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1. The Measurable Difference MGD i00 Gas Detector and Controllers Installation and Operation Manual Instruction 6109 9000 Revision 4 June 2014 Product Leadership e Training e Service e Reliability MGD 100 Manual 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 ALL GOODS MUST BE SHIPPED TO THE MANUFACTURER BY PREPAID FREIGHT ALL RETURNED GOODS MUST BE PRE AUTHORIZED BY OBTAINING A RETURN MERCHANDISE AUTHORIZATION RMA NUMBER CONTACT THE MANUFACTURER FOR A NUMBER AN
2. R404A propane and butane sensors should be located near ground level e 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 e With similar density or miscible gases such as CO or CO sensors should be mounted about head high about 5 feet 1 5 m e Sensors should be positioned just far enough back from any high pressure parts to allow gas clouds to form and be detected 6109 9000 Rev 4 15 MGD 100 Manual Otherwise a gas leak might pass by in a high speed jet and not be detected by the sensor e Make sure that pits stairwells and trenches are monitored since they may fill with stagnant pockets of gas e 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 e 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 loca
3. alarm and 25 30 seconds before a high level alarm 30 6109 9000 Rev 4 MGD 100 Manual Operation State Only the green light on the panel is on No gas is present Power If the green light is off power to the unit has been Interrupted interrupted Refer to Section 7 Alarm One alarm Units Conditions One or more red lights on the panel turn on The siren and the relays operate This indicates that gas at one or more sensors is at a level higher than the alarm point Description Two alarm Units Low Alarm One of more yellow lights on the panel turn on The audible alarm operates intermittently and the low alarm relay operates this indicates presence of a low level of gas On one or more sensors High Alarm One or more red lights on the panel turn on The audible alarm operates continuously and the high alarm relay operates this indicates presence of a high level of gas on one or more of the sensors Resetting On one alarm units all of which have automatic reset no Alarms user intervention is required The unit will reset shortly after the gas dissipates all one alarm systems reset automatically On two alarm units low level alarm conditions will reset automatically when the gas dissipates High level alarm conditions require a manual reset by pressing the reset button Please note that a high alarm condition can only be reset 30 60 seconds after the gas clears from around the sensors Audible For the pu
4. an approved type based on local regulations NOTE The blanking plugs for cable entries should only be removed if being replaced by conduit fittings NOTE f replacement of either main power fuse is required use only a 2A 250V slow fuse 0 79 in 20mm T2AL250V CE 5 CES 6109 9000 Rev 4 25 MGD 100 Manual Fuse 1 109679 1904 HLIM 3SN4 398 71d3 Fuse 2 Main Power IYNOEZ OOT ON 1 a c9 zn EZ seu SE lt 5 OD Aen 52 5 SENSOR 1 oNBosor v e e 7 Kai gu ee esi O O cu GE amp X OI 2 E lt Q 5 CS i 1 gt N Controller PCB NOTE Be sure to respect max cable length restrictions 2 Fail Safe Jumper Setting Kl e e TPA TP3 Gas Sensor PCB LED 1 Gas Sensor PCB TP4 Vs e LED 1 TP2 LOW el TP19 HIGH ON High Relay Is Normally Energized De energized on High Alarm or Mains Failure Condition OFF High Relay Is Energized On Alarm Energized on High Alarm Condition Figure 13 1 amp 2 Sensor One Alarm Installation Diagram 26 6109 9000 Rev 4 Low Alarm Relay Main Power Relay 2 09279219064 HLIM 3504 39Md3 Fuse 2 1 Lo gt O Controller PCB IYNOEZ OOT ON 1 NOTE Be sure to respect max cable length restrictions KEY RESET B
5. and the calibration beaker are clean and dry Unscrew the beaker wing nut and place the ampoule so that it sits in the base of the beaker see Figure 18 Tighten the wing nut screw onto the ampoule without breaking it Remove the enclosure lid of the gas detector Connect the voltmeter to the sensor under test between TP5 and TP4 to monitor sensor response Place the beaker over the sensor head using the multi sensor adaptor to fit the sensor or if an Exd IP66 or remote sensor head version screw the beaker on the remote sensor head M42 thread or M35 thread adaptor It should be as tight fitting as possible to allow maximum gas exposure allowing the gas to diffuse in the beaker It should be left in place for approximately 5 min The voltage output will increase This confirms that the sensor is responding response equivalent to at least 50 typical of the test gas confirms that the system is in order Remove the beaker from the sensor Carefully remove any ampoule remains from the gas detector and beaker 6109 9000 Rev 4 37 D Tighten the wing nut screw onto the ampoule until it shatters MGD 100 Manual 6 4 Calibration Overview To comply with the requirements of EN378 and the European F GAS regulation sensors must be tested annually However local regulations may specify the nature and frequency of this test CAUTION Check local regulations on calibration or testing requirements 6 5 Calibration O
