Bacharach HI FLOW Sampler Instruction

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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

WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture 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, INCLUDING 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.

www.mybacharach.com

Declaration of Conformity

Manufacturer’s name: Bacharach, Inc.

Manufacturer’s address: 621 Hunt Valley Circle New Kensington, PA 15068-7074

European operations: Bacharach Europe Sovereign House, Queensway Leamington Spa Warwickshire CV31 3JR United Kingdom

Product name: Hi Flow Sampler conforms to the following specifications: EMC Directive 61326:1998 IEC 61000-4-3: Radiated Immunity IEC 61000-4-2

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.

and HI FLOW® are registered trademarks of Bacharach, Inc. All other trademarks,

Instruction 0055-9017

Hi Flow Sampler Contents

Table of Contents

1 Introduction........................................................................................ 1

1.1 General Description................................................................................................. 1

1.2 Material Supplied .................................................................................................... 2

1.3 Why Use the Hi Flow Sampler?................................................................................ 2

1.4 Control Unit Description .........................................................................................3

1.5 Top Panel Connections & Controls .......................................................................... 3

2 Technical Data .................................................................................... 5

3 Operation............................................................................................ 7

3.1 Operating Precautions (Please Read)....................................................................... 7

3.2 Battery Connection ................................................................................................. 7

3.3 Sampling Hose & Attachment Connections.............................................................. 8

3.4 Grounding...............................................................................................................9

3.5 Attachments.......................................................................................................... 10

3.5.1 Flange Strap (34", 80" & 137") ................................................................. 10

3.5.2 Beveled Nozzle Tool (6.5" & 24")............................................................... 10

3.5.3 Capture Bag............................................................................................ 11

3.5.4 Disposable Bags with Nozzle ................................................................... 11

3.5.5 Bellows Tool ............................................................................................ 11

3.5.6 Claw Tool ................................................................................................ 12

3.5.7 3-Port Background Gas Sampler ............................................................. 12

3.6 Turning ON the Hi Flow Sampler ........................................................................... 12

3.7 Turning OFF the Hi Flow Sampler ......................................................................... 13

3.8 Selecting the Basic or Expanded Menu Mode......................................................... 13

3.8.1 Basic Main Screen................................................................................... 15

3.8.2 Expanded Main Screen ........................................................................... 16

3.9 Menu System ........................................................................................................17

3.10 Battery Status .......................................................................................................18

3.11 Calibration Menu ..................................................................................................18

3.12 Set Flow Units – lpm or cfm................................................................................... 18

3.13 Menu Mode – Basic or Expanded........................................................................... 19

3.14 Operating Mode – Automatic or Manual................................................................. 19

3.14.1 Automatic 2-Stage Measurement Mode ................................................... 19

3.14.2 Manual Measurement Mode .................................................................... 20

3.14.2.1 Manual 2-Stage Mode ........................................................... 20

3.14.2.2 Manual 1-Stage Mode ........................................................... 21

3.15 Access Records...................................................................................................... 22

3.15.1 Send Records .......................................................................................... 22

3.15.2 View Records........................................................................................... 24

3.15.3 Erase Records ......................................................................................... 24

3.16 Importing Saved Data into a Spreadsheet .............................................................. 25

3.17 Access Test IDs ..................................................................................................... 27

3.17.1 Select Test IDs ........................................................................................27

3.17.2 Edit Test IDs ........................................................................................... 28

3.17.3 Send Test IDs.......................................................................................... 29

3.17.4 Erase Test IDs......................................................................................... 30

3.18 Making a Leak Rate Measurement......................................................................... 32

3.18.1 Leak Rate Measurement – Basic Menu Mode ........................................... 32

3.18.2 Leak Rate Measurement – Automatic 2-Stage Mode................................. 33

3.18.3 Leak Rate Measurement – Manual 2-Stage Mode..................................... 36

3.18.4 Leak Rate Measurement – Manual 1-Stage Mode..................................... 38

3.19 Message Line......................................................................................................... 40

3.20 GPS Data ..............................................................................................................41

3.21 Barcode Scanner Data........................................................................................... 42

4 Calibration ........................................................................................ 43

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Contents Hi Flow Sampler

4.1 View Calibration Dates ..........................................................................................43

4.2 Gas Calibration Equipment Setup .........................................................................43

4.3 Check Calibration Procedure .................................................................................44

4.4 Gas Calibration Procedure .....................................................................................45

4.5 Calibration Amplifier Gain Check ..........................................................................47

4.6 Erase Calibration Procedure ..................................................................................47

5 Maintenance ......................................................................................49

5.1 Electrostatic Discharge Precautions .......................................................................49

5.2 Charging the 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 Replacement .......................................................................................54

5.6 Pump Replacement ................................................................................................55

5.7 Flow Rate Verification ............................................................................................56

5.8 Setting Date and Time ...........................................................................................59

5.9 Resetting the Microprocessor .................................................................................60

6 Troubleshooting .................................................................................61

6.1 Instrument Repair .................................................................................................61

6.2 Troubleshooting Guide ..........................................................................................61

6.3 Error Codes in Saved Test Records ........................................................................63

7 Parts & Service ..................................................................................65

7.1 Replacement Parts .................................................................................................65

7.2 Optional Accessories..............................................................................................65

7.3 Service Centers......................................................................................................66

Instruction 0055-9017

Hi Flow Sampler Introduction

1 Introduction

1.1 General Description

The Hi Flow Sampler is portable, intrinsically safe, battery-powered instrument designed to determine the rate of gas leakage around various pipefittings, valve packings, and compressor seals found in natural gas transmission, storage, and compressor facilities.

A component’s leak rate is measured by sampling at a high flow rate so as 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 Equation 1. The instrument automatically compensates for the different specific gravity values of air and natural gas, thus assuring accurate flow rate calculations.

Instruction 0055-9017

Leak = Flow x (Gas

sample

– Gas

background

where: Leak = rate of gas leakage from source (cfm) Flow = sample flow rate (cfm) Gas Gas

= concentration of gas from leak source (%)

sample

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 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.

For those mathematicians who are wondering how both calculations can be the same with different flow rates, note that the measured CH the lower flow rate will be higher due to less air being drawn in with the sample, thus balancing out the lower flow rate.

The instrument is packaged inside a backpack, thus leaving the operator’s hands free for climbing ladders or descending into manholes.

The instrument is controlled by a handheld unit consisting of an LCD and a 4-key control pad, which is attached to the main unit via a 6 foot coiled cord.

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 a venturi 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

) x 10–2 Eq. 1

level at

concentration in

Introduction Hi Flow Sampler

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 calculated values being displayed on the hand-held control unit.

