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User Manual (English)

1. Selections are made by using the Av keys to highlight the desired function and then pressing the I O J key to activate that function Instruction 0055 9017 17 Operation Hi Flow Sampler 2 9 Menu System Selecting Menu from either the Basic or Expanded Main Screen provides the user access to a system of submenus as shown in Figures 2 9 and 2 10 The items that are listed in the submenus depend on whether the instrument is in its Basic or Expanded menu mode The functions listed are described in their associated sections of this manual bso ad T od qe E red 3 St i RP RGF ERG E nR Mee ef ES Ta errn ei onn Ph si i i i pi e 5 ee aeg P op fee poe poeg ofe eon Sheep ae pa pa E bb do E Eui dP ois f FAS Sesso e 3 BERR REE O Egar BET AL ORIFI 333 evege H i a Y A Lo we Bed id Li LiL ms ee tii Paul i tip bad ed 33 5 e re es etess ns ss sos cosesee cescece O O e e e e 03 oe oe e e s 38 8 sss E eke oes amp LA 2 CP gip prap tat 2S E ds ii 3 0 JEJE 33 tock dt 303 de Ses crase Lalibration 3 i ony 3 eons Seos 3 teengi na ii co NE see wi 533 E cos pe pr pert ERE PE lebo li PEE thot pp r ii r tho oF 3 e he e Si i al vi My e e e e 7 enogono geeeeee coogeso gonesos e ete e oe Pv culos R E gni anig BIO TEL i Meri Pad e p3 s oy fener E rr Sao ake 5
2. HOSE COUPLING Push in latch mechanism to release hose Figure 2 6 Capture Bag 2 5 4 Bellows Tool This tool is useful in capturing leaks in valve stems and small fittings Figure 2 7 Bellows Tool 2 5 5 Aluminum Crevice Tool Use this tool when the leak source is spread out over a narrow area such as a crack in a pipe square flanges and cylinder heads Y Figure 2 8 Aluminum Crevice Tool Instruction 0055 9017 13 Operation Hi Flow Sampler 2 6 Turning ON the Hi Flow Sampler With the Hi Flow Sampler located in an area containing clean air no combustible gases or vapors turn ON the instrument by flipping the ON OFF switch to its ON position WARNING To ensure that the gas sensors are properly zeroed at startup the Hi Flow Sampler must be turned ON in clean air Turning ON the instrument in air contaminated with combustible gas will cause false readings to occur Use one of Bacharach s portable gas detection instruments to sample the surrounding area for levels of combustible gas before turning ON the instrument An initial banner screen is first displayed for 3 seconds that shows the instrument s name software version and the software s Month Day Year and Time of creation eeee Li amplia After the banner screen is displayed the sensors are automatically zeroed to ambient conditions Zeroing time is dependent on the temperature of the sensors and whether there is resi
3. e S o elese eSeee o edo R TREH 3 ee T Eu Po tr p f goe gege y PO MERRE do Rt GEES ae Po ug feeste 3 33 z Be pP E pam AO Speed Bar Instruction 0055 9017 Hi Flow Sampler Operation 6 Inthe example below the current flow rate is 216 5 lpm the background gas concentration is 0 8 the leak concentration is 15 gas and the calculated leak rate is 42 5 lpm FTE pete ose gt E o FEF FEE ing peet Eri PE oni m r eese pan ss e ose 2 18 2 Leak Rate Measurement Automatic 2 Stage Mode Note The Automatic 2 Stage Mode can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 1 If not already done place the instrument into its Automatic 2 Stage measurement mode denoted by the letter A appearing at the bottom of the screen Refer to Section 2 14 1 Automatic 2 Stage Measurement Mode 2 Choose an attachment that will ensure the complete capture of the gas leak Connect this attachment to the end of the Hi Flow Sampler s main sampling hose and position the attachment s inlet over the leak source 3 Position the inlet of the instrument s background gas sampling hose opposite the leak source such that the leak source will not contribute to the background measurement 4 Begin the measurement process by selecting Start from the Main Screen ate le ete to r 3 Sees ets ss S RiR IRE 7 Se See S
4. Message Explanation Check Background Calibration Error The background gas sensor needs calibrated Refer to Section 5 2 Check Leak Calibration Error The leak gas sensor needs calibrated Refer to Section 5 2 Check Background Offset Error The background gas sensor did not properly zero during startup Refer to Section 5 2 Check Leak Offset Error The leak gas sensor did not properly zero during startup Refer to Section 5 2 Check Zeroing Bypassed Error The ESC key was pressed during start up thus bypassing the normal sensor zeroing process Refer to Section 5 2 Check Leak Rate Difference Error The calculated leak rate difference between measurements 1 and 2 during an automatic or manual leak test was greater than 100 Refer to Section 5 2 Check Background Greater Error The measured background gas level was greater than the measured leak Than Leak gas concentration Refer to Section 5 2 Sample Time The amount of time that a leak rate measurement has been in progress Purging Sensors The instrument automatically turns on both sensor pumps to purge the background gas and leak gas sensor chambers This action occurred because during an idle period blower not running or during shutdown the instrument has detected that more than 50 ppm of natural gas is present in the sensor chamber s Low Battery Error Battery voltage has fallen below 4 0 volts Refer to Section 5 2 Instruction 0055 9017 39
5. PEro oio mi gt a TE i 9 Measurements that were saved can be downloaded to a personal computer at a later time for analysis Refer to Section 2 16 Importing Saved Data into a Spreadsheet 2 19 Message Line Various messages will appear at the bottom of the LCD that describe what functions are currently being performed or errors that have been detected The following list describes the meaning of these messages Note that detailed explanations of the error messages can be found in Section 5 2 Troubleshooting Guide TABLE 2 3 Message Line Explanations Message Explanation Calibration procedure was successful Error The calibration procedure was not successful Refer to Section 5 2 A test record is currently being saved to memory Error The instrument tried to save a test record with 1000 records already stored in memory Refer to Section 5 2 An attempt was made to send records to a computer with no test records stored in memory The flow rate has just been lowered signaling the start of measurement 2 during an automatic or manual leak test Refer to Section 2 14 All test records are being erased after selecting Erase records per Section 2 15 3 Error The background gas pump s flow rate has been severely reduced Refer to Section 5 2 Error The leak gas pump s flow rate has been severely reduced Refer to Section 5 2 38 Instruction 0055 9017 Hi Flow Sampler Operation
6. The Measurable Difference HI FLOW Sampler For Natural Gas Leak Rate Measurement Instruction 0055 9017 Operation and Maintenance Rev 7 July 2015 COMPUTER PROGRAM HI FLOW SAMPLER BACKGROUND 7 2 Y S SS A Product Leadership e Training e Service e Reliability WARRANTY Bacharach Inc warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufac ture and will conform substantially to Bacharach Inc s applicable specifications Bacharach s liability and Buyer s remedy under this warranty are limited to the repair or replacement at Bacharach s option of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc s reasonable satisfaction to have been defective provided that written notice of the defect shall have been given by Buyer to Bacharach Inc within one 1 year after the date of delivery of this Product by Bacharach Inc Bacharach Inc warrants to Buyer that it will convey good title to this Product Bacharach s liability and Buyer s remedy under this warranty of title are limited to the removal of any title defects or at the election of Bacharach to the replacement of this Product or parts thereof that are defective in title THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF I ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUD
7. Basic Menu mode or if all available information is displayed Expanded Menu mode Refer to Section 2 8 Selecting the Basic or Expanded Menu Mode for detailed information on how to select the desired menu mode and learn about what type of information is displayed in each mode 2 14 Operating Mode Automatic or Manual Note The Operating Mode can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 Selecting Operating Mode from the Expanded Menu System allows the user to set the instrument s operating mode to either Automatic or Manual 20 Instruction 0055 9017 Hi Flow Sampler Operation 2 14 1 Automatic 2 Stage Measurement Mode Instruction 0055 9017 In the Automatic 2 Stage Mode the unit performs a leak rate measurement at first a high flow rate for 1 minute and then automatically shifts to a lower flow rate and performs another measurement for another minute The final measured and calculated values are automatically saved in memory This mode is used to measure leaks that are easily identifiable and captured Select the automatic measurement mode as follows 1 From the Expanded Main Screen select Menu gt Operating Mode 2 3 Press ESC to return to the Main Screen Observe that A should appear at the bottom of the screen 21 Operation 22 Hi Flow Sampler 2 14 2 Manual Measurement Mode 2 14 2 1 Manual 2 Stage Mode In the Manual 2 Stage mode the user
8. dd a mm dd ue min dd idi mim ced ii L Cail High i mij High Gack Back Legk Leak a Le ih selene Back Back Ledk Ley ke Lom High FEE oir ER FEE EE HE E N F FG HHHH Hi gh ERE ER EE Yes No Figure 2 10 Expanded Menu System not show the pack s remaining percentage of charge It does 19 Operation Hi Flow Sampler 2 11 Calibration Menu Selecting Calibration from the Menu System allows the user to either 1 calibrate the sensors 2 verify calibration 3 view dates on which calibrations were performed 4 view amplifier gain values in hexadecimal of each sensor circuit or 5 erase calibration A detailed description of each calibration function is provided in Section 3 Calibration 2 12 Set Flow Units LPM or CFM Selecting Set Flow Units from the Menu System allows the user to select whether the flow rate is displayed in either lpm liters per minute or cfm cubic feet per minute Select the desired flow rate unit of measure as follows 1 From the Main Screen select Menu gt Set Flow Units hd i EE 3 ees cee see o Ses e eof ooe STi ss ss F Sree es ekki E iiot 2 10357 E uo SS Mees SS eee ees eee Zs 3 Press ESC to return to the Main Screen 2 13 Menu Mode Basic or Expanded Selecting Menu Mode from the Menu System allows the user to select whether only the most basic amount of information is displayed on the Main Screen
9. when the I O J key is pressed b Loosen battery connector Remove the instrument s cover and ensure that all wires are attached to the battery connector and that the connector is securely attached to the printed circuit board c Microprocessor needs to be reset Disconnect battery pack for several seconds Display freezes during start up Battery pack voltage is low Recharge battery pack per Section 4 2 For users in cold climates take the instrument inside a room at 70 degrees F until the LCD becomes readable After that use in 15 20 minute intervals when in a O degree F environment and alternating in warm environment to keep LCD Fluid Instrument turned itself OFF Battery pack is dead Recharge battery pack per Section 4 2 during operation Low Battery message appears Battery voltage is below 4 0 volts Recharge battery pack per Section 4 2 at bottom of display Instrument won t respond when a Microprocessor needs to be reset Disconnect battery pack for several control unit key is pressed seconds Instruction 0055 9017 57 Troubleshooting Hi Flow Sampler Symptom Probable Cause and Remedy Low flow rate reading with fully Flow path obstructed Check flow path and verify flow rate per Section 4 7 charged battery Slow response time Internal filters are dirty Replace filters per Section 4 4 Battery power does not last at Battery pack defective Replace least 4 5 hours Erratic gas readings a The