6. of Contents SECTION T 198617816555575877557555555858 555255855545875552545125545875575122557858158 5 kE GENS 1110101118110175775 7775777575525557757 78278757525575258555751785 5 1 2 ee butter EEN 10 SECTION 2 PLACING SENSORS 5 tien si exeo deele EEN REY RE PE T Pues cs 13 2 1 Installation Warnings 5 54255275595855855855558858585782558895854855875888848588 13 2 2 General Guldelllies uso ss due to Ie aa beUi SU Monte tue 13 2 3 Machinerv ROOMS da dpi S een OLAS 15 2 4 Reli geja led Spaces ie o dip as db daten sn nn Lee 16 Gi UE 16 2 6 Air Conditioning Direct Systems VRF VRV eee 17 SECTION 3 HOUSING DIMENSIONS ecce eee eee eene nennen nnno nnus 18 SECTION A WIRING INSTRUCTIONS e eee eee eee eee nennen REENEN REENEN 23 AAs WIFE MOD OS sn Amatai doom 23 452 Ee EE 24 EE EE 24 D E 25 AS Seene de NEE 25 SECTION 5 OPERATION AND STABILIZATION 555555 55 30 SECTION 6 FUNCTIONAL TESTS AND CALIBRATION eee eene 32 6 1 Vogel le EE 32 6 2 e de E 34 0 3 BUMP LESING c E 35 6 4 Calibration Overview ss 38 6 57 Calibration OPTIONS aequ adita d E AU P AMNIS d EE A LN 38 6 6 Sensor Board Excniall Be eegenen 38 6 7 Op Site Gas CIDI OM nent Is t Pie m 39 SECTION 7 TROUBLESHOOTING ecce eee eee eee nnn
7. on the label on the side of the enclosure and is unique to that sensor Tools required e Avoltmeter crocodile clips recommended e Factory set point electric values as shown on the rating label e Screwdriver depending on enclosure Electrical Reset For semiconductor sensors only connect a DC voltmeter between TP5 0 and TP4 as shown in Figure 14 and Figure 16 Adjust pot RV1 For two level sensors only connect your DC voltmeter between TP5 OV and TP2 V as shown in Figure 14 and Figure 16 Adjust pot P8 For high level alarm voltage connect your DC voltmeter between TP5 OV and TP1 V as shown in Figure 14 and Figure 16 Adjust pot P7 34 6109 9000 Rev 4 MGD 100 Manual 6 3 Bump Testing After installation the units should be bump tested Expose the sensors to test gas ampoules NH3 CO etc or test cylinder appropriate to the installation The gas is heavier than air and should fall into the sensor putting the system into alarm and lighting the red LED The delay will prevent the audible alarm from sounding or the relay from switching if a delay is set With a bump test you can see the functions of the sensor the yellow red LED will light and the relay and audible alarm will function Ideally bump tests are conducted on site in a clean air atmosphere NOTE Prior to carrying out a bump test check and adjust the zero setting as described in the Calibration section NOTE Proc
8. remaining MGD 100s q NOTE Install a 2200 Ohm resistor between input pins 2 and 3 Install a 2200 Ohm resistor between input pins 2 and 3 on any unused channels If unused channels do NOT have a resistor installed a fault will occur iN IMPORTANT Ensure that connections 1 to 4 on the sensor connect to their corresponding numbers on the terminal block in the main control unit otherwise it could cause damage to the MGD 100 i Maximum Wiring Lengths between MGD 100 and Controller Requirement Description Length 500 feet maximum AWG 22 AWG cable minimum Stranded 4 wire cable 6109 9000 Rev 4 23 MGD 100 Manual provided the corresponding resistance shown above is not d NOTE You may use different cables and longer distances exceeded 4 2 External Audible Alarm NOTE This section applies to the external audible alarm 4 6 channel systems only Wiring the External Audible Alarm To install the audible alarm connect positive red lead to the connection of the SIREN terminal 66 JI Connect the negative black lead to the connection of the SIREN terminal 4 3 DC Output NOTE This section applies to the 12 VDC output 4 6 channel systems only Wiring the DC Output The 12 VDC 500 mA output is obtained via the 12V terminal This output may be wired via the relays to obtain a switching 12 VDC output to drive an external relay or solenoid NOTE The 12VDC output shou
