UK MANUFACTURERS OF THE HYSCAN II, LYOSCIENCE (LS) RANGE OF FREEZE DRYERS & BESPOKE HIGH VACUUM SYSTEMS | VACUUM

PUMPS - SPARES - SERVICE

HYSCAN II Hydrogen in Aluminium Analyser

INSTALLATION AND OPERATION MANUAL

Issue Date

4 14/09/11

Please Read This Document before Operating the Machinery

MechaTech Systems Ltd, Unit 9, Brunel Way, Thornbury Industrial Estate, Thornbury, Bristol. BS35 3UR Tel: + 44 (0) 1454 414723 | Email: enquiries@mechatechsystems.co.uk | www.mechatechsystems.co.uk Registered in England and Wales No.6469333 | VAT Reg no: 928 7530 93
MechaTech Systems 2013 All Rights Reserved

INSTALLATION AND OPERATION MANUAL Hyscan II CONTENTS

1. 2.

DOCUMENTATION RECORDS INTRODUCTION

2.1 2.2 2.3 Purpose General safety Unpack and inspect

4 5
5 5 5 6 6 6

2.4 Installation and Commission 2.4.1 Electrical Requirements 2.4.2 Initial setup

3.

DESCRIPTION
3.1 3.2 3.3 Background Principle General Description

8
8 8 8

4.

OPERATION
4.1 4.2 4.3 Auto Zero Blank test Running a test

10
10 10 11

5.

CALIBRATION
5.1 5.2 5.3 General Calibration procedure Low pressure Set Point

13
13 13 14

6.

MAINTENANCE
6.1 6.2 6.3 6.4 6.5 Sample chamber/O ring Vacuum pump Regeneration of alumina desiccant Electrical circuits Routine maintenance

15
15 15 16 16 16

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INSTALLATION AND OPERATION MANUAL Hyscan II

6.6 Planned maintenance 6.6.1 Monthly 6.6.2 Six Monthly 6.6.3 Yearly 6.7 Recommended Spares 17 17 17 18 18 18 18 19 19 19 21 21

6.8 Fault Diagnosis 6.8.1 Leak in vacuum system 6.8.2 Replacement of O rings 6.8.3 Replacement of Pirani gauge 6.8.4 Identification of faults 6.8.5 Assistance from manufacturer 6.8.6 List of associated documents

7. 8. 9.

TECHNICAL SPECIFICATIONS ENVIRONMENT SPECIFICATIONS SCHEMATICS

9.1 9.2 9.3 9.4 9.5 9.6 9.7 Figure 1: Schematic of component layout Table 4: Schematic and logic diagrams Figure 2: Operation stage 1 Figure 3: Operation stage 2 Figure 4: Operation stage 3 Figure 5: Operation stage 4 Figure 6: Pipette filling and use of calibration lid

22 23 24
24 25 26 27 28 29 30

10.
10.1

CHART
Function chart

31
31

11. 12.

HYSCAN II PRINTER OPTION HYSCAN II SPARES

32 33

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INSTALLATION AND OPERATION MANUAL Hyscan II

1. DOCUMENTATION RECORDS

Issue

Documentation Update Details

Date

Approval

3a

Project version 1a developed and issued for internal review

06/03/06

JH

First formal issue to customer with new format Business Address Changed.

20/03/06

JH

14/09/11

JH

Section 1

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INSTALLATION AND OPERATION MANUAL Hyscan II

2. INTRODUCTION 2.1 Purpose This manual provides installation and operation instructions for the HYSCAN II. This manual and all accompanying documentation must be read before operating the vacuum system. Important safety information is highlighted as WARNING and CAUTION instructions; you must obey these instructions. The use of WARNINGS and CAUTIONS are defined below. 2.2 General safety

WARNING: Warnings are given where failure to observe the instruction could result in injury or death to persons.

CAUTION: Cautions are given where failure to observe the instruction could damage to the equipment, associated equipment or process. Refer to the accompanying manufacturers instruction manuals for the technical data on individual components.