10. 15 After selecting or creating a new Test ID start the measurement by pressing ESC until the Main Screen appears Selecting No returns the display to the Main Screen and starts the measurement using the current Test ID A Pt P of ofa ES ge PASS e PE His HETE ETE ETE H i 333 3 eee osese seoce AAA RS e 6 Begin measuring at the first flow rate until a stable leak measurement is achieved this may take several minutes If desired the flow rate can be manually controlled by using the Speed function Each press of the I O J key will lower the flow rate as indicated by the speed bar moving to the left 33 estos oo ey yee ae 3 Ps sects IA Speed Bar si Es sons BRE ES 35 Operation 9 Hi Flow Sampler Once a stable leak measurement is obtained highlight Save and press the I O key Observe that the measurement is saved in memory and that the flow rate is automatically lowered In the example below the measured leak concentration for measurement 1 was 15 gas and the calculated leak rate was 42 5 lpm Continue sampling at the reduced flow rate until once again a stable leak measurement is achieved If desired the flow rate can again be manually controlled by using the Speed function With Save highlighted press the I O 4 key to save measurement 2 in memory The blower then stops and the values in the Main Screen are put on hold as indicated by value
11. 6 1 Replacement Parts Complete Hi Flow Sampler ASS usas 0055 8020 Standard Attachments A o A O IS 0055 0259 Beveled Nozzle Tool O vanwscdtennsaacsnaaiee 0055 0213 A rae Get vadsdete on Set uaded euch N lousy S 0055 0247 Capture Bag Reusable VION 36 MID nao emai aeeeiuea 0055 0250 Alumina Crevice TON ibi 0055 0258 Disposable Bae INGZZ lO usina illa disdaas 0055 0214 Flange Strap ci 0055 0253 E 0055 0252 A asta A eae 0055 0251 572 8 e Geren o E O 0055 0286 Battery PACK ornas vciewci sree pases cia a E E nausea pao eae nations 0055 0240 Battery Charger requires power supply 24 0985 ccsccccccceseesseeeceeeeeeeeeeeeees 0055 0241 Filters Sample Gas Intake Wire Mesh cccccsssseccesseecceececceseeseeeseeseecesseeeeesees 0055 0261 LEAKHAGAS Plastic Snell scout dis 0007 1563 Sensor Leak Gas amp Background Gas Fiber package Of 2 o oo 0055 0045 Hose Assembly SATELE E PS E NE A aes cna ee ose T 0055 0215 A TEATE OE EEEE EAT AEE TA 0055 0287 Power Supply 100 240 VAC In 12 VDC Ot ooocnnnncnnccnncnnncnncnnonanonnnnnnononnnnnnnnanenos 0024 0985 Ue Cord ZO VACAS a N 4998 8986 Pump Assembly for Leak Gas and Background Gas Sensor Assembly 0055 0061 Serial Cable 9 Pin DIN Straight Through 6fO0t occcccoccncccnccnncnacononanoncnnanonnnnoss 0104 4027 Sensor Combustible GaS anssen a aa a A aE a a aot 0055 0040 TOLE BaL a ETEA 0024 1204 CONTO UNICA MDI a Aa 0
12. Control Unit comes with two magnets which can be easily attached to a steel pipe regulator box or compressor for easy viewing Alternately the Control Unit can be used in conjunction with the neck strap accessory Hi Flow Sampler 1 2 Material Introduction The gas sample is drawn into the unit through a flexible 1 5 inch I D hose Various attachments connected to the end of the sampling hose provide the means of capturing all the gas that is leaking from the component under test The main unit consists of an intrinsically safe high flow blower that pulls air from around the component being tested through a flexible hose and into a gas manifold located inside the unit The sample is first passed through an orifice restrictor where the measured pressure differential is used to calculate the sample s actual flow rate Next a portion of the sample is drawn from the manifold and directed to a combustibles sensor that measures the sample s CH concentration in the range of 0 05 to 100 gas by volume A second identical combustibles sensor channel measures the background CH level within the vicinity of the leaking component The final element in the sampling system is a blower that exhausts the gas sample back into the atmosphere away from the sampling area The measured flow rate and the measured CH levels both leak and background levels are used to calculate the leak rate of the component being tested with all measured and calculat
13. Hi Flow Sampler Calibration 3 Calibration It is recommended that the Hi Flow Sampler be calibrated by your nearest Bacharach Service Center every 30 days Calibration however can be performed in the field if your facility has the necessary equipment and qualified personnel to perform the procedures described in the following sections The following procedures describe how to e View the dates on which calibrations were performed e Verify calibration e Calibrate the background and leak gas sensors e Display the gain values of the calibration amplifier circuits e Erase calibration 3 1 View Calibration Dates Do the following to view the dates on which calibrations were performed on the background gas and leak gas sensors at both low 2 5 CH and high 100 CH calibration gas levels 1 From the Main Screen select Menu gt Calibration gt Calibration Dates 2 Thefollowing Calibration Dates Screen is displayed where mm dd yy is the month day and year calibration was performed 3 un a ithe chef as gege gege SO og fo S PPPs Fe eS 3 iio ts js AS SESE EES e I eseese oefose seese eotece ees 3 Press the ESC key twice to return to the Main Screen 3 2 Gas Calibration Equipment Setup Instruction 0055 9017 The following equipment is recommended to both check the calibration and perform a calibration procedure on the Hi Flow Sampler Calibration Kits o Hi Flow Cal Kit with Ret
14. HyperTerminal has never been run in association with the Hi Flow Sampler then a new HyperTerminal connection needs to be made as follows a Select Start gt Run In the Run box type hypertrm exe and click OK The New Connection dialog box should appear b Type in a New Connection Name such as HiFlow Click OK to select the default icon if desired select a different icon before clicking OK The Connect To dialog box should appear c Click the Connect using drop down menu and choose the COM port to which the Hi Flow is connected Then click OK to display the COM Properties dialog box for that COM port d Set Port Settings to Bits per second 115200 Data bits 8 Parity None Stop bits 1 Flow control None Then click OK to display HyperTerminal s main window e Click File gt Save This creates a file with an ht extension using the name that was entered in Step b 3 After HyperTerminal is running click Transfer gt Capture Text gt Start to accept the default drive directory filename to which all received data will be stored as an ASCII text file Note The captured text file will be stored on the hard drive in the folder shown in the File dialog box If desired click Browse to select a different drive directory and filename The next time data is captured it will be stored under the same location and filename 4 From the High Flow Sampler s Expanded Main Screen start the download
15. J key to start the calibration process Observe that the gas sampling pump motors start and the calibration screen appears gt Pri pri senses seeses If necessary use the Av keys to adjust the App 1 2 reading to match the gas concentration stamped on the calibration gas cylinder Wait until the measured gas reading stabilizes and then press the I O 4 key to calibrate the actual gas reading to that of the applied reading The message Calibration Passed will appear at the bottom of the screen if the calibration was successful If however the calibration was not successful the message Calibration Failed will appear Refer to Section 5 Troubleshooting for possible causes and remedies for this failure Disconnect the gas hose and then wait until the measured gas reading falls to zero percent Press the ESC key to return to the Calibration Menu Screen 10 Repeat this procedure as necessary to calibrate both sensors at 2 5 and 100 CH Instruction 0055 9017 Hi Flow Sampler Calibration 3 5 Calibration Amplifier Gain Check Use this procedure to display the gain values of the calibration amplifier circuits in hexadecimal This procedure is useful to service technicians for troubleshooting purposes 1 From the Main Screen select Menu gt Calibration gt Calibration Gains to display the Calibration Gains Screen A Be AE E i Es Se SE Seege 3 g A A ios s de ed S Back Loca HHHH Bark
16. immediate right of the number 2 H see see oep ofe op soe 90 3 33 137 33 33 3 H O RS ss Seese o ees os Se obe oo F eee Sone Paar 3 Pe gn A ear IE oh on After all characters have been selected press and hold down the I O J key to move the cursor to the end of the screen after which the screen shown in Step 2 should reappear Press the ESC key twice to return to the Main Screen 2 17 3 Send Test IDs Instruction 0055 9017 The following describes how to download the current list of Test IDs to a computer that is running Windows HyperTerminal as the communications program If a different operating system and or communications program is being used then please consult the appropriate instruction manuals for those products 29 Operation Hi Flow Sampler 1 Install serial data cable P N 104 4027 straight through 6 foot DB9 male to DB9 female between the computer s COM port and the Hi Flow COMPUTER connector For computers having a 25 pin or USB COM port the user must supply the appropriate adapter or use a serial cable with appropriate connectors on each end 2 On the computer start HyperTerminal by doing one of the following If HyperTerminal has already been set up to communicate with the Hi Flow Sampler then select Start gt Programs gt Accessories gt Communications gt HyperTerminal and double click the filename or icon that has been associated with the instrument If
17. process by selecting Menu gt Access Test IDs gt Send Test IDs 30 Instruction 0055 9017 Hi Flow Sampler Operation Observe that the Hi Flow LCD displays the message Sending record x of y 115 2kbps where x is the current record being sent and y is the number of records in memory Also observe that HyperTerminal displays the data as its being received 5 After all data has been transmitted stop HyperTerminal from capturing data by clicking Transfer gt Capture Text gt Stop 6 The saved data can now be viewed on the computer using any program capable of displaying txt files 2 17 4 Erase Test IDs Erase all Test ID information and reset the Test ID index back to 0001 as follows 1 From the Expanded Main Screen select Menu gt Access Test IDs gt Erase Test IDs 2 Select Yes to erase all Test ID information or select No to return to the previous screen 3 Press ESC twice to return to the Main Screen Instruction 0055 9017 31 Operation Hi Flow Sampler 2 18 Making a Leak Rate Measurement 32 Before making a leak rate measurement the user must decide whether to use e the Basic or Expanded Menu Mode Section 2 8 e lpm or cfm for the flow rate Section 2 12 e the Automatic 2 Stage Manual 2 Stage or Manual 1 Stage method of making a measurement when operating in the Expanded Menu Mode Section 2 14 e aTest ID when operating in the Expanded Menu Mode Section
