Page 1
HGM300 / RDM800 Refrigerant Gas Monitoring System Instruction 3015-4148 Installation / Operation / Maintenance Rev. 5 – April 2006 INSPECTION EQUIPMENT MEASURING EQUIPMENT 61KN Product Leadership • Training • Service • Reliability...
Page 2
Product improvements and enhancements are continuous; therefore the specifications and information contained in this document may change without notice. Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.
How to Use This Manual Thank you for investing in a BACHARACH HGM300 Refrigerant Gas Monitor. This manual provides important information on how to install, operate, and service the HGM300 Refrigerant Monitor and RDM800 Display Module. Please read this manual carefully before use.
Ensure the source voltage matches the voltage of the product before energizing the equipment. It is highly suggested that the HGM300 be placed on a separate circuit with UPS or surge protection. • A switch or circuit-breaker shall be included in the building installation •...
Safety Precautions (Cont.) Installation Category Installation Category II, Pollution Degree II, as defined by UL. Altitude Limit 2,000 meters Cleaning USE a dry cloth to clean the outside of the case. DO NOT use soap and water. Warning Statements The use of the word WARNING in this manual denotes a potential hazard associated with the use of this equipment.
System or it may be operated as a stand-alone system using the Bacharach Display Module (P/N 3015-2875). An RS-232C port is also provided for connection to a PC. This enables the HGM300 to be setup from a personal computer. Please refer to the Appendix for a more complete discussion of communication protocols.
Page 8
The HGM300 should be centrally located in the mechanical room and be readily accessible for easy visual monitoring and servicing. Air sample tubing may be run in lengths up to 500 feet. The fresh air purge line should draw from an area that does not contain any refrigerant gas and cannot exceed 300 feet in length. The exhaust line should run to an out side location if possible.
Dirt, grease, and oils can adversely affect the operation of the HGM300. The monitor should be installed out of direct sunlight in a clean, dry area that is not subject to temperature or humidity extremes. Installation of the monitor in a mechanical room is acceptable provided reasonable environmental conditions exist.
HGM300 - Mounting Instructions Screw Locations The HGM300 should be installed plumb and level and securely fastened to a rigid mounting surface. The enclosure utilizes keyhole mounting brackets designed for #12 pan head fasteners. Locate the four screws as shown in the diagram and leave the screw heads protruding approximately 3/16".
HGM300 - Connecting Air Lines Overview Individual sample lines are run from the HGM300 to each area of the facility to be monitored. Additionally, a purge line is installed to provide clean air for resetting the infrared zero baseline. An exhaust line is installed to vent residual gas away from the monitor.
Page 13
Connecting Sample Intake Lines The HGM300 is designed to accommodate up to 16 separate sample intake lines. The standard configuration of the unit includes one manifold of 4 intake connectors and 1 purge connector. Additional manifolds can be easily installed to increase monitoring capacity (field installation kit P/N 3015-3419, and 4 zone line end filter kit P/N 3015-3411).
HGM300 - Interior Schematic Primary Filter Intake Manifold Solenoids Intake Solenoid Connectors Power Supply Board Main Board Microcontroller Board Infrared Optical Bench Gas Sample Pump Primary Filter (P/N 3015-3071) Power Supply Board 120 or 240 VAC Determined by Sales Order...
Page 15
Ground Stud Auxiliary AC Out Connector T2 Alarm 1, 2, 3, Fault (Used to Supply AC power to Alarm Devices) (Overload Protected by Fuse F3) Switches / Fuses HGM300 Fuses (Refer to Maintenance Section for values Page 64) Connects to Aux. AC Out...
Locate service knockouts on exterior of enclosure and install electrical conduit in the typical manner. The HGM300 is available in either a 120 or 240 VAC configuration. The unit’s AC voltage rating is marked on the outside of the enclosure. Do one of the following to connect the AC power leads and ground: •...
Page 17
HGM300 AC Input Power and Ground Connections Instruction 3015-4148...
HGM300 and RDM800 must be connected in the following manner: Locate the RS-485 connector in the HGM300 (Page 7). Connect one lead of a twisted shielded pair to the “B” connection point (the far left point), note the wire color. Connect the second wire to the “A” connection point (the middle), note the wire color.
Page 19
The terminator switch is shipped from the factory in the terminated or “IN” position. This is the correct setting if the HGM300 is connected as a single device, or it is the last device on the network chain. If the HGM300 is being installed in the middle of a network, the terminator must be moved to the “OUT”...
RDM800 to the HGM300’s, but not physically on the HGM300/RDM800 network. NOTE: If the HGM300 is not at the end of the line in a series connection, then the terminator on the HGM must be set to “OUT.” Also, each end of the series must have the terminator set to “IN”.