2.3 Unpack and inspect Remove all packing material.

CAUTION: Remove all packing material before operating system. If the equipment is damaged notify your supplier and the carrier in writing within three days.

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INSTALLATION AND OPERATION MANUAL Hyscan II

2.4 Installation and Commission

2.4.1 Electrical Requirements

The HYSCAN II is factory configured for the supply stated below. Check that your voltage supply is compatible. If you operate the unit on the wrong voltage, you will damage it.
CAUTION:

Voltage 240Vac Frequency 50Hz Loading/power consumption 3 KW Earthing Class 1 (supply earth required) Fusing 13A Ensure that all framework panels are refitted before connecting to any services.

WARNING: Failure to refit all panels prior to connecting to mains power may result in injury or death to the operator.

2.4.2 Initial setup I. Locate the HYSCAN II in the required position, by pushing it on its casters, ensuring that the floor is adequate to support the equipment and that due consideration is given to: a) Air flow for ventilation b) Adequate space for maintenance. II. The unit is delivered under a vacuum and should always be maintained in this condition when not in use to prevent dirt and moisture entering the system. It is prepared for operation as follows: a) b) Section 2 Remove all packing materials. Check that the position of the two switches on the instrument panel are: Issue: 4 Page 6 of 33

INSTALLATION AND OPERATION MANUAL Hyscan II Left hand switch Up (between tests) Middle switch Down (test)

c) Remove the front panel of the unit and unscrew the transit bolt (if fitted) from the pump mounting plate using an M10 spanner. d) Examine all interconnections between components to check that the mating surfaces are parallel and that the O-rings are correctly in position. Tighten any connections that may have become loose during transit. e) Open the cable storage cover at the base of the rear panel, unscrew the transit bolt (if fitted) and uncoil the cable. f) Check that oil is present in the pump. The oil level can be observed through the sight glass on the front of the pump and should be at least half way between the "min and "max" lines. If oil is not present or there is insufficient oil, then Edwards Ultragrade 19 oil should be poured into the pump via the oil inlet port. Check that the oil inlet and gas ballast valves are closed before operation. g) Replace the front panel. h) Connect the instrument to the mains supply (see Section 2.4.1) and move the isolator switch to the "on" position (situated on the left hand side panel). Leave the unit pumping for about thirty minutes. The digital display should light up and read 0.00 after about 10 seconds.

CAUTION: Exhaust gases must be ducted away from the surrounding atmosphere and suitably disposed.

CAUTION: Do not obstruct any vacuum pump exhaust port (refer to manufacturers manual before operation).

Section 2

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INSTALLATION AND OPERATION MANUAL Hyscan II

3. DESCRIPTION 3.1 Background Hydrogen is the only gas that is appreciably soluble in aluminium and its alloys. Its solubility is small when compared with that in other metals but its effects are significant on the mechanical properties and finishing characteristics of aluminium alloys. The problem with hydrogen derives from the difference in the solubility of the gas between liquid and solid aluminium at the freezing point. At this temperature, the ratio of liquid to solid solubility is approximately 20:1 and this results in the formation of hydrogen bubbles which ultimately cause porosity in castings and ingots and blisters on sheets and plate. It is important therefore to be able to determine the hydrogen content of molten aluminium alloys before the metal is cast. This allows corrective procedures to be undertaken to minimise the hydrogen level and so improve the quality and reliability of the final product. The instrument described here (HYSCAN II), measures hydrogen in molten aluminium using a reduced pressure technique developed by the BNF Metals Technology Centre for the UK Light Metal Founders' Association. HYSCAN II is an updated version of the instruments used for some 20 years in foundries worldwide. Current models use a programmable logic controller to undertake the control, diagnostics and measurement functions. 3.2 Principle A constant mass of the melt (approximately 100g) is placed in a chamber and the pressure reduced rapidly to a predetermined value by a vacuum pump. The chamber and associated vacuum system is then isolated from the pump and the sample allowed to solidify. As the melt cools hydrogen is released and its partial pressure is measured by a calibrated Pirani gauge whose output is converted continuously to a digital display of hydrogen content. 3.3 General Description The unit is mounted on a rigid steel frame supported by four heavy-duty castors, two of which can swivel. The vacuum system comprises a vacuum pump, trap, Pirani gauge, solenoid valves and sample chamber. The components are mounted within the frame and in operation are enclosed behind panels. The sample chamber is mounted on the top panel of the instrument and maintained at a constant 120C by a heater coil wrapped round the base of the chamber. This temperature is regulated via a temperature controller situated on a plate near the base of the unit, adjacent to the vacuum pump. The control panel has two switches that operate the test and measure functions, a momentary switch to operate the auto zero function and a digital display of the hydrogen

