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- Operation & Maintenance Manual
Bacharach H25-IR Operation & Maintenance Manual
Summary of H25-IR
Page 1
H25-ir infrared refrigerant gas leak detector instruction 3015-5286 operation & maintenance rev. 4 – december 2010 product leadership • training • service • reliability.
Page 2: Warranty
A instruction 3015-5286 warranty bacharach, inc. Warrants to buyer that at the time of delivery this product will be free from defects in material and manufacture and will conform substantially to bacharach inc.'s applicable specifications. Bacharach's liability and buyer's remedy under this warrant...
Page 3: Table of Contents
H25-ir contents instruction 3015-5286 i table of contents 1 introduction ................................................................................................................................ 1 1.1 purpose of instruction manual .................................................................
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Contents h25-ir ii instruction 3015-5286 3.4.2 improving ppm measurement accuracy using the cal factor .....................................26 3.4.3 adjusting the cal factor ..................................................................................................26 3.5 restoring factory cal...
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H25-ir contents instruction 3015-5286 iii 5.4.5.5 factory calibration .........................................................................................52 5.5 replacement parts........................................................................................................................
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Contents h25-ir iv instruction 3015-5286 notes:.
Page 7: 1 Introduction
H25-ir introduction instruction 3015-5286 1 1 introduction 1.1 purpose of instruction manual this instruction manual provides important information on how to install, operate, and service the bacharach h25-ir refrigerant gas leak detector. To assure operator safety and the proper use of this instrum...
Page 8
Introduction h25-ir 2 instruction 3015-5286 1.2.5 explosive atmosphere do not operate this instrument in the presence of flammable liquids, vapors or aerosols. Operation of any electrical instrument in such an environment constitutes a safety hazard. 1.2.6 accessing the interior of the instrument on...
Page 9: 1.3 Ordering Information
H25-ir introduction instruction 3015-5286 3 1.3 ordering information the h25-ir instrument along with its probe type and hose length are ordered by specifying 3 codes. The codes must be listed in the following sequence: code a – model name code b – gas type code c – probe type and hose length table ...
Page 10
Introduction h25-ir 4 instruction 3015-5286 1.5 features and capabilities detects and measures (depending on instrument’s part number): o cfcs, hcfcs, hfcs and halogens o r600a o sf 6 o co 2 infrared detector internal calibration leak standard provision for external calibration on other types of gas...
Page 11: 1.6 Functional Overview
H25-ir introduction instruction 3015-5286 5 1.6 functional overview the h25-ir is an industrial gas leak analyzer for the detection of cfcs, hcfcs, hfcs and halogen gas compounds, r600a, sf 6 , or co 2 . This instrument can be used to locate and then quantify gas leaks, as well as log and totalize a...
Page 12
Introduction h25-ir 6 instruction 3015-5286 1.7 names and functions of components 1.7.1 front view front panel buttons ent (enter) • selects a highlighted menu item. • saves a selection or manually entered data (e.G. Date and time). Esc (escape) • displays a previously viewed menu or data screen. • ...
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H25-ir introduction instruction 3015-5286 7 1.7.2 rear view 1.7.3 interior connector for battery cable (on dual power only).
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Introduction h25-ir 8 instruction 3015-5286 1.7.4 standard probe with led and programmable pushbutton 1.7.5 smart probe led (flash rate increases as the detected gas level increases, or lights steady when a user selected leak rate is detected.) programmable pushbutton (can be programmed to either ze...
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H25-ir introduction instruction 3015-5286 9 1.7.6 smart probe keylock function the smart probe’s keypad can be locked to prevent accidental key presses when working in tight spaces..
Page 16: 1.8 Menu System
Introduction h25-ir 10 instruction 3015-5286 1.8 menu system press the ent and esc keys at the same time to access the main menu. The menu system enables the operator to perform such functions as setting up the instrument, viewing logged readings, configuring the four user-defined setups, entering c...
Page 17: 2 Preparing For Operation
H25-ir preparing for operation instruction 3015-5286 11 2 preparing for operation 2.1 connecting the probe plug the probe connector into the front panel probe receptacle by aligning the red dots on both the connector and receptacle. Screw the flexible probe tube onto the probe assembly. 2.2 connecti...
Page 18: 2.4 System Setup
Preparing for operation h25-ir 12 instruction 3015-5286 2.3 turning on the instrument warning! Explosion hazard. Do not operate this instrument in the presence of flammable liquids, vapors or aerosols. Operation of this instrument in such an environment constitutes a safety hazard. Turn on the instr...
