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1. zZ 30 777 2 33HS SIN 31 926 imde V N 7 Xa e wor L Z1 201L3I dG POE SER de INN G 919 01 YALNdWOO 33S n Q3393HO WIYSLVAN 015 MSN SNOO aos n LI IHON OLVA3HOS 5 3 8 SLNVIINSNOD HIV3H 19 iseuejui SIND SIND LON n E ea OLO XXX 00 vva8 LZ SINVITASNOO SO T XX T XX 90 Sbxe uojsnoH HLVAH SINEYISNOO iva Jos s Bulmoup si Jo sjuejuoo S3HONI NI 5 ALLON GSLON 3SIMH3HIO SSJINN LSSONO7 ONIHOLVYW 1 190093 38 15 q3 xsvW S4J4NL LID LON 349 104 HLIM SWSLI SALON 20 TANNA 4 2 13 JNION3 1 0r 20l 6110120 IIb YIZO S93iL3AAU 13 9781068 TANNA 4 DNIENL y w JAAHASOWLY D p 97810 8 OL LN3A 4CJ LNAWNALSNI 4 QNIGN 1 A 1 ASSV d WA x ASSY GIU JINVW Ja SHdSO2. do I 1 8 SLN TIYIN VIN x AH HSINIA a 60801 2 ava IATA ONIA VU 14715 TWYN AH GANDAHD L L L0 0 01 ava SAIYAS dd ATAAVS LNSIAQISNI ASSV VOS JON 0q OOEI pr8 SLNVLINSNOO DS T90LL Sexo 05 H LV3H avinon Siva BOY 901UO 0606 0 920001 IVNOLLdO 891 uo MIYA KORES H awuh 2 0 99S 01 ASSY 6 0 LSOd aaf 1 60 11 dar sar 01 0 6 ASSV ACVW A8 OOH Ami H TIGQQVS LNAWNULSNI ASSV 0 60 LYVd 1 1 9 4 8 en Schematic Electrical Drawing 102318
3. 40 Ja3Hs SIN m Y N 8iczoLMI dQ GER CR 17 0 916001 HN3lndWOO 335 i LI AB Q3403H29 LM 13 va JAHSH 8 NMYud C31VHOdMOONI SLNVIINSNOD HIV3H Jo 1s94ejul ONET 37905 ION 09 i UOISSIUJJO o0 1 vr9 12 SLNVLIIQSNOO xe 504 XX vat Dd poo L9Q uoisnoH HLVAH SNITS Se US S3HONI NI OLLON jJ AJLON 3SIMM3HIO SS3INn 30 109d LNOS HLIM NAV3 SWALI 5 LON Id G G90 8 AN3LIVE J19IH3A DNIDaIVH _ 9661120 o yrezor 0461601 3504 Bu LNSWNALSNI i1 ASSV Li X i 892 asd IDH3Sn 912 120 el OVE CI 2 120 0 0810 8 1I20 ASLASAN HILIMS aaa 919 cocoes JJOIH3 01 i 8661120 9 61120 d 121145 j IJIHdA yar 60 9 06011 0931 9 31vd NOlLdlMOS3d LM WOIMLOSTS OLLVIN3HOS BLECOL SNOISIASY NOLLdlal2S 3Q MJ3SADN LYYd Schematic Flow Drawing 102317
4. 4 Schematic Flow Drawing 4 Cone 102317 5 Schematic Flow Drawing 6 Cone 102333 6 Assembly Boom 4 Cone 100001 2 7 Assembly Boom 6 Cone 100001 0 8 Assembly Vehicle Pump Drawing 102340 ierit ertet uen tern nens 9 Assembly By Pass Valve 103517 10 CHAPTER TWO DP Mobile Kit Operation DP4 Operating Instructions e 11 DP IR Operating Instructions 11 CHAPTER THREE DP Mobile Kit Maintenance Maintenance Instructions ra ERE Ade 12 Parts E E NER mcs actrees E sev ved ee mend ese rome E 13 CHAPTER FOUR DP Mobile Kit Service Information Marranbes ang Warranty 14 C stomer Assistance 15 CHAPTER ONE DP Mobile Kit Installation NOTE This manual and all reference drawings are applicable to both 4 and 6 cone installations Installation Instructions This installation kit is designed to permit installation of a
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6. OL LNNOW 30 CI ONIEAL DIO dt SHNOO WO2L1 Uva Assembly Vehicle Pump Drawing 102340 x t z 1 48 T3AO3ddY 2 OPETOT 2 ATY 3213 LIA ATION ASSY ETL SLNVLINSNOO 904 SEXo tuojsnoH HIV3H non peor 0606 TELS SSLANSH 10 WIN HSIN INO d 331ndWWO2 338 TIMELY TALYA TADI NI SLNYLINSNOD P saver Srey prsnaqiorT ys SINYIINSNO3 HLYJH wy ur sruni usnm nd TO ps p mposdar D PORR sar PIIA FUL Q3IVSOHO2NI SIN Y LT NO HIYSH Jo os 2umup sue ni 8 1 068 XH TE OT LAN T T X ZE OT MAUS Id 0 Z c0T 9E6TTZO TITAS Id 0 27 lt 20 AALT 6 coT 8 X 8 JO 16 0 8 TIM MOVIE 0 IFECOT ALV Id 8661120 ST 0 Ldn t T X 8 PNIONGAA JO ATA Haft 0 21 6 T HSVd
7. PROPRIETARY NOTICE The contents of this instruction manual are proprietary to Heath Consultants Incorporated Heath Reproduc tion in whole or in part of this manual is prohibited without the express written consent of Heath Consultants Incorporated Heath Consultants Incorporated operates under a continual product improvement program and reserves the right to make improvements and or changes without prior notification This manual dated January 2012 supersedes all previous manuals for this kit 102315 0 MOBILE KIT INSTALLATION MANUAL REV F Copyright 2007 HEATH CONSULTANTS INCORPORATED MOBILE KIT Installation Manual Heath Consultants Incorporated Houston TX M 713 844 1300 Fax 713 844 1309 CONSULTANTS 1 800 HEATH US Heath Safety Leadership Innovation Performance WWW heath us com Then Now and Tomorrow TABLE OF CONTENTS CHAPTER ONE DP Mobile Kit Installation 1 Secondary Pump Installation 1 Saddle and Instrument Installation sscvicicacssuvesecoancanaeadesiesevesrasanannvareoonsereaesaeavenesaanernvenacs 1 Winne Rr erroe PW 1 Sample System and TUDING S EREE EE EREEREER ea EiS 2 Assembly Instrument Saddle Drawing 102309 3 Schematic Electrical Drawing 7102319