1.2 Material Supplied

 High Flow Sampler 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)

Flange Strap 34", 80", and 137" Capture Bag 36" x 36" Beveled Nozzle 6.5" and 24" Bag Nozzle w/ box of disposable bags Bellows Tool Claw Tool 3-Port Background Gas Sampler

1.3 Why Use the Hi Flow Sampler?

 Allows ranking of gas leaks in leak-rate order  Allows users to determine if the potential savings in lost gas by

repairing a leak

 Allows users to determine payback periods for particularly

expensive repairs

 Allows more cost-effective use of your maintenance budget  Identifies problem areas  Determines baseline leakage conditions  Provides permanent record of leakage and repair  Greenhouse gas credits  Pays for itself in recovered gas

Instruction 0055-9017

Hi Flow Sampler Introduction

1.4 Control Unit Description

The control unit consists of an 8 line by 20 character LCD and the four pushbuttons.

Figure 1-1. Control Unit

1.5 Top Panel Connections & Controls

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 connection used to collect gas from

leak source

 BACKGROUND Gas Inlet – Gas hose connection used to sample

background levels of CH

 GAS Inlet – Calibration gas connection  ON/OFF Switch – Turns unit ON and OFF

Figure 1-2. Top Panel Connections

Instruction 0055-9017

Introduction Hi Flow Sampler

Notes:

Instruction 0055-9017

Hi Flow Sampler Technical Data

2 Technical Data

Information Displayed .......... - Date and Time

- Battery voltage

- Sampling flow rate in cfm

- Background gas concentration in ppm or % by volume

- Leak concentration in ppm or % by volume

- Leak rate in cfm

- Percent difference between leak rate measurements #1 and #2

- Latitude, Longitude, Altitude, and Time of Fix, when the optional GPS receiver is attached

Display................................. 8 line by 20 character LCD



Pushbutton Controls ............ - I/O

- ESC (Escape)

Communication.................... Three DB9 connectors providing serial data transfer at 115200

baud to a personal computer, bar code 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 level

- Leak rate

- Percent difference between leak rate measurements #1 and #2

Measurable Leak Rate .......... 0.05 to 8.00 SCFM (1.42 to 226 LPM)

0.05 to 6.00 SCFM (1.42 to 170 LPM)

Accuracy of Calculated

Leak Rate ............................. ±10% of reading

Temperature:

Operating .......................... 0 to 50 °C (32 to 122 °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 approx. 10 SCFM (283 LPM)

Second flow approx. 8 SCFM (226 LPM)

(The second flow rate is 25% of the initial flow)

Measurement Method........ Differential pressure across restriction

Accuracy ........................... ±5% of reading

(Enter)



(Up Arrow)



(Down Arrow)

Instruction 0055-9017

Technical Data Hi Flow Sampler

Natural Gas Sensor:

Detection Method...............Catalytic oxidation / Thermal conductivity

Range:

Catalytic oxidation......... 0 to 5% by volume methane

Thermal conductivity ..... 5 to 100% by volume methane

Accuracy............................±5% of reading or 0.02 % methane, whichever is greater

Battery:

Type ..................................Intrinsically Safe NiMH rechargeable pack

Voltage ..............................4.8 V, max.

Recharge Time ...................8 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 Approvals .................Designed to be intrinsically safe for use in hazardous locations

Class I, Division 1, Groups A, B, C & D in 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 I, Division 1, Hazardous (Classified) Locations

CE Mark – See this manual’s inside front cover for Declaration of Conformity statement

Instruction 0055-9017

Hi Flow Sampler Operation

3 Operation

3.1 Operating Precautions

(Please Read)

To ensure that the gas sensors are properly zeroed at startup, the Hi Flow Sampler must be turned ON in clean air (free of combustible gases or vapors).

Calibrate the instrument about every 30 days to assure its accuracy. The frequency of calibration, however, may change depending on how often the instrument is used and the amount of gas that was sampled. Create a maintenance log to keep track of when an instrument was calibrated, and then use this log to help develop a calibration schedule. For example, an instrument 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 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 the sensor chambers and prolongs the life of the sensors.

3.2 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 3-1. Battery Pack Connection

Instruction 0055-9017

Operation Hi Flow Sampler

3.3 Sampling Hose & Attachment Connections

Connect the sampling hose to the instrument’s leak-gas inlet by clamping the hose to the inlet as shown in Figure 3-2. Also connect the background gas sampling hose to 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, or additional sections of hose can be added by simply clamping them together along with connecting together the background-gas hose.

Choose an attachment (refer to Section 3.5 Attachments) that will capture the entire leak and attach it to the end of the hose.

Instruction 0055-9017

Hi Flow Sampler Operation

3.4 Grounding

WARNING: To prevent the possibility 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 clamp can be stored by attaching it to

one of the shoulder straps.

Figure 3-3. Grounding Clamp

Instruction 0055-9017

Operation Hi Flow Sampler

3.5 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 below, and then connect it to the end of the instrument’s main sampling hose.

3.5.1 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 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.

3.5.2 Beveled Nozzle Tool (6.5" & 24")

For simple pin-hole type leaks, position this attachment directly over the leak source.

Instruction 0055-9017

Hi Flow Sampler Operation

3.5.3 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.

3.5.4 Disposable Bags with Nozzle

These disposable capture bags measure 38" x 60" 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.

When using a disposable bag to surround the leak source, insert the bag nozzle into the bag to take a gas sample.

DO NOT 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.

3.5.5 Bellows Tool

Instruction 0055-9017

Operation Hi Flow Sampler

This tool is useful in capturing leaks in valve stems and small fittings.

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 end of the background gas sample hose to give better average background gas readings.

3.6 Turning ON the Hi Flow Sampler

Instruction 0055-9017

Hi Flow Sampler Operation

With the Hi Flow Sampler located in an area containing clean air (no combustible gases or vapors), turn ON the instrument by first pulling up the ON/OFF switch and then moving it to its ON position.

WARNING: 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.

B a c h a r a c h , I n c .

H i F l o w S a m p l e r

v e r 1 . 4 0

N o v 1 3 2 0 0 4 1 1 : 2 0

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 the failure. Refer to Section 6 Troubleshooting for possible causes and remedies for this failure.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

Z e r o i n g S e n s o r s

P l e a s e W a i t . . .

[ 0 0 0 1 ] ( M ) S - -

After the sensors are zeroed, either the instrument’s Basic or Expanded Main Screen appears (refer to Section 3.8). The example below shows the Basic Main Screen.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 B a c k ( % ) 0 . 0 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 t a r t

[ 0 0 0 1 ] ( M ) S - -

T h e a r r o w s y m b o l s o n t h e l e f t i n d i c a t e t h a t t h e r e a r e m o r e i t e m s t o v i e w a b o v e a n d / o r b e l o w t h e c u r r e n t d i s p l a y .