9. 01716500017 Fail Safe Jumper Setting ON High Relay Is Normally Energized De energized on High Alarm or Mains Failure Condition OFF High Relay Is H Energized On Alarm Energized on High Alarm Condition 100 230VAc 50 60Hz Base Ground Connection ij REPLACE FUSE e WITH M205 T2AL250V FAIL SAFE TT T SD DO ooo LUC OFF 6 0mON gt o gt eee siREN KEY RESET NC COM NO NC COM NO NO COM NC LI 1 High Relay J D S3 si O uou wo ou uu uou uu gt gt c gt c gt uc gt e ow 06 06 OG ae AE kati Relay Outputs Low Relay Fault Relay 1 1 Chan 1 Chan 2 Chan 3 Chan 4 Chan 5 Chan 6 Sensor Enable Alarm LEDs Alarm LEDs Alarm LEDs Alarm LEDs Alarm LEDs Alarm LEDs Jumper Settings SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 ON ON Sensor is ON ie 9101 aii ee OFF nw OFF SENSE Jl enabled for this e channe D D 1 D D D 1 egen sl ajo oic mic d i i ui eee eee ETUDE E r Oe r Oe D Oe r Oe Oe z Oe i OFF OFF Sensor is N ZER nN EL Ss N ee N 8 N 1 H 1 d a a a a 7 disabled for this w Qe Qe De 1 De De v Os channel gt S Se laf Neel LE Ne U Se LE Us 1 1 Repeat for sensor channels 3 through 6 as required NOTE Be sure to adhere to ma
10. ATV nds voltage between TP5 OV 8 TP4 Ve OV and VS on IR units Apply the high concentration calibration gas to the sensor and wait until the sensor output signal stabilizes Record this voltage 7 Adjust P7 to the new value Record and use the new value for subsequent electrical set ups CAUTION The high alarm threshold voltage must be set higher than the low alarm threshold or the unit will not function correctly 40 6109 9000 Rev 4 MGD 100 Manual Section 7 Troubleshooting Symptom Possible Cause s No lights displayed Power failure check supply on panel Tripped circuit breaker or blown fuse on electrical supply Blown fuse at the electrical supply on the controller PCB board Red light is on but Make sure the siren has not been no alarm condition is deactivated by key switch active i e no siren This indicates a wiring or sensor fault call and no relay service provider operation after 3 minutes Controller is on but This may indicate a wiring fault between the MGD 100 is not the controller and sensor or a sensor fault Check power supply to the controller Check connections between the controller and the sensor to ensure that the wires from positions 1 to 4 on the sensor are connected to the corresponding 1 to 4 connectors on the controller NOTE f false alarms are being triggered by background gases paint fumes etc or extreme humidity or temperature d conditions you may adjust t
11. D PROCEDURES REQUIRED FOR PRODUCT TRANSPORT SERVICE POLICY BACHARACH INC MAINTAINS AN INSTRUMENT SERVICE FACILITY AT THE FACTORY SOME BACHARACH DISTRIBUTORS AGENTS MAY ALSO HAVE REPAIR FACILITIES HOWEVER BACHARACH ASSUMES NO LIABILITY FOR SERVICE PERFORMED BY ANYONE OTHER THAN BACHARACH PERSONNEL REPAIRS ARE WARRANTED FOR 90 DAYS AFTER DATE OF SHIPMENT SENSORS PUMPS FILTERS AND BATTERIES HAVE INDIVIDUAL WARRANTIES SHOULD YOUR INSTRUMENT REQUIRE NON WARRANTY REPAIR YOU MAY CONTACT THE DISTRIBUTOR FROM WHOM IT WAS 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 NAME SHIPPING BILLING INFORMATION AND A DESCRIPTION OF THE DEFECT AS YOU PERCEIVE IT YOU WILL BE CONTACTED WITH A COST ESTIMATE FOR EXPECTED REPAIRS PRIOR TO THE PERFORMANCE OF ANY SERVICE WORK FOR LIABILITY REASONS BACHARACH HAS A POLICY OF 2 6109 9000 Rev 4 MGD 100 Manual 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 PACK THE EQUIPMENT WELL IN ITS ORIGINAL PACKING IF POSSIBL
12. E AS BACHARACH CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE INCURRED DURING SHIPPING TO OUR FACILITY NOTICES COPYRIGHTS THIS MANUAL IS SUBJECT TO COPYRIGHT PROTECTION ALL RIGHTS ARE RESERVED UNDER INTERNATIONAL AND DOMESTIC COPYRIGHT LAWS THIS MANUAL MAY NOT BE COPIED OR TRANSLATED IN WHOLE OR IN PART IN ANY MANNER OR FORMAT WITHOUT THE WRITTEN PERMISSION OF BACHARACH INC ALL SOFTWARE USED AND OR DISTRIBUTED BY BACHARACH IS SUBJECT TO COPYRIGHT PROTECTION ALL RIGHTS ARE RESERVED NO PARTY MAY USE OR COPY SUCH SOFTWARE IN ANY MANNER OR FORMAT EXCEPT TO THE EXTENT THAT BACHARACH GRANTS THEM A LICENSE TO DO SO IF THIS SOFTWARE IS BEING LOADED ONTO MORE THAN ONE COMPUTER EXTRA SOFTWARE LICENSES MUST BE PURCHASED 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 6109 9000 Rev 4 3 MGD 100 Manual Table
13. EN61010 2011 EN61326 EN55011 declared The undersigned hereby declares that the above referenced products are in conformity with the provisions of the following standard s and is in accordance with the following directive s Directive s 2004 108 EC EU EMC Directive 2006 95 EC Low Voltage Directive LVD Standard s IEC 61010 1 2010 Electrical Equipment for Measurement Safety Standards Control and Laboratory Use Part 1 General Requirements Electromagnetic Electrical Apparatus for the Detection EN 61326 1 2006 Compatibility and Measurement of Combustible EMC Standards Gases Toxic Gases or Oxygen Signature Name Aaron Kennison Title Engineering Manager Date June 11 2014 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach Inc 6109 9000 Rev 4 43 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 help MyBacharach com