Section 3

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INSTALLATION AND OPERATION MANUAL Hyscan II content in cm /100g. Three LED lamps indicate the operational status of the instrument (test running, test complete, fault condition). When fitted, a printer is situated in the compartment behind the control panel. All operational and logic sequences of the instrument are controlled by a programmable logic controller (PLC) situated in a sealed metal casing below the control panel in the main body of the unit. The status of the PLC can be observed through a view port on the back panel. Power is supplied to the instrument via corrugated steel covered cable that can be stored, when the instrument is not in use, at the base of the frame. The instrument can be turned on or off with the mains isolator switch positioned near the top of the left hand side panel. A schematic diagram of the layout is shown in Figure 1 and details of the operational functions are provided in the logic table (Table 4), in Figures 2 - 5 and the function chart (S2488A3).
3

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INSTALLATION AND OPERATION MANUAL Hyscan II

4. OPERATION 4.1 Auto Zero After having pumped the unit for about thirty minutes set the instrument zero as follows: a) b) c) d) Move the middle switch to OPEN CHAMBER and the left hand switch to BETWEEN TESTS. Press the auto zero switch on the front panel. Move the middle switch to TEST. Move the left hand switch to TEST.

The TEST RUNNING LIGHT will flash for a 3-minute duration. There is no display during this period. If the auto zero function is successful the TEST COMPLETE light will illuminate and the user can proceed with a blank test (section 4.2). If the auto zero function is unsuccessful the FAULT LED will illuminate on completion of the test. In this case either the low-pressure set points will need to be adjusted (section 5.3), the alumina desiccant will require regeneration (section 6.3) or there is a fault on the system (section 6.8). Note: It is recommended that an auto zero test is performed prior to each sequence of hydrogen measurements. 4.2 Blank test After successful completion of the auto zero (section 4.1) make a blank test as follows: a) Move the middle switch to OPEN CHAMBER b) Move the left hand switch to TEST c) Move the middle switch to TEST. The TEST RUNNING light will illuminate and in less than 10 seconds the panel meter will light up and display 0.00cm3/100g. If the unit is correctly adjusted the hydrogen content will remain at 0.00cm3/100g until the TEST COMPLETE light illuminates after five minutes. If the display reads a non-zero value, repeat the auto zero (section 4.1). If successive zero and blank tests continue to fail the desiccant may require regeneration (section 6.3) or there may be a fault on the system (section 6.8). If an increasing value is observed throughout the test period, then the vacuum system may not be fully sealed. Check the O ring and surfaces of the sample pot. If these are satisfactory and other interconnections appear satisfactory the system may require evacuating for a more extended period to remove water vapour and adsorbed gases.

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INSTALLATION AND OPERATION MANUAL Hyscan II