P r e s s k e y s t o v i e w a d d i t i o n a l i t e m s .

3.7 Turning OFF the Hi Flow Sampler

Turn OFF the unit by simply pulling up the ON/OFF switch and moving it to its OFF position.

3.8 Selecting the Basic or Expanded Menu Mode

Instruction 0055-9017

Operation Hi Flow Sampler

Select the Basic or Expanded Menu Mode as follows:

1. From either the Basic or Expanded Main Screen, select Menu >

Menu Mode.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 C a 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 a n d e d M e n u

[ 0 0 0 1 ] ( M ) S - -

3. Press ESC to return to the Main Screen.

Refer to Sections 3.8.1 and 3.8.2 for detailed descriptions of the information contained in the Basic and Expanded Main Screens.

Instruction 0055-9017

Hi Flow Sampler Operation

3.8.1 Basic Main Screen

Date and Time: Date displayed as mm/dd/yy, while time is displayed in a 12hour format. The date and time are set per Section 5.8.

Btry(V): Battery voltage

Flow(lpm): Sample flow rate in either

liters/min or cu.ft./min.

: 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 instrument

detects that a barcode reader wand is connected to the unit’s SCANNER port

: Battery status icon (refer to Section 3.10)

Back(%): Measured background gas level in

[0001]: Current Test ID number

either percent-by-volume or ppm

(A)or (M): Automatic or Manual mode (refer to

Leak(%): Measured natural gas leak

Section 3.14)

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<––––|>HI): Blower speed indicator.

Start / Stop: Select to Start and Stop a test**

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 Section 3.19)

Menu: Select to display the first of several submenus (refer to Section 3.9)**

* “Not Avail.” is displayed when a value cannot be calculated from available information. ** Selections are made by using the  keys to highlight the desired function, and then

pressing the I/Okey to activate that function.

Instruction 0055-9017

Operation Hi Flow Sampler

3.8.2 Expanded Main Screen

Date and Time: Date displayed as mm/dd/yy, while time is displayed in a 12hour format. The date and time are set per Section 5.8.

Save: Select to save all current measurement parameters in memory**

Start / Stop: Select to Start and Stop a test**

Lat(°): Latitude in degrees*

Lon(°): Longitude in degrees*

Alt(ft): Altitude in feet*

Fix(sec): Time Of Fix between –1 and

−10 seconds (time lag between the received GPS signal and the displayed values of latitude, longitude, and altitude)*

Btry(V): Battery voltage

#1 – #2(%): Difference between test measure-

ments #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.*

Menu: Select to display the first of 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 instrument

detects that a barcode reader wand is connected to the unit’s SCANNER port

: Battery status icon (refer to Section 3.10)

[0001]: Current Test ID number (A)or (M): Automatic or Manual mode (refer to

Section 3.14)

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 Section 3.19)

Speed(LO<––––|>HI): Blower speed indicator.

* “Not Avail.” is displayed when a value cannot be calculated from available information. ** Selections are made by using the  keys to highlight the desired function, and then

pressing the I/Okey to activate that function.

Instruction 0055-9017

Hi Flow Sampler Operation

3.9 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 3-4 and 3-

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 3-4. Basic Menu System

Figure 3-5. Expanded Menu System

Instruction 0055-9017

Operation Hi Flow Sampler

3.10 Battery Status

Battery status is displayed as a single battery icon shown in the lowerleft 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 nearing depletion. 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)

3.11 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, 3) view amplifier gain values (in hexadecimal) of each sensor circuit, or 4) erase calibration.

A detailed description of each calibration function is provided in Section 4 Calibration.

3.12 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 > Set Flow Units.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 C a 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 units of measure and then press the I/O key.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 c f m ( c u . f t . / m i n . )

l p m ( l i t e r s / m i n . )

[ 0 0 0 1 ] ( M ) S - -

3. Press ESC to return to the Main Screen.

Instruction 0055-9017

Hi Flow Sampler Operation

3.13 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 Menu mode).

Refer to Section 3.8 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.

3.14 Operating Mode – Automatic or Manual

Note: The Operating Mode can only be selected if operating in the Expanded

Menu Mode. Refer to Section 3.8.

Selecting Operating Mode from the Expanded Menu System allows the user to set the instrument’s operating mode to 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 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 > Operating Mode.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 C a 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

O p e r a t i n g M o d e

A c c e s s R e c o r d s

[ 0 0 0 1 ] ( M ) S - -

2. Highlight Automatic 2-Stage, and then press the I/O key.

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0

A u t o m a t i c 2 - S t a g e

M a n u a l 2 - S t a g e M a n u a l 1 - S t a g e

3. Press ESC to return to the Main Screen. Observe that (A) should

Instruction 0055-9017

[ 0 0 0 5 ] ( M ) S - -

appear at the bottom of the screen

Operation Hi Flow Sampler

3.14.2 Manual Measurement Mode

3.14.2.1 Manual 2-Stage Mode

In the Manual 2-Stage mode the user 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 > Operating Mode.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 C a 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

O p e r a t i n g M o d e

A c c e s s R e c o r d s

[ 0 0 0 1 ] ( M ) S - -

2. Highlight Manual 2-Stage, and then press the I/O key.

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0 A u t o m a t i c 2 - S t a g e

M a n u a l 2 - S t a g e

M a n u a l 1 - S t a g e

[ 0 0 0 5 ] ( M ) S - -

3. Press ESC to return to the Main Screen. Observe that (M) should

appear at the bottom of the screen

Instruction 0055-9017

Hi Flow Sampler Operation

3.14.2.2 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 > Operating Mode.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 C a 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

O p e r a t i n g M o d e

A c c e s s R e c o r d s

[ 0 0 0 1 ] ( M ) S - -

2. Highlight Manual 1-Stage, and then press the I/O key.

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0 A u t o m a t i c 2 - S t a g e M a n u a l 2 - S t a g e

M a n u a l 1 - S t a g e

[ 0 0 0 5 ] ( M ) S - -

3. Press ESC to return to the Main Screen. Observe that (M) should

appear at the bottom of the screen

Instruction 0055-9017

Operation Hi Flow Sampler

3.15 Access Records

Note: Send Records can only be selected if operating in the Expanded Menu

Mode. Refer to Section 3.8.

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.

3.15.1 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.

The following describes how to download saved records to a computer that is running Windows 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 3.8.

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 Hi Flow’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 > Programs > Accessories > Communications > 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 > 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.

HyperTerminal as the communications

Instruction 0055-9017

Hi Flow Sampler Operation

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 > 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 > Capture Text >

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.