Page 19
H25-ir preparing for operation instruction 3015-5286 13 2.4.1 gas type the gas type function displays a list of gases that the instrument is programmed to monitor. Refer to section 6 for a complete list of these gases. Use the up and down buttons to highlight the desired gas. Press ent to save the s...
Page 20
Preparing for operation h25-ir 14 instruction 3015-5286 for example: if relay 1 is programmed to “close at log limit,” its n.O. Contacts can be connected to an external alarm device (e.G. Strobe light or buzzer) that will activate when the total accumulated leak value in the data log has reached its...
Page 21
H25-ir preparing for operation instruction 3015-5286 15 2.4.8 serial output leak rate data can be output as ascii text in two formats. After selecting the serial output function, the user can choose to have the text output to a file in two formats. Refer to section 4.6. This function allows the stri...
Page 22
Preparing for operation h25-ir 16 instruction 3015-5286 from the setups menu, use the up and down buttons to highlight the desired setup. Press ent to select that setup and display its configuration menu. From the configuration menu, use the up and down buttons to highlight the desired function. Pre...
Page 23
H25-ir preparing for operation instruction 3015-5286 17 setpoint – both the bar graph and audible tone go to their maximum values when the leak rate equals or goes above the setpoint. Enter a setpoint value per section 2.5.5 setpoint . H25c setpoint – this setting emulates the operation of the h25c ...
Page 24
Preparing for operation h25-ir 18 instruction 3015-5286 below 75% of sp – the auto-zero function is on when the leak-rate is below 75% of the setpoint value. If the leak rate goes above 75% of the setpoint value, then the auto-zero function turns off, allowing the probe to stay on the leak without t...
Page 25
H25-ir preparing for operation instruction 3015-5286 19 2.7 4–20 ma current loop connection an external 4 20 ma monitoring device (e.G., chart recorder) can be connected to the h25-ir using a shielded- twisted-pair cable. Important! The monitoring device must be isolated from ground (floating). Loca...
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Preparing for operation h25-ir 20 instruction 3015-5286 notes:.
Page 27: 3 Calibration
H25-ir calibration instruction 3015-5286 21 3 calibration it is recommended that a calibration be performed after the initial warm up and then once every 2-4 hours of use thereafter. During the calibration cycle internal pressures and flow rates are stored which are used to determine leak rate and d...
Page 28
Calibration h25-ir 22 instruction 3015-5286 3.1.2 external calibration selection and setup when using an external leak source, the instrument must be setup for external calibration along with entering the leak rate and gas type of the external leak source. Select external calibration and enter the p...
Page 29: 3.2 Internal Calibration
H25-ir calibration instruction 3015-5286 23 3.2 internal calibration internal calibration uses the instrument’s built-in leak source. Properties of the leak source (i.E. Gas type, leak rate, temperature coefficient, and specification temperature) are entered at the factory and do not need to be chan...
Page 30: 3.3 External Calibration
Calibration h25-ir 24 instruction 3015-5286 3.3 external calibration external calibration uses a customer-supplied leak source that matches the gas to be monitored. Properties of the leak source must be entered by the operator using the ext rate and ext gas type functions as described in section 3.1...
Page 31
H25-ir calibration instruction 3015-5286 25 leak-rate accuracy can be maintained by periodically calibrating the instrument on the gas being measured. If the instrument’s internal calibration gas is the same as the gas being measured, then it is a simple matter of calibrating the instrument using th...
Page 32
Calibration h25-ir 26 instruction 3015-5286 3.4.2 improving ppm measurement accuracy using the cal factor the cal factor can be adjusted to improve the accuracy of the ppm measurement by calibrating the instrument on the gas being measured. The accuracy of the ppm measurement after performing this p...
Page 33
H25-ir calibration instruction 3015-5286 27 3.5 restoring factory calibration note: factory calibration cannot be restored if the instrument was calibrated using an external leak source. Restore an instrument to its factory calibration value as follows: display the calibration data menu by first pre...
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Calibration h25-ir 28 instruction 3015-5286 notes:.
Page 35: 4 Operation
H25-ir operation instruction 3015-5286 29 gas measurement leak units gas type mode setup name (first 8 characters) range & mode graphical display of gas level 4 operation 4.1 instrument location the h25-ir refrigerant gas leak detector should be placed on a flat, horizontal surface such as a bench o...
Page 36
Operation h25-ir 30 instruction 3015-5286 4.2.3 range selection the h25-ir has three sensitivity ranges: sm (small), med (medium), and lg (large). The range used when searching for a leak depends on the size of the leak and the type of gas being monitored. Press the range button until the desired ra...
Page 37
H25-ir operation instruction 3015-5286 31 4.2.5 volume adjustment a speaker at the rear of the instrument produces an audible tone whose frequency increases as the detected level of gas increases. An earphone when plugged into the instrument’s earphone jack automatically disconnects the speaker, all...
