Danfoss HGM-400 User guide

User manual

Monitor a wide variety of refrigerants with your Multi-zone gas monitor

Easily programmed to monitor a variety of gases and independent leak, the evacuation levels may be designated for each zone

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User manual | HGM-400 - Multi-zone gas monitor

Index

1.0	Introduction			6
	1.1	About this manual		6
	1.2	Warning and caution conventions		6
	1.3	Safety precautions		6
	1.4	Key external hardware components		8
	1.5	Functional overview		9
		1.5.1	General description	9
		1.5.2	Communications options	9
		1.5.3	Understanding monitoring levels	9
		1.5.4	Response to the presence of multiple refrigerants (HGM Only)	9
		1.5.5	Suggested location of sampling points	10
		1.5.6	Locating a remote display (optional)	11
	1.6	Specifications		12
2.0	Installation			14
	2.1	Installation considerations		14
		2.1.1	Warnings and cautions	14
		2.1.2	Inspection	14
		2.1.3	Location of the monitor	14
		2.1.4	Mounting instructions	15
	2.2	Connecting gas sample lines		16
		2.2.1	Overview	16
		2.2.2	Tubing considerations	16
		2.2.3	Connecting purge line	17
		2.2.4	Connecting exhaust Line	17
		2.2.5	Connecting sample intake lines	17
		2.2.6	Installing an optional splitter kit	18
		2.2.7	Connecting the water trap	18
	2.3	Interior components		19
	2.4	Electrical wiring		19
	2.5	Connecting communications devices		20
		2.5.1	Remote display module (RD) connection	20
		2.5.2	Integrating with building management systems	21
		2.5.3	Larger integrated systems	21
		2.5.4	Changing terminator switch settings	22
		2.5.5	Personal computer	22
	2.6	Terminating multiple monitors		23
	2.7	Connecting to a building management system		23
	2.8	PC software		24
		2.8.1	Operation	24
		2.8.2	Saving and sending programs	25
		2.8.3	Trend data	25
		2.8.4	Converting the TREND text tile to an Excel file	26
		2.8.5	Saving and printing screens and logs	26
		2.8.6	USB type laptops	26
	2.9	Optional current loop interfaces		26
		2.9.1	Optional 4-20 mA DC outputs	26
		2.9.2	4-20 mA DC connections	27
	2.10	Connecting external alarms		29
		2.10.1	Overview	29
		2.10.2	Connection	29
3.0	Setup programming			31

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	3.1	Initial power up		31
	3.2	Data display screen		31
	3.3	Navigating to the 1st setup screen		31
	3.4	Navigating to the 2nd setup screen		32
		3.4.1	Location	32
		3.4.2	Number of zones installed	32
		3.4.3	Alarm acknowledge mode	32
		3.4.4	Audible alarm	33
		3.4.5	Zone hold	33
		3.4.6	Detection limit	33
		3.4.7	Loop mode	33
		3.4.8	Loop2 factor	34
		3.4.9	Re-zero mode	34
	3.5	Navigating to the 3rd setup screen		34
		3.5.1	Overview	34
		3.5.2	Baud rate	35
		3.5.3	Node address	35
		3.5.4	Password	35
	3.6	Additional service features		35
		3.6.1	Service timeout	36
		3.6.2	DET digipot	36
		3.6.3	Node address	36
		3.6.4	Sensor temperature coefficient (for factory use only)	36
		3.6.5	Password	37
		3.6.6	Acquiring temperature coefficient (for factory use only)	37
		3.6.7	IR digipot	37
	3.7	Establishing the CO2 sensor baseline		37
4.0	General operation			38
	4.1	Functional overview		38
	4.2	The zone setup screen		38
		4.2.1	Location	38
		4.2.2	Gas/refrigerant type	38
		4.2.3	Distance + EXH	39
		4.2.4	Temp @ zone	39
		4.2.5	Current detection reading	39
		4.2.6	Log interval	39
	4.3	Navigating to the 2nd zone setup screen		39
		4.3.1	Leak level	40
		4.3.2	Spill level	40
		4.3.3	Evacuation level	40
		4.3.4	Re-setting the peak PPM value	40
	4.4	Alarms		40
		4.4.1	Functional overview	40
		4.4.2	Responding to alarms	41
		4.4.3	Alarm detail screen	41
		4.4.4	Acknowledging alarms	42
		4.4.5	Silencing an alarm	42
		4.4.6	Clearing the alarm event log	43

