Related Manuals for Bacharach High Flow Sampler
Summary of Contents for Bacharach High Flow Sampler
- Page 1 HI FLOW Sampler ® For Natural Gas Leak Rate Measurement Instruction 0055-9017 Operation and Maintenance Rev. 7 – July 2015 Product Leadership • Training • Service • Reliability...
- Page 2 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.
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Page 3: Table Of Contents
Hi Flow Sampler Table of Contents Table of Contents INTRODUCTION .............................. 5 General Description and Use ......................... 5 Material Supplied ............................6 Control Unit Description ..........................6 Top Panel Connections and Controls ......................7 Technical Data ............................... 8 OPERATION ..............................9 Operating Precautions ........................... - Page 4 Table of Contents Hi Flow Sampler View Calibration Dates ..........................41 Gas Calibration Equipment Setup ....................... 41 Check Calibration Procedure ........................42 Gas Calibration Procedure .......................... 43 Calibration Amplifier Gain Check ........................ 45 Erase Calibration Procedure ........................45 MAINTENANCE............................. 46 Electrostatic Discharge Precautions ......................
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Page 5: Introduction
Introduction Hi Flow Sampler 1 Introduction General Description and Use WARNING: The High Flow Sampler is not to be used in any application that is beyond its intended purpose or beyond the scope of its specifications. Failure to follow this warning can result in personal injury or damage to the equipment. -
Page 6: Material Supplied
Material Supplied • High Flow Sampler Unit • Backpack • 6 Foot, 1.5 Inch Hose Assembly •... -
Page 7: Top Panel Connections And Controls
Introduction Hi Flow Sampler Top Panel Connections and Controls The top panel contains the following items. ON/OFF Switch Turns unit ON and OFF. Computer Port RS232 communications port for downloading stored test data to an external computer. Leak Gas Inlet Main hose connection used to collect gas from leak source. -
Page 8: Technical Data
Hi Flow Sampler Introduction Technical Data TABLE 1-1. TECHNICAL SPECIFICATIONS Specification Description • Leak concentration in ppm or % by volume Information • Date and Time • Background gas concentration in ppm or % by Displayed • Battery voltage volume •... -
Page 9: Operation
Hi Flow Sampler Operation 2 Operation Operating Precautions 2.1.1 Limits of Use The Hi Flow Sampler was developed for use on natural gas streams with high methane content. After introduction and industry acceptance, the instrument has been applied to additional areas in the natural gas industry, including upstream locations. -
Page 10: Battery Connection
Operation Hi Flow Sampler IMPORTANT: Avoid sampling leaded gasoline vapors, or gases or vapors that contain silicones or sulfur compounds. Tetraethyl lead, silicones, and sulfur compounds can form contaminating compounds on the sensor element (poison the sensor), with resulting loss in sensitivity. -
Page 11: Grounding
Hi Flow Sampler Operation The standard sampling hose is 6 foot long. If a longer length is needed, the optional 12 foot hose (P/N 0055-0287) can be ordered, or additional sections of hose can be added by simply clamping them together along with connecting together the background-gas hose. -
Page 12: Flange Strap (34", 80", And 137")
Operation Hi Flow Sampler 2.5.1 Flange Strap (34", 80", and 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. -
Page 13: Bellows Tool
Hi Flow Sampler Operation Figure 2-6. Capture Bag 2.5.4 Bellows Tool This tool is useful in capturing leaks in valve stems and small fittings. Figure 2-7. Bellows Tool 2.5.5 Aluminum Crevice Tool Use this tool when the leak source is spread out over a narrow area, such as a crack in a pipe, square flanges, and cylinder heads. -
Page 14: Turning On The Hi Flow Sampler