14. FAULT 9 e Relay O LLI ac emi Lu gt Chan 5 Alarm LEDs SENSOR 5 ON Ge 9 OFF Alarm LEDs SENSOR 6 ON e OFF NO COM NC Channel Controller PCB Dual Level Alarm Figure 4 MGD 100 4 and 6 6109 9000 Rev 4 MGD 100 Manual Qu Qo Gas Sensor PCB e P2 LOW P8 High P7 Low Figure 5 Examples MGD 100 PCBs 6109 9000 Rev 4 9 MGD 100 Manual 1 2 Technical Specifications Specification Description 100 230 VAC 50 60 Hz or 12 VDC specified at time of order Key Switch Preset 25 sec low 30 sec high Power Green Monitoring LED Alarm Relay s 10 A 120V 230V Warm up Delay Minimum of 3 minutes Communications 4 conductor cable stranded 500 ft 152 m max Wiring 22 AWG Max 8 80 wire Approvals UL CSA IEC EN 61010 1 CE 1 and 2 channel 4 and 6 channel systems systems Internal Internal Internal Internal Power Supply Alarm Silence Alarm Delay Sensor Channels Max Power Alarm Levels Audible Alarm continuous intermittent Buzzer Alarm Reset Visual Alarm LED s Fault 10 intermittent continuous Automatic Red LED Red LED Red LED Indication s low low continuous high Automatic low alarm continuous manual high Automatic alarm Yellow Red Red LED relay high low alarm manual high alarm Yellow Red 6109 9000 Rev 4 MGD 100 Manual Specific
15. FM 2800 3000 3400 3800 4000 4400 4800 5000 5400 5800 6000 6400 6800 7000 7400 7800 8000 8400 8800 9000 9400 9800 10000 x S 2800 n a 3000 n 3400 n a 3800 4000 n 4400 n a 4800 n a 5000 2500 5400 2700 5800 2900 6000 3000 6400 3200 6800 3400 7000 3500 7400 3700 7800 3900 8000 4000 8400 4200 8800 4400 9000 4500 9400 4700 9800 4900 10000 5000 n E Di d E to 5 to n SSS to gt ES to ti D ES d d 2 to to n a ES to ES to eb Sar ST d zx 5S d to E to d seji e SI d to z to D d 12 6109 9000 Rev 4 MGD 100 Manual 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 N components that can be easily damaged Do not touch nor d
16. Gas Calibration This section and the next cover calibration using calibration gas cylinders Bacharach offers a calibration kit that consists of a calibration gas cylinder and a flow regulation valve with flexible non absorbent tubing and vented calibration hood In some cases this option may be expensive relative to sensor exchange because of the cost of visiting a site calibration gas etc The procedure involves electrical set up followed by adjustment using calibration gases Equipment required is as follows e Gas cylinder with the appropriate target gas and concentration e Fixed flow regulator rate 0 3L min NOTE The sensor delay is approximately 25 seconds and cannot be deactivated All adjustments are performed on the MGD 100 sensor PCB The Sensor Standby Voltage and two Alarm Threshold Voltages must be adjusted Step Adjusting the Sensor Standby Voltage SSV adjust pot RV1 for 0 3V on IR units SSV is fixed Connect the voltmeter between TP5 OV amp TP4 Ve and 6109 9000 Rev 4 39 MGD 100 Manual Step Adjusting the Low Alarm Threshold Voltage ATV mm the voltage between TP5 OV amp TP4 Ve OV and VS on IR units Apply the low concentration calibration gas to the sensor and 3 wait until the sensor output signal stabilizes Record this voltage 4 Adjust P8 to the new value Record and use the new value for subsequent electrical set ups Step Adjusting the High Alarm Threshold Voltage
17. SENSOR 2 ONBeelort Va Qc 8 Bac co QU Oo go me 52 1 5 t SENSOR 1 ON eoor V am ge E J E lt Ers z dee e G 30 08 ss z 2 1 o i 1 GD eb si a ec o AN oui a K OFF MGD 100 Manual e e e TPS 724 763 Gas Sensor PCB Fail Safe Jumper Setting Gas Sensor PCB TP4 Vs LED 1 TP2 LOW ei o TP1 13 HIGH M01 d 8811 8d ON High Relay Is Normally Energized De energized on High Alarm or Mains Failure Condition OFF High Relay Is Energized On Alarm Energized on High Alarm Condition Figure 14 1 amp 2 Sensor Two Alarm Installation Diagram 6109 9000 Rev 4 27 MGD 100 Manual Horn 12 VDC 200 mA Max To Lid Ground Connection mm mm mm Fail Safe Jumper Setting ON High Relay Is Normally Energized De energized on i T Key High Alarm or Mains 8 Switch Failure Condition o un Q OFF OFF High Relay Is 3 Sc Energized On Alarm K SE Energized on High a PE 2 eg Alarm Condition v Gi wre See Se ere Ss 80 Ik B LI PHI LI REPLACE FUSE Je D WITH M205 z T2AL250V Re lay Output D FAIL SAFE ET 0719 0m ON e e NC COM NO e DU LI D DU High Relay LI le mm m m mm mm m
