to humidify it and the humidified span gas flows over the
sensor. See page 21 for ordering information.
NOTE: Values for Calibration Span Gas and Sensor Range in the above equations must have the same Engineering Units (e.g., PPM, % of LEL, % vol, etc.).
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5.6. Setting the Span Gas Value
Step Setting the Span Gas Value Procedure
1
Move the jumper to position P2 (see Figure 4-1 on page 15). The green
outer LED flashes once for confirmation. The system is now waiting for the user to set the desired value.
2
3
read the value indicated on the display.
Use the UP or DOWN push-buttons (see Figure 1-4 on page 3) until the
calculated voltage is displayed on the volt meter (or the optional LED digital display).
4
Move the jumper back to its resting position (P1). At this time the new value is saved and the green LED flashes once for confirmation.
5.7. Calibrating the Null (Zero) Value
Step Calibrating the Null (Zero) Value Procedure
1
2
3
4
Attach a regulator to a cylinder of zero air (or nitrogen).
Insert the calibration adapter into the sensor opening in the front of the enclosure door. Use a slight twisting motion as you gently push the calibration adapter into the sensor opening. If the calibration adapter is hard to insert, moisten the "O" ring slightly then try re-inserting it. If the transmitter has been fitted with an optional splash guard, remove the plastic plug from the center of the splash guard to gain access to the sensor opening. To remove the plastic plug, push inward at the center of the plug until the edges lift slightly then slip a small flat blade screwdriver under and pop the plug off.
Open the regulator valve fully and allow zero air to flow over sensor.
Move the jumper to position P3 (see Figure 4-1 on page 15). The outer
LED will change to a steady amber color. The system now waits 30 seconds to ensure the user is flowing zero air.
5
The GDC-150 then enters a count down during which time it adjusts the null value. The length of this count down period is:
•
90 seconds for catalytic and solid-state sensors
•
60 seconds for electrochemical sensors.
If desired, attach the volt meter leads to test points TP1 and TP2 (see
Figure 1-4 on page 3). The meter will show 0.0 VDC, climb to a higher
value, then slowly descend back to 0.0 VDC indicating the GDC-150 has null adjusted the circuit. Once the count down is finished, the outer LED changes back to green indicating the procedure is complete.
6 Move the jumper back to its resting position (P1) and remove the zero air.
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IMPORTANT: If the user attempts to null adjust the sensor without applying zero air and the sensor detects background gas the amber
LED flashes to advise the user that it is out of tolerance.
5.8. Calibrating the Span Value
Step Calibrating the Span Value Procedure
1
2
3
4
5
6
Attach regulator to cylinder of span gas.
Insert the calibration adapter into the sensor opening in the front of the enclosure door. Use a slight twisting motion as you gently push the calibration adapter into the sensor opening. If the calibration adapter is hard to insert, moisten the “o” ring seal slightly then try re-inserting it.
Open regulator valve fully and allow span gas to flow over sensor.
Move the jumper to J4 position (see Figure 4-1 on page 15). The tri-color
outer LED will change to a steady amber color. The system now waits 30 seconds to ensure the user is flowing span gas.
The GDC-150 then enters a count down (180 seconds for catalytic and solid-state sensors, 150 seconds for Electrochemical sensors) during which time it adjusts the circuit to the span value which was set earlier
(see “Setting the Span Gas Value”).
If the user wishes to view this, attach meter leads to test points TP1 and
TP2 (see Figure 1-4 on page 3). The meter will show an increasing
voltage indicating the GDC-150 sensor is responding to the span gas and the circuit is being adjusted for accuracy. Alternatively, If the optional
LED digital display has been fitted, read the value indicated on the outer digital display. Once the count down is finished, the outer LED changes back to green indicating the procedure is complete.
Before removing the span gas, move the jumper back to its resting position (J1) and the new value is saved.
IMPORTANT: If the user attempts to span adjust the sensor without applying span gas or the proper value of span gas, the sensor will produce a response that is outside of the circuit preset tolerance value.
The amber LED flashes to advise the user that it is out of tolerance.
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6. ACCESSORIES AND REPLACEMENT PARTS
6.1. Metal Protective Guards
GDC-150 series analog transmitters are all supplied in very rugged, non-metallic enclosures. However, in some applications more protection may be desired. Bacharach can provide protective guards made from 16 gauge galvanized metal with a pattern of square perforations to permit air and gas to diffuse easily to the sensor.
Figure 6-1. Protective Guard
6.2. Accessory and Replacement Part Numbers
Part
Number
Description
5209-0002 LED digital display (must be selected when ordering)
5209-0003 Relay (rated 2A @ 30 VAC)
5209-0005 Water- and dust-tight NEMA 4X enclosure
5209-0004 Splash guard (NEMA 4X enclosure only)
5209-0006 Calibration adapter for all other sensors
5209-0016 Calibration adapter for catalytic sensors
5209-0017 Sample draw pump (24 VAC-powered)
5209-0018 Sample draw pump (24 VDC-powered)
5209-0019 Transmitter guard (16 gauge galvanized metal)
5209-0021 Humidification chamber (for calibration of solid-state sensors)
∇ ∇ ∇
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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: [email protected]
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