Instruction/ maintenance manual of the product AGM300 Bacharach
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AGM300 / ADM800 Ammonia Gas Monitoring System Instruction 3015-4275 Installation / Operation / Maintenance Rev. 3 – May 2006 Product Leader ship • Training • Service • Re liability INSPECTION .
A Instruction 3015-4275 Notice: Product improvements and enhancements are contin uous; therefore the specifications and information contained in this docum ent may change without notice.
Instruction 3015-4275 i Table of Contents I NTRODUCTION .............................................................................................................................................................. II S AFETY P RECAUTIONS ............
ii Instruction 3015-4275 Introduction How to Use This Manual Thank you for investing in a BACHARACH Ammonia Gas Monitoring System. This manual provides important information on ho w to install, operate, and service the AGM3 00 Ammonia Gas Monitor and ADM800 Ammonia Displ ay Module.
Instruction 3015-4275 iii Safety Precautions AC Power Suppl y Ensure the source voltage matches the voltage of t he produ ct before energizing the equipmen t. It is highly suggested that the AGM300 be placed on a separat e circuit (with UPS or surge protection).
iv Instruction 3015-4275 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 .
Instruction 3015-4275 v Functional Overview General Description The AGM300 is designed to sup port compliance to federal, state and local safety codes governing a mmonia gas emissions. Avoiding significa nt ammonia gas lo ss reduce s equipment replacem ent costs, maintains equipment efficiency, promotes safety, and protects the environ ment.
vi Instruction 3015-4275 AGM300 / ADM800 Refrigeran t Gas Leak Monitor Mechanical Room Placement The ADM800 should be mounted o utside of the mechanical room or at least ju st inside of a door to the room. This is the “split architecture design” for safety of the operator.
Instruction 3015-4275 1 AGM300 Installation Upper Mounting Bracket Lower Mounting Br ac k et Water Trap STANDARD ACCESSORIES FOR A 4 POINT SYSTEM 5 Line-End Filters (P/ N 3015-3420) AGM300/ADM800 Inst.
2 Instruction 3015-4275 AGM300 - Installation Considerations Locating the Monitor The AGM300 should be centrally locate d in the facility and should be easily accessible for visual monitoring and servicing.
Instruction 3015-4275 3 AGM300 - Mounting Instructions Screw Locations The AGM300 should be in stalled plumb and level and se curely fastened to a rigid mounting surfa ce. The enclosure utilizes keyh ole mounting brackets designe d for #12 pan head fasteners.
4 Instruction 3015-4275 AGM300 - Connecting Air Lines Overview Individual sample lines are run from the AGM300 to each area of the facility to be monitored. Additionally, a purge line is installed to provide clean ai r for resetting t he infrared zero baseline.
Instruction 3015-4275 5 Tubing Considerations Use ¼" outside diameter (0.040" wall) flex tubing is us ed for all air lines (P/ N 304-2742). The tubing shoul d be clean and free of residual moistu re or other contaminant s. The tubing should be cut cle anly with a sharp knife and care should be taken not to distort the tubing end .
6 Instruction 3015-4275 AGM300 - Interior Schematic Primary Filter Intake Manifold Solenoids Intake Solenoid Connectors Power Supply Board Main Board Microcontroller Board Infrared Optical Bench Gas S.
Instruction 3015-4275 7 AC Power / RS-485 / Relay Connec tor / 4-20 mAdc Current Loop Switches / Fuses Auxiliary AC Out Connector T2 (Used to Supply AC power to Alarm Devices) (Overload Protected by F.
8 Instruction 3015-4275 AGM300 - Electrical Wiring It is highly recommended that the AGM300 be connected dire ctly to the AC power source, pref erably on its own circuit. The connection should be comp leted with a UL rated multi-conductor wire (14-18 AWG).
Instruction 3015-4275 9 AGM300 AC Input Po wer and Ground Connections.