Programming the HGM300 Using PC Software NOTE 1: There are two versions of PC software. Use Version 1.0 with HGM300 units with v1.0 Unit Firmware, which were built June 2001 or before (as indicated by a serial number that starts with AF01 or lower).
Page 22
To Send a Saved Program to an HGM300 Open the HGM300 PC software; open the proper saved program; connect the PC to the HGM300; and then go to HGM, SEND SETUP and press ENTER. The saved program will be sent to the HGM300.
Page 23
Fault Log, or Diagnostic Screen Open the software while connected to the HGM300. After the software gets the program, open the desired screen. With that screen as the active screen, press the ALT and PRINT SCREEN keys on the PC keyboard.
Loop 2 indicates PPM Connection The external devices are connected to the HGM300 using a shielded dual twisted pair cable. Use any of the remaining service knockouts to gain access to the interior of the monitor. Locate the Dual 4–20 mAdc Output connector (Page 7) and remove it from the circuit board.
HGM300 - Connecting External Alarms Overview Each HGM300 includes 4, Form C, SPDT relay contacts for the connection of external alarm devices. The relays are factory assigned to the following conditions: Relay #1 Leak Relay #2 Spill Relay #3 Evacuate...
Page 26
Typical HGM300 Relay 1 and Relay 2 Wiring LEAK SPILL EVACUATE FAULT Horn Strobe Aux. Power Main AC Input Jumper the ‘Neutral’ of the auxiliary power connector to the ‘Common’ on the relay block. Connect one end of strobe or horn to the ‘NO’ of whichever level of alarm is appropriate for application.
Up to four HGM300 monitors may be connected to a single RDM800. The RDM800 can be located anywhere up to 4500 feet from the furthest HGM300. The display module should be installed out of direct sunlight in a clean area that is not subject to temperature or humidity extremes.
RDM800 - Mounting Instructions Screw Locations The RDM800 should be installed plumb and level and securely fastened to a rigid mounting surface. The enclosure utilizes keyhole mounting brackets designed for #12 pan head fasteners. Locate the four screws as shown in the diagram and leave the screw heads protruding approximately 3/16". RDM800 Mounting Specs Installation Hold the display module flat against the mounting surface and allow it to slide down engaging the screw...
RDM800 - Interior Schematic Microcontroller Board CPU Reset Switch Main Board Ground Stud AC Power Microcontroller Board CPU Reset Switch Power Supply Board 120–230 VAC Input Main Board AC IN Connector T3 Front Panel Chassis Instruction 3015-4148...
Page 31
AC Power RS-485 Connectors Terminator Switches Relay Connector Fuses 1 Amp 250 VAC 3015-4011 Terminator Switches TO MONITORS TO HOST Relay AC IN Connector Connector T3 RS-485 to RS-485 to HGM300 Building Monitors Management System Instruction 3015-4148...
RDM800 - Electrical Wiring It is highly recommended that the RDM800 be connected directly to the AC power source, preferably on its own circuit. The connection should be completed with a UL rated multi-conductor wire (14-18 AWG). Locate service knockouts on exterior of enclosure and install electrical conduit in the typical manner. The RDM800 is available in either a 120 or 230 VAC configuration.
Page 33
RDM800 AC Input Power and Ground Connections Instruction 3015-4148...
RDM800 - Communication Connections HGM300 Network The RDM800 Display Module is connected to the HGM300 network using a shielded twisted pair cable. The maximum distance between the RDM800 and the farthest HGM300 is 4500 feet. Use any of the remaining service knockouts to gain access to the interior of the RDM800. The RS-485 communication wiring between the RDM800 and HGM300 must be connected in the following manner: Locate the RS-485 connector marked “TO MONITORS”...
The terminator switch for the RS-485 “TO MONITORS” connector is shipped from the factory in the terminated or “IN” position. This is the correct setting if the RDM800 is connected to only one HGM300, or if it is the last device on a network chain. If the RDM800 is being installed in the middle of a network, the terminator must be moved to the “OUT”...
RDM800 - Connecting External Alarms Overview Two SPDT relays are available for the connection of external alarm devices. These alarms are useful for alerting the user to global conditions anywhere on the network. Each relay can be programmed to respond to alarm, fault, or ready conditions (refer to Setting Relay Parameters on Page 36).
RDM800 - Overview The RDM800 displays comprehensive information about the HGM300 network status and enables complete programming control of all system operations. The prominent features of the display module are discussed below. Display Screen The display screen is a back-lit LCD.