8. ee V 7 J 2926170 NIVHO dr E 998 160 0 500001 1448 5 ES MOU ran G 0 vt 8 f B Id t ZE00E8 CETUR 796160 jquvHdSOH 2 WHLLOO 0191714405 LON SISSVHO OL LNNOW sae iiel d aaf cusva dy awa cod ama T ZT am SIN aw E 100001 10001 40 ax ATION 7008 ASSY 00 1 8 SINVLTASNOD T9OLL Sexo v _ 0606 Assembly Boom 6 Cone 100001 0 STIVLAC 1 OLLVINHHOS AAS SIILL NO NMOHS LON ONIE LL E i NV 9 uwo TANNNA 7 149 149 26159098 5250058 WUHSVA 0 200001 RIVE ISOH TINNVHO X 0700001 7 1 1 2 wem 149 1 Ada 8 1 N 0 500001 z 62 lt 90 8 5 B 527 9 9 19621500 5250058 1109 7 4 6660 LON 7 SISSVHO 1
9. 01 6 11 GHSVHTHa v Ad SNOISIA3H L 4 v lt 661100 ATEINYSSV 83048 7760666 N d Hd VL NO TH L SNYAL T SIVHIHL 9414 dVaM I SALON 00 aava v 1 X 8 1 ONLLLIT lt 61100 LdN 8 1 H JAL ML cm 8 1 MOMTA IA ATISOW AA TVA SSVdAd ASSV 0 15 lt 01 LUVd 8 10 CHAPTER TWO DP Mobile Kit Operation DP4 Mobile Kit Operating Instructions Turn instrument on For warm up and operating instructions see the DP 4 instruction manual Connect the Instrument Sample tube from the Flowmeter to the instrument Turn Secondary Pump ON Bump test the system injecting test gas butane lighter or 1000 ppm methane or higher into each cone one at a time Typical response time should be less than 4 seconds The system is now ready for survey DP IR Mobile Kit Operating Instructions Turn Instrument on For warm up and operating instructions see the DP IR instruction manual Connect the Instrument Sample tube to the instrument Turn Secondary Pump ON Bump test the system by injecting test gas 1000 ppm methane or higher into each cone one at a time Typical response time should be less than 4 seconds The system is now ready for survey CHAPTER THREE DP Mobile Kit Maintenance For detailed instru
10. 18 X gt SET SCREW 4 20 X 1 1 2 BUSHING HEYCO WEDGE FLOOR MOUNT BOLT 4 20 X 1 1 2 HEX NUT 4 20 Hose 1 8 ID x OD REFERENCE DRAWINGS Assy Instrument Saddle Schematic Wiring Schematic Flow 4 Cone Schematic Flow Drawing 6 Cone Assy Boom 4 Cone Assy Boom 6 Cone Assy Pump Assy By Pass Valve QUANTITY 1 RNP SP Re 00 CHAPTER FOUR DP Mobile Kit Service Information Warranties and Warranty Repair All instruments and products manufactured by Heath Consultants Incorporated are warranted to be free from de fects in material and workmanship for one year from date of shipment The warranty on authorized repairs in the Houston factory service center FSC is 90 days materials and 30 days labor This repair warranty does not extend any other applicable warranties Our warranty covers only failures due to defects in materials or workmanship which occur during normal use It does not cover failure due to damage which occurs in shipment unless due to improper packaging It does not cover failures which result from accident misuse abuse neglect mishandling misapplication alteration modi fication or service other than at a Heath Consultants warranty repair location Heath Consultants responsibility is expressly limited to repair or replacement of any defective part provided the product is returned to an authorized warranty repair