18. rate tests should be made because of the potential inaccuracy of the sensor channels Check Background Greater Than The measured background gas level is greater than the measured leak gas Leak message appears at bottom concentration Make sure the background gas sample hose is not of display positioned too close the leak source Low Battery message appears Battery voltage is below 4 0 volts Recharge battery pack per Section 4 2 at bottom of display 5 3 Error Codes in Saved Test Records When saved test records are sent to a personal computer and later viewed in a spreadsheet program refer to Section 2 16 Importing Saved Data into a Spreadsheet Field 18 Error Codes in the saved records contains letter codes that identify problems that have occurred during that particular test Refer to Table 5 2 for a listing and description of these codes TABLE 5 2 FIELD 18 ERROR CODES Error Descripti Code escription A Background gas sample pump blocked BO Leak gas sample pump blocked C The background gas sensor needs calibrated at 2 5 and or 100 CH4 The leak gas sensor needs calibrated at 2 5 and or 100 CHy The measured background gas level was greater than the measured leak source gas level This is an indication of improper equipment setup Instruction 0055 9017 59 Troubleshooting Hi Flow Sampler 60 Instruction 0055 9017 Hi Flow Sampler Parts amp Service 6 Parts amp Service
19. s main sampling hose and position the attachment s inlet over the leak source Position the inlet of the instrument s background gas sampling hose opposite the leak source such that the leak source will not contribute to the background measurement Begin the measurement process by selecting Start from the Main Screen The user is now asked to choose a new or different Test ID Selecting Yes causes the Access Records menu to appear refer to Section 2 15 After selecting or creating a new Test ID start the measurement by pressing ESC until the Main Screen appears Selecting No returns the display to the Main Screen and starts the measurement using the current Test ID SSE LGR peu st Pete oft oe e eree o 3 3 3 EE nase he Soe cose de Set o ete E EEE ETENE ES i be Eee See ue Bd Begin measuring until a stable leak measurement is achieved this may take several minutes If desired the flow rate can be manually controlled by using the Speed function Each press of the I O J key will lower the flow rate as indicated by the speed bar moving to the left Speed Bar Once a stable leak measurement is obtained all current readings can be saved in memory by highlighting Save and pressing the I O 4 key In the example below the current measured leak concentration is 15 gas and the calculated leak rate is 42 5 lpm 37 Operation Hi Flow Sampler forests PEE frente i 3 i
20. starts a measurement at a high flow rate waits for a stable leak rate reading and then manually saves the readings using the Save function The unit then automatically lowers the flow rate at which time the user makes a second leak rate measurement After waiting for the leak rate reading to once again stabilize the user then manually saves all final measured and calculated measurements in memory This mode is used when more control of the leak rate measurement process is required Select Manual 2 Stage operation as follows 1 From the Expanded Main Screen select Menu gt Operating Mode 2 Highlight Manual 2 Stage and then press the I O key 3 Press ESC to return to the Main Screen Observe that M should appear at the bottom of the screen 2 14 2 2 Manual 1 Stage Mode In the Manual 1 Stage mode the user starts a measurement at a high flow rate and then waits for a stable leak rate reading to occur During this time the flow rate can be changed using the Speed function on the Main Screen After a stable leak rate reading is obtained the user can manually save all final measured and calculated values in memory using the Save function on the Expanded Main Screen This mode is used when more control of the leak rate measurement process is required Select Manual 1 Stage operation as follows 1 From the Expanded Main Screen select Menu gt Operating Mode Instruction 0055 9017 Hi Flow Sampler 2 3 Operat
21. 055 0262 Ground Clamp Assemb sac apscdecsstice eve ieceds Gain A 0055 0265 Neck Strap COME Ol UIE e nena 0051 1550 6 2 Optional Accessories Calibration Kits Complete Kit with Disposable Gas Cylinder See Section 3 2 on page 41 Complete Kit with Refillable Gas Cylinders See Section 3 2 on page 41 Calibration Gases 100 MIEtNane 56 L Taiana 0055 0060 2 5 Methane 103 Tora 0051 1121 Zero Alr 20 9 05 103 LTank iia eiie E a 0051 4049 Combustible Gas Detectors A aS 0019 8041 EE A O E A E ere eee 0019 7075 Instruction 0055 9017 61 Parts amp Service 6 3 Service Centers 62 United States Bacharach Sales Service Center 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5001 Email help mybacharach com Canada Bacharach of Canada Inc 20 Amber St Unit 7 Markham Ontario L3R SP4 Canada Phone 905 470 8985 Fax 905 470 8963 E mail support bachcan ca Hi Flow Sampler Instruction 0055 9017 Hi Flow Sampler Declaration of Conformity 7 Declaration of Conformity The Measurable Difference C DECLARATION OF CONFORMITY The manufacturer of the Bacharach Inc products covered by this 621 Hunt Valley Circle declaration New Kensington PA 15068 Year conformity is declared ee Product s Natural Gas Leak Rate Measurement Model s High Flow Sampler The undersigned hereby declares that the above referen
22. 14 ete ia de PE SO iii ar Mi Pads ond dez A ITEE L 2 eee ose Se ade eee cto ooo 3 3 ele Se e T usd case A A APA AO ge FFs L g E cee E g Bs 3 EDGE e dd RSP mmg HEA PES Br me peg E he Basco n ii da E gr oie A wo Seen ake ees tas Se Seese e8 A A Sooo on ssa EMP ro perce bet pen FO Bd cote A BE A Figure 2 9 Basic Menu System 18 Instruction 0055 9017 Hi Flow Sampler Meri Calibration Set Flow Units select Language Meru Mode Operating Mode sss sss sss sess sono 1 1 Sa aaa case sss ss eee Records Test Ds Act ess 2 10 Battery Status Battery status is displayed as a single battery icon shown in the lower left hand portion of the LCD Since the voltage curve of the battery pack drops off rapidly towards the end of its charge the Battery status icon is useful only in showing when the battery pack is Instruction 0055 9017 nearing depletion It does not show the pack s remaining percentage of charge lia A d E Calibrate 5 Verify Calibration Calibration Dates Calibration Gains Erase Calibration c m Ecs ft mire lpm Cliters mina english Russian Basic Meru Expanded menu Automatic Stage Manual 2 5Staqge Manual il Staqe send Records View Records Records Erdagi 11110 Operation Backand E ins CH4 Backgnd 18143 Leak 2 3 CH4 Ledak E i CH4 gt Gack 23 A d Leak 22 au mim
23. 2 17 2 18 1 Leak Rate Measurement Basic Menu Mode While operating in the Basic Menu Mode the user starts a measurement at a high flow rate and then waits for a stable leak rate reading to occur During this time the flow rate can be changed using the Speed function on the Main Screen This mode is used when more control of the leak rate measurement process is required and when saving data is not desired 1 If not already done place the instrument into its Basic Menu Mode per Section 2 8 Selecting the Basic or Expanded Menu Mode 2 Choose an attachment that will ensure the complete capture of the gas leak Connect this attachment to the end of the Hi Flow Sampler s main sampling hose and position the attachment s inlet over the leak source 3 Position the inlet of the instrument s background gas sampling hose opposite the leak source such that the leak source will not contribute to the background measurement 4 Select Start from the Main Screen e e H Soco 333 3 e A 3 i foss MERE PPr FEE lui peet 3 F 5 Begin measuring until a stable leak measurement is achieved this may take several minutes If desired the flow rate can be manually controlled by using the Speed function Each press of the I O key will lower the flow rate as indicated by the speed bar moving to the left 3 S e sde ete 2 2 3 3 8 323 sip fi Ha if i e dee Me e
24. BAUE Sta GUS dad didas 19 ZW Calpa Mendo 20 22 gt Set ROW UNITS LPM On CAM seus vasteoedcunsaaneuetaa indeed E E 20 2 13 Menu Mode Basic or Expanded ccccssccccssssccceseccccsnscccseesceseaeceesescessenecesaaeseeseuecessuseessaeseeseaeeesseasessees 20 2 14 Operating Mode Automatic or Manual csser irrena i EE O E AO ETEA 20 2 14 1 Automatic 2 Stage Measurement MoOde ccccsssccccsssecccenscccceseceseescccssseesseuecesauseessaesessenseess 21 2 14 2 Manual Measurement Mode cccccccssscccccsscccsenscccauscecseuscceseusceseuueceseseessaeeessaesesseuseessanseess 22 DNS ACCESS RECO OS ti 23 Poe SENA RECO a a O A tees 23 DAS 2 WICW RECO Sa aia 25 PMS Erase RECOLOR A newest SLE SEE eee 25 2 16 Importing Saved Data into a Spreadsheet ccsccccsssecccceescccescccsescccseuseeseaececseecesseeeeseuesesseecessensesseas 26 27 ACCESS OSU IDS o idas 28 Deli TTESI DS eA a weeassenipaca nan a 28 ALZ O A A A A ease ews 29 LIS A Ed 29 2 17 4 Erase TestIDS A OS 31 2 18 Making a Leak Rate MeasureMent cccccnccnnccnccnnnnnnonnnnncnnnnonnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnananinns 32 2 18 1 Leak Rate Measurement Basic Menu Mode occcccnccnncnnccnccnncnnnnnnnnnononononnnonnnnnnononnnnnnnnnncnnnnananonns 32 2 18 2 Leak Rate Measurement Automatic 2 Stage Mode oocccccnccnncnncnnncnocnnononnnnnnanonnnnnnnnnnnnnnnonaninonns 33 2 18 3 Leak Rate Measurement Man
25. Ds gt Select Test IDs 2 Use the Av keys to scroll through any previously stored Test IDs until the desired ID is displayed In the example below Test ID 0005 has been chosen Tip To quickly scroll through the Test IDs press and hold down the nor v key 3 Select the displayed Test ID by pressing the I O J key and then return to the Main Screen by pressing ESC twice Observe that 0005 is now displayed at the bottom of the screen Pos f reto ERRE Instruction 0055 9017 Hi Flow Sampler Operation 2 17 2 Edit Test IDs Edit a previously entered Test ID or to create a new one as follows First select the Test ID to edit per Section 2 17 1 Select Test IDs To create a new Test ID select the last Test ID number that can be displayed the last Test ID number will always be blank From the Expanded Main Screen select Menu gt Access Test IDs gt Edit Test IDs eo H q H 3 ote Use the following keys to select and then enter the desired character AV displays desired alphanumerical character I O selects displayed character and moves cursor one space to the right ESC moves cursor one space to the left Tip To quickly scroll through the characters press and hold down the nor v key Tip The space character is between the number 9 and the capital A In the example below the Test Location has been changed from 1 to 2 with the cursor positioned to the