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	4.5	System faults		43
		4.5.1	Functional overview	43
		4.5.2	Navigating to the fault screen	44
		4.5.3	Critical faults	44
		4.5.4	Reset to factory default settings	45
		4.5.5	Clearing system faults	46
		4.5.6	Viewing fault log	46
		4.5.7	Viewing flow log	47
	4.6	The trend screen		47
		4.6.1	Navigating to the trend screen	47
	4.7	The calibration screen		48
		4.7.1	Overview	48
		4.7.2	Navigating to the calibration screen	48
		4.7.3	Calibration procedure (HGM and AGM only)	48
		4.7.4	Adjusting calibration factor (HGM and AGM only)	49
		4.7.5	CO2 atmospheric concentration	49
		4.7.6	Programming new gases (HGM only)	50
	4.8	Zone hold mode		51
	4.9	The diagnostic screen		51
		4.9.1	Navigating to the diagnostic screen	51
		4.9.2	Diagnostic screen overview	52
5.0	Maintenance			53
	5.1	Troubleshooting		53
6.0	APPENDIX A			55
7.0	APPENDIX B			56
	7.1	Overview		56
	7.2	MODbus RTU Protocol		56
	7.3	Multi-zone MODbus RTU operation		56
		7.3.1	Overview	56
		7.3.2	Protocol details	56
		7.3.3	Multi-zone monitor polling	57
		7.3.4	Network topologies	57
		7.3.5	Key comm protocol parameters	58
		7.3.6	Summary of registers	58
		7.3.7	System data register 0x0010 (16 Dec) (R/W, 54 Bytes)	59
		7.3.8	Status register 0x011 (17 Dec) (R/W, 10 Bytes)	60
		7.3.9	Fault code table	60
		7.3.10	Zone data register 0x12xx (R/W, 78 Bytes)	61
		7.3.11	Alarms and alarm acknowledge	62
		7.3.12	Date time register 0x0015 (21 Dec) (R/W, 14 Bytes)	63
		7.3.13	Sensor data register 0x0016h (22 Dec) (R, 82 Bytes)	63
		7.3.14	Release zone hold register 0x0017h (23 Dec) (W, 10 Bytes)	64
		7.3.15	Hold zone register 0x0018h (23 Dec) (W, 10 Bytes)	64
		7.3.16	Multi-zone hold mode	64
		7.3.17	Fault log register 0x1900-01 (6400-6401 Dec) (R, 302 Bytes)	64
		7.3.18	Flow log register 0x001F (31 Dec) (R, 142 Bytes)	65
		7.3.19	Alarm log register 0x1A00-02 (6656-58 Dec) (R, 582 Bytes)	65
		7.3.20	Service mode register 0x001B (27 Dec) (W, 10 Bytes)	65
		7.3.21	Release service mode 0x001C (28 Dec) (W, 10 Bytes)	65
		7.3.22	Multi-zone service mode	66
		7.3.23	PPM register 0x001E (30 Dec) (R, 32 Bytes)	66
		7.3.24	Zone log registers 0x3xyy (R, 1502 Bytes)	66
		7.3.25	MODbus exception responses	67
		7.3.26	MODbus gas enumeration	67

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8.0	APPENDIX C	68
9.0	Replacement parts & optional accessories	70

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1.0Introduction

1.1About this manual

To assure operator safety and the proper use of the monitor please read this manual.

It provides important information on the installation, operation, maintenance, and servicing of the monitor and display module.

If you have a working knowledge of your gas monitor, you will find this manual useful as a reference tool. If you are new to the use of gas monitors, this document is educational in the principles of gas detection and the proper operation of this device.

1.2Warning and caution conventions

When used in this manual or as labeled on the gas monitor, the following hazard symbols and/or associated words are defined as follows.

WARNING: this symbol and/or the use of the word WARNING indicates a potential ! hazard associated with the use of this equipment. It calls attention to a procedure,

practice, condition, or the like, which if not correctly performed or adhered to, could result in death or serious injury

WARNING: this symbol and/or the use of the word WARNING indicates a potential

! hazard from electrical shock. It calls attention to a procedure, practice, condition, or the like, which if not correctly performed or adhered to, could result in death or serious injury

CAUTION: this symbol and/or the use of the word CAUTION indicates a potential hazard associated with the use of this equipment. It calls attention to a procedure, practice, condition, or the like, which if not correctly performed or adhered to, could result in minor or moderate injury

IMPORTANT: the use of the word IMPORTANT in this manual calls attention to a procedure, practice, condition, or the like, which if not correctly performed or adhered to, could result in incorrect performance of or damage to the equipment and may void the warranty

1.3Safety precautions

WARNING: this instrument has not been designed to be intrinsically safe for use in areas ! classified as hazardous locations. For your safety, DO NOT use it in hazardous (classified)

locations

WARNING: this is NOT a safety device. Some gases which this instrument can detect may be combustible/flammable. When properly configured, this instrument is designed to

! alarm at concentrations that are lower than the explosive limit of the gas. As such, it is the buyer’s responsibility to initiate an immediate planned response to any gas leaks as soon as they are detected. This equipment should NEVER be used to measure or sample gases at or above their respective lower explosive limits

IMPORTANT: the gas monitor uses a universal power supply that is capable of accepting inputs of 100 to 240VAC, 50/60Hz. The monitor’s power consumption is 20Watts.