4.3 Running a test Switch and valve positions together with a typical pressure profile are shown on the function chart (drawing S2488A3) and in Figures 2 - 5. a) Move the isolator switch to the "ON" position (if not already in this position). The unit should be pumped for at least 10 minutes before proceeding with a test. b) Move the middle switch to OPEN CHAMBER (up) and open the sample chamber. c) Place a short length of pre-heated stainless steel rod into the chamber. d) Pre-heat the ladle and dip it into the melt. e) Stir the melt with the ladle to ensure that it is hot and that a representative sample can be taken. IT IS IMPORTANT THAT INSTRUCTIONS (f) TO (i) ARE NOW UNDERTAKEN AS QUICKLY AS POSSIBLE. f) Fill the ladle, wipe it and carefully pour the melt sample into the chamber. g) Remove any alloy spillage from the chamber lip before lowering the lid. h) Move the left hand switch to the TEST position. i) Move the middle switch to the TEST position. The TEST RUNNING light will illuminate. The hydrogen test is now underway. In less than ten seconds, the panel meter will light up and the hydrogen content displayed will increase from zero to the melt hydrogen content (in cm3/100g). The value will remain displayed when the TEST COMPLETE light illuminates after about five minutes. j) Move the middle switch on the front panel to the OPEN CHAMBER (up) position and the left hand switch to the BETWEEN TESTS (up) position. k) Remove the solidified sample by applying a pair of pliers to the exposed length of stainless steel rod. (If the sample has solidified without a length of stainless steel rod in the chamber, then place a rod on the top of the solidified sample and pour a half ladle of melt into the chamber. Remove the contents after about five minutes). At this stage another test can be initiated by repeating the procedure above from instruction (c) above. Note 1 In normal operation the sample chamber is heated to 120C to minimise surface adsorption of water vapour and other condensable gases. However, at the start of a series of measurements it is recommended that the first result obtained using molten aluminium should be discarded to ensure that the chamber i s hot and fully baked. Note 2 When the tests have been completed the switch positions should be as follows: Left Hand Switch Up (BETWEEN TESTS) Middle Switch Down (TEST)

Leave the unit operating for five to ten minutes before turning the instrument off (using the isolator switch). The unit can now be moved or stored under vacuum in the

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INSTALLATION AND OPERATION MANUAL Hyscan II knowledge that it will be ready for immediate use when required. Note 3 The unit has a built-in safety device so that if the test pressure is not achieved within a pre-set time, various parts of the system will be isolated from the vacuum pump and the fault LED will illuminate. In this situation the switches s hould first be returned to the BETWEEN TEST/OPEN CHAMBER mode. The sample should then be removed from the chamber and the chamber lip and O ring examined for damage or contamination (see section 6.8 for further details).

Section 4

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INSTALLATION AND OPERATION MANUAL Hyscan II

5. CALIBRATION 5.1 General The full calibration procedure involves admitting known volumes of hydrogen into the system and making adjustments to the potentiometers on the Pirani gauge. A supply of dry hydrogen is required and one or two calibrated gas pipettes having volumes in the range of interest to the user. The instrument will have been calibrated at the factory over the commonly used range of approximately 0 - 0.5cm3/100g and should not need to be recalibrated on delivery. However, should the operator wish to check the calibration or to perform a calibration over a different range, it is probable that only a minor adjustment to the ATM potentiometer on the Pirani gauge will be necessary. The full calibration procedure is described below. 5.2 Calibration procedure a) Move the switches to the following positions Left Hand Switch Up (between tests) Middle switch Up (open chamber)

b) Run an auto zero test as described in section 4.1. Run a blank test as described in section 4.2 and place an ammeter across the test points adjacent to the panel display. When the test complete light illuminates the ammeter should read approximately 10.18 mA and the digital reading on the analyser should be 0.00cm3/100g. If this is not the case refer to section 5.3. c) Open the sample chamber lid and place the calibration plate on the sample chamber. d) Fill the highest value calibration pipette with hydrogen as shown in Figure 6. e) Attach the calibration pipette to the tube protruding from the centre of calibration lid as shown in figure 6. f) Switch the left hand switch down (TEST) and middle switch down (TEST). g) When the panel meter displays 0.00cm3/100g open Tap A (anticlockwise for ~1.5 turns). Close tap A after about 15 seconds and note the final value on digital display and on the ammeter. h) Adjust the ATM potentiometer on the Pirani gauge head until the hydrogen value shown on the display corresponds to the appropriate value for the pipette. i) Move the switches on the front panel as follows: Left Hand Switch Up (between tests) Middle Switch Up (open chamber)

j) Remove the pipette. Fill a second pipette of lower value than the first with hydrogen and repeat instructions f) to i) above.