26. ER eoogose H Date and Time Date displayed as mm dd yy while time is displayed in a 12 hour format The date and time are set per Section 4 8 Btry V Battery voltage Flow Ipm Sample flow rate in either liters min or cu ft min Back Measured background gas level in either percent by volume or ppm Leak Measured natural gas leak concentration at the current sample flow rate in either percent by volume or ppm Leak lpm Calculated leak rate in either liters min or cu ft min Speed LO lt gt HI Blower speed indicator Start Stop Select to Start and Stop a test Menu Select to display the first of several submenus refer to Section 2 9 ii Battery status icon refer to Section 2 10 Hi Flow Sampler 3 H we e ong 3 e aoe e e 333 35 e cose seos soe os e E E Sos Cares eee eves ese e 0001 Current Test ID number A or M Automatic or Manual mode refer to Section 2 14 S Standby 1 Measurement 1 maximum flow rate 2 Measurement 2 reduced flow rate Message Line Various messages appear during operation describing the current function being performed or errors that have occurred refer to Section2 19 Message Line on page 38 Calibration Allows user to perform various calibration functions including calibrate verify view calibration dates view amplifier gain values or erase calibration
27. Figures 4 8 and 4 9 e Clean the gas sample inlet screen e Ensure that the exhaust port is not obstructed e Remove the unit s cover and ensure that the high and low sampling point hoses are properly connected between the flow measurement tube and their corresponding solenoid valves and that these hoses are not pinched or kinked e Ensure that no obstruction is present inside the flow measurement tube e If none of the above solves the problem return the unit to your nearest Bacharach Service Center for evaluation 52 Instruction 0055 9017 Maintenance Hi Flow Sampler Instruction 0055 9017 x GAS SAMPLE INLET SCREEN PSSS POPPY POOOY MODO PO OO OO MOF lt x one DJ 5 Y HIGH PRESSURE SAMPLING POINT Used to switch sampling point from the Flow Measurement Tube to the Calibration Gas connector mounted on top of the unit FLOW MEASUREMENT TUBE FLOW RESTRICTOR LOW PRESSURE SAMPLING POINT LEAK GAS SAMPLING POINT Figure 4 8 Gas Flow System 53 Maintenance Hi Flow Sampler Exhaust Background Gas Calibration Gas oe ee R AA m T E E E E m 7 Solenoid Valve Reducer 3 Places Pressure Transducer Leak Gas Detector Background Gas Detector Leak Gas Filter Figure 4 9 Plumbing Diagram 54 Instruction 0055 9017 Hi Flow Sampler Maintenance 4 8 Setting Date and Time Instruct
28. Hird Hiit Bes SF Soo T EI E RC ima Loran 9 REE lanai ia Hiit foose Sese Se E 1340 33 ORCOS pii pe geep pep et HEO LKL O LPA ee Where is the gain value in hexadecimal Hexadecimal or hex is like decimal except e hex uses the 16 hex digits 0 9 and A F vs using only the 10 digits 0 9 in decimal notation and e each position in a hex number is an exponent of 16 16 1 s place 16 16 s place 16 256 s place etc rather than an exponent of 10 as in decimal i e 10 1 s place 10 10 s place 10 100 s place etc For example a gain value of 298 decimal or base 10 equals 012A hex or base 16 2 Press ESC three times to return to the Main Screen 3 6 Erase Calibration Procedure The following procedure resets the gain of each calibration amplifier circuit to the factory default hexadecimal value of FFFF 1 From the Main Screen select Menu gt Calibration gt Erase Calibration to display the Erase Calibration Screen E E A A E a st 3 2 Select Yes to erase the calibration values Observe that the message Erasing Calibration appears at the bottom of the screen Select No to abort this procedure and return to the Calibration Menu Screen 3 Press ESC twice to return to the Main Screen VVV Instruction 0055 9017 45 Maintenance Hi Flow Sampler 4 Maintenance Routine maintenance of the Hi Flow Sampler consists of the following Charging the ba
29. ING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARISING FROM BACHARACH S NEGLIGENCE ACTUAL OR IMPLIED The remedies of the Buyer shall be limited to those provided herein to the exclusion of any and all other remedies including without limitation incidental or consequential damages No agreement varying or extending the foregoing warranties remedies or this limitation will be binding upon Bacharach Inc unless in writing signed by a duly authorized officer of Bacharach Register Your Warranty by Visiting www mybacharach com NOTICE 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 No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Bacharach Inc Patent 5 563 335 and 6 489 787 Copyright 2015 Bacharach Inc all rights reserved BACHARACH and HI FLOW are registered trademarks of Bacharach Inc All other trademarks trade names service marks and logos referenced herein belong to their respective owners Hi Flow Sampler Ta
30. Leak Gas Inlet Calibration Gas Inlet Background Gas Inlet HI FLOW SAMPLER BACKGROUND Figure 1 2 Top Panel Connections Instruction 0055 9017 7 Hi Flow Sampler Introduction 1 5 Technical Data TABLE 1 1 TECHNICAL SPECIFICATIONS Specification Information Displayed Description Date and Time Leak concentration in ppm or by volume Battery voltage Background gas concentration in ppm or by Leak rate in cfm volume Sampling flow rate in cfm Percent difference between leak rate measurements 1 and 2 Display 8 line by 20 character LCD Pushbutton Controls I O Enter V Down Arrow Up Arrow ESC Escape Communication Three DB9 connectors providing serial data transfer at 115200 baud to a personal computer or other peripheral device Measured Values Calculated Values Accuracy racy Sampling flow rate Sample gas concentration Battery voltage e Background gas concentration Leak concentration corrected for background gas level Leak rate Percent difference between leak rate measurements 1 and 2 Measurable Leak 0 05 to 8 00 SCFM 1 42 to 226 LPM e 0 05 to 6 00 SCFM ee 42 to 170 LPM Calculated Leak Rate 10 of Calculated Leak Rate 10 of reading by volume methane by volume methane Operating Oto 50 C 32 to 122 F Storage 40 to 60 C 40 to 140 F 5 to 95 RH non condensing Maximum 10 5 SCFM 297 LPM at full battery charge Operating Flow Points I
31. Replace cover that was removed in Step 1 PUMP BRACKET PUMP a CH SENSOR AAA ES PUMP BRACKET PUMP MULTI PIN SCREW CONNECTOR CONNECTOR PUMP a 00 PRINTED CIRCUIT BRACKET BOARD SCREW 3 PLACES Figure 4 6 Sensor or Pump Replacement 51 Maintenance Hi Flow Sampler 4 7 Flow Rate Verification This procedure verifies the Hi Flow blower is operating at proper capacity and the flow rate measurement is accurate Use a calibrated flow rate meter or anemometer with a minimum accuracy of 5 IMPORTANT To assure accurate flow readings conduct the following procedure in clean air free of any combustible gases 1 Install the flow meter onto the Hi Flow Sampler s gas intake see Figure 4 7 2 Place the Hi Flow Sampler into its Manual 1 Stage Mode per Section 2 14 2 2 Then start the blower by selecting Start from the Main Screen 3 The Flow cfm value as displayed on the Hi Flow Sampler s LCD should be within 5 of the measured cfm taking into account the flow meter s measurement error and any pressure or temperature corrections Attach the external flow meter to the Hi Flow Sampler s gas intake using the assembly s flexible coupling View A A Figure 4 7 Flow Meter Installation 4 With a fully charged battery pack the measured flow rate should be greater than 9 cfm If not perform the following see
32. Section 4 4 3 Check Leak Pump message Flow to the leak gas pump has been severely reduced Check that the appears at bottom of display internal tubing has not become blocked see Figure 4 10 Also check the condition of leak gas sensor filter replace as necessary per Section 4 4 2 Check Background Calibration The background gas sensor needs to be calibrated per Section 3 message appears at bottom of display Check Leak Calibration The leak gas sensor needs to be calibrated per Section 3 message appears at bottom of display Check Background Offset The background gas sensor did not zero properly during start up Switch message appears at bottom of OFF instrument and restart in an area with clean air Replace sensor if display necessary Check Leak Offset message The leak gas sensor did not zero properly during start up Switch OFF appears at bottom of display instrument and restart in an area with clean air Replace sensor if necessary 58 Instruction 0055 9017 Hi Flow Sampler Troubleshooting Symptom Probable Cause and Remedy Check Leak Rate Difference The calculated difference between leak rates 1 and 2 was greater than message appears at bottom of 10 display Check Zeroing Bypass message The ESC key was pressed during startup thus bypassing the normal sensor appears at bottom of display zeroing process Although the instrument will operate under this condition no leak
33. Set Flow Units Select to set flow rate display to either lpm liters per minute or cfm cubic feet per minute Select Language Select to set menu language to English or Russian Menu Mode Select to set menu to basic mode or expanded mode Not Avail is displayed when a value cannot be calculated from available information Selections are made by using the Av keys to highlight the desired function and then pressing the I O J key to activate that function 16 Instruction 0055 9017 Hi Flow Sampler 2 8 2 Expanded Main Mode Date and Time Date displayed as mm dd yy while time is displayed in a 12 hour format The date and time are set per Section 4 8 Btry V Battery voltage 1 2 Difference between test measurements 1 and 2 in percent Flow lpm Sample flow rate in either liters min or cu ft min Back Measured background gas level in either percent by volume or ppm Leak Measured natural gas leak concentration at the current sample flow rate in either percent by volume or ppm Leak lpm Calculated leak rate in either liters min or cu ft min Speed LO lt gt HI Blower speed indicator Save Select to save all current measurement parameters in memory Start Stop Select to Start and Stop a test Menu Select to display the first of several submenus refer to Section 2 9 ii Battery status icon refer to Section 2 10 0001 Current Test ID num
34. adsheet Instruction 0055 9017 Hi Flow Sampler Operation 2 15 2 View Records View the records stored in memory on the unit s LCD screen as follows 1 Access the Review Record Screen from the Expanded Main Screen by selecting Menu gt Access Records gt View Records This screen allows the user to view a short summary of each record stored in memory If no records are in memory then the message No Records Saved briefly appears in the message line The first two lines in this screen contain the Test ID information as entered per Section 2 17 Access Test IDs Where x xx is the recorded leak rate in ether lpm or cfm yy y is the percent difference between measurements 1 and 2 2 Usethe Av keys to scroll through the saved records 3 Press ESC three times to return to the Main Screen 2 15 3 Erase Records Erase all records from memory as follows 1 From the Expanded Main Screen select Menu gt Access Records gt Erase Records so qe one es seg ooo fp fs pis EME a S oF oad Ba P eneo 33 irie 33 3 Observe the message Erasing all records appears at the bottom of the display during the erase process Instruction 0055 9017 25 Operation Hi Flow Sampler 2 16 Importing Saved Data into a Spreadsheet Test records that were downloaded to a personal computer per Section 2 15 1 can be imported into spreadsheet programs that are capable of importing comma delimited f