It is highly recommended that the monitor be connected directly to the AC power source, preferably on its own circuit with UPS or surge protection

WARNING: A switch or circuit breaker must be included in the building installation. ! The switch must be in close proximity to the monitor and within easy reach of the

operator.

The switch must be clearly marked as the disconnecting device for the equipment

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WARNING: under no circumstances should the monitor 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

WARNING: do not operate this equipment in the presence of flammable liquids, vapors, or aerosols. Operation of any electrical instrument in such an environment constitutes a safety hazard

WARNING: it is imperative that the exhaust port on this instrument be properly vented as described in this manual. Failure to do so may constitute a safety hazard

WARNING: extreme care should be exercised when accessing the interior of the monitor. Only qualified electrical maintenance personnel should make connections and perform adjustments. Always remove AC power before opening the monitor’s enclosure

WARNING: the protection provided by the monitor may be impaired if the monitor is used in a manner not specified by Danfoss. Modifications to this monitor, not expressly approved, will void the warranty

WARNING: 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 Danfoss Service Center.

WARNING: this device uses type "F" fuses ("F1" and "F2") rated at 1.0A, 250VAC.

Replace ONLY with Danfoss-approved fuses

WARNING: electrical installation should be performed by a certified electrician, and must comply with all applicable NEC/CEC and local electrical safety codes

IMPORTANT: use ONLY the provided knockouts for electrical and communications wiring. Drilling into the box will void the warranty

IMPORTANT: this device is classified as Installation Category II, Pollution Degree II, as defined by UL

IMPORTANT: this device is designed for operation at or below an altitude of 6.562ft (2,000 m). Do not operate this device above this altitude limit

NOTE: to clean the outside of the case use a dry cloth. To avoid shock hazard and/or equipment damage, DO NOT use soap and water

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1.4Key external hardware components

Product label showing	Enclosure knockout
gas type (halogen shown)

Display screen

					Alarm
					LED (red)
Solenoid					System fault
					LED (yellow)
connections
(1 bank of					Power
4 shown)
					LED (green)
Purge port					Keypad
Exhaust port
		Enclosure door

NOTE: mounting cutouts are located on the back of the monitor, and are visible from inside the Multi-zone monitor. A mounting template is also shipped with the monitor. For mounting information, (see 2.1.4 "Mounting instruction")

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1.5Functional overview

1.5.1General description

Gas monitors are specified to support compliance to federal, state and local safety codes governing emissions. Avoiding significant loss reduces equipment replacement costs, maintains equipment efficiency, promotes safety, and protects the environment.

The Danfoss Multi-zone monitor provides continuous monitoring of gas levels in up to 16 separate test zones. The instrument is easily programmed to monitor a variety of gases (dependent on particular model) and independent leak (small), spill (medium), and evacuation (large) levels may be designated for each zone. The instrument also retains a log of previous readings that can be easily accessed for analysis.

An audible alarm and front panel indicators are provided to signal alarm and fault conditions, and relay contacts are provided that can be used to trigger external alarm devices in the event of a system fault, or if a leak (small), spill (medium), or evacuation (large) level of gas is detected. The system also may be fitted with and optional two-channel 4-20mA current loop board for connection to remote monitoring equipment.

The Multi-zone monitor requires only minor periodic maintenance such as the occasional replacement of filters. The monitor incorporates active diagnostics that continuously check the system for proper operation. A front panel indicator is provided to alert an operator of system malfunctions, and fault codes are generated that enable the user to identify the cause of the fault.

1.5.2Communications options

The Multi-zone monitor features full two-way communications via an RS-485 interface. MODbus RTU is the communications protocol standard. The instrument can be connected directly to a Building Management System or it may be operated as a stand-alone system.

An RS-232C port is also provided for connection to a PC. This enables the monitor to be setup from a personal computer. (See 7.0 "Appendix B").