4. From the High Flow Sampler’s Expanded Main Screen, start the

download process by selecting Menu > Access Records > Send Records.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

S e n d R e c o r d s

V i e w R e c o r d s E r a s e R e c o r d s

Instruction 0055-9017

[ 0 0 0 1 ] ( M )

S - -

Observe that the Hi Flow’s 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.

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 1 ] ( M )

S - -

5. After all data has been transmitted, stop HyperTerminal from

capturing data by clicking Transfer > Capture Text > Stop.

6. The saved data can now be viewed in a spreadsheet for analysis as

described in Section 3.16 Importing Saved Data into a Spreadsheet.

Operation Hi Flow Sampler

3.15.2 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 > Access Records > 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 3.17 Access Test IDs.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 T e s t I 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 )

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.

3.15.3 Erase Records

Erase all records from memory as follows:

1. From the Expanded Main Screen, select Menu > Access Records >

Erase Records.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 S e n d R e c o r d s V i e w R e c o r d s

E r a s e R e c o r d s

[ 0 0 0 1 ] ( M )

2. Confirm or cancel the erase process by selecting Yes or No.

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0

S - -

E r a s e a l l r e c o r d s ? Y e s N o

[ 0 0 0 1 ] ( A )

3. Observe the message “Erasing all records” appears at the bottom of

the display during the erase process.

S - -

Instruction 0055-9017

Hi Flow Sampler Operation

3.16 Importing Saved Data into a Spreadsheet

Test records that were downloaded to a personal computer per Section

3.15.1 can be imported into spreadsheet programs that are capable of importing comma-delimited files. Note that each data record consists of 24 fields, some of which may be blank because of options not being installed.

TABLE 3-1. COMMA-DELIMITED FIELDS

Field

1 Record# Test Record Number 2 Inst.Serial# Instrument’s Serial Number 3 Date#1(MM/DD/YY) Date (Measurement #1) 4 Time#1(HH:MM:SS) Time (Measurement #1) 5 Btry#1(V) Battery Voltage (Measurement #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

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#2(%) Background Gas Level (Measurement #2) in % 15 Leak#2(%) Sample Leak Rate (Measurement #2) in % 16 Leak#2(cfm) Leak Rate of Component Under Test (Measurement #2) in

17 Leak#1-#2(%) Percent Difference Between Leak Measurements #1 and #2 18 Error Codes Error Codes identifying problems that occurred during the

19 Barcode# Barcode Type (UPC, EAN, Code 128, Cadabar) 20 Barcode Symbology Barcode Number Scanned 21 GPS Latitude(deg) Latitude of Instrument in Degrees 22 GPS Longitude(deg) Longitude of Instrument in Degrees 23 GPS Altitude(ft) Altitude of Instrument in Meters 24 Test Description Test ID Information (refer to Section 3.15 Access Test IDs)

Instruction 0055-9017

Label in Column

Heading

Description

cfm

test (refer to Section 6.3 Error Codes in Saved Test Records)

Operation Hi Flow Sampler

TABLE 3-2. TYPICAL SPREADSHEET*

Record# Instr.Serial# Date#1(MM/DD/YY) Time#1(HH:MM:SS) Btry#1(V) Flow#1(cfm)

1 123456 01/20/03 10:15:05 4.9 9.9 2 123457 01/20/03 01:25:30 4.8 9.8

Back#1(%) Leak#1(%) Leak#1(cfm) Date#2(MM/DD/YY) Time#2(HH:MM:SS) Btry#2(V)

0.0350 15.1500 1.49 01/20/03 10:16:05 4.9

0.0155 21.3250 2.09 01/20/03 01:27:45 4.8

Flow#2(cfm) Back#2(%) Leak#2(%) Leak#2(cfm) Leak#1-#2(%) Error Codes Barcode#

7.4 0.0375 21.2300 1.5 5.0 UPC

7.3 0.0245 29.1800 2.1 1.8 UPC

Barcode Symbology GPS Latitude(deg) GPS Longitude(deg) GPS Altitude(ft)

031323078 56098 40.5370 –80.252 900 031323078 56099 40.5450 –80.300 1000

GPS Fix(s) Test Description

–3 Test Location 1 Operator John Doe –6 Test Location 2 Operator John Doe

* Line 1: Column Headings Line 2: Record 1, Typical Test Automatic Mode Line 3: Record 2, Typical 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 to its instruction manual for information on how to import comma-delimited text files.

Tip: If the text file was saved with the filename extension “CSV” as

described in Section 3.13.1, 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 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

Hi Flow Sampler Operation

3.17 Access Test IDs

Note: Access Test IDs can only be selected if operating in the Expanded

Menu Mode. Refer to Section 3.8.

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.

3.17.1 Select Test IDs

Select a Test ID as follows:

1. From the Expanded Main Screen, select Menu > Access Test IDs >

Select Test IDs.

1 1 / 2 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 4 ] ( A ) S - -

2. Use the  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  or  key.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

T e s t L o c a t i o n 1 O p e r a t o r J o h n D o e

[ 0 0 0 5 ] ( A ) S - -

Instruction 0055-9017

Operation Hi Flow Sampler

3. Select the displayed Test ID by pressing the I/Okey, and then

return to the Main Screen by pressing ESC twice. Observe that [0005]

is now displayed at the bottom of the screen.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 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

M e n u

[ 0 0 0 5 ] ( A ) S - -

3.17.2 Edit Test IDs

Edit a previously entered Test ID or to create a new one as follows:

1. First select the Test ID to edit per Section 3.17.1 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.

2. From the Expanded Main Screen, select Menu > Access Test IDs >

Edit Test IDs.

1 1 / 2 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.



– 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  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.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

T e s t L o c a t i o n 2 | O p e r a t o r J o h n D o e

[ 0 0 0 5 ] ( A ) S - -

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; after which, the

screen shown in Step 2 should reappear.

Instruction 0055-9017

Hi Flow Sampler Operation

5. Press the ESC key twice to return to the Main Screen.

3.17.3 Send Test IDs

The following describes how to download the current list of Test IDs to a computer that is running Windows 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

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 > Programs > Accessories > Communications > 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 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 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 > 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 > Capture Text >

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.

HyperTerminal as the

Instruction 0055-9017

Operation Hi Flow Sampler

4. From the High Flow Sampler’s Expanded Main Screen, start the

download process by selecting Menu > Access Test IDs > Send Test IDs.

1 1 / 2 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

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

5. After all data has been 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.

3.17.4 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.

1 1 / 2 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 4 ] ( A ) S - -

[ 0 0 0 4 ] ( A )

S - -

[ 0 0 0 4 ] ( A ) S - -

Instruction 0055-9017

Hi Flow Sampler Operation

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 twice to return to the Main Screen.