35. attery pack s charger jack Note Connecting the charger to the Battery Pack disables the battery s output making it impossible to both charge the battery and run the instrument 3 Allow a completely discharged battery pack to charge from 8 to 10 hours 46 Instruction 0055 9017 Hi Flow Sampler 120 VAC Power Cord supplied with instrument 240 VAC Power Cord must be supplied by customer Maintenance CHARGER FEF BATTERY PACK Figure 4 1 Charging the Battery Pack 4 3 Removing the Cover Instruction 0055 9017 When instructed to do internal maintenance remove its protective cover as follows 1 Do the following before removing the instrument from the backpack Disconnect battery pack Unscrew metal cage diffuser from the instrument s gas exhaust port Disconnect ground clamp wire 2 Remove instrument from backpack 3 Remove screws from cover as shown in Figure 4 2 then pull cover away from unit Remove 4 screws from top and bottom N 9 Va Remove 11 screws from both sides Remove 2 screws 9 S After removing all screws pull cover S S away from unit O N S Figure 4 2 Removing the Cover 47 Maintenance Hi Flow Sampler 4 4 Replacing the Internal Filters Three internal filters protect the instrument from being contaminated by dust and dirt Replace these filters when they look contaminated A good indication that a filter needs rep
36. ber Operation set e y 53 59 5 56 98 3 Seeeede 8 3 3 8 3 3 8 ss ose e eee a i OA A Sed 2 FF E E S E os FS Steet Sono eS 3 Eee od e S sees eee 03 sce ced see o SS 35 8 e a EA E oe BE iaa r Asi E Poe ey 2 233 33 Ass 3 SiS sos Se See See See A or M Automatic or Manual mode refer to Section 2 14 S Standby 1 Measurement 1 maximum flow rate 2 Measurement 2 reduced flow rate Message Line Various messages appear during operation describing the current function being performed or errors that have occurred refer to Section2 19 Message Line on page 38 Calibration Allows user to perform various calibration functions including calibrate verify view calibration dates view amplifier gain values or erase calibration Set Flow Units Select to set flow rate display to either lpm liters per minute or cfm cubic feet per minute Select Language Select to set menu language to English or Russian Menu Mode Select to set menu to basic mode or expanded mode Operating Mode Select to set operating mode to automatic or manual mode Access Records Select to send to a PC view on LCD or erase all saved records Access Test IDs Create a new Test ID edit an old one send the Test IDs to a computer or erase all existing Test IDs Not Avail is displayed when a value cannot be calculated from available information
37. ble of Contents Table of Contents L INTRODUCTION cieee aa aaaea aa e a Oa aa vawsu boas cual aaa ewes adoa i de aae eaa e aaea Ea 5 1 1 General Description and Use ia 5 1 2 Material UPOO esa aS 6 1 3 CONTO UNED IN eo eds ad 6 1 4 Top Panel Connections and Control Ssss nesar E E A RS E NS 7 1 5 Tech ical Data idad ds 8 O A cemecace vac E das eagecace oumsiiaces etuicasecumeccacvetvcecscupecuacecmeacs conscaneeusedaaseuree 9 2 1 Operatine PRECAUTIONS S eea a sae vannones R a saa Sammune me tesaataa seas 9 2 1 1 UMSS tra 9 2 1 2 E ateretacacactasiacesis saeacsunatarcset N ener eussauncasanenn aaee 9 2 1 3 sensor Hooding ANG POISONING iii 9 2 2 Ee ys COPS 110 liz A und ssanteieeanaeaees 10 2 3 Sampling Hose and Attachment CONNECTIONS ccccsssscccsssceccesccccescccceusceseucecseaaecesseecessueseeseeeessaeeess 10 2 4 GVO UGS arras 11 2 5 Eure lo af 0 gy od a sna A Eo o O Oar A A eS a oR a 11 2 5 1 Flange Strap34 30 and Ls ao 12 2 5 2 Beveled Nozzle TOOG S ad A il eee 12 2 5 3 Capture BaP A T E wenden eee eae 12 2 5 4 sn EAE EE E OAA 13 2 5 5 ACMA CreViGe TOO leeran T O E T eee 13 2 6 Turning ON the Hi Flow o A E ee eaeaneIS 14 2 7 Turning OFF the Hi Flow Sampe aana T A AO eee ee ek 14 2 8 Selecting the Basic or Expanded Menu Mode 2 cccccsssscccesseccceneccccenecccaenecesaeccesauecessauecessaeeeesauesessaneeees 15 2 8 1 Basie Malm MOG GC orde 16 2 8 2 Expanded Mal MOE ee ee es 17 2 9 Menus dd 18 2 10
38. ced product is in conformity with the provisions of the following standard s and is in accordance with the following directives and standards Standard s EN 50270 2006 Product specific standard EN 55011 2009 Emissions Product specific standard Directive s 2004 108 EC In accordance with EMC Directive Signature Name Doug Keeports Title VP of Product Development Date 5 December 2011 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach Inc Instruction 0055 9017 63 Printed in U S A BACHARACH Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Fax 724 334 5001 Toll Free 1 800 736 4666 Website www mybacharach com E mail help mybacharach com A 1509001
39. dual gas present inside the sensor chambers If a sensor fails to zero a message appears at the bottom of the LCD describing the cause of the failure Refer to Section 6 Troubleshooting for possible causes and remedies for this failure ity sgis qee pan ees e Seest geere ense geoes Levees oe ense e 3 3 3 After the sensors are zeroed either the instrument s Basic or Expanded Main Screen appears refer to Section 2 8 The example below shows the Basic Main Screen LIZ SSS A ds Aa i The arrow symbols on the left indicate that TEack E i UA there are more items to view above and or MAS Hia MiK below the current display Lak Lol AVOL ia 3 TE e Press the A and v keys to view additional items mes PARE 2 7 Turning OFF the Hi Flow Sampler 14 Turn OFF the unit by flipping the ON OFF switch to its OFF position Instruction 0055 9017 Hi Flow Sampler Operation 2 8 Selecting the Basic or Expanded Menu Mode Select the Basic or Expanded Menu Mode as follows 1 From either the Basic or Expanded Main Screen select Menu gt Menu Mode 2 3 Press ESC to return to the Main Screen Refer to Sections 2 8 1 and 2 8 2 for detailed descriptions of the information contained in the Basic and Expanded Main Screens Instruction 0055 9017 15 Operation 2 8 1 Basic Main Mode id A T jj 33 47 3 peat e s gO fop pr wee EF A
40. e captured by wrapping this attachment around the edge of the flange and securing in place using the two Velcro strips Attach the Hi Flow Sampler s main sampling hose to the flange strap by simply pushing the end of the hose into the attachment s hose coupling A click should be heard when the hose has been successfully connected Release the hose by pushing in the coupling s release mechanism VELCRO STRIP 7 e pe VELCRO STRIP HOSE COUPLING A Push in latch mechanism to release hose Figure 2 4 Flange Strap 2 5 2 Beveled Nozzle Tool 6 5 and 24 For simple pin hole type leaks position this attachment directly over the leak source Figure 2 5 Beveled Nozzle Tool 2 5 3 Capture Bag This reusable capture bag measures 36 x 36 and can be used to completely surround a component that may have multiple leak sources or contains a leak source that is difficult to pinpoint or reach Attach the Hi Flow Sampler s main sampling hose to the bag by simply pushing the end of the hose into the bag s hose coupling A click should be heard when the hose has been successfully connected Release the hose by pushing in the coupling s release mechanism Use the draw strings to close up the end of the bag DO NOT however completely close off the bag allow air to flow into the bag so as to replace the volume of gas and air being removed during the test 12 Instruction 0055 9017 Hi Flow Sampler Operation
41. e the Hi Flow Sampler s time display 4 9 Resetting the Microprocessor Should the instrument lock up or fail to turn OFF reset the microprocessor by disconnecting the battery pack for several seconds 56 Instruction 0055 9017 Hi Flow Sampler Troubleshooting 9 Troubleshooting 5 1 Instrument Repair It is recommended that field repair of the Hi Flow Sampler be limited to e Cleaning gas inlet screen e Replacing internal filters e Replacing sensors e Replacing sensor assembly pump e Simple checks of printed circuit board connectors All other repairs should be performed by an authorized Bacharach Service Center Any repairs performed by an unauthorized service organization will void the instrument s warranty and release Bacharach Inc of any implied or written product liability Before returning an instrument for repair you may be able to determine and resolve a problem using the Troubleshooting Guide in Section 5 2 5 2 Troubleshooting Guide The following table lists the causes and remedies for most of the problems that may arise with the instrument If none of the suggested remedies resolves the problem or for help with any problem that is not listed contact one of Bacharach Service Centers listed in Section 6 3 TABLE 5 1 TROUBLESHOOTING GUIDE Symptom Probable Cause and Remedy Instrument completely a Battery pack is dead Recharge battery pack per Section 4 2 nonfunctional won t turn ON
42. ed values being displayed on the hand held control unit Supplied e High Flow Sampler Unit e Backpack e 6 Foot 1 5 Inch Hose Assembly e Battery Pack Qty 2 e Battery Charger w Power Supply e Control Unit with LCD and 4 button keypad e Assortment of Attachments for complete capture of the gas leak e Flange Strap 34 80 and 137 e Capture Bag 36 x 36 e Beveled Nozzle 6 5 and 24 e Bag Nozzle e Bellows Tool e Claw Tool 1 3 Control Unit Description The control unit consists of an 8 line by 20 character LCD and the four pushbuttons I O 4 Turns unit ON or selects highlighted item on LCD A Scrolls up through displayed items on LCD V Scrolls down through displayed items on LCD ESC Cancels warm up Cancels a leak rate test Cancels calibration Exits to previous display 8 Line by 20 Character LCD Figure 1 1 Control Unit Instruction 0055 9017 Introduction Hi Flow Sampler 1 4 Top Panel Connections and Controls The top panel contains the following items ON OFF Switch Turns unit ON and OFF Computer Port RS232 communications port for downloading stored test data to an external computer Leak Gas Inlet Main hose connection used to collect gas from leak source GAS Inlet Calibration gas connection Background Inlet Gas hose connection used to sample background levels of CH RS232 Communications Port COMPUTER PROGRAM Cable to Control Unit ON OFF Switch
43. ee See ote Instruction 0055 9017 33 Operation 34 Hi Flow Sampler The user is now asked to choose a new or different Test ID Selecting Yes causes the Access Records menu to appear refer to Section 2 15 After selecting or creating a new Test ID start the measurement by pressing ESC until the Main Screen appears Selecting No returns the display to the Main Screen and starts the measurement using the current Test ID Pda de de od HETESTE ETE 3 3 fe eet foet Foo olo o Optional The instrument normally controls the flow rate for measurements 1 and 2 however the user can manually set the flow rate using the Speed function Each press of the I O key will lower the flow rate as indicated by the speed bar moving to the left y 3 E mad Rind FF Peer pene Speed Bar Eeee Sees es ee 3 a gny j e ps eces pmo pm py pim Es After both measurements are complete the values in the Main Screen are put on hold as indicated by H appearing at the bottom of the screen allowing the user to make note of these values before turning off the instrument or proceeding to the next measurement In the examples below the measured leak concentration was 15 gas during the first measurement and 18 gas in the second while the calculated leak rates were 42 5 and 40 8 lpm respectively A difference of 4 IMPORTANT For a test to be considered valid the percent difference between measure