11. DP mobile kit in virtually any vehicle Follow the step by step instructions carefully Depending on your specific installation all parts in the kit may not be used Save any extra parts until the instal lation is complete Secondary Pump Installation Note Due to vehicle variations installation of some parts will be described referring to schematics only not re ferring to mechanical drawings Select a level area to mount the Secondary Pump Typical locations may be within the engine compartment in side the cab or inside a tool compartment Ensure that the position will allow easy access to the glass filter bowls on the pump but away from moving parts or hot surfaces Minimize the distance from the front cones to the in strument as much as possible Long tube runs will increase the delay of the system Mark the location of the Secondary Pump mounting holes on the vehicle surface and drill four 257 diameter mounting holes through the surface making sure the opposite side is clear of obstacles Mount the Secondary Pump Assembly using four 4 20 x 1 1 2 bolts 8306610 and 74 20 nuts 8301459 Saddle and Instrument Installation Ref drawing 102309 Position Floor Mounting Plate 0414493 on the vehicle floor so there is ample clearance for legs shift levers etc When the desired position has been determined drill four 257diameter mounting holes through the floor making sure the opposite side is clear of obstacles Mount Floor Plate inside
12. and Tubing Ref Schematic Drawing 102317 Attach Boom Assembly 100001 2 to the vehicle front centered on the bumper with 2 holders 0413599 Adjust the funnel height to be one inch above the ground with the vehicle fully loaded Route and connect Sample Line Tubing 8301846 between boom manifold outlet and Secondary Pump inlet Route and connect Sample Line Tubing between the Secondary Pump outlet the By Pass Valve inlet Route and connect Sample Line Tubing from the By Pass Vale exhaust port to the outside of the vehicle typically through the floor Route and connect Instrument Sample Line Tubing from the By Pass Vale Instrument Port to the Instrument loca tion Attach the proper connector for either the DP4 or DP IR Completing installation Use as many Tie Wraps 8300319 as needed to tie all wires and tubing into a bundle Tie gently to prevent tubing restriction Don t pinch the tubing Adhesive Clamps 0211942 are used for final positioning Alcohol or another cleaning agent must be used to clean each area where the clamp is to be placed NOTE KEEP WIRES AND TUBING AWAY FROM MOVING PARTS AND HOT SURFACES Assembly Instrument Saddle Drawing 102309 L
13. location shipped prepaid and adequately insured Return shipping and insurance will be at no charge to the purchaser We do not assume liability for indirect or consequential damage or loss of any nature in connection with the use of any Heath Consultants product There are no other warranties expressed implied or written except as listed above Return Procedure The following suggestions will expedite the repair of your equipment 1 Contact Heath Factory Service at 1 800 432 8487 to request a repair form The form is available on line at www heathus com 2 Package carefully using original shipping carton if available and return all components including the repair form The repair from request information such as complete shipping and billing addresses product name model num ber or serial numbers Also include a brief description of the problem you are experiencing and the person and phone number to be contacted for additional information and approvals CUSTOMER ASSISTANCE MANUFACTURING AND SERVICE LOCATIONS If for any reason assistance is required technical or otherwise please contact Heath Customer Service at 1 800 HEATH US 1 800 432 8487 CORPORATE HEADQUARTERS Heath Consultants Incorporated 9030 Monroe Road Houston Texas 77061 Phone 713 844 1300 Fax 713 844 1309 MANUFACTURING AND WARRANTY SERVICE CENTERS Heath Consultants Factory Service Center 9030 Monroe Road Houston Texas 77061 Phone 713 844 1350 F