Sampler must be turned ON in clean air. Turning ON the instrument in air contaminated with combustible gas will cause false readings to occur. Use one of Bacharach’s portable gas detection instruments to sample the surrounding area for levels of combustible gas before turning ON the instrument. -
Page 15: Selecting The Basic Or Expanded Menu Mode
Hi Flow Sampler Operation Selecting the Basic or Expanded Menu Mode Select the Basic or Expanded Menu Mode as follows: 1. From either the Basic or Expanded Main Screen, select Menu > Menu Mode. 2. Highlight the desired menu mode, and then press the I/O ↵ key to select that mode. -
Page 16: Basic Main Mode
Operation Hi Flow Sampler 2.8.1 Basic Main Mode Date and Time: Date displayed as mm/dd/yy, while [0001]: Current Test ID number time is displayed in a 12-hour format. The date and (A) or (M): Automatic or Manual mode (refer to Section time are set per Section 4.8. -
Page 17: Expanded Main Mode
Hi Flow Sampler Operation 2.8.2 Expanded Main Mode Date and Time: Date displayed as mm/dd/yy, while (A) or (M): Automatic or Manual mode (refer to Section time is displayed in a 12-hour format. The date and 2.14) time are set per Section 4.8. S--: Standby Btry(V): Battery voltage -1-: Measurement #1 (maximum flow rate) -
Page 18: Menu System
Operation Hi Flow Sampler Menu System Selecting Menu from either the Basic or Expanded Main Screen provides the user access to a system of submenus as shown in Figures 2-9 and 2-10. The items that are listed in the submenus depend on whether the instrument is in its Basic or Expanded menu mode. -
Page 19: Battery Status
Hi Flow Sampler Operation Figure 2-10. Expanded Menu System 2.10 Battery Status Battery status is displayed as a single battery icon shown in the lower-left hand portion of the LCD. Since the voltage curve of the battery pack drops off rapidly towards the end of its charge, the Battery status icon is useful only in showing when the battery pack is nearing depletion. -
Page 20: Calibration Menu
Operation Hi Flow Sampler 2.11 Calibration Menu Selecting Calibration from the Menu System allows the user to either: 1) calibrate the sensors 2) verify calibration 3) view dates on which calibrations were performed 4) view amplifier gain values (in hexadecimal) of each sensor circuit, or 5) erase calibration. -
Page 21: Automatic 2-Stage Measurement Mode
Hi Flow Sampler Operation 2.14.1 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. -
Page 22: Manual Measurement Mode
Operation Hi Flow Sampler 2.14.2 Manual Measurement Mode 2.14.2.1 Manual 2-Stage Mode In the Manual 2-Stage mode the user 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. -
Page 23: Access Records
Hi Flow Sampler Operation 2. Highlight Manual 1-Stage, and then press the I/O ↵ key. 3. Press ESC to return to the Main Screen. Observe that (M) should appear at the bottom of the screen. 2.15 Access Records Note: Send Records can only be selected if operating in the Expanded Menu Mode. Refer to Section 2.8. - Page 24 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. ...
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Page 25: View Records
Hi Flow Sampler Operation 2.15.2 View Records View the records stored in memory on the unit’s LCD screen as follows: 1. Access the Review Record Screen from the Expanded Main Screen by selecting Menu > Access Records > View Records. This screen allows the user to view a short summary of each record stored in memory. -
Page 26: Importing Saved Data Into A Spreadsheet
Operation Hi Flow Sampler 2.16 Importing Saved Data into a Spreadsheet Test records that were downloaded to a personal computer per Section 2.15.1 can be imported into spreadsheet programs that are capable of importing comma-delimited files. Note that each data record consists of 24 fields, some of which may be blank because of options not being installed. - Page 27 Hi Flow Sampler Operation TABLE 2-2. TYPICAL SPREADSHEET Row 1: Column Headings Row 2: Record 1, Typical Test Automatic Mode Row 3: Record 2 The following describes how to generate a spreadsheet from a comma-delimited text ® file using Microsoft Excel 2000.