44. em together along with connecting together the background gas hose Choose an attachment refer to Section 2 5 Attachments that will capture the entire leak and attach it to the end of the hose 2 4 Grounding WARNING To prevent the possibility of a static discharge the Hi Flow Sampler must be grounded while conducting a leak test Attach the unit s grounding clamp to the nearest earth ground Tip When not in use the grounding clamp can be stored by attaching it to one of the shoulder straps Before conducting a test attach grounding clamp to nearest earth ground QRS 599598 POSISI Figure 2 3 Grounding Clamp 2 5 Attachments Instruction 0055 9017 A A variety of attachments are available for the Hi Flow Sampler that simplifies the task of capturing the entire gas leak Choose the appropriate attachment for the type of component being tested from the ones listed below and then connect it to the end of the instrument s main sampling hose CAUTION Attachments can have the effect of concentrating the leak Ensure that enough air is present when first sampling to support catalytic mode of the instrument Flooding the sensor with high concentrations of methane at startup can result in erroneously low readings and prevent transition to thermal conductivity mode 11 Operation Hi Flow Sampler 2 5 1 Flange Strap 34 80 and 137 Flange leaks can b
45. entire gas leak is not being captured Use the proper attachment to capture leak b Faulty sensor s Calibrate both CH sensors per Section 3 Replace any sensor that fails to calibrate c Flooding poisoning or high VOC content results in erroneously low or unstable readings Sensor does not calibrate a Wrong calibration gas or insufficient flow being applied to sensor properly Ensure that the calibration setup is correct b Depleted sensor Replace sensor and recalibrate Calibration Failed message Calibration parameters not within programmed limits due to either appears at bottom of display insufficient calibration gas flow or new calibration value was greater than 50 of the old value Check calibration setup and re perform the calibration procedure Replace sensor if necessary Memory Full message appears 1000 test records have already been stored in memory Save all test at bottom of display records per Section 2 15 1 and or erase memory per Section 2 15 3 No Records Saved message A send records command was given with no records stored in memory appears at bottom of display Check Background Pump Flow to the background gas pump has been severely reduced Check that message appears at bottom of the background hose is not kinked or blocked or the internal tubing has display not become blocked see Figure 4 10 Also check the condition of background gas sensor filter replace as necessary per
46. g the name that was entered in Step b After HyperTerminal is running click Transfer gt Capture Text gt Start to accept the default drive directory filename to which all received data will be stored as an ASCII text file Note The captured text file will be stored on the hard drive in the folder shown in the File dialog box If desired click Browse to select a different drive directory and filename The next time data is captured it will be stored under the same location and filename Tip Changing the filename extension to CSV comma separated variable will allow the file to be directly opened in the spreadsheet program For example double clicking the filename CAPTURE CSV in Windows Explorer will automatically start Microsoft Excel and load the file From the High Flow Sampler s Expanded Main Screen start the download process by selecting Menu gt Access Records gt Send Records Observe that the Hi Flow LCD displays the message Sending record x of y 115 2kbps where x is the current record being sent and y is the number of records in memory Also observe that HyperTerminal displays the data as its being received nn e e o After all data has been transmitted stop HyperTerminal from capturing data by clicking Transfer gt Capture Text gt Stop The saved data can now be viewed in a spreadsheet for analysis as described in Section 2 16 Importing Saved Data into a Spre
47. he COMPUTER connector of the Hi Flow For computers having a 25 pin or USB COM port the user must supply the appropriate adapter or use a serial cable with appropriate connectors on each end On the computer start HyperTerminal by doing one of the following If HyperTerminal has already been set up to communicate with the Hi Flow Sampler then select Start gt Programs gt Accessories gt Communications gt HyperTerminal and double click the filename or icon that has been associated with the instrument If HyperTerminal has never been run in association with the Hi Flow Sampler then a new HyperTerminal connection needs to be made as follows a Select Start gt Run In the Run box type hypertrm exe and click OK The New Connection dialog box should appear b Type in a New Connection Name such as HiFlow Click OK to select the default icon if desired select a different icon before clicking OK The Connect To dialog box should appear 23 Operation 24 Hi Flow Sampler c Click the Connect using drop down menu and choose the COM port to which the Hi Flow is connected Then click OK to display the COM Properties dialog box for that COM port d Set Port Settings to Bits per second 115200 Data bits 8 Parity None Stop bits 1 Flow control None Then click OK to display HyperTerminal s main window e Click File gt Save This creates a file with an ht extension usin
48. he sensor chambers and prolongs the life of the sensors 2 2 Battery Connection WARNING Explosion hazard DO NOT connect or disconnect the battery in an unsafe atmosphere The instrument s power cord is located inside the backpack s right side pocket Insert a battery pack into this pocket and connect it to the power cord oe POWER CORD located inside ae Sa backpack pocket Figure 2 1 Battery Pack Connection 2 3 Sampling Hose and Attachment Connections Connect the sampling hose to the instrument s leak gas inlet by clamping the hose to the inlet as shown in Figure 2 2 Also connect the background gas sampling hose to the unit s BACKGROUND inlet Connect appropriate attachment capable of capturing entire gas leak When installing multiple sections of _7 hose use this connector to interconnect the background gas hoses Close clamps to secure hose During a measurement position the background gas hose opposite the leak Aight sta Mad Nn source such that the leak source will not contribute to the background unit s BACKGROUND inlet dle 3 Figure 2 2 Hose and Attachment Connections 10 Instruction 0055 9017 Hi Flow Sampler Operation The standard sampling hose is 6 foot long If a longer length is needed the optional 12 foot hose P N 0055 0287 can be ordered or additional sections of hose can be added by simply clamping th
49. ialog box 3 Change the Files of type to Text Files Then navigate to the directory containing the text file to be imported 4 Double click the desired filename to display the Text Import Wizard Step 1 of 3 dialog box 5 Select the Delimited radio button then click Next to display the Text Import Wizard Step 2 of 3 dialog box 6 Under Delimiters select the Comma check box Then click Next to display the Text Import Wizard Step 3 of 3 dialog box 7 Click Finish to create the spreadsheet Instruction 0055 9017 27 Operation Hi Flow Sampler 2 17 Access Test IDs 28 Note Access Test IDs can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 Saved test records can be identified e g location of test type of test name of operator etc by manually entering up to two lines of text with each line containing a maximum of 20 alphanumerical characters This information will be associated with all succeeding tests and will appear when the test record is either viewed or printed The chosen Test ID remains in effect until a new Test ID is selected Selecting Access Test IDs from the Expanded Menu System allows the user to select a previously entered Test ID create a new Test ID or edit an old one send the Test IDs to a computer or erase all existing Test IDs 2 17 1 Select Test IDs Select a Test ID as follows 1 From the Expanded Main Screen select Menu gt Access Test I
50. iles Note that each data record consists of 24 fields some of which may be blank because of options not being installed TABLE 2 1 COMMA DELIMITED FIELDS Field Label in Column Heading Description z Section 5 3 Error Codes in Saved Test Records Test Description Test ID Information refer to Section 3 15 Access Test IDs 26 Instruction 0055 9017 Hi Flow Sampler Operation TABLE 2 2 TYPICAL SPREADSHEET RECORD INSTRUMENT DATE 1 TIME 1 BTRY 1 FLOW 1 BACK 1 LEAK 1 LEAK 1 SERIAL MM DD YY HH MM SS CFM CFM as ss ooo saso 19 7 a ue pas a DATE 2 TIME 2 BTRY 2 FLOW 2 BACK 2 LEAK 2 LEAK 2 LEAK 1 2 ERROR MM DD YY HH MM SS V CFM CFM CODES TEST DESCRIPTION Test Location 1 Operator John Doe Test Location 2 Operator John Doe Row 1 Column Headings Row 2 Record 1 Typical Test Automatic Mode Row 3 Record 2 The following describes how to generate a spreadsheet from a comma delimited text file using Microsoft Excel 2000 If a different spreadsheet program is being used then please refer to its instruction manual for information on how to import comma delimited text files Tip f the text file was saved with the filename extension CSV as described in Section 2 15 1 a spreadsheet will automatically be created when that file is opened in Microsoft Excel 1 Start Microsoft Excel 2 Click File then click Open to display the Open d
51. ion Highlight Manual 1 Stage and then press the I O 4 key ai mal i g pob eee pope eor pe 3 8 F 223308 EO OPN te owe F535 OS te e o nat op poe g g eeg iiri pri iri eo iT IE E vf ii Press ESC to return to the Main Screen Observe that M should appear at the bottom of the screen 2 15 Access Records Note Send Records can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 Selecting Access Records from the Expanded Menu System allows a user to either 1 send all saved records to a personal computer 2 view the records on the unit s LCD screen or 3 erase all saved records 2 15 1 Send Records All the measured and calculated values that were saved in memory can be downloaded to a personal computer as comma delimited ASCII text which can later be imported into most spreadsheet programs for analysis Instruction 0055 9017 The following describes how to download saved records to a computer that is running Windows HyperTerminal as the communications program If a different operating system and or communications program is being used then please consult the appropriate instruction manuals for those products Note Send Records can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 1 Install serial data cable P N 104 4027 straight through 6 foot DB9 male to DB9 female between the computer s COM port and t
52. ion 0055 9017 The following describes how to set the date and time as displayed on the Hi Flow Sampler s LCD using a personal computer that is running Windows HyperTerminal as the communications program If a different operating system and or communications program is being used then please consult the appropriate instruction manuals for those products 1 Install serial data cable P N 104 4027 straight through 6 foot DB9 male to DB9 female between the computer s COM port and the Hi Flow Sampler s COMPUTER connector For computers having a 25 pin or USB COM port the user must supply the appropriate adapter or use a serial cable with appropriate connectors on each end 2 On the computer start HyperTerminal by doing one of the following If HyperTerminal has already been set up to communicate with the Hi Flow Sampler then select Start gt Programs gt Accessories gt Communications gt HyperTerminal and double click the file name or icon that has been associated with the instrument If HyperTerminal has never been run in association with the Hi Flow Sampler then a new HyperTerminal connection needs to be made as follows a Select Start gt Run In the Run box type hypertrm exe and click OK The New Connection dialog box should appear b Type in a New Connection Name such as HiFlow Click OK to select the default icon if desired select a different icon before clicking OK The Connect To dialog bo