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INSTALLATION AND OPERATION MANUAL Hyscan II

5.3 Low pressure Set Point It may be necessary to adjust the low-pressure set point if it is not possible to obtain a display value of 0.00cm3/100g (corresponding to an ammeter reading of approximately 10.18 mA across the test points) when running a blank test (see section 4.2), or if the auto zero function continually fails (section 4.1). The set point can be adjusted via two, 2 position switches mounted in a box situated adjacent to the programmable logic controller (PLC). Remove the back panel to access the switches. If a non-zero reading is displayed persistently during successive tests, record the ammeter reading given across the test points after completion of a auto zero test and set the low pressure set point switches according to the following: mA Reading < 10.18 ~ 10.18 >10.18 >>10.18 Set point Status Low Standard High Very high Required Switch Position S1 on, S2 on S1 off, S2 off S1 on, S2 off S1 off, S2 on

Note: If it is necessary to lower the set points to obtain a satisfactory zero, then the vacuum system should be first checked for leaks, the desiccant renewed and the system pumped out for one hour.

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INSTALLATION AND OPERATION MANUAL Hyscan II

6. MAINTENANCE

WARNING: Ensure that the electrical supply is isolated before starting any maintenance work. The unit has been designed to require the minimum of servicing during its working life. Nevertheless, the following simple checks are advised at frequent intervals in order to ensure optimum performance of the instrument. 6.1 Sample chamber/O ring If the O ring in the sample chamber lid is damaged, or if the surface of the sample chamber rim is scratched or pitted, it will not be possible to achieve a vacuum tight seal during testing. The O ring should be regularly inspected and if it is damaged or has particulate material embedded into it, it must be replaced. Damage to the sample chamber should be removed by careful abrasion with fine abrasive paper (grade 240 to remove scratches and 800 to polish). Damage to the chamber rim can be caused by removing solidified aluminium with a screwdriver or pliers, or by tapping the ladle on the rim when pouring the sample. Care should also be taken when removing the solidified sample when the test is completed. The rod inserted into the aluminium should be gripped by pliers and removed vertically. The rim of the chamber should not be used as a levering point. When pouring the molten alloy into the sample chamber, care must be taken to ensure that any aluminium on the outside of the ladle does not drop onto the junction between the sample chamber and the elbow. This junction is sealed with a viton O ring that can be damaged by drops of molten aluminium alloy, and will then require replacement. This is achieved by removing the collars around the elbow where it passes through the top surface and unscrewing the two bolts which attach the elbow to the sample chamber. The O ring, carrier and integral sintered metal filter can then be removed and replaced. 6.2 Vacuum pump Observe the pump oil level through the window on the front panel. Top up the pump with Ultragrade 19 oil as necessary. For detailed servicing of the pump and other vacuum components, refer to the individual manuals written by BOC Edwards appended to this manual.

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INSTALLATION AND OPERATION MANUAL Hyscan II 6.3 Regeneration of alumina desiccant Depending on the frequency of use and ambient humidity it will be necessary to regenerate the desiccant from time to time. This should be done at least every 500 hours and when an increasing blank value is observed. Follow the instructions below to regenerate the desiccant. a) Move the isolator switch to the off position. b) Remove the front panel. c) Turn the manual air admittance valve anti-clockwise to admit air to the trap and then close the valve. d) Unscrew the three retaining nuts around the trap and remove the glass disc. e) Remove the mesh envelope containing the desiccant from the trap, replace the glass disc and tighten the nuts. f) Check that the manual air admittance valve is closed and switch on the mains isolator to keep the system under vacuum. g) Either dry the desiccant in an oven at 150C for at least one hour, or replace it with a new desiccant envelope that has been heated at 150C for at least one hour immediately before use (see note below). h) Quickly transfer the regenerated / new desiccant to the trap by repeating the procedure described above. i) Check that retaining nuts are tight. j) Replace the front panel. k) Turn the instrument on and leave the system pumping for at least half an hour before running a zero test. Note: If the desiccant removed from the vacuum system has an oily smell then it may have a limited service life. In this case the desiccant should be replaced with a new one. 6.4 Electrical circuits Wiring diagrams are available from the manufacturer on request. Further details of the electrical circuits for the pump and solenoid valves are provided in the relevant instruction manuals appended to this document. 6.5 Routine maintenance To obtain the best performance of the instrument it is recommended that: a) The system is kept under vacuum when not in use. This does not mean that the unit should be kept running in the between tests mode. When it has been pumped down it can be switched off. b) When the unit has not been used for several days it should be pumped down for about half an hour (left hand switch up, middle switch down) to ensure that the