Page 38
Operation h25-ir 32 instruction 3015-5286 4.2.7 measuring the leak rate after finding a leak, a measurement can be made to determine its leak rate as follows: 1. Press the mode button to display “mers” at the bottom of the data display screen or “measr” on the smart probe. 2. Allow the instrument to...
Page 39
H25-ir operation instruction 3015-5286 33 in the following example, a reading of 0.48 oz/yr is about to be logged in memory location 11. Pressing the ent button will confirm this action and then display a measurement logged screen, which confirms that the data has been saved while also showing the c...
Page 40
Operation h25-ir 34 instruction 3015-5286 4.2.10.3 viewing the total of all logged measurements the ability to display the total of all logged measurements (up to 50) is useful in situations where it is necessary to test an installation or piece of equipment that has a maximum permissible total leak...
Page 41: 4.4 Pchk
H25-ir operation instruction 3015-5286 35 4.3 responding to fault conditions when the instrument’s diagnostics detects that a fault has occurred, the word “fault” appears in place of the gas type, and a beep will be heard every 2 seconds. The cause of the fault can be determined by viewing the diagn...
Page 42: 4.6 Serial Output Types
Operation h25-ir 36 instruction 3015-5286 4.6 serial output types text packet when text packet is selected, a 16 character ascii string is output approximately 10 times per second. The string is formatted as follows: xx.X,-p.Ppcc xx.X is the leak rate as displayed on the front panel, -p.Pp is the in...
Page 43
H25-ir operation instruction 3015-5286 37 notes:.
Page 44: 5 Maintenance
Maintenance h25-ir 38 instruction 3015-5286 5 maintenance 5.1 diagnostics menu the diagnostics menu provides information about the instrument’s operation that will be useful to service technicians for the purpose of troubleshooting various fault conditions. To display the diagnostics menu, first pre...
Page 45
H25-ir operation instruction 3015-5286 39 5.1.2 last fault the last fault screen provides a text description of all current faults being detected by the instrument. Once the cause of the fault(s) has been cleared, its description is removed from the screen. The name of the last fault, however, is re...
Page 46
Parts &service h25-ir 40 instruction 3015-5286 5.1.3 ir emitter the ir emitter screen provides readouts of the detector’s voltage, current, resistance, and power consumption. When contacting the bacharach service department, the operator may be asked to provide this information to help in the troubl...
Page 47: 5.2 Factory Menu
H25-ir operation instruction 3015-5286 41 5.1.7 auto gain important! The instrument must be sampling fresh air (zero gas) when the auto gain function is selected. Selecting the auto gain function automatically sets the ir detector’s voltage to its baseline 0 ppm level by controlling the instrument’s...
Page 48
Parts &service h25-ir 42 instruction 3015-5286 important! Be sure to enter the leak rate using the same units of measure as displayed on the leak rate screen. In this example, the units of measure is g/yr. If your leak source is marked in oz/yr, then multiply that value by a factor of 28.35. For exa...
Page 49
H25-ir operation instruction 3015-5286 43 move the blinking cursor across the screen to highlight the digit to be modified, and then using the up and down buttons to modify that digit. Press ent to save the new ambient pressure value. Tip: to convert inhg into psia, multiply inhg by 0.491. For examp...
Page 50: 5.3 Flashing Memory
Parts &service h25-ir 44 instruction 3015-5286 5.2.8 probe type use the probe type function to select the probe type that is connected to the instrument. Use the up and down buttons to select the appropriate probe type. Press ent to activate the selection. Refer to sections 1.7.3, 1.7.4, and 1.7.5 f...
Page 51
H25-ir operation instruction 3015-5286 45 note: com1 is the default port used by the flash memory program. If com1 is already in use by another device, then connect the instrument to the next available com port. The software will need to be reconfigured as described in step 9 to use this port. 3. Wi...
Page 52
Parts &service h25-ir 46 instruction 3015-5286 10. Select setup > file locations and verify that the coldload.Bin, pilot.Bin, and flash.Ini files are all located in the c:\rfu folder. Click ok if these files are in the correct folder. If necessary, use the browse buttons in the choose file locations...
Page 53: 5.4 Part Replacement
H25-ir operation instruction 3015-5286 47 16. Turn on the instrument. The following message should appear: note: flashing memory with the same firmware version will not cause the instrument to reset. After flashing memory, the instrument will perform a complete system reset, causing all system param...
Page 54
Parts &service h25-ir 48 instruction 3015-5286 5. Drop down the rear panel far enough to allow the top cover to clear, being careful not to stress the cables attached to the inside of the panel. 6. Remove top cover by sliding it toward rear of instrument. 5.4.2 fuse replacement the h25-ir is protect...