18. Z Loi Lo 2 Ss JU po ON TI TI Channel 2 Optional oooo 0000 le 3 4 Figure 1 MGD 100 1 and 2 Channel Controller PCB Single Level Alarm NOGZWWZ1 GOZW HLIM 3SN4 30 73 ON WO ON MO Relay 1 Chan 1 Alarm LEDs 8 JJO e e Bl NO Channel 1 0060 ON WO IN HOIH e e e za ON OFF Chan 2 Alm LEDs Opt FAIL SAFE 1353 A35 T HOSN3S HOSN3S 3301 e B NO Channel 2 Optional O S le 34 le 3 4 Figure 2 MGD 100 1 and 2 Channel Controller PCB Dual Level Alarm 6109 9000 Rev 4 MGD 100 Manual Chan 1 Alarm LED SENSOR 1 ON me 9 OFF EH SIREN KEY Chan 2 Alarm LED SENSOR 2 ON Ge 9 OFF FAIL SAFE NC COM NO OFF OG ON svo HIGH e e Relay Chan 3 Chan 4 Alarm LED Alarm LED SENSOR 3 SENSOR 4 ONEIO o OFF ON Ge 9 OFF Chan 5 Alarm LED SENSOR 5 ON Ge 9 OFF Chan 6 Alarm LED SENSOR 6 ON Ge 9 OFF Channel Controller PCB Figure 3 MGD 100 4 and 6 Single Level Alarm 6109 9000 Rev 4 MGD 100 Manual al e LLI LLI gt ac Chan 1 Alarm LEDs SENSOR 1 ON Ge OFF FAIL SAFE gg OFF OG ON HIGH SIREN KEY RESET O O Lu Lu LI gt a ac Chan 2 Chan 3 Alarm LEDs Alarm LEDs SENSOR 2 ON Ge 0 OFF SENSOR 3 ON o 91017 Relay Lu oc Chan A Alarm LEDs SENSOR 4 ON oe OFF NC COM NO NC COM NO LOW e e el
19. alibrated in the environment in which d NOTE For improved accuracy and response the instrument it is being installed There are two concepts that need to be differentiated Bump Test Exposing the sensor to a gas and observing its response to the gas The objective is to establish if the sensor is reacting to the gas and all the sensor outputs are working correctly There are two types of bump test e Quantified A known concentration of gas is used e Non Quantified A gas of unknown concentration is used Calibration Exposing the sensor to a calibration gas setting the zero or Standby voltage the span range and checking adjusting all the outputs to ensure that they are activated at the specified gas concentration 6109 9000 Rev 4 33 MGD 100 Manual CAUTION Before you carry out the bump test or calibration e Advise occupants plant operators and supervisors e Check if the MGD 100 is connected to external systems such as sprinkler systems plant shut down external N sirens and beacons ventilation etc and disconnect as instructed by the customer e ideally for bump test or calibration the MGD 100 should be powered up overnight See Section 5 for more information 6 2 Electrical Reset If necessary reset the Standby and low high Alarm Threshold Voltages to the factory settings as shown on the calibration label This is performed on the MGD 100 Sensor PCB Electrical reset information is listed
20. arm 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 e Plant room maintenance activity involving solvent or paint fumes or refrigerant leaks e Accidental gas migration in fruit ripening storage facilities bananas ethylene apples carbon dioxide e Heavy localized exhaust fumes carbon monoxide dioxide propane from engine driven forklifts in confined spaces or close to sensors A sensor response d
21. ation Description 1 and 2 chan systems 4 and 6 chan systems Std Enclosure MGD 1P41 MGD 1P41 Ratings Controller IP51 Controller IP51 Dimensions 8 4 x 4 1 x 3 15 10 3 x 10 4 x 303 and Weight 214 x 105 x 80 mm 262 x 265 x 84 mm Controller 2 2 lbs 1 0 kg 5 1 Ibs 2 3 kg 3 35 x 5 59 x 2 09 6 3 oz 86 x 142 x 53 mm 180 g CSS 6 89 x 6 5 x 3 29 175 x 165 x 82 mm 629 g 6 89 x 8 9 x 3 29 Guard 175 x 225 x 82 mm 7009 Sensor 175 x 155 x 82 mm O 790 g Remote Head 175 x 155 x 82 mm 1185 g 6 89 x 6 1 x 3 29 210 0 3 175 x 155 x 82 mm OZ 916g IP66 Airflow 6 89 x 4 9 x 3 29 1 Ib 4 oz Duct See Table 175 x 125 x 82 mm 578 g 5 12 x 6 3 x 3 54 9 Ib 4 oz Exd ATEX onl Ss only 130 x 160 x 90 mm 4200 g NOTE The hazardous area Exd Gas Monitor products are designed with individually certified Exd main housing d enclosures and certified Exd remote or attached sensor IP66 w PRV Sensor Head 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 6109 9000 Rev 4 11 MGD 100 Manual Supported CFM and Duct Sizes for the Duct Mount Housing Ft min Based on CFM and Duct Size T na n a n a Units Duct Size 12 x 12 12 x 24 18 x 18 1x2 1 5x1 5 Area ft C
22. e enhn snos e sth nte o se uus 41 DECLARATION OF CONFORMIITY 5 43 4 6109 9000 Rev 4 MGD 100 Manual 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 e detecting refrigerant gases including NH and CO e speedy detection of combustible gases e 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 6109 9000 Rev 4 5 MGD 100 Manual W JYNOEZ 001 ONT ln NOSZWZL SOZH HLIM 3504 33973 Chan 1 Alarm LED ON WO JN HOIH ON Niar bs OFF Chan 2 Alm LED Opt Z Relay FAIL SAFE 43019 e ll NO Channel 1 12834 O Fh Z m Pd