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INSTALLATION AND OPERATION MANUAL Hyscan II c) d) e) vacuum system is clean. The first test with molten aluminium should be disregarded (see section 4.3). Zero and blank tests should be made at the start of a series of tests (section 4.1 and 4.2). The hydrogen release profile should be observed during a series of tests. If the hydrogen level continues to rise rapidly throughout the five minute test period and does not start to level off after about 3 minutes then it is probable that the system has not sealed properly (see section 6.1). The sampling procedure should be reproducible and the instrument placed as close to the sampling point as possible.

f)

6.6 Planned maintenance 6.6.1 Monthly a) Check the condition of the sample chamber O ring. Remove and replace as necessary. b) Check the condition of the sample chamber/elbow O ring. Remove and replace as necessary. c) Check the condition of the sample chamber sealing surfaces; if necessary remove any scratches or pitting as indicated in section 6.1. d) Note: The paper must be used dry; do not attempt to use the abrasive in a moistened condition. e) Check the vacuum system for leaks. f) Check pump oil level and top up as necessary. g) Carry out a calibration check with hydrogen.

6.6.2 Six Monthly a) Remove particulate material from the analyser, especially around all electrical connections. b) Strip and clean the vacuum system. c) Replace O rings, carriers and clamps where necessary. d) Replace air admittance valve filter (valve V3). e) Replace main cooling fan filter. f) Replace sintered bronze disc filter, carrier and "O" ring. g) Remove scratches or damage to the sealing surfaces of the sample chamber (see section 6.1). h) Drain and replace the oil in the vacuum pump. i) Replace the desiccant with a re-generated desiccant. j) Check all electrical connections to ensure that they are secure. k) Check all mechanical fixings to ensure that they are secure. l) Carry out a calibration check with hydrogen and make the necessary adjustments. Section 6 Issue: 4 Page 17 of 33

INSTALLATION AND OPERATION MANUAL Hyscan II

6.6.3 Yearly Remove vacuum pump and return to Mechatech Systems Ltd for servicing. It is recommended that all vacuum gauging and sensors fitted to this unit be returned to Mechatech Systems Ltd (or a relevant competent body) for service and calibration at least every 12 months. The time interval between services must to be reviewed by the customer during the units operating life. 6.7 Recommended Spares Table 1: Recommended Spare Parts List Description Active Pirani Gauge Head KF25 O rings KF10 O rings KF25 Clamp KF10 Clamp Sample Pot O Rings Ladles Calibration Pipette Ultragrade 19 Oil O rings, Carrier and Filter Alumina desiccant envelopes Sets of Rods KF25 Blanking Plate KF10 Blanking Plate 6.8 Fault Diagnosis 6.8.1 Leak in vacuum system The most common fault that is encountered with the instrument is a leak in the vacuum system. The presence of leaks will be indicated by various fault conditions (see below) or by a continuing increase in reading on the display throughout a test. Leaks usually occur either at the O ring/sample chamber interface due to damage or contamination of the O ring, from damage to the sample chamber lip (section 6.1) or at the outlet connection to the elbow joint at the side of the sample chamber. Leaks may also occur between component interconnections if the instrument has been moved over very rough surfaces or has been mishandled during transit. A leak can be detected by systematically blanking off individual sections of the vacuum system; the following tests will help identify the problem area. Section 6 Issue: 4 Page 18 of 33 Part No QRP 69 QRP 13 QRP 14 QRP 15 QRP 16 QRP 24 QRP 51 QRP 62A QRP 25C QRP 27 QRP 21 QRP 58 QRP 59 QRP 60 Qty 1 1 Pk 1 Pk 1 1 5 5 1 2 litres 5 5 5 1 1