RDM800 - Screen Displays When first powered up a splash screen appears indicating the serial number and firmware revision number. After a brief moment the System Screen is displayed. Please refer to the Appendix for a logic diagram of all the screen displays.
RDM800 - System Programming Setup Parameters Before working with the HGM300 network, several global parameters must be defined. Most of these are entered in the RDM Setup Screens or via the PC software. Parameters must also be defined for each HGM300 monitor connected to the network.
• Press the SET HGM CLOCKS key to synchronize all HGM300 monitors to the current date/time setting. • Press the QUIT key to reject all edits and revert to the previous setting.
Page 42
3. Press ENTER to accept the new entry or QUIT to revert to the previous setting. NOTE: When first powered up, the RDM800 will automatically detect all HGM300’s on the network with unique node addresses. Refer to HGM Node Address Dip Switch Settings on Page 11.
Page 43
Audible Alarm This parameter selects the function of the RDM800’s internal audible alarm. 1. Press the adjacent key to adjust the setting. 2. Use the UP/DOWN cursor keys to select unused, monitor on, evacuate, spill, leak, fault, or alarm. 3. Press ENTER to accept the new entry or QUIT to revert to the previous setting. Enabling Building Management System Connection This enables or disables the connection to a Building Management System.
Page 44
HGM Node Address This value is the node address from 1 to 15 assigned to each HGM300 which is on the network. These values must match the dip switch settings on each HGM300 circuit board. Refer to HGM Node Address Dip Switch Settings on Page 11.
Navigating to the 1 and then 2 HGM Setup Screen From the System Screen press the key adjacent to the target HGM300 to go to that unit’s HGM Setup Screen #1. HGM Setup Screen #1 From HGM Setup Screen #1 press the SETUP key to go to HGM Setup Screen #2. Press the QUIT key to return to the System Screen.
Page 46
Location This is the name you assign to the HGM300 to identify its location. It may have up to 12 alphanumeric characters. 1. Press the adjacent key to adjust the setting. 2. Use the LEFT/RIGHT cursor keys to move across the entry field and the UP/DOWN cursor keys to modify the individual characters.
Page 47
Loop2 Factor This sets the PPM scale factor for current loop number 2. To calculate the current output, multiply the scale factor by the PPM and add 4. For example, at the default scale factor of 0.016, a measurement of 100ppm would generate a current output of 5.6 mAdc.
Page 48
Navigating to the 3 HGM Setup Screen From HGM Setup Screen #2, press the MORE key to go to HGM Setup Screen #3. Press the BACK key to return to HGM Setup Screen #2. HGM Setup Screen #3 Service Timeout Sets the length of time the Service Mode is in effect.
Distance This is the tubing length in feet from the HGM300 to the termination of the air intake line. This value may range from 0 to 500 feet. The default value is 100 feet. Setting this value to “0” causes the zone to be bypassed during normal operation, and the word “DISABLED”...
Page 50
Average Temperature This temperature reading may be changed to the exact temperature at the sample point for greater accuracy. The adjustment range is from –50 to +70 degrees C. 1. Press the AVG TEMP key to adjust the temperature value. 2.
Page 51
Spill Level This is the concentration level in PPM that will activate a spill alarm condition. 1. Press the adjacent key to adjust the value. 2. Use the UP/DOWN cursor keys to modify the setting. 3. Press ENTER to accept the new entry or QUIT to revert to the previous setting. NOTE: This value must be less than the evacuate level and greater than the leak level.
The RDM800 operates by polling the network approximately once every 12 seconds to determine the current status of the HGM300 monitors. If more than one HGM300 is connected to the network, it will sequentially poll each monitor for its status. As a practical matter this simply means that the more complicated the network, the longer it will take the RDM800 to update the status information for all zones.
Page 53
Zone Hold Mode A zone can be placed on hold and continuously monitored for a length of time determined by the Zone Hold Time value (Page 38). To place a zone on hold, press and hold down the key adjacent to that zone until you hear a beep.
Page 54
If the current Zone Screen appears normal, scroll through the displays using the NEXT/BACK keys or the UP/DOWN cursor keys until you locate the affected zone. You can further investigate the status of the affected zone by pressing the adjacent key and going to that Zone’s Setup Screen #1 (Page 41). You may also press the ALARMS key to go directly to the Alarm Summary Screen (Page 50).
Page 55
Working with the System Screen The System Screen provides a summary view of the entire HGM300 network. The boxes on the left side of the screen indicate the status of each HGM300 monitor including the name, the current zone, and whether fault or alarm conditions are present on the network.
