Bacharach HGM300 Guide

HGM300 / RDM800
Refrigerant Monitoring System
Instruction 3015-4149
Installation & Operation Mini Manual
Rev. 8 – April 2006
SECTION 1 (Page 2) Introduction, standard accessories and mounting specifications
SECTION 2 (Page3) Suggested location of HGM300/RDM800 and pickup points
SECTION 3 (Page 4) HGM300/RDM800 component locations
SECTION 4 (Page6) Basic HGM300/RDM800 monitor system connections
SECTION 5 (Page 10) Multiple HGM connections
SECTION 6 (Page 12) Powering up the monitoring system
SECTION 7 (Page 13) Programming the HGM300 using the RDM800
SECTION 8 (Page 15) Programming the HGM300 using PC software
SECTION 9 (Page 17) Responding to alarms
SECTION 10 (Page 19) Log interval and trend screen
SECTION 11 (Page 20) Working with the fault and fault log screens, and
resetting to factory default settings
SECTION 12 (Page 22) Working with the diagnostic screen.
SECTION 13 (Page 24) Whom to contact.

2Instruction 3015-4149
SECTION 1
Introduction
Welcome – This mini manual is an introduction to the installation and operation of the HGM300/RDM800
refrigerant monitoring system. For detailed installation / operation / maintenance information, please refer
to Instruction 3015-4148.
As you open the shipping carton locate the following items:
•HGM300 – Manufactured to your order specifications, that is, number of zones, AC input voltage,
and dual 4–20ma DC option (if ordered)
•RDM800 – Remote Display Module (if ordered)
•Charcoal filter with “T” bolt bracket; line end filter assembly (Quantity dependant on number of
zones ordered – for 4 zones, 5 filters; for 8 zones, 9 filters; 12 zones, 13 filters; and for 16 zones,
17 filters. Do not use a filter on the exhaust line)
•Instruction manuals 3015-4148 and 3015-4149
•Optional items – Audio/Visual alarms, visual alarm, audio alarm, air sample tubing, etc. as
ordered.
Proper Mounting of the HGM300 and RDM800
HGM300 Mounting Specs RDM800 Mounting Specs

Instruction 3015-4149 3
SECTION 2
HGM300 / RDM800 Refrigerant Gas Leak Monitor
Mechanical Room Placement
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 outside location if possible.
The length of the exhaust line cannot exceed 300 feet.
Ideally, two to three pick up points spaced around each chiller will provide sufficient coverage. It may be
necessary to perform a “smoke” test of the mechanical room to determine the best locations. The smoke
test would provide the pattern of air currents present in the mechanical room.
The RDM800 should be mounted outside of the mechanical room, or at least just inside of a door to the
room. This is the “split architecture design” for safety of the operator. The RDM800 can be located up to
4500 feet from the HGM300. The RDM800 is the man-machine interface by which an operator programs
the HGM300, acknowledges alarms, and observes conditions inside of the mechanical room. Note that
there are two additional alarm relay contacts in the RDM800 that can be programmed to alarm with leak,
spill, evacuate, fault, or monitor on.
RDM800
Remote Display
Module outside of
mechanical room
HGM300
Halogen
Gas
Monitor
Outside Hallway
Machine Room
Sample Inlet Pickup Points
Chiller
Exhaust Fan
Sample Inlet
Pickup Point
Fresh air purge
from area away
from refrigerant
gas
Aux. Horn/Strobe
Remote Alarm

4Instruction 3015-4149
SECTION 3
HGM300 Components
Dual 4-20 mAdc
Outputs
(Signal Out Only)
DO NOT APPLY
POWER!
RS-485
Connector
Terminator
Switch
4–20 mAdc
Interface Board
(Optional)
Factory Default
Switch
Relay Connector
Leak, Spill, Evac, Fault
Ground
Stud
AC IN
Connector
T1
Location of
AC Input
Line Filter
(230 VAC
Units Only)
AC Power
ON/OFF
Switch
Node
Address
Switches
Auxiliary AC Power Out Connector T2
(Used to Supply AC power to Alarm Devices)

Instruction 3015-4149 5
RDM800 Components
Terminator
Switches
RS-485 to
HGM300
Monitors
RS-485 to
Building
Management
S
y
stem
Relay
Connector
AC IN
Connector T3