53. laced is when the instrument s gas response time increases 4 4 1 Leak Gas Filter The leak gas filter is located between the sampling port on the flow measurement tube and its associated solenoid valve on the printed circuit board See Figure 4 3 Equipment Required e Medium Phillips Head Screwdriver e Replacement Filter P N 07 1563 Procedure 1 Remove the cover per Section 4 3 2 Remove tubing from old filter s inlet and outlet 3 Install tubing on new filter making sure that the filter s flow arrow points away from the flow measurement tube 4 Replace the cover that was removed in Step 1 Install filter with its arrow pointing away from the flow measurement tube Figure 4 3 Leak Gas Filter 48 Instruction 0055 9017 Hi Flow Sampler Maintenance 4 4 2 Leak Gas Sensor Filter The leak gas sensor filter is located inside the flow block of the leak gas sensor assembly See Figure 4 4 Equipment Required Medium Phillips Head Screwdriver Replacement Filter P N 0055 0045 Procedure 1 Remove the cover per Section 4 3 2 Remove tubing from inlet of sensor assembly 3 Unscrew the filter chamber s gas inlet fitting then pull out old filter and discard 4 Insert new filter reinstall the inlet fitting then reinstall tubing 5 Replace the cover that was removed in Step 1 4 4 3 Background Gas Sensor Filter The background gas sensor filter is located inside the flow block of the backg
54. ments 1 and 2 must be less than 10 Scroll up to the 1 2 function on the Main Screen to see the percent difference between the last two measurements zun PA nmr MAS i ege i mtg ET den y When in the automatic mode measurements are automatically saved These saved measurements along with their associated Test IDs can be downloaded to a personal computer at a later time for analysis Refer to Section 2 16 Importing Saved Data into a Spreadsheet Instruction 0055 9017 Hi Flow Sampler Operation 2 18 3 Leak Rate Measurement Manual 2 Stage Mode Instruction 0055 9017 Note The Manual 2 Stage Mode can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 1 If not already done place the instrument into its Manual 2 Stage mode Refer to Section 2 14 2 1 Manual 2 Stage Mode 2 Choose an attachment that will ensure the complete capture of the gas leak Connect this attachment to the end of the Hi Flow Sampler s main sampling hose and position the attachment s inlet over the leak source 3 Position the inlet of the instrument s background gas sampling hose opposite the leak source such that the leak source will not contribute to the background measurement 4 Begin the measurement process by selecting Start from the Main Screen 5 The user is now asked to choose a new or different Test ID Selecting Yes causes the Access Records menu to appear refer to Section 2
55. nitial flow 10 SCFM 283 LPM Second flow 8 SCFM 226 LPM The second flow rate is approximately 75 of the initial flow Measurement Method Differential pressure across restriction Humidity Sampling Flow Rate Natural Gas Sensor Battery Agency Approvals PCCUACY ina 5 of reading Detection Method Catalytic oxidation Thermal conductivity Range Catalytic oxidation O to 5 by volume methane Range Thermal conductivity 5 to 100 by volume methane ACCUNACY df 5 of reading or 0 02 methane whichever is greater Voltage 4 8 V max Type Intrinsically Safe NiMH rechargeable pack Recharge Time 8 to 10 hrs Run Time gt 4 5 hours continuous operation 20 C 68 F Stores up to 1000 individual test parameters 18L x 12W x 7H inches 457 x 305 x178 mm 2015 09 Designed to be intrinsically safe for use in hazardous locations Class Division 1 Groups A B C amp Din North America CAN CSA C22 2 No 157 June 1992 ANSI June 27 2002 UL913 2002 Intrinsically Safe Apparatus and Associated Apparatus for use in Class Division 1 Hazardous Classified Locations CE Mark See section 8 for Declaration of Conformity statement VVV Instruction 0055 9017 Hi Flow Sampler Operation 2 Operation 2 1 Operating Precautions 2 1 1 Limits of Use The Hi Flow Sampler was developed for use on natural gas streams with high methane content After introduction and industry acceptance
56. nstall printed circuit board into flow block taking care to properly position the board as shown in Figure 4 6 6 Replace three screws and tighten to secure board Reattach the pump and multi pin connectors to the circuit board 7 Replace cover that was removed in Step 1 8 Calibrate the instrument per Section 3 Calibration Note that if a new sensor is installed without performing a calibration either the message Check Background Calibration or Check Leak Calibration will appear at the bottom of the LCD when the instrument is turned ON 50 Instruction 0055 9017 Hi Flow Sampler Maintenance 4 6 Pump Replacement Instruction 0055 9017 The pump located in either the leak gas or background gas sensor assembly see Figure 4 5 may become inoperative due to water or solid particles getting into the valves This will require replacement of the pump to correct Equipment Required e ea Allen Wrench e Replacement Pump Assembly P N 0055 0061 Procedure 1 Remove cover per Section 4 3 2 Back off the pump bracket screw using a gt 64 Allen wrench then rotate bracket arm to free pump See Figure 4 6 3 Unplug pump connector from printed circuit board and lift pump straight up 4 Install the new pump by lining up the pump s inlet and outlet tubes with the two flow block holes and pushing into place Swing bracket arm over pump and tighten realigning pump as necessary to make a proper fit 5
57. on 1 The instrument automatically compensates for the different specific gravity values of air and natural gas thus assuring accurate flow rate calculations Leak Flow x GaS sample GaS background X 10 where Leak rate of gas leakage from source cfm Flow sample flow rate cfm GaS sample concentration of gas from leak source Gas packeraund background gas concentration To ensure that the instrument is capturing all the gas that is escaping from the component two measurements are performed at two different flow rates The first measurement is taken at the highest possible flow rate followed by a second measurement at a flow rate that is approximately 70 80 of the first If the two calculated leak rates are within 10 of each other then it can be assumed that all gas has been captured during the test CAUTION Additional precautions and considerations are required when using the instrument in natural gas streams of mixed composition Refer to section 2 1 for guidelines The instrument is packaged inside a backpack thus leaving the operator s hands free for climbing ladders or descending into a confined space The instrument is packaged inside a backpack thus leaving the operator s hands free for climbing ladders or descending into tight spaces The instrument is controlled by a handheld Control Unit consisting of an LCD and a 4 key touch pad which is attached to the main unit via a 6 foot coiled cord The
58. pled Create a maintenance log to keep track of when an instrument was calibrated and then use this log to help develop a calibration schedule In the case of mixed gas streams it is recommended to calibrate prior to use each day 2 1 3 Sensor Flooding and Poisoning Instruction 0055 9017 The Hi flow sensors operate in catalytic mode from O up to 5 by volume methane concentration and in thermal conductivity mode from 5 up to 100 methane by volume The rapid introduction of high methane concentrations may inhibit the sensors operation in catalytic mode by starving the catalytic reaction of oxygen Flooding the sensor in this way can result in erroneously low readings and prevent transition to thermal conductivity mode In cases where very large leaks are suspected approaching the limits of the instrument s measurement range 8SCFM the Hi Flow should be turned on sampling air adjacent to the leak and slowly moved toward the largest source of the leak Please refer to section 2 3 for specific details on the attachments provided for leak capture Operation Hi Flow Sampler IMPORTANT Avoid sampling leaded gasoline vapors or gases or vapors that contain silicones or sulfur compounds Tetraethyl lead silicones and sulfur compounds can form contaminating compounds on the sensor element poison the sensor with resulting loss in sensitivity Always purge the instrument with clean air after testing This removes combustibles from t
59. round gas sensor assembly See Figure 4 4 Replace filter as previously described for the leak gas sensor filter Leak Gas Sensor Assembly Background Gas Sensor Assembly Unscrew inlet gas fitting and pull filter from sensor assembly Ab ae ees 4 st 7 FILTER Figure 4 4 Leak Gas amp Background Gas Sensor Filter Replacement Instruction 0055 9017 49 Maintenance Hi Flow Sampler 4 5 Gas Sensor Replacement Replace a gas sensor when it fails to calibrate per Section 3 Calibration The gas sensors are located inside their associated flow blocks of the leak gas and background gas sensor assemblies See Figure 4 5 Leak Gas sensor Assembly Background Gas sensor Assembly Figure 4 5 Leak Gas amp Background Gas Sensor Assemblies Equipment Required e Medium Phillips Head Screwdriver e Replacement Sensor P N 0055 0040 Procedure 1 Remove cover per Section 4 3 2 Remove the pump connector and multi pin connector from printed circuit board noting orientation of connectors See Figure 4 6 3 Remove three screws from printed circuit board then carefully pry the board straight up from the flow block The gas sensor is the silver cylindrical piece in the center of the circuit board 4 Pull sensor from circuit board and replace with a new sensor making sure that the new sensor is firmly seated into its receptacles and bottomed on circuit board 9 Rei
60. s before turning off the instrument or proceeding to the next measurement In the example below the leak concentration was 18 gas the leak rate was 40 8 lpm and the percent difference between measurements 1 and 2 was 4 IMPORTANT For a test to be considered valid the percent difference between measurements 1 and 2 must be less than 10 Scroll up to the 1 2 function on the Main Screen to see the percent difference between the last two measurements E poete gt s gereees es a3 Cy o Maar ees 333 cd cti 3 3 rr Ta ee EEE EE 24 it eeseees coseose seseeee o o O i e oe oe e 7 3 H H H does qe e 333 te e Sooke ose r Pas ae ae AS PAarars dF HETESTE ETE SE M EAn An E a SO Saved measurements can be downloaded to a personal computer at a later time for analysis Refer to Section 2 16 Importing Saved Data into a Spreadsheet 2 18 4 Leak Rate Measurement Manual 1 Stage Mode Note The Manual 1 Stage Mode can only be selected if operating in the Expanded Menu Mode Refer to Section 2 8 l 36 If not already done place the instrument into its Manual 1 Stage mode Refer to Section 2 14 2 2Error Reference source not found Instruction 0055 9017 Hi Flow Sampler Instruction 0055 9017 Operation Choose an attachment that will ensure the complete capture of the gas leak Connect this attachment to the end of the Hi Flow Sampler