23. eak occurs 6109 9000 Rev 4 17 MGD 100 Manual Section 3 Housing Dimensions 0 28in 7 0 mm 4 07 in 103 50 mm 18 3 39 in 86 0 mm 2 09 in 53 mm 1 0 18 in 1 i gt I I I i I gt 4 50 mm 1 69 in 43 0 mm I I EER 0 35 in 9 0 mm 4 72 in 120 mm 5018 in 4 50 mm 1 4 in 36 00 mm EL X gt 1 0 in 1 0 in 25 00 mm 25 00 mm Figure 6 MGD 100 Standard Housing 6109 9000 Rev 4 MGD 100 Manual eU 5 1in se e 130 mm U E Lef 1 5 1 in 130 mm Figure 7 MGD 100 Exd Housing 4 8 in 1 za 122 mm e 4 8in 123 mm z Eh x 35 in 9mm long x 0 24 in emm e 2 3 in Use 3 16 inch screws 59 mm I I I I I I 5mm 6mm I D il 5 7 in 146 mm Figure 8 MGD 100 IP66 Housing with Splash Guard 4 0 in 6109 9000 Rev 4 19 MGD 100 Manual 4 8 in za 122mm PRV IP66 Vent Pipe Exd Remote Head Monitoring 1 in BSP Head mounting slots 0 35 in dh long x 0 24 in 6mm wide Use 3 16 inch screws 5mm 6mm M42 thread Thread varies 1 BSP thread with model Figure 9 MGD 100 IP66 Housing with Remote Sensor 32 H See Figure 8 for mounting locations G Cut out in duct for pitot 22mm 57 O fig fc Figure 10 MGS 100 IP66 Housing with Airflow Duct Mount 20 6109 9000 R
24. edures for bump test and calibration vary depending on the sensor technology used and the gas in question The MGD 100 is available in two sensor versions Semiconductor SC and Infrared IR NOTE For semiconductor sensors you MUST use calibration gas in a balance of air not N d NOTE Do not pressurize the sensor Step Bump Testing Using Calibration Gas Cylinders Remove the enclosure lid of the gas sensor and controller Expose the sensor to gas from the cylinder by using a plastic hose hood to direct gas to the sensor head 2 Connect the voltmeter to the sensor under test between TP5 and TP4 to monitor sensor response 6109 9000 Rev 4 35 MGD 100 Manual Fixed Flow Regulator 0 3 L Min A Flexible lt non absorbant tubing 1 4 O D Vented Calibration Hood Cylinder Figure 17 Gas Cylinder and Test Hardware NOTE If the bump test is unsuccessful perform a calibration as described later in this manual IMPORTANT After a semiconductor sensor is exposed to a d substantial gas leak the sensor should be checked and replaced if necessary Gas ampoules are convenient and inexpensive alternatives to using gas cylinders for bump testing 36 6109 9000 Rev 4 MGD 100 Manual TEST BEAKER M42 Thread GAS AMPOULES SENSOR ADAPTER M35 ADAPTER Figure 18 Gas Ampoules for Bump Testing Step Bump Testing Using Gas Ampoules sure that both the ampoules
25. elay is built in to the system to minimize the possibilities of false alarms 14 6109 9000 Rev 4 MGD 100 Manual 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 e When mechanical or natural ventilation is present mount a sensor in the airflow e 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 where sensors completely surround the area or equipment e For heavier than air gases such as halocarbon and hydrocarbon refrigerants such as
26. ev 4 MGD 100 Manual 10 26 in 260 50mm 5 13 in 130 25 mm 0 20 in 5 10 mm Mounting Hole 9 47 in 240 50 mm 8 85 in 224 70 mm 0 18 in 4 60 mm 9 55 in 242 50 mm 10 26 in 260 50mm V O O 67 70 mm 0 0 0 0 0 o 3 21 in 81 50 mm 2 67 in Hole Diameters x 0 5 in 12 7 mm Figure 11 4 amp 6 Sensor Controller Housing 6109 9000 Rev 4 21 MGD 100 Manual Screw Z 0 2 in 5 0 mm 15 5 mm 2 0 in 50 0 mm Z 0 4 in 10 0 mm 0 6 in 15 0 mm 0 5 in 12 7 mm 2 9 in 74 5 mm 0 5 in 12 7 mm 3 0 in 77 2 mm 3 ples Figure 12 1 to 2 Sensor Controller Housing 22 6109 9000 Rev 4 MGD 100 Manual Section 4 Wiring Instructions 4 1 Wiring MGD 100s Step Wiring MGD 100s Connect a 4 conductor cable 18 AWG recommended to a terminal block on the MGD 100 controller CN1 CN2 etc Route the cable to an MGD 100 For standard IP41 MGD 100 housings remove the lid by e turning the cable clamp turn counter clockwise to loosen the internal nut e depressing the clip on top of the enclosure to open Mount the MGD 100 See Section 3 for dimensions Connect the other end of the cable to the MGD 100 using terminal block CN1 positions 1 2 3 amp 4 Installation should be such that pin 1 of the MGD 100 controller is connected to pin 1 of the MGD 100 Close the housing Repeat above sequence for any all
27. he settings to compensate You should adjust the relevant sensor alarm threshold voltage upwards in 0 2 V increments until the condition clears To make sure the gas detectors are wired up correctly you can check the voltages at the sensor cable terminal blocks on the controller PCB or sensor PCB using a voltmeter as outlined below in Table 1 Place the negative probe on terminal position 4 and with the positive on 1 3 2 check the values The readings are lower at the sensor due to power drop in the line The terminals should have the values shown in the table below You can monitor this as follows 6109 9000 Rev 4 41 MGD 100 Manual e Connect voltmeter and monitor voltage between TP5 OV and TP4 Ve For IR monitor between OV and VS Table 1 Connections Correct Values Position Number At the Sensor Controller 2 Sensor output These are approximate O Fault typical internal reference values Approximately 4 5V 4 8 5V Is the negative side of the power supply The voltage signal from the sensor will start high and gradually fall in clean air to the SSV value shown on the calibration label IR unit will display O Volts until the 2 minute warm up has finished 42 6109 9000 Rev 4 MGD 100 Manual C DECLARATION OF CONFORMITY The manufacturer of the Bacharach Inc products covered by this 621 Hunt Valley Circle declaration New Kensington PA 15068 Y f ear s conformity is 2014 IEC