1.5.3Understanding monitoring levels

Effective use of this instrument requires an understanding of what constitutes reasonable alarm set points for the types of gas being monitored. Manufacturers define allowable exposure levels and threshold limit values in units of parts per million (ppm). In a good "tight" installation these background levels will be acceptably low and often do not require corrective action. You can reduce nuisance alarms and needless service calls if the alarm levels are set at practical limits. Danfoss has developed recommended monitoring refrigerant gas levels based on compliance to ANSI/BSR ASHRAE 15-2007 and ASHRAE Safety Code 34-2007. (See 6.0 "Appendix A").

Setting the monitor at these recommended alarm levels will satisfy the needs of most users. However, the ppm levels generated by system leaks into the environment are greatly influenced by the volume of air in the sampling area, air circulation, size of the leak, distance to the monitoring point, and a host of other variables. In some cases the set points may need to be adjusted either up or down to achieve effective monitoring.

1.5.4Response to the presence of multiple refrigerants (HGM Only)

The HGM-400 multi-zone is a refrigerant level monitor, not a gas analyzer. You must program the monitor to test for a specific refrigerant, and it will only return accurate concentration readings for that particular refrigerant. If a leak occurs of another refrigerant gas type, the monitor may return incorrect readings.

Most applications only require detection of a single refrigerant and the problems that are associated with monitoring multiple gases are rarely an issue. If there is a possibility of multiple refrigerants leaking in the same sampling zone, then you should carefully consider which refrigerant compound you program the unit to monitor.

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1.5.5Suggested location of sampling points

At the point of a leak the gas is nearly pure. As the gas is dispersed into the air, the gas molecules diffuse, causing a dilution of the original concentration. The monitor measures the concentration at the sample collection point. Therefore, if the termination of the collection line is not at the exact point of the leak, the unit will read a diluted mixture of the gas and air.

It should also be noted that gases of interest are heavier than air and tend to collect below the point of a leak. Therefore a sample taken near the floor will have a greater concentration of gas than that collected above the source of a leak. Therefore, sampling points should be located as close as possible to the sources of potential leaks. If this is impractical, then the alarm set points should be adjusted for that zone to compensate for the dilution of the gas. Sample inlet filters should be mounted 12-18" (30.5-45.7cm) above the floor.

DO NOT block any of the zones, unused zones may be disabled by setting the distance parameter to zero feet in the zone setup screen.

The Multi-zone monitor should be centrally located in the mechanical room and be readily accessible for easy visual monitoring and servicing. The combined length of sample tubing plus exhaust tubing should not exceed 1200 ft (366m) for any zone. The fresh air purge line should draw from an area that does not contain any gas. The exhaust line should run to an outside location if possible.

NOTE: the combined length of the purge line and the exhaust line cannot exceed 500ft

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 provides the pattern of air currents present in the mechanical room.

The Multi-zone monitor should be kept dry, when used in a wet or humid area, it is highly recommended to use the optional water stop accessory to avoid internal damage.

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1.5.6Locating a remote display (optional)

The Remote display module should be mounted outside of the mechanical room, or just inside the room’s doorway if the first option isn’t possible. This is the "split architecture design" for safety of the operator. The Remote display can be located up to 4500ft (1372m) from the Multi-zone monitor. The Remote display is the man machine interface by which you program the Multi-zone, acknowledge alarms and observe conditions inside of the mechanical room. Note that there are two additional alarm relay contacts in the Remote display that can be programmed to alarm on leak, spill, evacuate, fault, or monitor on conditions.

MZ/RD gas leak monitor placement in a mechanical room

••		A	Sample inlet pickup poin.
••		B	Outside pickup point away from refrigerant gas (fresh air for Multi-zone purge cycle).
••		C	Charcoal filter.
••		D	Exhaust air (to outside).
••		E	Multi-zone gas monitor.
••		F	Remote display (outside mechanical room).
••		G	Exhaust fan.
••		H	Horn/strobe alarm outside mechanical room door.
••		I	2nd auxiliary horn/strobe remote alarm.
••		J	Chiller.
			NOTE: the pickup points located on the floor in the above illustration are examples for
			refrigerants which are heavier than air. Placement of pickup points should be determined
			based on characteristics of the gas being monitored and ambient conditions of the
			sampling area.
			(Air=28.9 g/mole, CO2=44.0 g/mole, NH3=17.0 g/mole, and halogens = 100+ g/mole)