10 Instruction 3015-4275 AGM300 - Connecting Communication Devices Ammonia Display Modul e (ADM800) Connection The AGM300 is connected to the ADM800 usi ng a shielded twisted pair instrume nt cable. The maximum distance between the farthest away AGM300 and ADM800 is 4500 feet.
Instruction 3015-4275 11 Changing Terminator Settings The terminator switch is shipped from the factory in the terminated or “IN” position. This is the corre ct setting if the AGM300 is connected as a si ngle device, or it is the last device on the network chain.
12 Instruction 3015-4275 Multiple AGM’s MULTIPLE AGM300’S WITH ADM800 NOTE 1: The last AGM300 or ADM800 on either end of the network must have its terminator in the “IN” position, and all other units m ust have their terminators in the “OUT” position.
Instruction 3015-4275 13 MULTIPLE AGM300’s CONNECTED TO A BUILDI NG MANAGEMENT SYSTEM DAISY CHAIN FASHION RS-485 TERMINATOR “IN” TERMINATOR TERMINATOR TERMINATOR TERMINATO R “OUT” “OUT” “OUT” “IN” AGM300 - PC Software Programming the AGM300 Using PC Software NOTE 1: There are two versions of PC softw are.
14 Instruction 3015-4275 7. Using the arrow keys go to EDIT; press ENTER – the EDIT Menu DROPS DOWN; select SYSTEM and then press ENTER – the AGM LOCATION be comes highlighted. Press ENTER to move to the AGM TAG area; use the BACKSPACE key to remove the existing tag; then enter in a new tag.
Instruction 3015-4275 15 USB Type Laptops Some of the newer laptops have USB ports and no RS -232 9-pin ports. You will be required to purchase a PCMCIA card that provides an RS-232 output. We recommend the PCMCIA card manufactured by: SEALEVEL SYSTEMS, INC.
16 Instruction 3015-4275 AGM300 - Current Loop Interfaces Optional 4–20 mAdc Outputs Upon installation of the optional 4–20 m Adc Interface Board (Page 7) (P/N 3015-313 3), the AGM300 has the capability of providing dual 4-20 mAdc scrolling cu rrent loop outputs for connectio n to external monitoring devices.
Instruction 3015-4275 17 AGM300 - Connecting External Alarms Overview The AGM300 includes 4 Form C SPDT alarm contacts for the connection of external alarm devices.
18 Instruction 3015-4275 Typical AGM300 Relay 1 and Relay 2 Wiring Jumper the ‘Neutral’ of the auxilia ry power connector to the ‘Com mon’ on the relay block. Connect one end of strobe or horn to the ‘NO’ of whichever level of alarm is appropriate for applicatio n.
Instruction 3015-4275 19 ADM800 Installation ADM800 Oblique Photo Upper & Lower Mounting Bracket s Upper Mounting Bracket Lower Mounting Bracket.
20 Instruction 3015-4275 ADM800 - Installation Considerations Overview Up to four AGM300 monitors may be connected to a single ADM800 display mod ule. The ADM800 can be located anywhere up to 4500 feet from the furthest AGM300.
Instruction 3015-4275 21 ADM800 - Mounting Instructions Screw Locations The ADM800 should be in stalled plumb and level and se curely fastened to a rigid mountin g surface. The enclosure utilizes keyh ole mounting brackets designe d for #12 pan head fasteners.
22 Instruction 3015-4275 ADM800 - Interior Schematic Microcontroller Board CPU Reset Switch Main Board Ground Stud AC Power Front Panel Chassis Power Supply Board 120–230 VAC Input Microcontroller B.
Instruction 3015-4275 23 AC Power RS-485 Connectors Terminator Switches Relay Connector Fuses 1 Amp 250 VAC P/N 3015-4011 Terminator Switches F2 F1 TO MONITORS RS-485 to HGM300 Monitors TO HOST RS-485.