28. insofar as permitted by law the manufacturer accepts no responsibility for the calibration testing or operation of this unit The frequency and nature of testing or calibration may be determined by local regulation or standards 71378 and the F GAS Regulation require an annual check in accordance with the manufacturer s recommendation 32 6109 9000 Rev 4 MGD 100 Manual IMPORTANT Before testing the sensors on site the MGD 100 must have been powered up and allowed to stabilize for at least 24 hours See Section 5 IMPORTANT Failure to test or calibrate the unit in accordance with applicable instructions and with industry guidelines may result in serious injury or death The manufacturer is not liable for any loss injury or damage arising from improper testing incorrect calibration or inappropriate use of the unit CES CES IMPORTANT Bacharach recommends annual checks and gas calibration Bacharach also recommends sensor replacement every 3 years or as required Calibration frequency may be extended based on application but should never exceed 2 years CES IMPORTANT In applications where life safety is critical calibration should be done quarterly every 3 months or on a more frequent basis Bacharach is not responsible for setting safety practices and policies Safe work procedures including calibration policies are best determined by company policy industry standards and local codes should be zeroed and c
29. isturb 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 6109 9000 Rev 4 13 MGD 100 Manual 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 w
30. ld not exceed 500 mA If a switching 12VDC signal is required connect the of the 12V terminal to the COM terminal of the relay and the device to be switched to either the N O or N C terminal depending on whether a 12V output is required during an alarm condition or while the system is on standby The return from the device is connected to on the 12V terminal 24 6109 9000 Rev 4 MGD 100 Manual 4 4 Relays All relay outputs are labeled HIGH LOW and FAULT on the silkscreen Connect leads to terminal block for Common COM and N O and or N C connections as required Note that relays are rated as 10A 120 230 VAC NOTE N O normally open and N C normally closed refer to contact status in standby mode On a two alarm system a high level alarm condition on any sensor will override a low level alarm condition on another sensor operation by setting the fail safe jumper on the control units d NOTE The high level relay may be set for normal or Fail Safe printed circuit board 4 5 Power Connection Use 3 wire 20 AWG wire for 230V systems or 3 wire 18 AWG wire for 120V systems Connect the main power supply to the MAINS input terminal block NOTE Connection to the main power supply must be made via an approved readily accessible switched and fused plug and socket or as per local wiring regulations which should be within 10 feet 3 meters of the control unit NOTE The main power supply cable should be of
31. m mm mm mm mm mm mm mm ne mm mm lue ne o ne mm mm Q e a O c a C O C e ol vuv Chan 1 Chan 2 Chan 3 Chan 4 Chan 5 Chan 6 Sensor Enable Alarm LED Alarm LED Alarm LED Alarm LED Alarm LED Alarm LED Jumper Settings SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 ON ON Sensor is ON Be 91067 ON Ge OFF ON lo eJ OFF ON o 0 OFF ON Bo 1077 ON e OFF 1 enabled for this e gt channel mm mm m mim m m eee om om mi m m wm m m m wm mm mm wm mm e wb wi mm mm wm m o wm 1 Oe T Oe ki Oe Oe OFF Sensor is Ae Ao Aloe bp Aloe isabled for thi ofl ef o Conn Miu EY d Ge X Ge ski d Ge EN NI Se Repeat for sensor channels 3 through 6 as required NOTE Be sure to adhere to li Di afin P7 Low P8 High An max cable length restrictions NI S DO i LEE KSE ae Js 1234 m Ensure that connections 1to 4 ZE gt dech on each sensor connect to their e TAY de TP1 8 corresponding numbers on the TP1 S HIGH terminal block in the main alarm unit otherwise the e 7 4 system will not function Gas Sensor PCB TP3 correctly and could be damaged LED 1 D w D Figure 15 4 amp 6 Sensor One Alarm Installation 28 6109 9000 Rev 4 MGD 100 Manual Horn To Lid 12 VDC 200 mA Max k Ground I