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1.6Specifications

HGM-MZ Specifications

Product type	Multiple refrigerant gases and multiple area monitoring system for low level
	continuous monitoring of CFC, HCFC and HFC refrigerant gases used in most
	commercial refrigeration systems. System design supports compliance to the
	refrigerant monitoring requirements of ANSI/BSR ASHRAE 15-2007 and ASHRAE
	Safety Code 34-2007
Sensitivity	All gases 1 ppm
Measuring range	All gases 0 to 10.000 ppm
Accuracy1	±1 ppm ±10% of reading from 0-1000 ppm
	(R11, R22, and R113 ±10 ppm ±15% of reading 0-1000 ppm)
Gas library	CFC:	HFP, R-11, R-12, R-113, R-114, R-502;
	HFC:	R125, R-134a, R236FA, R245Fa, R32, R-404a (HP62), R-407a,
		R-407c (AC9000), R-410a (AZ20), R422a, R422d, R427a, R-507 (AZ50),
		R-508b (SUVA95);
	HCFC:	R-123, R-124, R21, R-22, R227, R-23, R-401a (MP39), R-402a (HP80),
		R 402b (HP81), R-408a, R-409a, R-500, R-503;
	Halon:	H1211, H1301, H2402;
	Other:	FA188, FC72, H1234YF, N1230, R424A, R426A, R438A, CUSTOM.
AGM-MZ Specifications
Product type	The AGM-MZ provides multiple area monitoring system for low level continuous
	monitoring of Ammonia gases used in most commercial systems
Sensitivity	20 ppm
Measuring range	25 to 10,000 ppm
Accuracy1	±10 ppm ±10% of reading from 0-10,000 ppm
Gas library	Ammonia (NH3)/R-717
CO2-MZ Specifications
Product type	The CO2-MZ provides multiple area monitoring for low level continuous
	monitoring of carbon dioxide gases used in most commercial systems.
	System design supports compliance to the gas monitoring requirements of
	ANS/BSR ASHRE 15-1994
Sensitivity	10 ppm
Measuring range	300-8.000 ppm
Accuracy1	±5 PPM ±5% of reading from 300-1000 ppm, ±10% of reading
	from 1001-3000 ppm
Gas library	Carbon Dioxide (CO2)/R-744

1 At reference environmental conditions (25°C, 45% RH non-condensing, 1 ATM)

General Multi-zone Specifications

Coverage	4 point standard, expandable to 16 points in 4 point increments
Detector type	Infrared non-dispersive
Front panel	3 Indicator lights:
	•• Green: monitor is powered ON. LED glows during normal operation;
	flashes when unit is in warm-up mode
	•• Red: alarm. LED flashes when any point has exceeded the alarm setting
	•• Yellow: fault. LED flashes when there is a system fault

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General Multi-zone Specifications

Size (HxWxD)	12.23" x 13.7" x 4.96" (31.06cm x 34.80cm x 12.60cm)
Weight	15lbs. (6.8kg)
Sampling mode	Automatic or manual (hold)
Re-zero	Auto or on zone change
Response time	5 to 315 seconds - depending on air line length and number of zones
System noise	Less than 40dB(A) @ 10ft (3m)
Monitoring	1.200ft (366m) maximum for combined length of sample + exhaust tubing
distance	(each zone)
Conditioned	Dual optional 4-20mA DC isolated outputs. Channel 1 = zone area,
signal	Channel 2 = PPM
Alarms	Four SPDT alarm contacts rated 2A at 250VAC (inductive) 5A at 250VAC (resistive).
	Three are assigned to PPM level alarms, one assigned to system faults
Communications	Full two-way communications with Remote Display Module or Building
	Management System via RS 485 serial interface. RS-232C communications port
	standard
Power safety	Fully automatic system reset. All programmed parameters retained
mode
Operating	32 to 122°F (0 to 50°C)
temperature
Ambient	5% to 90% RH (non-condensing)
humidity
AC power	100 to 240VAC, 50/60Hz, 20W
Certification	UL 61010-1, CAN/CSA 22.2 No. 61010-1 & CE Mark
Warranty	2 years from date of shipment
Altitude limit	6.562ft (2,000m)
Sensor life	7-10 years

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2.0Installation

2.1Installation

considerations

2.1.1Warnings and cautions

			WARNING: explosion hazard! Do not mount the Multi-zone monitor in an area that may
	!
			contain flammable liquids, vapors, or aerosols. Operation of any electrical equipment in
			such an environment constitutes a safety hazard
			WARNING: shock hazard! Always disconnect AC power before working inside the
			monitor
	!		CAUTION: drilling holes in the Multi-zone enclosure may damage the unit and will void
			the warranty. Please use the knockouts provided for electrical connections
	!		CAUTION: the Multi-zone monitor contains sensitive electronic components that can be
			easily damaged. Do not touch nor disturb any of these components

2.1.2Inspection

The Multi-zone monitor has been thoroughly inspected and tested prior to shipment from the factory. Nevertheless, it is recommended that the monitor be re-checked prior to installation. Inspect the outside of the enclosure to make sure there are no obvious signs of shipping damage. Open the enclosure and inspect the interior of the monitor for loose components that may have become dislodged during shipment. If damage is discovered, please contact the nearest Danfoss Service Center for assistance.