Instruction 0055-9017

Operation Hi Flow Sampler

3.18 Making a Leak Rate Measurement

Before making a leak rate measurement, the user must decide whether to use . . .

 the Basic or Expanded Menu Mode (Section 3.8)  lpm or cfm for the flow rate (Section 3.12)  the Automatic 2-Stage, Manual 2-Stage, or Manual 1-Stage

method of making a measurement when operating in the Expanded Menu Mode (Section 3.14)

 a Test ID when operating in the Expanded Menu Mode (Section

3.17)

3.18.1 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 3.8 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.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 B a c k ( % ) 0 . 0 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 t a r t

[ 0 0 0 1 ] ( M ) S - -

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.

Instruction 0055-9017

Hi Flow Sampler Operation

1 1 / 2 2 / 0 4 0 9 : 4 7 : 3 0 F l o w ( l p m ) 2 1 6 . 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 )

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 2 : 0 0

6. In the 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.

1 1 / 2 2 / 0 4 0 9 : 4 7 : 3 0 F l o w ( l p m ) 2 1 6 . 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 )

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 2 : 0 0

7. The measurement process continues until Stop is selected.

1 1 / 2 2 / 0 4 0 9 : 5 0 : 0 0 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 t o p S a v e

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 4 : 3 0

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. Refer to Section 3.8.

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 3.14.1 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.

Instruction 0055-9017

Operation Hi Flow Sampler

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 ] ( A ) S - -

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 3.15). 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.

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 ) S - -

6. (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.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 F l o w ( l p m ) 0 . 0 B a c k ( % ) 0 . 0 0 L e a k ( % ) 0 . 0 0 L e a k ( l p m ) 0 . 0

S p e e d ( L O < > H I )

[ 0 0 0 1 ] ( A ) - 1 -

Speed B

Instruction 0055-9017

Hi Flow Sampler Operation

7. 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 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 1 0 : 4 6 : 3 0 F l o w ( l p m ) 2 1 6 . 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 )

[ 0 0 0 5 ] ( A ) - 1 -

S a m p l e T i m e - > 0 1 : 0 0

0 2 / 2 1 / 0 3 1 0 : 4 7 : 3 0 F l o w ( l p m ) 1 8 0 . 5 B a c k ( % ) 0 . 0 7 L e a k ( % ) 1 8 . 0 0 L e a k ( l p m ) 4 0 . 8

S p e e d ( L O < > H I )

[ 0 0 0 5 ] ( A ) - - 2

S a m p l e T i m e - > 0 2 : 0 0

8. 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 3.16 Importing Saved Data into a Spreadsheet.

Instruction 0055-9017

Operation Hi Flow Sampler

3.18.3 Leak Rate Measurement – Manual 2-Stage Mode

Note: The Manual 2-Stage Mode can only be selected if operating in the

Expanded Menu Mode. Refer to Section 3.8.

1. If not already done, place the instrument into its Manual 2-Stage

mode. Refer to Section 3.14.2.1 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.

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.

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 ] ( M ) S - -

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 key will lower the flow rate as

indicated by the speed bar moving to the left.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 F l o w ( l p m ) 0 . 0 B a c k ( % ) 0 . 0 0 L e a k ( % ) 0 . 0 0 L e a k ( l p m ) 0 . 0

S p e e d ( L O < > H I )

[ 0 0 0 1 ] ( M ) - 1 -

Speed B

Instruction 0055-9017

Hi Flow Sampler Operation

7. 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.

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

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 1 : 4 5

8. 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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 “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 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.

1 1 / 2 2 / 0 4 0 9 : 4 9 : 0 0 B a c k ( % ) 0 . 8 0 L e a k ( % ) 1 8 . 0 0 L e a k ( l p m ) 4 0 . 8 S p e e d ( L O < > H I )

S a v e

[ 0 0 0 1 ] ( M ) - - 2

S a v e

S a m p l e T i m e - > 0 3 : 3 0

9. Saved measurements can downloaded to a personal computer at a

later time for analysis. Refer to Section 3.16 Importing Saved Data into a Spreadsheet.

Instruction 0055-9017

Operation Hi Flow Sampler

3.18.4 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 3.8.

1. If not already done, place the instrument into its Manual 1-Stage

mode. Refer to Section 3.14.2.2 Manual 1-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.

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.

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 ] ( M ) S - -

6. 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.

Instruction 0055-9017

Hi Flow Sampler Operation

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 F l o w ( l p m ) 0 . 0 B a c k ( % ) 0 . 0 0 L e a k ( % ) 0 . 0 0 L e a k ( l p m ) 0 . 0

S p e e d ( L O < > H I )

[ 0 0 0 1 ] ( M ) - 1 -

Speed B

7. Once a stable leak measurement is obtained, all current readings can be saved in memory by highlighting Save and pressing the I/Okey.

In the example below, the current measured leak concentration 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

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 1 : 4 5

8. The measurement process continues until Stop is selected.

1 1 / 2 2 / 0 4 0 9 : 4 9 : 0 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 t o p S a v e

[ 0 0 0 1 ] ( M ) - 1 -

S a m p l e T i m e - > 0 3 : 3 0

9. Measurements that were saved can be downloaded to a personal

computer at a later time for analysis. Refer to Section 3.16 Importing Saved Data into a Spreadsheet.

Instruction 0055-9017

Operation Hi Flow Sampler

3.19 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 6.2 Troubleshooting Guide.

Calibration Passed

Calibration procedure was successful.

Calibration Failed

Error – The calibration procedure was not successful. Refer to Section 6.2.

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 6.2.

No Records Saved

An attempt was 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 leak test. Refer to Section 3.14.

Erasing All Records

All test records are being erased after selecting “Erase records” per Section 3.15.3.

Check Background Pump

Error – The background-gas pump’s flow rate has been severely reduced. Refer to Section 6.2.

Check Leak Pump

Error–The leak-gas pump’s flow rate has been severely reduced. Refer to Section 6.2.

Check Background Calibration

Error – The background-gas sensor needs calibrated. Refer to Section 6.2.

Check Leak Calibration

Error – The leak-gas sensor needs calibrated. Refer to Section 6.2.

Check Background Offset

Error – The background-gas sensor did not properly zero during startup. Refer to Section 6.2

Check Leak Offset

Error – The leak-gas sensor did not properly zero during startup. Refer

to Section 6.2.

Instruction 0055-9017

Hi Flow Sampler Operation

Check Zeroing Bypassed

Error – The ESC key was pressed during start up, thus bypassing the normal sensor-zeroing process. Refer to Section 6.2.

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 6.2.