24 Instruction 3015-4275 ADM800 - Electrical Wiring It is highly recommended that the ADM800 be connect ed dire ctly to the AC power source, preferably on its own circuit. The connection should be comp leted with a UL rated multi-conductor wire (14-18 AWG).
Instruction 3015-4275 25 ADM800 AC Input Power and Ground Connections.
26 Instruction 3015-4275 ADM800 - Communication Connections AGM300 Network The ADM800 Ammonia Display Module is connected to the AGM300 network using a shielded twisted pair cable. The maximum distance betwe en the ADM800 and the farthest AGM300 is 4500 feet.
Instruction 3015-4275 27 Changing Terminator Switch Settings The terminator switch for the RS-485 “TO MONITORS” con n ector is shipped from the factory in the terminat ed or “IN” position. This is the correct setting if the ADM800 is connected to only on e AGM300, or if it is the last device on a network chain.
28 Instruction 3015-4275 ADM800 - Connecting External Alarms Overview Two SPDT alarm contacts are available for the connection of external alarm device s.
Instruction 3015-4275 29 ADM800 Operation ADM800 Exterior Schematic Display Screen Navigation Buttons Cursor Pad LED Indicators LED In d i cato r s Display Sc r ee n Cursor Pad Navigation Buttons.
30 Instruction 3015-4275 ADM800 - Overview The ADM800 displays compreh ensive information about the AGM300 network status an d enables complete programming control of all system o perations. The pr ominent features of the display module are discu ssed below.
Instruction 3015-4275 31 Display showing “WARM UP” ADM800 - Screen Displays When first powered up a splash screen appears indicati ng the serial numbe r and firmware revision num ber. After a brief moment the System Screen is displaye d. Please refer to the Appendix for a logic diagra m of all the screen displays.
32 Instruction 3015-4275 ADM800 - System Programming Setup Parameters Before working with the AGM300 network, seve ral glo bal parameters must be defined. Most of these are entered in the ADM Setup Screens or via the PC so ftware . Parameters must also be defined for each AGM300 monitor connect ed to the network.
Instruction 3015-4275 33 ADM800 - Setup Programming Setting the Clock From the top level System Screen press the key adjace nt to the date/time field to go to the Clock Setup Screen . Clock Setup Screen Use the LEFT/RIGHT cursor key s to move the cursor across the field to the value you wish to edit.
34 Instruction 3015-4275 Navigating to the 1 st ADM Setup Screen From the top level System Screen press the ADM SE TUP key to go to ADM Setup Screen #1 . ADM Setup Screen #1 Contrast This value sets the screen brightn ess. 1. Press the CONTRAST key to adjust its setting.
Instruction 3015-4275 35 Audible Alarm This parameter select s the function of the ADM800’s internal a udible alarm. 1. Press the AUDIBLE ALARM key to adjust the setting. 2. Use the UP/DOWN cursor keys to select unused, monitor on, evacu ate, spill, leak, fault, or alarm.
36 Instruction 3015-4275 Navigating to the 2 nd ADM Setup Screen From ADM Setup Screen #1 press the MORE key to go to ADM Setup Screen #2 . Press the BACK key to return to ADM Setup Screen #1 . ADM Setup Screen #2 Setting Relay Parameters This setting determines the function of re lays 1 and 2 mounted inside the ADM unit.
Instruction 3015-4275 37 AGM300 - Setup Programming Navigating to the 1 st and then 2 nd AGM Setup Screen From the System Screen , press the key adjacent to the target AGM300 to go to that unit's AGM Setup Screen #1 . AGM Setup Screen #1 From AGM Setup Screen #1 press the SETUP key to go to AGM Setup Screen #2 .
38 Instruction 3015-4275 Location This is the name you assign to the AGM300 to identify its location. It may have up to 12 alpha numeric characte rs. 1. Press the LOCATION key to modify the setting. 2. Use the LEFT/RIGHT cursor key s to move across the entry field and the UP/DOWN cursor keys to modify the individual characters.