32. ptions There are two available calibration options e Exchanging the sensor board for a new pre calibrated one and send old one to Bacharach for recalibration available for two alarm units and 1 and two alarm IR units e On site gas calibration These are explained in the next two sections 6 6 Sensor Board Exchange There are a number of advantages to sensor board exchange It is simpler and quicker than gas calibration NOTE Bacharach recommends exchanging your sensor PCB for a new pre calibrated one every 3 years Tools required e A pre calibrated sensor board e Avoltmeter crocodile clips recommended Step Sensor Board Exchange Power off the unit and remove lid of sensor enclosure 2 Note the color code of the cable in positions 1 2 3 and 4 of the connector block 3 Undo the cable and 2 screws securing the sensor board and remove the board 38 6109 9000 Rev 4 MGD 100 Manual Step Sensor Board Exchange Fit the new pre calibrated sensor and reconnect the cable in the correct color sequence at positions 1 2 3 and 4 Power on the unit and allow to stabilize for 15 minutes minimum Check voltage readings on positions 1 2 3 and 4 see Table 1 on page 42 to ensure that wiring is correct Note also in the table how to monitor the sensor as it stabilizes Carry out a bump test to confirm the sensor is responding Keep records of the test date sensor serial number and any observations 6 7 On Site
33. rflow sensor to monitor airflow to the start up fans in the front or rear sections e 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 under mirrors 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 away from drafts and heat sources like at vanity units radiators etc to avoid sources of steam in or near bathrooms sensors A few extra sensors could make a significant d IMPORTANT Carefully consider ramifications of using too few difference if a gas l
34. rpose of system maintenance the audible Alarm alarm may be disabled temporarily by using the key switch Faut This indicates a wiring or sensor problem 6109 9000 Rev 4 31 MGD 100 Manual Section 6 Functional Tests and Calibration 6 1 Introduction To comply with the requirements of EN378 and the European F GAS regulation sensors must be tested annually However local regulations may specify the nature and frequency of this test CAUTION Check local regulations on calibration or testing requirements components that can be easily damaged Do not touch nor disturb any of these components NOTE The MGD 100 15 calibrated at the factory After installation a zero adjustment may be required due to differences in environmental conditions IMPORTANT If the MGD 100 is exposed to a large leak it should be tested to ensure correct functionality by electrically resetting the zero setting and carrying out a bump test See procedures below CAUTION The MGD 100 contains sensitive electronic IMPORTANT The testing and or calibration of the unit must be carried out by a qualified technician and must be done in accordance with this manual and in compliance with locally applicable guidelines and regulations Suitably qualified operators of the unit should be aware of the regulations and standards set down by the industry country for the testing or calibration of this unit This manual is only intended as a guide and
35. ted 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 e 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 e lf there is an enclosed machinery section locate a sensor there In the case of units with enclosed compressors mount sensors in the enclosures e Where you have protective or acoustic panels mount the sensor low and under the compressors where it is protected by the panels 16 6109 9000 Rev 4 MGD 100 Manual e 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 ai
36. x cable length restrictions Ld 8d P7 Low P8 High TT M y sq Ensure that connections 1 to 4 LEE A 1234 oneach sensor connect to their TP2 e e e TP2 corresponding numbers on the e TAS de TP1 e terminal block in the main TP1 w HIGH alarm unit otherwise the system will not function e sud correctly and could be Gas Sensor PCB TP3 Vs damaged Gas Sensor PCB ip w D Figure 16 4 amp 6 Sensor Two Alarm Installation 6109 9000 Rev 4 29 MGD 100 Manual Section 5 Operation and Stabilization When power to the unit is switched on the green LED is illuminated and then there is a 3 minute delay before the system activates This allows the sensors to warm up to the correct temperature for gas detection 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 using the key switch until stabilization is complete After the MGD has been installed in accordance with the installation instructions the MGD system is ready to monitor the chosen air space and detect gas leaks Each of the remote sensors has a green light to indicate that power is present To minimize false alarms the system has a built in delay enforced between the arrival time of gas at the sensor unit and the time when the alarm occurs This delay is 20 25 seconds before a low level
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