Check Background Greater Than Leak

Error–The measured background gas level was greater than the measured leak gas concentration. Refer to Section 6.2

Sample Time

The amount of time that a leak rate measurement has been in progress.

Barcode Scanned

A barcode has been successfully scanned and its data stored in memory.

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 6.2.

3.20 GPS Data

Note: GPS data is only displayed if operating in the Expanded Menu Mode.

Refer to Section 3.8.

When a GPS receiver is connected to the instrument’s GPS port, the instrument acknowledges this connection by displaying left corner of the LCD.

At this time the instrument’s Expanded Main Screen displays the receiver’s Lat (latitude) and Lon (longitude) in degrees; it’s Alt (altitude) in feet; and the Fix (Time of Fix) in seconds.

If the Fix time is greater than –10 seconds, the Lat, Lon, and Alt values are considered invalid, causing their values to be displayed as "Not Avail."

at the bottom

Instruction 0055-9017

Operation Hi Flow Sampler

The GPS data is saved along with all other measured and calculated values at the conclusion of an automatic test, or when Save is selected during a manual test.

3.21 Barcode Scanner Data

Note: Barcode scanning can only be performed if operating in the

Expanded Menu Mode. Refer to Section 3.8.

When a barcode scanner is connected to the instrument’s SCANNER port, the instrument acknowledges this connection by displaying 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 data is stored and will be associated with all following tests until another barcode is scanned, or until the instrument is turned OFF. The barcode data is also saved along with all other measured and calculated values at the conclusion of an automatic test, or when Save is selected during a manual test.

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 ] ( A )

B a r c o d e S c a n n e d

S - -

at the

Instruction 0055-9017

Hi Flow Sampler Calibration

4 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:

 View the dates on which calibrations were performed  Verify calibration  Calibrate the background and leak gas sensors  Display the gain values of the calibration amplifier circuits  Erase calibration

4.1 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 high (100% CH

) 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:

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0 B a c k L o w m m / d d / y y B a c k H i g h m m / d d / y y L e a k L o w m m / d d / y y L e a k H i g h m m / d d / y y

) and

[ 0 0 0 5 ] ( A ) S - -

3. Press the ESC key twice to return to the Main Screen.

4.2 Gas Calibration Equipment Setup

The following equipment is recommended to both check the calibration and perform a calibration procedure on the Hi Flow Sampler:

 Calibration Kit, P/N 0055-8002  Calibration Gas:

2.5% CH 100% CH Zero Air, P/N 0051-7131 (optional)

Connect the components of the calibration kit, calibration gas cylinder, and Hi Flow Sampler together as shown in Figure 4-1. DO NOT, however, attach the calibration equipment to the instrument until instructed to do so in the calibration procedure.

Instruction 0055-9017

in air, P/N 0051-1121

, P/N00 55-0060

Calibration Hi Flow Sampler

Figure 4-1. Calibration Equipment Setup

4.3 Check Calibration Procedure

This procedure checks the calibration of both the leak-gas sensor and the background-gas sensor using 2.5% CH calibration equipment as described in Section 4.2, 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

BACKGROUND inlet port.

4. From the Main Screen select Menu > Calibration > 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.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

from the calibration equipment to the instrument’s

. After setting up the

B a c k ( % ) 2 . 5 0 L e a k ( % ) 0 . 0 0

[ 0 0 0 5 ] ( M ) S - -

Instruction 0055-9017

Hi Flow Sampler Calibration

5. 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.

1 1 / 2 2 / 0 4 1 0 : 4 5 : 3 0

B a c k ( % ) 0 . 0 0 L e a k ( % ) 2 . 5 0

[ 0 0 0 5 ] ( M ) S - -

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: If gas is 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.

4.4 Gas Calibration Procedure

This procedure calibrates both the leak-gas sensor and the backgroundgas sensor at 2.5% and 100% CH equipment as described in Section 4.2, proceed to calibrate the sensors 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 its warm-up period to complete

before proceeding to Step 3.

3. From the Main Screen select Menu > Calibration > Calibrate

Sensors to display the Sensor Calibration Screen.

0 2 / 2 1 / 0 3 0 9 : 4 5 : 3 0

B a c k g n d @ 2 . 5 % C H 4

B a c k g n d @ 1 0 0 % C H 4 L e a k @ 2 . 5 % C H 4 L e a k @ 1 0 0 % C H 4

. After setting up the calibration

4. Using the  keys, highlight the sensor to be calibrated along with its

Instruction 0055-9017

[ 0 0 0 5 ] ( A ) S - -

gas level. (In the example above, the background sensor will be calibrated using 2.5% CH

Calibration Hi Flow Sampler

5. 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key to start the calibration process. Observe that the

gas-sampling-pump motors start and the calibration screen appears.

1 1 / 2 2 / 0 4 1 0 : 4 5 : 3 0 B a c k ( % ) 0 . 0 0

A p p l ( % ) 2 . 5 0 , = A d j . A p p l i e d E N T E R = C a l i b r a t e E S C = E x i t

[ 0 0 0 5 ] ( M ) S - -

6. If necessary, use the  keys to adjust the Appl(%) reading to match

the gas concentration stamped on the calibration 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 6 Troubleshooting for possible causes and remedies for this failure.

1 1 / 2 2 / 0 4 1 1 : 4 5 : 3 0

B a c k ( % ) 2 . 5 0

A p p l ( % ) 2 . 5 0 , = A d j . A p p l i e d E N T E R = C a l i b r a t e E S C = E x i t

[ 0 0 0 5 ] ( M ) S - -

C a l i b r a t i o n P a s s e d !

8. Disconnect the gas hose, and then wait until the measured gas

reading falls to zero percent.

9. 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

4.5 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 > Calibration > Calibration

Gains to display the Calibration Gains Screen.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0 B a c k L o w # # # # B a c k H i g h # # # # L e a k L o w # # # # L e a k H i g h # # # #

[ 0 0 0 1 ] ( M )

S - -

Where: #### is 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 factory default hexadecimal value of “FFFF”.

1. From the Main Screen select Menu > Calibration > Erase

Calibration to display the Erase Calibration Screen.

1 1 / 2 2 / 0 4 0 9 : 4 5 : 3 0

E r a s e c a l i b r a t i o n ? Y e s N o

[ 0 0 0 1 ] ( M )

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.

S - -

Instruction 0055-9017

Calibration Hi Flow Sampler

Notes:

Instruction 0055-9017

Hi Flow Sampler Maintenance

5 Maintenance

Routine maintenance of the Hi Flow Sampler consists of the following:

 Charging the battery pack  Replacing the internal filters  Replacing the gas sensors  Verifying flow rate  Setting the time and date  Resetting the microprocessor

5.1 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%

Instruction 0055-9017

Maintenance Hi Flow Sampler

5.2 Charging the Battery Pack

WARNING: Explosion hazard! DO NOT charge the battery pack in an

unsafe atmosphere.