Instruction 3015-4275 39 Loop 2 Factor This sets the PPM scale fa ctor for curr ent loop nu mber 2. To calculate the cu rrent output, multiply the scale factor by the PPM and add 4. For example, at the default sca le factor of 0.016, a measurement of 100 PPM would generate a current of 5.
40 Instruction 3015-4275 Navigating to the 3 rd AGM Setup Screen From AGM Setup Screen #2 , press the MORE key to go to AGM Setup Screen #3 . Press the BACK key to return to AGM Setup Screen #2 . AGM Setup #3 Screen Service Timeout Sets the length of time the Service Mode is in effect.
Instruction 3015-4275 41 ADM800 - Zone Setup Programming Navigating to the 1 st Zone Setup Screen There are two ways to display Zone Setup Screen #1 : • From the System Screen (Page 31) press the key adjacent to the AG M300 unit associated wi th the zone you wish to work with.
42 Instruction 3015-4275 Average Temperature This temperature reading may be changed to the exact temp erature at the sample point for greater accura cy. The adjustment range is from –50 to +70 degrees C. 1. Press the AVG TEMP key to adjust the temperature value.
Instruction 3015-4275 43 Spill Level This is the concentration level in PPM that will activate a spill alarm condition. 1. Press the SPILL LEVEL key to adjust the value. 2. Use the UP/DOWN cursor ke ys to modify the setting. 3. Press ENTER to accept the new entry or QUIT to revert to the previous setting.
44 Instruction 3015-4275 General Operation Functional Overview Normally each AGM300 will sequentially perform mea surem ents on its active zones without user input. The total time it takes an AGM300 to complete a measurement cycle is directly prop ortional to the number of active zones and the physi cal length of the sample-gas lines.
Instruction 3015-4275 45 Zone Hold Mode A zone can be placed on hold and conti nuously 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.
46 Instruction 3015-4275 If the current Zone Screen appears n ormal, scroll through the displa ys using the NEXT/BACK keys or the UP/DOWN cursor keys un til you locate the affected zone. You can further investigate the status of the affected zone by pressing the adjacent key and going to the Zone Setup #1 Screen (Page 41).
Instruction 3015-4275 47 Working with the System Screen The System Screen provides a summary view of the entire AGM3 00 network. The boxes on the left side of the screen indicate the status of each AGM300 monitor incl uding the name, the cu rrent zone, and whether fault or alarm conditions are present on the network.
48 Instruction 3015-4275 Alarm Log From the System Screen press the key adjacent to the AGM300 unit that you wish to view. AGM Setup #1 Screen Press the ALARM EVENT LOG key to display Alarm Log Screen . Alarm Log Screen Use the LEFT/RIGHT and UP/DOWN cursor keys to move through the log.
Instruction 3015-4275 49 Fault Conditions If a system malfunction occurs, the yellow FAULT LED will glow. Additionally, an external ala rm device may activate and an audible alarm may sou nd if those features have been enabled (Pages 28 & 35).
50 Instruction 3015-4275 Working with Alarms Functional Overview If the PPM level for any zone exceed its designated spill, leak, or evacuate thresholds, an alarm conditio n will be created. Once the AGM300 completes a measure ment cycle in the affected zone the alarm condition will be indicated.
Instruction 3015-4275 51 Alarm Detail Screen To further investigate an alarm, press the adja cent key to go to the Alarm Detail Screen . Alarm Detail Screen The Alarm Detail Screen displays more compr.
52 Instruction 3015-4275 Acknowledging Alarms Each pending alarm may require, de pending upon sel ect ed alarm mode, acknowledgme nt before the system returns to normal operation (refer to Alarm Ack Mode 11 on Page 38). To acknowledge an al arm, navigate to the Alarm Detail Screen and press the ACK key as previously de scrib ed.
