Bacharach High Flow Sampler Instructions Manual Download

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HI FLOW

Sampler

For Natural Gas

Leak Rate Measurement

Instruction 0055-9017

Operation and Maintenance

Rev. 7 – July 2015

Product Leadership • Training • Service • Reliability

Summary of Contents for High Flow Sampler

Page 1: ...HI FLOW Sampler For Natural Gas Leak Rate Measurement Instruction 0055 9017 Operation and Maintenance Rev 7 July 2015 Product Leadership Training Service Reliability ...

Page 2: ...ES 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 varyi...

Page 3: ...8 Selecting the Basic or Expanded Menu Mode 15 2 8 1 Basic Main Mode 16 2 8 2 Expanded Main Mode 17 2 9 Menu System 18 2 10 Battery Status 19 2 11 Calibration Menu 20 2 12 Set Flow Units LPM or CFM 20 2 13 Menu Mode Basic or Expanded 20 2 14 Operating Mode Automatic or Manual 20 2 14 1 Automatic 2 Stage Measurement Mode 21 2 14 2 Manual Measurement Mode 22 2 15 Access Records 23 2 15 1 Send Record...

Page 4: ...ng the Cover 47 4 4 Replacing the Internal Filters 48 4 4 1 Leak Gas Filter 48 4 4 2 Leak Gas Sensor Filter 49 4 4 3 Background Gas Sensor Filter 49 4 5 Gas Sensor Replacement 50 4 6 Pump Replacement 51 4 7 Flow Rate Verification 52 4 8 Setting Date and Time 55 4 9 Resetting the Microprocessor 56 5 TROUBLESHOOTING 57 5 1 Instrument Repair 57 5 2 Troubleshooting Guide 57 SYMPTOM 57 PROBABLE CAUSE R...

Page 5: ...urate flow rate calculations Leak Flow x Gas sample Gas background x 10 2 Eq 1 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 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 f...

Page 6: ...s by volume A second identical combustibles sensor channel measures the background CH4 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 CH4 levels both leak and background levels are used to calculate the leak rate of the c...

Page 7: ...witch 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 CH4 Figure 1 2 Top Panel Connections ...

Page 8: ...F Storage 40 to 60 C 40 to 140 F Humidity 5 to 95 RH non condensing Sampling Flow Rate Maximum 10 5 SCFM 297 LPM at full battery charge Operating Flow Points Initial 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 Accuracy 5 of reading Natural Gas Sensor Detection Method Catalyt...

Page 9: ...e 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 o...

Page 10: ...ers 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 Figure 2 1 Battery Pack Connection 2 3 Sampling Hose and Attachment Connections Connect the sam...

Page 11: ...nding 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 Figure 2 3 Grounding Clamp 2 5 Attachments 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 be...

Page 12: ...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 ...

Page 13: ...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 Figure 2 8 Aluminum Crevice Tool ...

Page 14: ...t s name software version and the software s Month Day Year and Time of creation 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 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 of t...

Page 15: ...ode as follows 1 From either the Basic or Expanded Main Screen select Menu Menu Mode 2 Highlight the desired menu mode and then press the I O key to select that mode 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 ...

Page 16: ...nt 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...

Page 17: ... 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 ...

Page 18: ...d 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 Figure 2 9 Basic Menu System ...

Page 19: ...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 nearing depletion It does not show the pack s remaining percentage of charge It does not show the pack s remaining percentage of charge 4 0 volts and above Shutdown imminent less than 5 minutes of operating time remain ...

Page 20: ...in Screen select Menu Set Flow Units 2 Highlight the desired units of measure and then press the I O key 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 Basic Menu mode or if all available information is displayed Expanded Me...

Page 21: ...erforms 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 Operating Mode 2 Highlight Automatic 2 Stage and then press the I O key 3 Press ESC to return to the Main Sc...

Page 22: ...tage operation as follows 1 From the Expanded Main Screen select Menu 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 Du...

Page 23: ...ppropriate 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 the COMPUTER connector of the Hi Flow For computers having a 25 pin or USB COM port the user must supply the appropriate adapte...

Page 24: ...erent 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 4 From the...

Page 25: ...e 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 Use the 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 Fr...

Page 26: ...easurement 1 6 Flow 1 cfm Sample Flow Rate Measurement 1 in cfm 7 Back 1 Background Gas Level Measurement 1 in 8 Leak 1 Sample Leak 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 Measurement 2 13 Flow 2 cfm Sample Flow Rate Measurement 2 in cfm 14 Back ...