1. Unplug battery pack from the instrument’s power cord; then remove

battery 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 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.

Figure 5-1. Charging the Battery Pack

Instruction 0055-9017

Hi Flow Sampler Maintenance

5.3 Removing the Cover

When instructed to do maintenance inside the instrument, 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 5-2; then pull cover

away from unit.

Figure 5-2. Removing the Cover

Instruction 0055-9017

Maintenance Hi Flow Sampler

5.4 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 replaced is when the instrument’s gasresponse time increases.

5.4.1 Leak-Gas Filter

The leak-gas filter is located between the sampling port on the flowmeasurement tube and its associated solenoid valve on the printed circuit board. See Figure 5-3.

Equipment Required:

 Medium Phillips Head Screwdriver  Replacement Filter (P/N 07-1563)

Procedure:

1. Remove cover per Section 5.3.

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 cover that was removed in Step 1.

Figure 5-3. Leak-Gas Filter

Instruction 0055-9017

Hi Flow Sampler Maintenance

5.4.2 Leak-Gas Sensor Filter

The leak-gas sensor filter is located inside the flow block of the leak-gas sensor assembly. See Figure 5-4.

Equipment Required:

 Medium Phillips Head Screwdriver  Replacement Filter (P/N 0055-0045)

Procedure:

1. Remove cover per Section 5.3.

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 cover that was removed in Step 1.

5.4.3 Background-Gas Sensor Filter

The background-gas sensor filter is located inside the flow block of the background-gas sensor assembly. See Figure 5-4.

Replace filter as previously described for the leak-gas sensor filter.

Figure 5-4. Leak Gas & Background Gas Sensor Filter Replacement

Instruction 0055-9017

Maintenance Hi Flow Sampler

5.5 Gas Sensor Replacement

Replace a gas sensor when it fails to calibrate per Section 4 Calibration. The gas sensors are located inside their associated flow blocks of the leak-gas and background-gas sensor assemblies. See Figure 5-5.

Figure 5-5. Leak-Gas & Background Gas Sensor Assemblies

Equipment Required:

 Medium Phillips Head Screwdriver  Replacement Sensor (P/N 0055-0040)

Procedure:

1. Remove cover per Section 5.3.

2. Remove the pump connector and multi-pin connector from printed

circuit board, noting orientation of connectors. See Figure 5-6.

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.

5. Reinstall printed circuit board into flow block; taking care to properly

position the board as shown in Figure 5-6.

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 4 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.

Instruction 0055-9017

Hi Flow Sampler Maintenance

5.6 Pump Replacement

The pump located in either the leak-gas or background-gas sensor assembly (see Figure 5-5) may become inoperative due to water or solid particles getting into the valves. This will require replacement of the pump to correct.

Equipment Required:

/64" Allen Wrench

  Replacement Pump Assembly (P/N 0055-0061)

Procedure:

1. Remove cover per Section 5.3.

2. Back off the pump-bracket screw using a

rotate bracket arm to free pump. See Figure 5-6.

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. Replace cover that was removed in Step 1.

/64" Allen wrench; then

Figure 5-6. Sensor or Pump Replacement

Instruction 0055-9017

Maintenance Hi Flow Sampler

5.7 Flow Rate Verification

This procedure verifies the instrument’s ability to provide sufficient airflow to capture the entire gas leak, and to verify the accuracy of the instrument’s calculated flow rate by using the optional external flow meter (P/N 0055-0270).

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 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 Screen.

3. Make note of the Flow(cfm) value as displayed on the Hi Flow

Sampler’s LCD, and the fpm flow rate as displayed on the external flow meter.

4. Both Hi Flow Sampler's flow rate and the externally measured flow

rate should intersect within the two lines of the graph shown in Figure 5-8. If the intersect point falls outside the two graph lines, then return the unit to your nearest Bacharach Service Center for evaluation.

Figure 5-7. Flow Meter Installation

Instruction 0055-9017

Hi Flow Sampler Maintenance

Figure 5-8. Flow Rate Validation Graph

5. With a fully charged battery pack, the measured flow rate should be

greater than 9 cfm. If not, perform the following (see Figures 5-9 and 5-10):

 Clean the gas sample inlet 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 flowmeasurement tube and their corresponding solenoid valves, and that these hoses are not pinched or kinked.

 Ensure that no obstruction is present inside the flow-

measurement tube.

 If none of the above solves the problem, return the unit to your

nearest Bacharach Service Center for evaluation.

Instruction 0055-9017

Maintenance Hi Flow Sampler

Figure 5-9. Gas Flow System

Instruction 0055-9017

Hi Flow Sampler Maintenance

Figure 5-10. Plumbing Diagram

5.8 Setting Date and Time

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 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

2. On the computer, start HyperTerminal by doing one of the following:

Instruction 0055-9017

HyperTerminal as the communications program. If a different

male to DB9 female) between the computer’s COM port and the Hi Flow Sampler’s COMPUTER connector. (For computers having a 25pin or USB COM port, the user must supply the appropriate adapter, or use a serial cable with appropriate connectors on each end.)

- If HyperTerminal has already been set up to communicate with

the Hi Flow Sampler, then select Start > Programs > Accessories > Communications > HyperTerminal, and double-click the file name or icon that has been associated with the instrument.

Maintenance Hi Flow Sampler

- 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 > 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 Sampler 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. Set up the terminal program to ‘echo’ typed characters by

selecting File > 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 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 > Save. This creates a file with an .ht extension

using the name that was entered in Step b.

3. Set the date by typing “DATWmm/dd/yy” where mm/dd/yy is the

current month, day and year (e.g., DATW02/24/03 for February 24,

2003). Press Enter on the computer’s keyboard to update the 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.

5.9 Resetting the Microprocessor

Should the instrument ‘lock up’ or fail to turn OFF, reset the microprocessor by disconnecting the battery pack for several seconds.

Instruction 0055-9017

Hi Flow Sampler Troubleshooting

6 Troubleshooting

6.1 Instrument Repair

It is recommended that field repair of the Hi Flow Sampler be limited to:

 Cleaning gas-inlet screen  Replacing internal filters  Replacing sensors  Replacing sensor assembly pump  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 6.2.

6.2 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 7.3.

TABLE 6-1. TROUBLESHOOTING GUIDE

Symptom Probable Cause & Remedy

Instrument completely nonfunctional; won’t

turn ON when the I/Okey is pressed.

a. Battery pack dead. Recharge battery pack per Section 5-2.

b. Loose 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 reset. Disconnect battery pack for several seconds.