2.1.3Location of the monitor

The Multi-zone monitor should be centrally located in the facility and should be easily accessible for visual monitoring and servicing. Combined length of the intake sample line and the exhaust line cannot exceed 1200ft (366m) in length, but it is important to remember that sampling cycle time is proportional to the total number and length of individual sample lines.

Dirt, grease, and oils can adversely affect the operation of the Multi-zone monitor.

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. If there is a question, consider installing the unit outside of the mechanical room in a cleaner area of the facility.

NOTE: the mounting location of the monitor should allow it to be easily accessible for visual monitoring and servicing

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2.1.4Mounting instructions

NOTE: the Multi-zone monitor should be installed plumb and level and securely fastened to a rigid mounting surface

The enclosure utilizes keyhole mounting brackets designed for ¼ inch fasteners. Locate the four screws as shown in the diagram below or by using the provided mounting template. Allow the screw heads to protrude approximately ¼ inch.

Multi-zone Monitor mounting specifications

A

C B

TOP

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Mounting instructions

Four ¼ inch (6.35mm) fasteners are required to mount

the Multi-zone enclosure. Allow approximately ¼ inch (6.35mm) of each fastener to remain exposed.

The enclosure can slide directly on to the screw heads for mounting.

Verify position of enclosure on fasteners and tighten all fasteners.

A = 13		9			“ = 13.56” = 34.44cm	D = 2		1		“ = 2.03” = 5.16cm
								32
	16
B = 9	5			“ = 9.31” = 23.65cm		E = 8	55			“ = 8.86” = 22.50cm
	16
							64
C = 2	55			“ = 2.86” = 7.26cm		F = 12			1		“ = 12.25” = 31.12cm
	64							4

Hold the monitor flat against the mounting surface and allow it to slide down, engaging the screw heads in the keyhole slots of the mounting brackets. Adjust the screws as necessary to hold the monitor securely against the mounting surface.

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2.2Connecting gas sample lines

2.2.1Overview

Individual gas sample lines are run from the Multi-zone monitor 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.

All air, sample, and purge line connections are located on the left side of the enclosure. (See the illustration below).

Multi-zone monitor side view

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<![endif]>7

Inlet ports (quantity = 4,8,12 or 16)

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<![if ! IE]> <![endif]>5

<![if ! IE]> <![endif]>4

<![if ! IE]> <![endif]>3

Purge port

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<![endif]>PURGE

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				Serial communications (PC) port				Exhaust port

2.2.2Tubing considerations

Use ¼" (6.35mm) outside diameter (0.040" or 1.016mm wall) flex tubing for all air lines or equivalent. The tubing should be clean and free of residual moisture or other contaminants. The tubing should be cut cleanly with a sharp knife and care should be taken not to distort the tubing end. To connect the air lines to the monitor simply push the tubing firmly onto the connector. To remove a line, press the plastic ring on the connector with one hand, then withdraw the tube with your other hand.

(See the image below).

Using PTC connectors: connecting (left) and disconnecting (right)

The Multi-zone monitor uses push-to-connect (PTC) style connectors.

To insert sample lines, firmly push the appropriate tubing into the hole in the center of the connector until it seats in the connector. Refer to the figures at the left.

To remove tubing from a PTC connector, push and hold the spring-loaded collar inwards, then simultaneously withdraw the tubing.

Refer to the figures at the right.

All tubing bends should have a radius of no less than 5" (12.7cm) to ensure proper airflow.

If kinks or obstructions occur in any of the air lines the instrument may not function properly.

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2.2.3Connecting purge line

A purge line is an intake line that is required to draw fresh air into the instrument and should not exceed 300ft (91.44mm) in length. It is advisable to terminate the purge line outdoors, provided the input is not exposed to rain, snow, ice, exhaust fumes, or other airborne contaminates.

If an outdoor installation is impractical, the line should be run to an area inside the facility that you are certain is not contaminated with ambient gas. If this is not possible, an optional charcoal filter assembly can be used with the Halogen Gas Monitor to filter refrigerant from the purge line. It may be mounted adjacent to the monitor. A line-end filter should be attached to the end of the purge line when the charcoal filter is not used.