Page 27: ...ion 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 dialog 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 ...

Page 28: ...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 Access Test IDs Select Test IDs 2 Use the keys to scroll through any pr...

Page 29: ...ft Tip To quickly scroll through the characters press and hold down the or 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 immediate right of the number 2 4 After all characters have been selected press and hold down the I O key to move the cursor to the end of the screen aft...

Page 30: ...s 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 co...

Page 31: ...en transmitted stop HyperTerminal from capturing data by clicking Transfer Capture Text 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 Access Test IDs Erase Test IDs 2 Select Yes to erase all T...

Page 32: ...s 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 ...

Page 33: ...t 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 th...

Page 34: ...ues 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...

Page 35: ...site 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 15 After selecting or creating a new Test ID start the measurement by pressing ESC until the Mai...

Page 36: ...en allowing the user to make note of these values 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 ...

Page 37: ... 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 6 Begin measuring until a stable leak measurement is achieved this may take several minutes If desired the flow rate can be manu...

Page 38: ...bration procedure was successful Calibration Failed Error The calibration procedure was not successful Refer to Section 5 2 Saving Record A test record is currently being saved to memory Memory Full Error The instrument tried to save a test record with 1000 records already stored in memory Refer to Section 5 2 No Records Saved An attempt was made to send records to a computer with no test records ...

Page 39: ...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 Than Leak Error The measured background gas level was greater than the measured leak gas concentration Refer to Section 5 2 Sample Time The amount of time that a leak rate measurement has been ...

Page 40: ......

Page 41: ... 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 calibration was performed 3 Press the ESC key twice to return to the Main Screen 3 2 Gas Calibration Equipment Setup The following equipment is recommended to both check the calibration and perform a calibration ...

Page 42: ... 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 CH4 from the calibration equipment to the instrument s...

Page 43: ...ure 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 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 turn...

Page 44: ...alibration gas cylinder 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 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 ...

Page 45: ...6 16 0 1 s place 16 1 16 s place 16 2 256 s place etc rather than an exponent of 10 as in decimal i e 10 0 1 s place 10 1 10 s place 10 2 100 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 th...

Page 46: ...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 betw...

Page 47: ...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 Figure 4 2 Removing the Cover ...

Page 48: ...s 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 Medium Phillips Head Screwdriver 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 ...

Page 49: ...ve 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 background gas sensor assembly See Figure 4 4 Rep...

Page 50: ...n 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 5 Reinstall printed circuit board into flow block taking care to properly position the board as s...

Page 51: ...p Assembly P N 0055 0061 Procedure 1 Remove cover per Section 4 3 2 Back off the pump bracket screw using a 5 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...

Page 52: ...splayed 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 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 Figures 4 8 and 4 9 Clean the gas sample inlet screen Ensure that the...

Page 53: ...Hi Flow Sampler Maintenance Instruction 0055 9017 53 Figure 4 8 Gas Flow System ...

Page 54: ...Maintenance Hi Flow Sampler 54 Instruction 0055 9017 Figure 4 9 Plumbing Diagram ...

Page 55: ...n in association with the Hi Flow Sampler 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 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 ...

Page 56: ...he Hi Flow Sampler s date display 4 Set the 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 update 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 ba...

Page 57: ...ted in Section 6 3 TABLE 5 1 TROUBLESHOOTING GUIDE Symptom Probable Cause and Remedy Instrument completely nonfunctional won t turn ON when the I O key is pressed a Battery pack is dead Recharge battery pack per Section 4 2 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 prin...

Page 58: ...ed in memory Save all test records per Section 2 15 1 and or erase memory per Section 2 15 3 No Records Saved message appears at bottom of display A send records command was given with no records stored in memory Check Background Pump message appears at bottom of display Flow to the background gas pump has been severely reduced Check that the background hose is not kinked or blocked or the interna...

Page 59: ...tion 4 2 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 c...

Page 60: ...Troubleshooting Hi Flow Sampler 60 Instruction 0055 9017 ...

Page 61: ...er 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 and Background Gas Sensor Assembly 0055 0061 Serial Cable 9 Pin DIN Straight Through 6 foot 0104 4027 Sensor Combustible Gas 0055 0040 Tote Bag 0024 1204 Control Unit Assembly 0055 0262 Ground Clamp Assembly 0055 0265 Nec...

Page 62: ...tes 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 ...

Page 63: ...signed hereby declares that the above referenced 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 Immunity 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 Produ...

Page 64: ...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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