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HI FLOW

Sampler

Natural Gas

Leak Rate Measurement

Instruction 0055-9017

Operation & Maintenance

Rev. 5 – June 2010

Product Leadership • Training • Service • Reliability

Summary of Contents for HI FLOW Sampler

Page 1: ...HI FLOW Sampler Natural Gas Leak Rate Measurement Instruction 0055 9017 Operation Maintenance Rev 5 June 2010 Product Leadership Training Service Reliability...

Page 2: ...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 limita tion incidental or consequen...

Page 3: ...8 1 Basic Main Screen 15 3 8 2 Expanded Main Screen 16 3 9 Menu System 17 3 10Battery Status 18 3 11Calibration Menu 18 3 12Set Flow Units lpm or cfm 18 3 13Menu Mode Basic or Expanded 19 3 14Operatin...

Page 4: ...e Battery Pack 50 5 3 Removing the Cover 51 5 4 Replacing the Internal Filters 52 5 4 1 Leak Gas Filter 52 5 4 2 Leak Gas Sensor Filter 53 5 4 3 Background Gas Sensor Filter 53 5 5 Gas Sensor Replacem...

Page 5: ...owed 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...

Page 6: ...Unit Backpack 6 Foot 1 5 Inch Hose Assembly Battery Pack Qty 2 Battery Charger w Power Supply Control Unit with LCD and 4 button keypad Assortment of Attachments for complete capture of the gas leak...

Page 7: ...The top panel contains the following items SCANNER Bar code scanner input COMPUTER RS232 communications port for downloading stored test data to an external computer Leak Gas Inlet Main hose connectio...

Page 8: ...Introduction Hi Flow Sampler Instruction 0055 9017 4 Notes...

Page 9: ...de reader and GPS receiver Measured Values Sampling flow rate Background gas concentration Sample gas concentration Battery voltage Calculated Values Leak concentration corrected for background gas le...

Page 10: ...to 10 hours Run Time 4 5 hours continuous operation 20 C 68 F Memory Stores up to 1000 individual test parameters Dimensions 18L x 12W x 7H inches 457 x 305 x178 mm Weight 20 lbs 0 9 kg Agency Approva...

Page 11: ...t that fails its calibration after only being calibrated a single time should be calibrated more often Important Avoid sampling leaded gasoline vapors or gases or vapors that contain silicones or sulf...

Page 12: ...o the unit s BACKGROUND inlet Figure 3 2 Hose and Attachment Connections 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 o...

Page 13: ...ssibility of a static discharge the Hi Flow Sampler should 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 clam...

Page 14: ...5 1 Flange Strap 34 80 137 Flange leaks can be 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 s...

Page 15: ...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 durin...

Page 16: ...ngs 3 5 6 Claw 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 3 5 7 3 Port Background Gas Sampler Attaches to the...

Page 17: ...pendent on the temperature of the sensors and whether there is residual gas present inside the sensor chambers If a sensor fails to zero a message appears at the bottom of the LCD describing the cause...

Page 18: ...l i b r a t i o n S e t F l o w U n i t s M e n u M o d e 0 0 0 1 M S 2 Highlight the desired menu mode and then press the I O key to select that mode 1 1 2 2 0 4 0 9 4 5 3 0 B a s i c M e n u E x p...

Page 19: ...several submenus refer to Section 3 9 GPS Global Positioning System icon appears when instrument detects that a GPS receiver is connected to the unit s GPS port Barcode icon appears when the instrume...

Page 20: ...d LO 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...

Page 21: ...vides the user access to a system of submenus as shown in Figures 3 4 and 3 5 The items that are listed in the submenus depend on whether the instrument is in its Basic or Expanded menu mode The funct...

Page 22: ...ration 3 view dates on which calibrations were performed 3 view amplifier gain values in hexadecimal of each sensor circuit or 4 erase calibration A detailed description of each calibration function i...

Page 23: ...o either Automatic or Manual 3 14 1 Automatic 2 Stage Measurement Mode In the Automatic 2 Stage Mode the unit performs a leak rate measurement at first a high flow rate for 1 minute and then automatic...

Page 24: ...anually 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...

Page 25: ...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 sel...

Page 26: ...rial 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 s COMPUTER connector For computers having a 25 pin or USB COM port the user...

Page 27: ...iable 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 th...

Page 28: ...D L i n e 1 T e s t I D L i n e 2 L e a k l p m x x x 1 2 y y y 0 0 0 1 M S 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 Use...

Page 29: ...eak Rate Measurement 1 in 9 Leak 1 cfm Leak Rate of Component Under Test Measurement 1 in cfm 10 Date 2 MM DD YY Date Measurement 2 11 Time 2 HH MM SS Time Measurement 2 12 Btry 2 V Battery Voltage Me...

Page 30: ...al Test Manual Mode 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...

Page 31: ...ting 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...

Page 32: ...2 0 4 0 9 4 5 3 0 S e l e c t T e s t I D s E d i t T e s t I D s S e n d T e s t I D s E r a s e T e s t I D s 0 0 0 5 A S 3 Use the following keys to select and then enter the desired character dis...

Page 33: ...een run in association with the Hi Flow Sampl er then a new HyperTerminal connection needs to be made as follows a Select Start Run In the Run box type hypertrm exe and click OK The New Connection dia...

Page 34: ...observe that HyperTerminal displays the data as its being received 1 1 2 2 0 4 0 9 4 5 3 0 S e n d i n g r e c o r d x o f y 1 1 5 2 k b p s 0 0 0 4 A S 5 After all data has been transmitted stop Hype...

Page 35: ...tion 0055 9017 31 2 Select Yes to erase all Test ID information or select No to return to the previous screen 1 1 2 2 0 4 0 9 4 5 3 0 E r a s e A l l T e s t I D s Y e s N o 0 0 0 4 A S 3 Press ESC tw...

Page 36: ...nt 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 3 8 Selecting the Basic or Expanded Menu Mode 2 Choose an att...

Page 37: ...t o p S a v e S a m p l e T i m e 0 4 3 0 0 0 0 1 M 1 3 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 R...

Page 38: ...e Main Screen appears Selecting No returns the display to the Main Screen and starts the measurement using the current Test ID 1 1 2 2 0 4 0 9 4 5 3 0 A s s i g n n e w t e s t I D Y e s N o 0 0 0 1 A...

Page 39: ...id 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 1 1 2 2 0 4...

Page 40: ...ain Screen 1 1 2 2 0 4 0 9 4 5 3 0 L e a k 0 0 0 L e a k N o t A v a i l S p e e d L O H I S a v e S t a r t 0 0 0 1 M S 5 The user is now asked to choose a new or different Test ID Selecting Yes caus...

Page 41: ...ent 2 in memory The blower then stops and 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 tu...

Page 42: ...nd measurement 4 Begin the measurement process by selecting Start from the Main Screen 1 1 2 2 0 4 0 9 4 5 3 0 L e a k 0 0 0 L e a k N o t A v a i l S p e e d L O H I S a v e S t a r t 0 0 0 1 M S 5 T...

Page 43: ...entration is 15 gas and the calculated leak rate is 42 5 lpm 1 1 2 2 0 4 0 9 4 7 1 5 B a c k 0 8 0 L e a k 1 5 0 0 L e a k l p m 4 2 5 S p e e d L O H I S a v e S a m p l e T i m e 0 1 4 5 0 0 0 1 M 1...

Page 44: ...as made to send records to a computer with no test records stored in memory Flow Rate Lowered The flow rate has just been lowered signaling the start of measurement 2 during an automatic or manual lea...

Page 45: ...s 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 tha...

Page 46: ...his connection by displaying at the bottom left corner of the LCD When the barcode scanner is swiped across a barcode the message Barcode Scanned briefly appears at the bottom of the LCD The barcode d...

Page 47: ...nd high 100 CH4 calibration gas levels 1 From the Main Screen select Menu Calibration Calibration Dates 2 The following Calibration Dates Screen is displayed where mm dd yy is the month day and year c...

Page 48: ...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 CH4 from...

Page 49: ...emoved from the instrument 4 4 Gas Calibration Procedure This procedure calibrates both the leak gas sensor and the background gas sensor at 2 5 and 100 CH4 After setting up the calibration equipment...

Page 50: ...inder 7 Wait until the measured gas reading stabilizes and then press the I O key to calibrate the actual gas reading to that of the applied reading The message Calibration Passed will appear at the b...

Page 51: ...the gain value in hexadecimal 2 Press ESC three times to return to the Main Screen 4 6 Erase Calibration Procedure The following procedure resets the gain of each calibration amplifier circuit to the...

Page 52: ...Calibration Hi Flow Sampler Instruction 0055 9017 48 Notes...

Page 53: ...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...

Page 54: ...pack from backpack 2 Interconnect the supplied power supply power cord and charger as shown in Figure 5 1 Then plug the output of the charger into the battery pack s charger jack Note Connecting the c...

Page 55: ...e 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 clam...

Page 56: ...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 5 3 Equipment Required Mediu...

Page 57: ...e 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 Rep...

Page 58: ...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 senso...

Page 59: ...Assembly P N 0055 0061 Procedure 1 Remove cover per Section 5 3 2 Back off the pump bracket screw using a 5 64 Allen wrench then rotate bracket arm to free pump See Figure 5 6 3 Unplug pump connector...

Page 60: ...er onto the Hi Flow Sampler s gas intake as shown in Figure 5 7 2 Place the Hi Flow Sampler into its Manual 1 Stage Mode per Section 3 14 2 2 Then start the blower by selecting Start from the Main Scr...

Page 61: ...screen Ensure that the exhaust port is not obstructed 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...

Page 62: ...Maintenance Hi Flow Sampler Instruction 0055 9017 58 Figure 5 9 Gas Flow System...

Page 63: ...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...

Page 64: ...Properties Settings 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 If the typed characters do not echo on the sc...

Page 65: ...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...

Page 66: ...ibration 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 at bottom of display 1000 t...

Page 67: ...entration Make sure the background gas sample hose is not positioned too close the leak source Low Battery message appears at bottom of display Battery voltage is below 4 0 volts Recharge battery pack...

Page 68: ...Troubleshooting Hi Flow Sampler Instruction 0055 9017 64 Notes...

Page 69: ...iber package of 2 0055 0045 Hose Assembly 6 foot 0055 0215 12 foot 0055 0287 Power Supply 100 240 VAC In 12 VDC Out 0024 0985 Line Cord 120 VAC 4998 8986 Pump Assembly for Leak Gas Background Gas Sens...

Page 70: ...s Bacharach Sales Service Center 621 Hunt Valley Circle New Kensington PA 15068 Phone 724 334 5051 Fax 724 334 5723 Email help mybacharach com Canada Bacharach of Canada Inc 20 Amber St Unit 7 Markham...

Page 71: ......

Page 72: ...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 Printed in U S A...

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