Display freezes during start up. Battery pack voltage low. Recharge battery

Instrument turned itself OFF during operation.

“Low Battery” message appears at bottom of display.

Instruction 0055-9017

pack per Section 5-2.

Battery pack dead. Recharge battery pack per Section 5-2.

Battery voltage is below 4.0 volts. Recharge battery pack per Section 5.2.

Troubleshooting Hi Flow Sampler

TABLE 6-1. TROUBLESHOOTING GUIDE (Cont.)

Instrument won’t respond when a control unit key is pressed.

Microprocessor needs reset. Disconnect battery pack for several seconds.

Low flow rate reading with fully charged battery.

Flow path obstructed. Check flow path and verify flow rate per Section 5.7.

Slow response time. Internal filters are dirty. Replace filters per

Section 5.2.

Battery power does not last at least

Battery pack defective. Replace.

4.5 hours.

Erratic gas readings. a. The entire gas leak is not being captured.

Use the proper attachment to capture leak.

b. Faulty sensor(s). Calibrate both CH

sensors per Section 4. Replace any sensor that fails to calibrate.

Sensor does not calibrate properly. a. Wrong calibration gas or insufficient flow

being applied to sensor. Ensure that the calibration setup is correct.

b. Depleted sensor. Replace sensor and recalibrate.

“Calibration Failed” message appears at bottom of display.

Calibration parameters not within programmed limits due to either 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 at bottom of display.

“No Records Saved” message appears at bottom of display.

“Check Background Pump” message appears at bottom of display.

“Check Leak Pump” message appears at bottom of display.

“Check Background Calibration” message appears at bottom of display.

“Check Leak Calibration” message appears at bottom of display.

1000 test records have already been stored in memory. Save all test records per Section

3.15.1 and/or erase memory per Section

3.15.3.

A send records command was given with no records stored in memory.

Flow to the background-gas pump has been severely reduced. Check that the background hose is not kinked or blocked, or the internal tubing has not become blocked (see Figure 5-10). Also check the condition of background-gas sensor filter, replace as necessary per Section 5.4.3.

Flow to the leak-gas pump has been severely reduced. Check that the internal tubing has not become blocked (see Figure 5-10). Also check the condition of leak-gas sensor filter, replace as necessary per Section 5.4.2.

The background-gas sensor needs calibrated per Section 4.

The leak-gas sensor needs calibrated per Section 4.

Instruction 0055-9017

Hi Flow Sampler Troubleshooting

TABLE 6-1. TROUBLESHOOTING GUIDE (Cont.)

“Check Background Offset” message appears at bottom of display.

The background-gas sensor did not zero properly during start-up. Switch OFF instrument and restart in an area with clean air. Replace sensor if necessary.

“Check Leak Offset” message appears at bottom of display.

The leak-gas sensor did not zero properly during start-up. Switch OFF instrument and restart in an area with clean air. Replace sensor if necessary.

“Check Leak Rate Difference” message appears at bottom of display.

“Check Zeroing Bypass” message appears at bottom of display.

The calculated difference between leak rates 1 and 2 was greater than 10%.

The ESC key was pressed during startup, thus bypassing the normal sensor zeroing process. Although the instrument will operate under this condition, no leak rate tests should be made because of the potential inaccuracy of the sensor channels.

“Check Background Greater Than Leak” message appears at bottom of display.

The measured background gas level is greater than the measured leak gas concentration. 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 per Section 5.2.

6.3 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 3.16 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 6-2 for a listing and description of these codes:

TABLE 6-2. FIELD 18 ERROR CODES

Error

Code

A Background gas sample pump blocked. B Leak gas sample pump blocked. C The background gas sensor needs calibrated at 2.5% and/or 100% CH4. D The leak gas sensor needs calibrated at 2.5% and/or 100% CH4. E The instrument failed to zero the background gas sensor during start up. F The instrument failed to zero the leak gas sensor during startup. G The user pressed the ESC key during start up before the sensors had a chance to

completely zero.

H The leak rate measurement #1 – #2 calculation failed.

I The measured background gas level was greater than the measured leak source gas

level. (This is an indication of improper equipment setup.)

Description

Instruction 0055-9017

Troubleshooting Hi Flow Sampler

Notes:

Instruction 0055-9017

Hi Flow Sampler Parts & Service

7 Parts & Service

7.1 Replacement Parts

Complete Hi Flow Sampler Assembly ...................................... 0055-8020

Standard Attachments:

3-Port Background Gas Sampler ....................................... 0055-0271

Bellows Tool ...................................................................... 0055-0259

Beveled Nozzle Tool:

6.5" ............................................................................. 0055-0213

24" .............................................................................. 0055-0247

Capture Bag:

Disposable, clear plastic, 38" x 60", roll of 25 .............. 0006-5438

Reusable, nylon, 36" x 36" ........................................... 0055-0250

Claw Tool .......................................................................... 0055-0258

Disposable Bag Nozzle ....................................................... 0055-0214

Flange Strap:

34" .............................................................................. 0055-0253

80" .............................................................................. 0055-0252

137"............................................................................. 0055-0251

Backpack................................................................................ 0055-0286

Battery Pack ........................................................................... 0055-0240

Battery Charger (requires power supply 24-0985) ................... 0055-0241

Filters:

Sample-Gas Intake, Wire Mesh.......................................... 0055-0261

Leak-Gas, Plastic Shell ...................................................... 0007-1563

Sensor, Leak-Gas & Background-Gas, Fiber (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 Sensor Assy’)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

Neck Strap, Control Unit ......................................................... 0051-1550

7.2 Optional Accessories

Calibration Kits: Complete kit includes on-demand regulator, 3 feet of tubing, calibration hose adapter, and a female quick connect fitting0055-8002

On-demand regulator only................................................. 0055-0064

Calibration Gases:

100% Methane, 58 L Tank................................................. 0055-0060

2.5% Methane, 103 L Tank................................................ 0051-1121

Zero Air, 20.9% O

Flow Meter .............................................................................. 0055-0270

Combustible Gas Detectors:

Gas Pup ............................................................................ 0055-8000

Gas Hunter ....................................................................... 0055-8001

Informant II ....................................................................... 0019-8041

Leakator Jr........................................................................ 0019-7075

Instruction 0055-9017

, 103 L Tank ......................................... 0051-7131

Parts & Service Hi Flow Sampler

7.3 Service Centers

United States

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, Ontario L3R SP4 Canada Phone: 905-470-8985 FAX: 905-470-8963 E-mail: bachcan@idirect.com

Instruction 0055-9017

Printed in U.S.A.

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

Bacharach HI FLOW Sampler Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual