Bacharach HGM300 Use and care manual

HGM300
Halogen Gas Monitor
Power Supply Replacement
Instruction 3015-5686
Rev. 0 – June 2012
Product Leadership • Training • Service • Reliability

HGM300 Power Supply Replacement
2 P/N 3015-5686 Rev 0
SECTION 1: SCOPE
This document explains how to replace the 120 VAC power supply circuit board of an HGM300
with a new power supply circuit board (P/N 3015-5675).
SECTION 2: PREREQUISITES
Before replacing the power supply circuit board, it is important to:
•review all safety precautions
•understand specification changes (for example, new fuse specifications)
•familiarize yourself with the internal hardware components of the HGM300 and their
locations within the HGM300 enclosure
•gather tools required to perform the replacement.
2.1. SAFETY PRECAUTIONS
Be sure to review all of the safety precautions listed below before performing ANY maintenance
on the HGM300 – including replacing the power supply circuit board.
AC POWER SUPPLY WARNING:
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. It shall be in close
proximity to the equipment and within easy reach of the operator. It shall be
marked as the disconnecting device for the equipment.
PROTECTIVE GROUNDING WARNING:
Under no circumstances should this
equipment be operated without connection to a protective ground.
Failure to
observe this warning p
oses a potential shock hazard and is also a violation of
electrical safety standards applicable to this type of equipment.
WORKING INSIDE THE INSTRUMENT:
Extreme care should be exercised when
accessing the interior of this instrument.
Only qualified electrical maintenance
personnel should perform connections and adjustments. Always de-energize the
power supply before working inside the instrument.
EXPLOSIVE ATMOSPHERE WARNING:
Do not operate this equipment in the
presence of flamm
able liquids, vapors or aerosols. Operation of any electrical
instrument in such an environment constitutes a safety hazard.
EXHAUST VENTING WARNING:
It is imperative that the exhaust port on this
instrument be properly vented as described in this man
ual. Failure to do so
constitutes a safety hazard.

HGM300 Power Supply Replacement
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INSTRUMENT MODIFICATIONS:
Under no circumstances should this instrument be
modified without written consent from Bacharach, Inc. Changes or modifications
to this instrument, not expressly approved, will void the warranty.
IN CASE OF MALFUNCTION:
Do not continue to use this equipment if there are any
symptoms of malfunction or failure. In the case of such occurrence, de-energize
the power supply and contact a qualified repair technician or the nearest
Bacharach Service Center.
WIRE ROUTING WARNING: Only provided knockout(s) are to be used for electrical
and communications wiring. Drilling into the box will void the warranty.
2.2. SPECIFICATION CHANGES
Table 1 summarizes the fuse requirements for old and new power supply boards.For fuse
locations, refer to Figure 1, Figure 2, and Figure 3.
Table 1. HGM300 Fuse Specifications
Power Supply Fuse Description Dimensions P/N
Old Power Supply PCBs
120 VAC Input
(3015-3167)
F1 0.5 A, 250V Fast Acting
5mm x 20mm
0604-2538
F2 250 mA, 250V Fast Acting 0604-2537
F3 5 A, 250V Fast Acting 0604-2539
F4 63 mA, 250V Fast Acting 0604-2535
230 VAC
(3015-3161)
F1 250 mA, 250V Fast Acting
5mm x 20mm
0604-2537
F2 125 mA, 250V Fast Acting 0604-2536
F3 5 A, 250V Fast Acting 0604-2539
F4 32 mA, 250V Fast Acting 0604-2534
New
100-240 VAC
(3015-5675)
F1 2.5 A, 250V Fast Acting 5mm x 20mm 0604-2612
F2 5 A, 250V Fast Acting 0604-2613
Figure 1. Fuse Locations on Old and New HGM300 Power Supply Boards

HGM300 Power Supply Replacement
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2.3. HARDWARE OVERVIEW
Refer to the following illustrations to locate the Power Supply printed circuit board.
Figure 2. HGM300 Interior Components (Showing Old Power Supply PCB)

HGM300 Power Supply Replacement
P/N 3015-5686 Rev 0 5
Figure 3. Comparison of Old Style and New Style Power Supply Boards
NOTE:
Agency approval for the new power supply has changed from UL to MET
Laboratories.

HGM300 Power Supply Replacement
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Figure 4. Comparison of Old Style and New Style Power Wiring and Grounding
2.4. REQUIRED TOOLS
•New Power Supply printed circuit board (P/N 3015-5675)
•HGM300 Operations Manual (P/N 3015-4148)
•Phillips head screwdriver
SECTION 3: PROCEDURE
Step Description
1 Refer to the HGM300 Operations Manual (P/N 3015-4148) originally supplied with your HGM300. It
contains warnings, wiring, and operation information that is supplemental to this replacement
procedure.
2 Remove power that supplies the HGM300. Perform appropriate lock-out/tag-out procedures to ensure
power remains off during the power supply board replacement process.
3 Open the HGM300 enclosure and locate the Power Supply board to be replaced. See Figure 2.
4 Remove all connectors from the Power Supply board, noting their orientation. This includes the two
input power connectors, the power supply connector to the pump, and the two power supply
connectors to the main board.

HGM300 Power Supply Replacement
P/N 3015-5686 Rev 0 7
Step Description
5 Carefully remove the five (5) screws holding the Power Supply board to the back of the enclosure. Two
screws are located at the top of the board, two are at the bottom, and one is in the middle of the
board. Set these screws aside for later installation of the new board.
6 Carefully remove the old Power Supply Board. Dispose of it according to local laws and practices.
7 Carefully install the new Power Supply board by aligning the five holes on the board to the five stand-
offs on the back of the enclosure. Use the five screws you removed in the previous step to secure the
new board to the enclosure. Do not over-tighten the screws.
8 Replace all cables and connectors to their original locations. This includes the two input power
connectors, the power supply connector to the pump, and the two power supply connectors to the
main board. When installing these connectors, do not use excessive force as this could bend the
connector pins and/or damage the connectors.
9 Restore power to the HGM300.
10 Confirm normal operation to ensure that the power supply has been replaced correctly.
WARNING: Drilling holes in the HGM300 enclosure will void the warranty. Please
use knockouts provided for electrical connections. Drilling into the box will void
the warranty.
WARNING: Electrical installation should be performed by a certified electrician and
should comply with all applicable local, state, and federal electrical safety codes.
WARNING:
Under no circumstances should this instrument be operated without
connection to a protective ground. Doing so poses a potential shock hazard and is
also a violation of electrical safety standards applicable to this type of equipment.
∇∇∇

HGM300 Power Supply Replacement
8 P/N 3015-5686 Rev 0
Headquarters:
621 Hunt Valley Circle, New Kensington, PA 15068
Website: www.bacharach-inc.com • E-mail: [e-mail]
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