Page 55
H25-ir operation instruction 3015-5286 49 5.4.4 internal filter replacement a filter located inside the instrument may become blocked due to dust or water being drawn into the instrument. A blocked filter is identified by a “search flow fault,” “measure flow fault,” or a “no flow” fault occurring. R...
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Parts &service h25-ir 50 instruction 3015-5286 5.4.5.1 top cover removal (see section 5.4.1 removing the top cover ) 5.4.5.2 installing the new ir optical bench 1. Carefully remove tubing and electrical connectors from old ir bench. See illustration below. 2. Cut off two cable ties that secure ir be...
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H25-ir operation instruction 3015-5286 51 5.4.5.3 ir emitter adjustment warning! Shock hazard . When performing the following step, be careful not to come in contact with ac voltages when working inside the instrument with the cover off and ac voltage applied. 1. Reconnect the ac power cord, and the...
Page 58
Parts &service h25-ir 52 instruction 3015-5286 5.4.5.5 factory calibration note: factory calibration establishes the instrument’s default calibration setting that is recalled when “restore factory cal” is selected from the cal data menu. 1. With all covers in place, turn the instrument back on while...
Page 59: 5.5 Replacement Parts
H25-ir operation instruction 3015-5286 53 5.5 replacement parts replacement parts item description part number complete instrument refer to section 1.3 ordering information h25-ir unit: cfc, hfc, hcfc & halogen gases 3015-5260 r600a 3015-5263 sf6 3015-5266 standard probe with pushbutton and led asse...
Page 60: Service Centers
Parts &service h25-ir 54 instruction 3015-5286 service centers service and replacement parts can be obtained by contacting one of the following bacharach service centers: united states bacharach, inc. 621 hunt valley circle new kensington, pa 15068 phone: 724-334-5051 fax: 724-334-5723 email: help@m...
Page 61: 6 Troubleshooting
H25-ir specifications instruction 3015-5286 55 6 troubleshooting 0001 box temp error inside chassis temperatures greater than 55degc or less than -5degc yes no move to cooler or warmer environment to correct temp sensor defective replace motherboard does fault code also indicate a/d failure 0400? A/...
Page 62
Specifications h25-ir 56 instruction 3015-5286 0004 manifold pressure sensor error manifold pressure is greater than 16.0psia or less than 3.0psia yes no correct over or under pressure condition, check probe input and exhaust output for pressure or vacuum does fault code also indicate a/d failure 04...
Page 63
H25-ir operation instruction 3015-5286 57 0020 internal cal error indicates one or more of the 4 flow parameters collected during the internal cal cycle, deviate from the “factory” value by 25% or more probe removed during cal cycle yes no repeat internal cal cycle replace internal filter and store ...
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Specifications h25-ir 58 instruction 3015-5286 0100 leak pressure fault internal leak pressure transducer reports a pressure that deviates more that 15% from the pressure predicted from the box temperature sensor and the pressure temperature curve for the leak gas type internal leak is low or empty ...
Page 65
H25-ir operation instruction 3015-5286 59 0800 search flow fault indicates current pressure drop in search mode deviates from the value store during the last calibration cycle by more than 20% too long since last cal and ambient pressure or filter flow has changed yes no repeat cal cycle replace int...
Page 66
Specifications h25-ir 60 instruction 3015-5286 4000 zero volt error indicated the sensor voltage stored during auto or manual zero was less that 3.9v or greater than 4.5v sensor voltage is zero or near zero yes no detector cable loose or disconnected no yes ir emitter resistance show **.* in diagnos...
Page 67: 7 Specifications
H25-ir operation instruction 3015-5286 61 7 specifications gases detected .........................Detects and measures, depending on instrument’s part number: • cfcs, hcfcs, hfcs and halogens r11, r12, r21, r22, r23, r113, r114, r123, r124, r125, r134a, r227, r236fa, r245fa, r401a, r402a, r402b, r4...
Page 68
Specifications h25-ir 62 instruction 3015-5286 notes:.
Page 69
H25-ir appendix a instruction 3015-5286 63 appendix a – factory defaults table a-1 lists the factory default parameters that are determined by the instrument’s part number (as marked on the rear panel), while table a-2 lists the default parameters that are user definable. Table a-1. Default paramete...
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Headquarters: 621 hunt valley circle, new kensington, pa 15068 ph: 724-334-5000 • fax: 724-334-5001 • toll free: 1-800-736-4666 website: www.Mybacharach.Com • e-mail: help@mybacharach.Com ° printed in u.S.A..