Page 56
Alarm Log From the System Screen press the key adjacent to the HGM300 unit that you wish to view. HGM Setup #1 Screen Press the ALARM EVENT LOG key to display the Alarm Log Screen. Alarm Log Screen Use the LEFT/RIGHT and UP/DOWN cursor keys to move through the log.
Page 57
Fault Conditions If a system malfunction occurs, the yellow FAULT LED will glow. Additionally, an external alarm device may activate and an audible alarm may sound if those features have been enabled (Pages 28 & 35). The FAULTS box on the right of the screen will blink and then counts the number of HGM units on the system with a fault.
Once the HGM300 completes a measurement cycle in the affected zone the alarm condition will be indicated. At that time the red ALARM LED on the HGM300 will glow. Additionally, an external alarm device may activate and an audible alarm may sound if those features have been enabled (Pages 17 & 38).
Page 59
Alarm Detail Screen To further investigate an alarm, press the adjacent key to go to the Alarm Detail Screen. Alarm Detail Screen The Alarm Detail Screen displays more comprehensive information about the nature of the alarm including: • Complete location information •...
Page 60
Repeat this procedure to acknowledge any remaining alarms. Alarm Summary Screen (Acknowledge Mode) Once all the alarms associated with a given HGM300 are acknowledged, its RED LED will turn off and any external alarms connected to the HGM300 relays will de-activate. All pending alarms across the entire network must be acknowledged before the RDM800 returns to normal operation.
Overview - Log Interval The HGM300 retains a data log of 100 measurements for each zone. The log interval is the number of minutes from 1 to 1440 between each log point. This parameter can be changed from Zone Setup Screen #1 (Page 41).
Working with System Faults Functional Overview If a system malfunction occurs, the HGM300 will detect the problem and cause its yellow FAULT LED to glow. Additionally, an external alarm device may activate and an audible alarm may sound if those features have been enabled (Pages 17 &...
Page 63
Screen will display a “NO FLOW” message in each individual zone affected. Check for a blockage in the air sample line or at the line end filter. Once the blockage has been cleared, the HGM300 will return to normal operation after the zone has been sampled. NOTE: This can take some several minutes since it is dependent upon how many zones there are and their lengths.
Page 64
Clearing System Faults If the fault condition is associated with an HGM300, the monitor will return to normal operation soon after the problem is corrected. At that time the YELLOW LED will turn off and any external alarms connected to the monitor’s alarm relays will also turn off.
Navigating to the Calibration Screen Display the System Screen (Page 31); press the key adjacent to the target HGM300 unit to go to that monitor’s HGM Setup Screen #1 (Page 37); and then press the CAL key to go to the selected monitor’s Calibration Screen.
Page 66
(Page 45). Connect the sample bag directly to the intake port for the zone you have set up and allow the HGM300 to sample the entire bag. When sampling is complete, view the trend data for the zone used to sample (Page 53).
Page 67
Programming New Gasses As new refrigerants come into use the HGM300 allows the addition of these new gases to its on-board refrigerant gas library. At the end of the gas library list are five place-holders for adding new gases. They are labeled “NEW GAS1 –...
Navigating to the Diagnostic Screen Display the System Screen (Page 31); press the key adjacent to the target HGM300 unit to go to that monitor’s HGM Setup Screen #1 (Page 37); and then press the DIAG key to go to the selected monitor’s Diagnostic Screen.
Page 69
LINE 7: PPM – Parts Per Million is the volume concentration referenced to standard temperature and pressure and is computed from lines 5, 8 and 13. There are two figures given. The first (annotated by a B) is the actual PPM at the IR bench. The second is a PPM reading normalized to standard temperature and pressure.
Service Mode When activated, the Service Mode will disable a specific HGM300 unit for a specified length of time. The default is 60 minutes. This time interval can be changed as described under the heading Service Timeout on Page 40.
Charcoal Filter Locate and replace the purge line charcoal filter (P/N 3015-3125). NOTE: Bacharach offers an annual maintenance kit containing one primary filter and one charcoal filter as P/N 3015-3423. Servicing Air Lines System air lines (P/N 3015-3235) should be checked periodically for obvious signs of kinks, damage, and contamination.
HGM300. The interface board plugs into the socket provided on the main circuit board, and the external devices are then cabled to the HGM300 as described earlier in this manual.
RS-485 Communication Protocol Overview The following instructions are intended as a guide for integrating the HGM300 network into a Building Management System. If you are unfamiliar with complex systems of this type, it is recommended that you contact Bacharach for technical assistance.
(NOTE: This document will assume that the reader is familiar with the various parameters used to setup the HGM300, as well as the different operational modes that the HGM300 may be placed in. If you are unfamiliar with this information, please reference the HGM300 operations manual.) Protocol Details A 2 wire RS-485 bus is used for transmission, therefore communication occurs in a Half-Duplex mode.