Note that the charcoal filter option must NOT be used in ammonia or CO2 applications.

IMPORTANT (CO2 Only): because CO2 is present in ambient air, the purge line MUST BE run outside, away from any known sources of CO2 gas. An atmospheric CO2 concentration value can be manually entered by the user in the CAL screen.

(See 4.7.5 "CO2 Atmospheric concentration").

2.2.4Connecting exhaust Line

An exhaust line can be used when it is required to vent gas samples away from the instrument and should not exceed 300ft (91.44mm) in length. The exhaust line should terminate in a location that is completely isolated from the purge line termination point and other areas of the facility that will be monitored. Ideally this line should terminate outdoors in a location that is not exposed to the elements. This line does not require a line-end filter.

If the exhaust line terminates outside the building, position the tubing so that no water or moisture can enter it.

2.2.5Connecting sample intake lines

The Multi-zone monitor 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, and 4 zone line end filter kit).

Sample intake lines can be up to 1.200ft (366m) when no exhaust tubing is used, otherwise, the combined length of the sample line and the exhaust line cannot exceed 1.200ft (366m).

All line terminations should be positioned to reduce the possibility of mists, aerosols, oil, water, dust, or other contaminates being drawn into the instrument. A line-end filter should be attached to the end of each sample intake line. Line-end filters should be placed 12" to 18"

(30.5cm to 45.7cm) above the floor.

IMPORTANT: DO NOT block any of the zones. Unused zones may be disabled by setting their length parameter to zero in the zone setup screen.

Depending on type of use and location of lines, the end-of-line water stop filter assembly can be used to prohibit moisture from entering the intake lines. Three end-of-line water stop filters are supplied with a standard unit.

Place the end of the intake line into the blue receiver of the end of line water stop and tighten sufficiently.

NOTE: only one filter assembly, either the line-end filter or end-of-line water stop, should be used for each line.

Please (see 1.5.5 "Suggested location of sampling points") to learn more about where to place the ends of the sample intake lines.

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2.2.6Installing an optional splitter kit

Splitter kits are made available which allow the Multi-zone unit to take gas sample readings from several sample points while utilizing just a single zone. These kits are designed for use ONLY in confined/defined spaces with high potential for leaks, such as food cases, cold rooms, refrigeration rack rooms, etc.

Multi-zone gas monitor’s 2 way and 3-way splitter kits are available as optional accessories.

Chiller

Condenser

Coldstores

Compressor Receiver

2-way splitter

3-way splitter

HGM-400

HALOGEN GAS MONITOR Multi-Zone

Additional sample lines

Additional sample lines

Purge line

2.2.7Connecting the water trap

The water trap is an optional accessory for applications that result in water or condensation frequently entering the intake lines. This is available in a manual style trap which is manually emptied once it has become filled. Install the water trap close to the unit for the most effective results.

The intake line may be cut where the user finds appropriate (preferably close to monitor).

Each side of the intake line should be inserted into the receivers on either side of the water trap. Secure tightly, a replacement filter for the water trap is available and is replaced by unscrewing the clear plastic cup of the water trap, pulling the filter directly out (do not unscrew), and inserting the new filter into place.

Replace the cup of the water trap, If desired, an optional mounting bracket may be used to secure the water trap in place.

NOTE: the termination filter or end-of-line water stop filter should be used, regardless of the presence of a water trap

IMPORTANT: extreme or humid temperatures may cause water to condense in the tubes.

A water trap is highly recommended for use in these scenarios

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2.3Interior components

Multi-zone monitor interior components

Hydrophobic	IR	Pressure	Line fuses
lter	bench	connector	(1 A, 250 V)
Gas inlet			Gas outlet
			12-pin connector
10-pin connector			(IR source)
(detector)			AC input
Main PC board			terminals
			J5 connector
J6 connector			(IR source)
(detector)
Relay connectors			Microprocessor
(leak, spill,
evacuate			board
and fault
Manifolds			Termination
4-20 mA DC
			switches
outputs (optional)			CPU reset
Pump
			RS-485
			connector

NOTE: the plastic cable ties surrounding the air pump are to ensure safe handling during shipping. Please remove before operation, reinstall a plastic cable around the air pump if the unit is shipped to Danfoss for service or repair.