Instruction 3015-4275 53 Working with the Trend Screen Overview - Log Interval The AGM300 retains a data log of 100 measurement s for ea ch zone. The log in terval is the number of minutes from 1 to 1440 between each log point. This pa rameter can be changed fro m the Zone Setup #1 Screen (Page 41).
54 Instruction 3015-4275 Working with System Faults Functional Overview If a system malfunction occurs, the AGM300 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 & 38) .
Instruction 3015-4275 55 CRITICAL FAULTS • NO FLOW ON ZONE – Go to the System Screen (Page 47 ) and press the ZONES key. The Zone Screen (Page 44) will display a “NO FLOW” message in each individual zo ne affected. Check for a blockage in the air sample line or at the line end filter.
56 Instruction 3015-4275 Clearing System Faults If the fault condition is associated with an AGM300, the monitor will return to no rmal 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.
Instruction 3015-4275 57 Working with the Calibration Screen Overview The Calibration Screen is used to adjust the IR sensor’s calibration factor. IMPORTANT: Changing information on CAL FACTORS will VOID the factory calibration. Typically, the unit will remain within the factory-calibrated accuracy indefinitely and no calibration is required.
58 Instruction 3015-4275 Calibration Procedure The CAL FACTOR is determine d by sampling a known dilution of ammonia gas. The sampl e must be prepared to less than half the desired accuracy, and the conce n tration must be corrected for ambient temperature an d pressure at the time of measurement.
Instruction 3015-4275 59 Working with the Diagnostic Screen Overview The Diagnostic Screen display s reference values for use by r epair techni cians for troublesho oting purposes.
60 Instruction 3015-4275 LINE 7: PPM – Parts Per Million is the volume concentra tion refe renced to standard temperature and pressure and is computed from line s 5, 8 and 13. There are two figures given. The first (annotat ed by a B) is the actual PPM at the IR bench.
Instruction 3015-4275 61 Service Mode When activated, the Service Mode will disabl e a specific AGM300 unit for a specif ied length of time. The default is 60 minutes. This time interval can be change d per Section Service Timeout on Page 40. IMPORTANT: Note that while in the Service Mode no measurements are made, nor are any alarms activated.
62 Instruction 3015-4275 Notes:.
Instruction 3015-4275 63 Appendix.
64 Instruction 3015-4275 AGM300 / ADM800 Maintenance Warnings and Cautions WARNING - Always remove AC input power to the monitor before working on the interior of the instrument. CAUTION - When working inside the instrument be very careful not to dislodge any electrical wiring or pneumatic tubing.
Instruction 3015-4275 65 Optional Accessories Intake Manifolds Up to three additional intake manifolds (P/N 3015-34 19 & P/N 3015-3411) can be install ed in the AGM300 to increase the total capacity to 16 zones. Each manifold requi res a sample line-end filter for each of the 4 zones.
66 Instruction 3015-4275 ADM800 - Logic Diagram.
Instruction 3015-4275 67 RS-485 Communication Protocol Overview The following instructions are intended as a guide for integrating the AGM300 network into a Building Management System. If you are unfamiliar with compl ex systems of this type, it is recommended that you contact Bach arach for tech nical assistan ce.
68 Instruction 3015-4275 AGM300 MODBUS RTU Operation Overview The AGM300 and ADM800 are equi pped to communicate with other equipment using the M ODBUS RTU protocol.
Instruction 3015-4275 69 Notes on Network Topologies AGM300s may be connect ed directly to the MODBUS network or they may be co nnected to the network through an ADM800. In either case, ea ch AGM300 must have a unique node I D. Up to 15 AGM300s can be connected directly to the MODBUS network.
70 Instruction 3015-4275 Summary of Registers Register Name Number Type Description System Data 0x0010h R/W AGM System Setup Data Status 0x0011h R/W Operati ng summary of faults, alarms and status Zon.
Instruction 3015-4275 71 System Data Register Register 0x0010h R/W 54 by tes Variable Type Length Description Type UI 2 bytes Indicates EEPPROM ha s been initialized if value = 300 DO NOT MODIFY REV F.