6Instruction 3015-4149
SECTION 4
Basic HGM300/RDM800 Monitor System Connections
Most applications for the HGM300/RDM800 monitor system will consist of a single HGM300 and a single
RDM800. The HGM300 should be mounted in the mechanical room and the RDM800 should be located
in a control room, on an outside wall of the mechanical room or at least, just inside the door to the
mechanical room.
Connect 120 or 230 VAC power (voltage dependent on sales order) to the HGM300 as follows:
•120 VAC Installations – Connect power to the two-lead AC IN power connector on the far right
bottom of the power supply PC board. Make the ground connection to the Ground Stud located
just below the power connector. IMPORTANT: The AC input ground wire (green) must be on the
bottom of the Ground Stud to meet agency approval.
•230 VAC Installations – Connect power to the AC Input Line Filter mounted below the Power
Supply board. Make the ground connection to the Ground Stud located just below the power
connector. IMPORTANT: The AC input ground wire (green) must be on the bottom of the Ground
Stud to meet agency approval.
Auxiliary power to supply 120 or 230 VAC to the external alarms is available from the second two-lead
connector located to the left of the main power connector. Connect any alarms required to the four-relay
connector marked “LEAK, SPILL and EVAC”. Connect the “SYSTEM FAULT” relay if used.
The dual 4-20mAdc output connector is located on the left side of the HGM300 main PC board. This is a
SIGNAL OUT ONLY function. Both loops must be wired if this option is installed. If only one loop is used,
the unused loop must have a jumper wire installed.
Connect 120–230 VAC power to the RDM800 by removing the four screws holding the front panel to the
RDM800 chassis. Turn the front panel over and perform one of the following:
•120 VAC Installations – Connect power to the two-lead connector on the far right bottom of the
PC board. Make the ground connection to the Ground Stud provided on the chassis.
IMPORTANT: The AC input ground wire (green) must be on the bottom of the Ground Stud to
meet agency approval.
•230 VAC Installations – Connect power to the AC Input Line Filter located on the chassis. Make
the ground connection to the Ground Stud provided on the chassis. IMPORTANT: The AC input
ground wire (green) must be on the bottom of the Ground Stud to meet agency approval.
Connect any alarms to the two-relay connector located on the bottom center of the RDM800 PC board.
The RS-485 communication wiring between the HGM300 and RDM800 must be connected in the
following manner:
Locate the RS-485 connector marked “TO MONITOR” on the RDM800. This connector should be on
the far-left bottom of the RDM800 PC board. 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. Connect the ground to the “GND” connection point.
Make the wire run to the HGM300 and connect the twisted shielded pair to the HGM300 RS-485
connector using the same color code as used on the RDM800.
NOTE: With a basic system consisting of a single HGM300 and a single RDM800 the position of the
“Terminator” switches is not critical.

Instruction 3015-4149 7
HGM300 WIRING SCHEMATIC
GND
L N
MAIN
PWR
L N
AUX
PWR
MAIN
PWR
BKR
1C NO NC 2C NO NC 3C NO NC 4C NO NC
LEAK SPILL EVACUATE FAULT
ALARM RELAYS 5 AMP, 240 VDC
B A GND
RS-485
OPTIONAL
DUAL LOOP
4-20 mADC
COMMON
COMMON
LOOP 1 ZONE
LOOP 2 PPM
SPECIAL NOTE: TO ESTABLISH THE RS-485 COMMUNICATION LINK WITH THE RDM800 OR WITH A BUILDING
MANAGEMENT SYSTEM, USE #18 GAGE AWG, MULTI-STRANDED, SHIELDED AND TWISTED PAIR, INSTRUMENT
CABLE. ENSURE THAT THE DRAIN WIRE IS CONNECTED TO THE GND TERMINAL AT BOTH ENDS.

8Instruction 3015-4149
RDM800 WIRING SCHEMATIC
L N
MAIN
PWR
C NO NC C NO NC
AUXILIARY ALARM RELAYS
5 AMP, 240 VAC
USER DEFINABLE
RS-485
TO
HOST
SPECIAL NOTE: TO ESTABLISH THE RS-485 COMMUNICATION LINK WITH THE RDM800 OR WITH A BUILDING
MANAGEMENT SYSTEM, USE #18 GAGE AWG, MULTI-STRANDED, SHIELDED AND TWISTED PAIR,
INSTRUMENT CABLE. INSURE THE DRAIN WIRE IS CONNECTED TO THE GND TERMINAL AT BOTH ENDS.
RS-485
TO
MONITORS
B A GND
GND
B A GND

Instruction 3015-4149 9
Typical HGM300 Relay 1 and Relay 2 Wiring
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.
The other end of strobe or horn is connected to the ‘Line’ of the auxiliary power connector (5 A max.).
Aux. Power
LEAK SPILL EVACUATE FAULT
Line Neutral
Line Neutral
Horn
Strobe
Main AC Input

10 Instruction 3015-4149
SECTION 5
Multiple HGM’S
MULTIPLE HGM300’S WITH RDM800
NOTE 1: The last HGM300 or RDM800 on either end of the network must have its
terminator in the “IN” position, and all other units must have their terminators in the
“OUT” position.
NOTE 2: The total length of the RS-485 cable cannot exceed 4500 feet. (Use
instrument cable 20 gage multi-strand shielded and twisted pair – similar or equal to
Belden cable #8762.)
RS-485 CONNECTIONS BETWEEN HGM300’s
NOTE: The terminators in the RDM800 and HGM300 Unit 4 must be in the “IN”
position. The terminators in HGM300 Units 1, 2 & 3 must be in the “OUT” position.
TERMINATOR TERMINATOR TERMINATOR TERMINATOR
“OUT” “OUT” “OUT” “IN”
Connecting To A Building Management System
The HGM300 may be connected to a Building Management System via the RS-485 connector. The node
address switch on each HGM300 can be set from “1” to “15” in order to identify itself to the Building
Management System. Note that Building Management Systems set to a “0” or “1” address both respond
to messages from the RDM800 as address “1” therefore you should not have a unit set to “0” and another
set to “1” on the same network.
If the HGM300 network is connected directly to a Building Management System it may not be connected
to the RDM800. However, the RDM800 has two communication ports, an “upstream” port (labeled TO
HOST) and a “downstream port (labeled TO MONITORS). A BMS node may be connected to the up
stream RDM800 port while the downstream RDM800 port talks to the HGM300’s. In this case, the BMS is
talking “through” the 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”.
TERMINATOR
“OUT”
TERMINATOR TERMINATOR TERMINATOR TERMINATOR
“IN” “OUT” “OUT” “IN”
HGM300
NODE 1
HGM300
NODE 2
HGM300
NODE 3
HGM300
NODE 4
BMS
TERMINATOR
“IN”
RMD800
HGM300
UNIT 2
NODE 2
HGM300
UNIT 3
NODE 3
HGM300
UNIT 4
NODE 4
HGM300
UNIT 1
NODE 1
RS-485