HGM300s may be connected directly to the MODBUS network or they may be connected to the network through an RDM800. In either case, each HGM300 must have a unique node ID. Up to 15 HGM300s can be connected directly to the MODBUS network.
Page 79
0x001Ch Release HGM300 from service mode 0x001Eh PPM values for all zones Zone Log 0x3yxxh Trend data for each HGM300 zone (y = zone number (starting at 0), xx = 00 – 06)Data Data Type Abbreviations Character Float Floating Point...
Page 80
13 bytes Array defining text name of unit Stop_Bits 1 byte Number of stop bits used in the HGM300 data stream. Default = 1. Other available value is 2 Aud_Alarm 1 byte Sounds internal board buzzer on condition; 0 = no buzzer;...
Page 81
Status Register Register 0x0011h R/W 10 bytes Variable Type Length Description Mode 1 byte Defines Operating Mode of HGM-300. 0 = normal Mode; 1 = Zone_Hold Mode; 2 = Diagnostic Mode; 3 = Service mode. DO NOT MODIFY (use zone hold register or service mode register to change this parameter) State 1 byte...
Page 82
Register 0x12xxh R/W 78 bytes Each zone for an HGM300 has a separate Zone data structure that is 78 bytes long. The zone number is the low order byte in the register address (i.e., Zone 1 data register = 0x1201h)
Page 83
For purposes of this discussion, the term “Alarm” refers to a HGM300 state where the alarm light is on and the appropriate alarm relay is activated. The term “Alarm condition” refers to the external condition (i.e., refrigerant leak) that initially causes the HGM300 to go into an alarm.
Page 84
It is strongly recommended that any New Gas curves that are added be done in conjunction with help from Bacharach, Inc. Date Time Register...
Page 85
Sensor Data Register Register 0x0016h R 82 bytes Variable Type Length Description Pressure Float Manifold Pressure is PSIA P_Volts Float Pressure sensor output Voltage Vacuum_P Float Pressure with all value closed and pump on in PSIA Ambient_P Float Absolute Ambient Pressure in PSIA Box_T Float Enclosure Temperature in Degrees C...
Page 86
The HGM-300 can be made to hold or “dwell” on a particular zone if necessary. The length of the hold time is defined by the HOLD TIME parameter in the System Data Register. In order to place the HGM300 into hold mode use the following sequence: •...
Page 87
Fault Log Register Register 0x1900, 0x1901h 302 bytes These registers contain the 20 most recent fault events, the time they occurred, and a pointer to the most recent event. The data is split into 2 registers. The first register contains 200 bytes and the second register contains 102 bytes.
Page 88
The unit automatically comes out of service mode after a preset interval defined by the service_mode_TO parameter in the System Data Register. In order to place the HGM300 into service mode use the following sequence: •...
Page 89
The following MODBUS exception response are supported by the HGM300: Illegal Function Illegal Data Address Slave Device Busy (Occurs only when HGM300 is connected to the bus through an RDM800 and the RDM800 is not in the SYSTEM or ZONE VIEW screen) Instruction 3015-4148...
Service Pursuant to the stated warranty, Bacharach, Inc. warrants the products to be free of manufacturers defect for two (2) years from the date of shipment or installation and will replace any part free of charge during that period. Labor beyond ninety (90) days of shipment or installation is subject to charge. FAILURE TO LOCATE THE AGM300 OR ADM800 IN A LOCATION COMPATIBLE WITH THE CRITERIA SET FORTH IN THIS MANUAL CONSTITUTE ABUSE OF THE EQUIPMENT AND MAY VOID THE WARRANTY.
Page 91
United States. The Bacharach, Inc. is not liable for any charges, from the customer, purchaser or any third party that may be acting on the behalf of the purchaser, customer or end user, resulting from non-warranty field service, field upgrades, preventative maintenance, etc.
HGM300 - Specifications Product Type: Multiple refrigerant gas and multiple area monitoring system for low level continuous monitoring of CFC, HCFC and HFC refrigerant gasses used in most commercial refrigeration systems. System design supports compliance to the refrigerant monitoring requirements of ANS/BSR ASHRE 15-1994.
ANS/BSR ASHRE 15-1994. Inputs: The RDM800 accepts inputs from up to four HGM300 monitors. It offers a wide variety of displays and can fully program any associated monitor. Display: Back lit LCD.
Page 94
Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ® Registered Trademark of Bacharach Inc.
Need help?
Do you have a question about the HGM300 and is the answer not in the manual?
Questions and answers