72 Instruction 3015-4275 Status Register Register 0x0011h R/W 10 bytes Variable Type Length Description Mode UC 1 byte Defines Operating M ode of AGM300.
Instruction 3015-4275 73 Zone Data Register 0x12xxh R/W 78 bytes Each zone for an AGM300 has a separa te Zone data struct ure that is 78 bytes long. The zone number is the low order byte in the register addre ss (i.
74 Instruction 3015-4275 Notes on Alarms and Alarm Acknowledge The AGM300 can be operated in two different ala rm acknowledge modes, Auto and Manual (set via the alarm_ack_mode variable i n the system data register).
Instruction 3015-4275 75 Cal Data Register Register 0x0014h R/W 174 bytes Variable Type Length Description Factor Float 132 bytes 33 element array cont aining cal factor s for each of the 33 gases.
76 Instruction 3015-4275 Sensor Data Register Register 0x0016h R 82 by tes Variable Type Length Description Pressure Float 4 Manifold Pressure is PSIA P_Volts Float 4 Pressure sensor output Vo ltage V.
Instruction 3015-4275 77 Release Zone Hold Register Register 0x0017h W 10 bytes Variable Type Length Description Rel_Hold * * See description of STATUS REGISTER Hold Zone Register Register 0x0018h W 1.
78 Instruction 3015-4275 Fault Log Register Register 0x1900, 0x1901h R 302 b ytes These registers contain the 20 most re cent 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 2 00 bytes and the second re gister contains 102 bytes.
Instruction 3015-4275 79 Service Mode Register Register 0x001Bh W 10 b ytes Variable Type Length Description Rel_Svc_Mode * * See description of STAT US REGISTER Release Service Mode Register Register.
80 Instruction 3015-4275 PPM Register Register 0x001Eh R 32 b ytes Variable Type Length Description PPM UI 32 bytes 16 Unsigned Integers t hat rep resent the PPM values for each AGM300 zone NOTE: 16 values are returned independ ent of the number of actual zones installed in the unit.
Instruction 3015-4275 81 WARRANTY and SERVICE Warranty Subject to the terms herein, Seller wa rrants the orig inal equipment catalo ged or manufactured by the Seller and furnished hereunder is free from defects in material and workman ship, and will be of the kind and quality designated or described on the quotation .
82 Instruction 3015-4275 Return Procedure To return equipment to the factory for repair a Return Authorization (RA) number should be requested from the factory. Equipment will not be received without an RA number. Returned equipme nt should be sent to the factory at the following address: Bacharac h, Inc.
Instruction 3015-4275 83 AGM300 - Specifications Product Type: Ammonia gas, multiple area infrared monitoring syste m for low level continuous monitoring of ammonia refrigera nt gas used in most commercial refri geration systems. System design support s compliance to the refrigerant monitoring re quirements of ANS/BSR ASHRE 15-1994.
84 Instruction 3015-4275 ADM800 - Specifications Product Description: The ADM800 Ammonia Display Mod ule provides remote programm ing, interrogation and display functionality to support the AGM300 Am monia Gas Monitor. The system design supports compliance to the refrig er ant monitoring requirements of ANS/BSR ASHRE 15-1994.
Instruction 3015-4256 85 Notes:.
Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-33 4-5001 • Toll Free: 1-800-736-4666 Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A. ® Registered Tra demark of Bacharac h Inc.
An important point after buying a device Bacharach AGM300 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Bacharach AGM300 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Bacharach AGM300 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Bacharach AGM300 you will learn all the available features of the product, as well as information on its operation. The information that you get Bacharach AGM300 will certainly help you make a decision on the purchase.
If you already are a holder of Bacharach AGM300, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Bacharach AGM300.
However, one of the most important roles played by the user manual is to help in solving problems with Bacharach AGM300. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Bacharach AGM300 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