61. s still present in either sensor chamber when ESC is pressed the instrument will automatically begin to purge the sensors until all gas is removed from the instrument 3 4 Gas Calibration Procedure Instruction 0055 9017 This procedure calibrates both the leak gas sensor and the background gas sensor at 2 5 and 100 CH After setting up the calibration equipment as described in Section 3 2 proceed to calibrate the sensors as follows NOTE The Hi Flow Sampler can be calibrated on the low end with a mixture of methane between 0 75 2 75 for catalytic and 95 100 methane on the thermal conductivity side 1 Before turning ON the instrument be sure that the calibration equipment is not connected to the instrument s GAS or BACKGROUND inlet port and that the instrument is in an area of clean air 2 Turn ON the instrument and wait its warm up period to complete before proceeding to Step 3 3 From the Main Screen select Menu gt Calibration gt Calibrate Sensors to display the Sensor Calibration Screen 4 Using the Av keys highlight the sensor to be calibrated along with its gas level In the example above the background sensor will be calibrated using 2 5 CH 43 Calibration 44 J Hi Flow Sampler Apply the appropriate level of calibration gas from the calibration equipment to the instrument s GAS or BACKGROUND inlet port In the example above apply 2 5 CH to the BACKGROUND port Then press the I O
62. saseducdsnvsvdsevecicuensecussdsyddedus nnes E a 59 6 PARTS Gt SERVICE ooo ooo coseno 61 6 1 Replacement PES A i 61 6 2 Optional ACCESOO ur 61 6 3 SEF ES CONOS aia aia 62 7 DECLARATION OF CONFORMITY oia 63 VVV 4 Instruction 0055 9017 Introduction Hi Flow Sampler 1 Introduction 1 1 General Description and Use Instruction 0055 9017 A A WARNING The High Flow Sampler is not to be used in any application that is beyond its intended purpose or beyond the scope of its specifications Failure to follow this warning can result in personal injury or damage to the equipment For details on appropriate use refer to the general description application and operation discussions in this manual WARNING The High Flow Sampler is not to be used as a safety device for the personal protection of the user or others The Hi Flow Sampler is a portable intrinsically safe battery powered instrument designed to determine the rate of gas leakage around various pipe fittings valve packings and compressor seals found in natural gas transmission storage and compressor facilities The Hi Flow Sampler determines a component s leak rate by sampling at a high flow rate to capture all the gas leaking from the component along with a certain amount of surrounding air By accurately measuring the flow rate of the sampling stream and the natural gas concentration within that stream the gas leak rate can be calculated using Equati
63. ter setting up the calibration equipment as described in Section 3 2 proceed to check the instrument s sensor calibration as follows 1 Before turning ON the instrument be sure that the calibration equipment is not connected to the instrument s GAS or BACKGROUND inlet port and that the instrument is in an area of clean air 2 Turn ON the instrument and wait for its warm up period to complete before proceeding with Step 3 3 Apply 2 5 CH from the calibration equipment to the instrument s BACKGROUND inlet port 4 From the Main Screen select Menu gt Calibration gt Verify Calibration to begin the calibration verification process Observe that the gas sampling pump motors should start Wait several minutes for the gas reading to stabilize At this time the gas concentration shown on the display should match the concentration stamped on the calibration gas cylinder Instruction 0055 9017 Hi Flow Sampler Calibration 9 Disconnect the hose from the BACKGROUND inlet port and connect it to the GAS inlet port 6 Again wait several minutes for the gas reading to stabilize At this time the gas concentration shown on the display should match the concentration stamped on the calibration gas cylinder 7 Disconnect the hose from the GAS port and then allow the pumps to run until both the Back and Leak readings fall to zero percent 8 Press the ESC key three times to return to the Main Screen Note f gas i
64. the instrument has been applied to additional areas in the natural gas industry including upstream locations These locations potentially contain less methane as a percentage of the overall mixture As methane becomes less of the overall mixed gas stream a response correction factor is recommended The response correction factor modifies Equation 1 as follows and must be determined and applied by the user to the measurements reported by the instrument Leak Flow x GaS sample GAS background X 10 x k where Leak rate of gas leakage from source cfm Flow sample flow rate cfm GaS sample concentration of gas from leak source GaS background background gas concentration k response correction factor user determined An alternative approach for use in mixed gas streams is to calibrate the instrument on the actual gas in which case the response correction factor k is not required The Hi Flow instrument includes a temperature sensor and compensates for changes in density associated with temperature in the reported measurement The Hi Flow does not however measure absolute pressure and as a result does not compensate for the effects of altitude 2 1 2 Calibration The instrument is calibrated to pure methane at the factory Calibrate the instrument about every 30 days to assure its accuracy More frequent calibrations may be required depending on how often the instrument is used and the amount of gas that was sam
65. ttery pack Replacing the internal filters Replacing the gas sensors Verifying flow rate Setting the time and date Resetting the microprocessor 4 1 Electrostatic Discharge Precautions CAUTION Electrostatic discharge ESD can destroy sensitive electronic components inside the Hi Flow Sampler when its cover is removed When performing any maintenance procedure that requires the Hi Flow Sampler s cover to be removed take the following precautions to prevent ESD from possibly destroying sensitive electronic components on the main circuit board Make sure you have a reliable ground point available near the work site Connect your body to the ground point using a wrist strap Always stand on an approved conductive floor mat when touching or handling equipment Ground all equipment you are working on with ground straps Handle components only on a grounded anti static work surface Do not wear clothing that generates static electric charges every time you move Do not handle static generating objects while working Maintain relative humidity in the work area between 40 and 50 4 2 Charging the Battery Pack WARNING Explosion hazard DO NOT charge or disconnect the battery pack in an unsafe atmosphere 1 Unplug battery pack from the instrument s power cord then remove battery pack from backpack Interconnect the supplied power supply power cord and charger as shown in Figure 4 1 Then plug the output of the charger into the b
66. ual 2 Stage Mode cccccccccncccccnnonocnnnnnnnnnnnnnnnnononennnnnnnnnnnannnnnanonos 35 2 18 4 Leak Rate Measurement Manual 1 Stage Mode cccccoccnncccccnnononnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnanononanenos 36 219 IWiICSSACS Na AS 38 3 CALIBRATION colita cian 41 Instruction 0055 9017 3 Table of Contents Hi Flow Sampler 3 1 WIC We Calor atom Date S etd Re a e 41 3 2 Gas CallOration Equipment SETUD scania a a a vonndes Maken ae ee 41 3 3 Check Callloration PROCE UEC dale 42 3 4 Gas Callbration Procede nee ee ese cdi eee 43 3 5 Calibration Amplifier Gain CA lianas Iii 45 3 6 Erase Callbratio Procedure lee dto donas ano ed dd AO sl ao ideal 45 4 MAINTENANCE ini cas 46 4 1 Electrostatic DiScharse PrecaU ON Susana dio psaeiendss 46 4 2 CharemetneBattery Pack dida 46 4 3 REMOVINE ME COVE add 47 4 4 Replacing the Internal Ple iii 48 4 4 1 E o e 48 4 4 2 La G as Sensor Hlterraaiid eae ee ae 49 4 4 3 BacCKerOUNG GaS SENSO A a 49 4 5 SA o naa seasnete ean nian penanees e A 50 4 6 PUMP Replace Menta NA 51 4 7 PIOW Rate MA e da e od O 52 4 8 Settine Date anda TIME 55 4 9 Resettine the WICROProces Onil dali 56 3 AROUBLESHODIUN GO iota ee eros ta aa eae acca ce ar a eee ate ek Mati clas Mec Natit ie a oa cadena 57 5 1 MUMENT REDA aarne scan casa sattaaa EE E E A 57 5 2 MOU ES IO OUI Os AU liada dd 57 SYMPTOM inana condes 57 PROBABLE CAUSE amp REMEDY criaria REEE EEEE E 57 5 3 Error Codes in Saved Test RECOMS i sssewsscd
67. urnable or Disposable Cylinders Contains 2 5 100 Methane Case with 2 demand flow regulators 2 way ball valve with demand regulator P N HPN 300060 0 o Hi Flow Cal Kit with Refillable Cylinders Contains 2 5 amp 100 Methane Pelican Style Case with two stage demand flow regulators and transfillers for mother tanks P N HPN 300004 0 o Available from Heath Consultants Inc Ph 713 844 1300 or info heathus com Calibration Gas 2 5 CH in air P N 0051 1121 100 CH P NOO 55 0060 Zero Air P N 0051 7131 optional 41 Calibration GAS INLET FITTING Do not connect to instrument until instructed to do so in the calibration procedure Gas inlet ports located on top of Hi Flow Hi Flow Sampler Connect the components of the calibration kit calibration gas cylinder and Hi Flow Sampler together as shown in Figure 3 1 DO NOT however attach the calibration equipment to the instrument until instructed to do so in the calibration procedure lt lt ON DEMAND GAS REGULATOR TUBING A BACKGROUND Apply gas to this port CALIBRATION GAS CYLINDER See Accessories Section for Part Numbers GAS Apply gas to this port when calibrating the Leak Gas Sensor when calibrating the Background Gas Sensor Figure 3 1 Calibration Equipment Setup 3 3 Check Calibration Procedure 42 This procedure checks the calibration of both the leak gas sensor and the background gas sensor using 2 5 CH4 Af
68. x should appear c Click the Connect using drop down menu and choose the COM port to which the Hi Flow Sampler is connected Then click OK to display the COM Properties dialog box for that COM port d Set Port Settings to Bits persecond 115200 Data bits 8 Parity None Stop bits 1 Flow control None Then click OK to display HyperTerminal s main window e Setup the terminal program to echo typed characters by selecting File gt Properties gt Settings gt ASCII Setup and placing a checkmarks in the Send line ends with line feeds box and the Echo typed characters locally box Click OK Tip f the typed characters do not echo on the screen then your version of HyperTerminal needs to be upgraded Download and install HyperTerminal Private Edition v4 0 or greater from Hilgraeve s website http www hilgraeve com f Select File gt Save This creates a file with an ht extension using the name that was entered in Step b 99 Maintenance Hi Flow Sampler 3 Set the date by typing DATWmm dd yy where mm dd yy is the current month day and year e g DATWO2 24 09 for February 24 2009 Press Enter on the computer s keyboard to update the Hi Flow Sampler s date display 4 Setthe time in 24 hour format by typing TIMWhh mm ss where hh mm ss is the current hour minute and second e g TIMW18 00 00 for exactly 6 o clock PM Press Enter on the computer s keyboard to updat

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