14. the vehicle and Sup port Plate outside the vehicle using 4 20 x 1 1 2 screws 8304160 and 74 20 nuts 8301459 Install Post 0413819 in Floor Plate and secure with two 5 16 18 set screws 0111685 If required use optional wedges 100026 0 to straighten or angle Post as desired Slip Saddle Assembly 103566 0 on Post and secure with screws supplied in Saddle Adjust Saddle to desired position and angle then place your DP instrument in the Saddle If desired secure instrument to Saddle with elas tic straps Wiring Ref Schematic drawing 102318 Determine the shortest distance for running wires from the vehicle instrument panel through the firewall to the Secondary pump Assembly Once determined drill a 34 diameter hole through the firewall and install bushing 8305905 Drill a gt hole in the vehicle instrument panel and mount the Switch part of Cable Assembly 102314 0 and ON OFF plate 0214274 in the hole Make sure the switch is in the off position before connecting any wiring Feed the white and red wires of the Cable Assembly thru the bushing in the firewall Connect the ring terminal from the white wire of the Cable Assembly to the plus terminal of the vehicle battery Connect the red wire of the Cable Assembly to the fused side of the Secondary Pump wiring using splice 0211936 Connect the non fused wire from the Secondary Pump to the negative terminal of the vehicle battery using the Black wire supplied in the kit Sample System
15. O SSFINN HION34 79703 40 38 15 HLIM S38nl Z IIPv 120 I4 JD LNVd LON LNO4 SIHL HLIM NAVA SW3LI 1 TANNIN 3 iS 20 NISV2 LN3A L3IVdDO 3 TSIHAA OI2v120 8 90 sius 6110 m 9v810 8 JASHdSOWLYV OO DONIS L 1N3WNXLSNI INN 0 m 4INVW 55 JASHdSOWLY 01 INNA SSUd 55 49 Ilppi20 G06G0 8 _ x ISNNN4 Jar oiez ii Hivd SHO 76611 0931 JOLE sar 01 2 6 7821 OO3 2 Ag alva 0116 M N 9 LIM JION 5 0 lt 201 SNOISIAZY LuV 0 00 SIN a a 100001 l Anl 1 31 25 STIVLAC I LIETOI OLLVINHHOS MOTA AAS ITA ITION NOOS ASSV Assembly Boom 4 Cone 100001 2 SINVEIISNOQTT ONIA V3G SIHL NO NAOHS LON ONILOSNNOOISINI 1 37 me SHLON NE uy EM A ava ISOH HTAINNNA ASSY Idt 0 00001 7 1 c00001 atte Id it SHNOO 7 1 0 4 01 o OF b ay OS CTIOSINVW ASSV ees
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17. ax 713 844 1398 Heath Consultants Incorporated operates under a continual product improvement program and reserves the right to make improvements and or changes without prior notification Heath Consultants Incorporated Houston TX 713 844 1300 Fax 713 844 1309 HEATH CONSULTANTS Heath Safety Leadership Innovation Performance www heathus com Then Now and Tomorrow
18. ment maintenance see the DP4 or DP IR instruction manual Daily e Check the Secondary Pump Assembly filters for water dirt and the DP filters for dirt Remove replace and empty as needed e Check cone height Once a week e Use a vacuum gauge to measure the Secondary Pump vacuum pressure The vacuum pressure should not be less than 12 in WC e Blow out sample lines and cones with compressed air Disconnect the line from the Secondary Pump inlet and blow out through the cones CAUTION Do not use high pressure to the instrument severe damage may occur Filters Dirty filters restrict air flow and if not corrected could lead to possible motor overloading and early pump failure Check the filters periodically and clean them when necessary by removing the elements from the filter and replace 12 PART NO 0210119 102345 0 103137 0211942 102314 0 102340 1 0214411 0413819 0414193 8301846 101807 0 102309 0 102315 0 8300319 103517 0 102322 0 0111683 8304160 8305905 100026 0 8306610 8304159 0618343 102309 102318 102317 102333 100001 2 100001 0 102340 103517 SYSTEM PARTS LIST DESCRIPTION FLOWMETER 6 5 LPM ELEMENT FILTER FUSE 3AG SLO BLO 15 A CLAMP CABLE SELF ADH CABLE PUMP POWER PUMP SECONDARY ASSY FUNNEL POST SADDLE PLATE FLOOR MOUNTING HOSE 3 16 ID X 5 16 OD INVERTER 12 V 120 V ASSY SADDLE MANUAL DP SERIES MOBILE TIE CABLE ASSY BYPASS VALVE PLATE SUPPORT SCREW 5 16
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