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Page 28: Access Test Ids
Operation Hi Flow Sampler 2.17 Access Test IDs Note: Access Test IDs can only be selected if operating in the Expanded Menu Mode. Refer to Section 2.8. Saved test records can be identified (e.g., location of test, type of test, name of operator, etc.) by manually entering up to two lines of text, with each line containing a maximum of 20 alphanumerical characters. -
Page 29: Edit Test Ids
Hi Flow Sampler Operation 2.17.2 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 2.17.1 Select Test IDs. To create a new Test ID, select the last Test ID number that can be displayed –... - Page 30 The next time data is captured, it will be stored under the same location and filename. 4. From the High Flow Sampler’s Expanded Main Screen, start the download process by selecting Menu > Access Test IDs > Send Test IDs.
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Page 31: Erase Test Ids
Hi Flow Sampler Operation Observe that the Hi Flow LCD displays the message “Sending record x of y @ 115.2kbps,” where “x” is the current record being sent and “y” is the number of records in memory. Also observe that HyperTerminal displays the data as its being received. -
Page 32: Making A Leak Rate Measurement
Operation Hi Flow Sampler 2.18 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 2.8) • lpm or cfm for the flow rate (Section 2.12) •... -
Page 33: Leak Rate Measurement - Automatic 2-Stage Mode
Hi Flow Sampler Operation 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. 7. The measurement process continues until Stop is selected. 2.18.2 Leak Rate Measurement –... - Page 34 Operation Hi Flow Sampler 5. The user is now asked to choose a new or different Test ID. Selecting Yes causes the Access Records menu to appear (refer to Section 2.15). After selecting or creating a new Test ID, start the measurement by pressing ESC until the Main Screen appears.
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Page 35: Leak Rate Measurement - Manual 2-Stage Mode
Hi Flow Sampler Operation 2.18.3 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 2.8. 1. If not already done, place the instrument into its Manual 2-Stage mode. Refer to Section 2.14.2.1 Manual 2-Stage Mode. -
Page 36: Leak Rate Measurement - Manual 1-Stage Mode
Operation Hi Flow Sampler 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. - Page 37 Hi Flow Sampler Operation 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.
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Page 38: Message Line
Operation Hi Flow Sampler 8. The measurement process continues until Stop is selected. 9. Measurements that were saved can be downloaded to a personal computer at a later time for analysis. Refer to Section 2.16 Importing Saved Data into a Spreadsheet. - Page 39 Hi Flow Sampler Operation Message Explanation Check Background Calibration Error – The background-gas sensor needs calibrated. Refer to Section 5.2. Check Leak Calibration Error – The leak-gas sensor needs calibrated. Refer to Section 5.2. Check Background Offset Error – The background-gas sensor did not properly zero during startup. Refer to Section 5.2.
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Page 41: 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. -
Page 42: Check Calibration Procedure
Calibration Hi Flow Sampler Connect the components of the calibration kit, calibration gas cylinder, and Hi Flow Sampler together as shown in Figure 3-1. DO NOT, however, attach the calibration equipment to the instrument until instructed to do so in the calibration procedure. Figure 3-1. -
Page 43: Gas Calibration Procedure
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. - Page 44 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% to the BACKGROUND port.) Then press the I/O ↵ key to start the calibration process.
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Page 45: Calibration Amplifier Gain Check
Hi Flow Sampler Calibration 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. -
Page 46: Maintenance
Maintenance Hi Flow Sampler 4 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 •... -
Page 47: Removing The Cover
Hi Flow Sampler Maintenance Figure 4-1. Charging the Battery Pack Removing the Cover When instructed to do internal maintenance, remove its protective cover as follows: 1. Do the following before removing the instrument from the backpack: - Disconnect battery pack - Unscrew metal-cage diffuser from the instrument’s gas exhaust port - Disconnect ground clamp wire 2. -
Page 48: Replacing The Internal Filters
Maintenance Hi Flow Sampler 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 gas-response time increases. 4.4.1 Leak-Gas Filter The leak-gas filter is located between the sampling port on the flow-measurement tube... -
Page 49: Leak-Gas Sensor Filter
Hi Flow Sampler Maintenance 4.4.2 Leak-Gas Sensor Filter The leak-gas sensor filter is located inside the flow block of the leak-gas sensor assembly. See Figure 4-4. Equipment Required: • Medium Phillips Head Screwdriver • Replacement Filter (P/N 0055-0045) Procedure: 1. -
Page 50: Gas Sensor Replacement
Maintenance Hi Flow Sampler Gas Sensor Replacement Replace a gas sensor when it fails to calibrate per Section 3 Calibration. The gas sensors are located inside their associated flow blocks of the leak-gas and background-gas sensor assemblies. See Figure 4-5. Figure 4-5. -
Page 51: Pump Replacement
Hi Flow Sampler Maintenance Pump Replacement The pump located in either the leak-gas or background-gas sensor assembly (see Figure 4-5) may become inoperative due to water or solid particles getting into the valves. This will require replacement of the pump to correct. Equipment Required: •... -
Page 52: Flow Rate Verification
• 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... - Page 53 Hi Flow Sampler Maintenance Figure 4-8. Gas Flow System Instruction 0055-9017...