This prevents damage during shipping

2.4Electrical wiring

The Multi-zone monitor uses a universal power supply that is capable of accepting inputs of 100 to 240VAC, 50/60Hz. The monitor’s power consumption is 20W, it is highly recommended that the monitor be connected directly to the AC power source, preferably on its own circuit. The AC power connection should be completed with UL listed 3 conductor wire (minimum 16 AWG), rated 300VAC at 105°C. Locate a convenient service knockout and install electrical conduit in the typical manner. Locate the AC input terminals and ground stud on the inside of the monitor, secure the incoming AC power neutral (white/blue) and live (black/brown) wires to the LINE 1 and LINE 2 terminals. Using the supplied crimp-on ring terminals, washers, and nuts, connect the incoming AC power ground wire (green) to the monitor’s AC input ground stud, and then install a separate wire between the ground stud and the GND terminal.

	!	WARNING: electrical installation should be performed by a certified electrician, and must
		comply with all applicable NEC/CEC and local electrical safety codes
	!	WARNING: copper conductors for connection to supply mains must be made in
		accordance with NEC/CEC and local codes
		WARNING: the AC power ground wire must first be connected to the monitor’s ground
		stud. Under no circumstances should this monitor be operated without 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.
		IMPORTANT: drilling holes in the Multi-zone enclosure may damage the unit and will
		void the warranty. Please use the knockouts provided for electrical connections

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A switch or circuit breaker rated 1.0A, 250VAC must be attached to the monitor’s AC power leads. This switch must also be located in close proximity to the monitor, and be in easy reach of the operator. This switch should also be clearly marked as the monitor’s main AC disconnect device.

The circuit breaker or switch must disconnect all current-carrying conductors (e.g., live and neutral).

Multi-zone AC input power and ground connections

LINE 2 (live)

LINE 1 (neutral)

GND

Use supplied crimp-on ring terminal, washers, and nuts to connect AC ground wires to ground stud as shown to meet approval

agency requirements

Ground stud

LINE 2

LINE 1

IMPORTANT! AC input ground wire always

on bottom of Ground stud

2.5Connecting communications devices

2.5.1Remote display module (RD) connection

The Multi-zone is connected to the optional Remote display using a shielded twisted pair instrument cable, the maximum distance between the farthest Multi-zone and Remote display is 4500ft.

Use any of the remaining service knockouts to gain access to the interior of the monitor, the RS-485 communications wiring between the Multi-zone and Remote display must be connected in the following manner:

1.Locate the RS-485 connector in the Multi-zone, (see figure "Monitor interior components").

2.Connect one lead of a twisted shielded pair to the "B" connection point, note the wire colour.

3.Connect the second wire to the "A" connection point, note the wire color.

4.Connect the ground to the "GND" connection point.

5.Locate the RS-485 connector marked "TO MONITORS" in the Remote display.

This connector is located on the bottom of the Remote display PC board, second from the right.

6.Run the wire to the Remote display and connect the twisted shielded pair to the RS-485 "TO MONITORS" connector using the same color code as used on the Multi-zone.

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2.5.2Integrating with building management systems

The Multi-zone may be connected directly to a Building Management System using a shielded twisted pair cable. The cable from the Building Management System is connected to the RS-485 connector inside the Multi-zone monitor. MODbus RTU is the standard communications protocol.

Use any of the remaining service knockouts to gain access to the interior of the monitor:

••locate the RS-485 connector and remove it from the circuit board

••secure the wire leads to the connector orienting them as shown in the diagram below

••check to make sure that the polarity matches the wiring to the Building Management System

When you are through securing the connections, carefully plug the connector back onto the circuit board.

2.5.3Larger integrated systems

You may also connect the Multi-zone monitor to a Building Management System through a Remote Display, in this case, first connect the Multi-zone to the Remote display as described above, then, follow the instructions in the Communications Connections section of the Remote display manual for information on how to connect the Remote display to a Building Management System.

RS-485 connector

RS-485

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<![endif]>GROUND

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<![endif]>LEAD A

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<![endif]>LEAD B

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2.5.4Changing terminator switch settings

The terminator switch is shipped from the factory in the "OUT" position (no termination), this is the correct setting if the Multi-zone is to be installed in the middle of a network, if the Multi-zone monitor is connected as a single device or if it is the last device on the network chain, the terminator must be moved to the "IN" position.

Locate switch #4 and determine its position, if it must be moved, slide the switch to the appropriate position. Note that switches 1-3 are for service use.

Termination switches

ON
1	2	3	4

ON
1	2	3	4

Terminator IN

Terminator OUT

Terminator switch

ON

1 2 3 4

2.5.5Personal computer

The Multi-zone may be connected to a personal computer using the RS-232 interface on the left side of the enclosure. Software will be provided upon request.

NOTE: (see 2.8 "PC Software")

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