- Page 54 Maintenance Hi Flow Sampler Figure 4-9. Plumbing Diagram Instruction 0055-9017...
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Page 55: Setting Date And Time
Hi Flow Sampler Maintenance 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 HyperTerminal as the communications program. If a different operating system and/or communications program is being used, then please consult the appropriate instruction manuals for those products. -
Page 56: Resetting The Microprocessor
Maintenance Hi Flow Sampler 3. Set the date by typing “DATWmm/dd/yy” where mm/dd/yy is the current month, day and year (e.g., DATW02/24/09 for February 24, 2009). Press Enter on the computer’s keyboard to update the Hi Flow Sampler’s date display. 4. -
Page 57: Troubleshooting
The following table lists the causes and remedies for most of the problems that may arise with the instrument. If none of the suggested remedies resolves the problem, or for help with any problem that is not listed, contact one of Bacharach Service Centers listed in Section 6.3. TABLE 5-1. TROUBLESHOOTING GUIDE Symptom... - Page 58 Troubleshooting Hi Flow Sampler Symptom Probable Cause and Remedy Low flow rate reading with fully Flow path obstructed. Check flow path and verify flow rate per Section 4.7 charged battery. Slow response time. Internal filters are dirty. Replace filters per Section 4.4. Battery power does not last at Battery pack defective.
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Page 59: Error Codes In Saved Test Records
Hi Flow Sampler Troubleshooting Symptom Probable Cause and Remedy “Check Leak Rate Difference” The calculated difference between leak rates 1 and 2 was greater than message appears at bottom of 10%. display. “Check Zeroing Bypass” message The ESC key was pressed during startup, thus bypassing the normal sensor appears at bottom of display. - Page 60 Troubleshooting Hi Flow Sampler Instruction 0055-9017...
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Page 61: Parts & Service
Hi Flow Sampler Parts & Service 6 Parts & Service Replacement Parts Complete Hi Flow Sampler Assembly ..............0055-8020 Standard Attachments: Bellows Tool ....................0055-0259 Beveled Nozzle Tool: 6.5" ......................0055-0213 24" ......................0055-0247 Capture Bag: Reusable, nylon, 36" x 36" ..............0055-0250 Aluminum Crevice Tool .................0055-0258 Disposable Bag Nozzle ..................0055-0214 Flange Strap:... -
Page 62: Service Centers
United States Bacharach Sales/Service Center 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5001 Email: help@mybacharach.com Canada Bacharach of Canada, Inc. 20 Amber St. Unit #7 Markham, Ontario L3R SP4 Canada Phone: 905-470-8985 Fax: 905-470-8963 E-mail: support@bachcan.ca ∇... -
Page 63: Declaration Of Conformity
In accordance with EMC Directive Signature: Doug Keeports Name: VP of Product Development Title: 5 December 2011 Date: The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach, Inc. ∇ ∇ ∇ Instruction 0055-9017... - Page 64 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 1-800-736-4666 Website: www.mybacharach.com • E-mail: help@mybacharach.com Printed in U.S.A.
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