INSTALLATION AND OPERATION MANUAL Hyscan II a) Place an ammeter across the test points b) In the between test/test mode record the mA reading when stable. c) Put the test/open chamber switch to open chamber. This closes valve V2. Record the mA reading across the test points when stable. If the reading is significantly lower than in b) above, the leak is probably between valve V2 and the sample chamber and the O rings and mating surfaces through to the sample chamber should be checked. If the readings are similar, then a leak may be present in the section from V2 to the pump. Note: When dismantling the vacuum system, the unit should be switched off otherwise the Pirani gauge head may be damaged and the pump oil contaminated. 6.8.2 Replacement of O rings All O rings except two are manufactured from nitrile rubber. The two exceptions, which are made of viton, are used for sealing the hot surfaces of the sample chamber lid and the elbow connection to the vacuum system. The outlet from the sample chamber to the vacuum system is protected by a sintered bronze filter to ensure metallic particles do not penetrate the vacuum system. When replacing O rings vacuum grease must not be used.

6.8.3 Replacement of Pirani gauge In the event that the Pirani gauge requires replacement, the instrument should be switched off, the manual air admittance valve opened and the old gauge head removed by unscrewing the clamping ring and disconnecting the lead from the head. Retain the centring ring and replace with the new gauge making sure that the O ring and the mating surfaces are clean and undamaged. Before switching on the instrument, make sure that the manual air admittance valve has been closed.

6.8.4 Identification of faults The red (fault) LED on the front panel will illuminate when the instrument is in a fault condition. The fault can be identified more specifically by examining the status of the output LEDs on the PLC (viewed through the perspex window on the back panel of the instrument). The red LED on the front panel will also illuminate if there is a large leak in the vacuum system. This condition is non-latching and the LED will extinguish when the leak has been sealed. The following tables provide details of how to detect and rectify faults that may occur over the lifetime of the instrument. Many of these faults can be avoided if the recommended maintenance procedures have been adopted (section 6).

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INSTALLATION AND OPERATION MANUAL Hyscan II

Table 2: Identification of faults PLC Output LED on

Probable Fault

Suggested Action

1) Leak in vacuum system (see section 6.8.1)

8 or 9

1) a. Check sample chamber for scratches, pitting or particulate contamination. Remove any scratches by careful abrasion with fine emery paper. b. Check O ring in sample chamber lid for damage or contamination. Replace as necessary. Use Viton O rings c. Check all component interconnections. d. Leak in sample chamber body replace. e. Failure of bellows between pump and valve V1. f. Valve V3 not closing. 2) Remove desiccant, dry or replace.

2) Saturated desiccant (see section 6.3) Overload tripped Valve V3 not opening a) Valve V2 not opening b) Valve V1 not opening c) Pump not working 5

Reset overload Check electrical connections and fuses. Replace as appropriate.

5,6,or 7

a) Check fuses on valve boards and all electrical connections. b) As in B above.

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6.8.5 Assistance from manufacturer In the event that a fault occurs in the unit, the manufacturer may be contacted by fax on 01454 414723 (UK), +44 1454 414723 (international) or by telephone 01454 414723 (UK), +44 1454 414723 (international). For speedy advice please indicate which PLC output LED (5 to 9) is illuminated. 6.8.6 List of associated documents Manufacturers literatures for all major components have been included. a) b) c) d) e) f) g) RV3, RV5, RV8 and RV12 Rotary Vane Pumps (A652 01 880) PVEK valves (C411 02 885) Active Pirani Gauge (D021 71 885) IT20K, IT100, IT300 and IT800 inlet traps. (A441 01 880) AV5A & AV10K air admittance valves (C350 03 880) Panel meter CUB 4I, Red Lion Alphanumeric printer (where fitted) IPP144-40

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INSTALLATION AND OPERATION MANUAL Hyscan II

7. TECHNICAL SPECIFICATIONS Table 3: Technical Specifications

FUNCTION Vacuum Pump Measurement time Power requirement a) Supply UK b) Supply Europe Dimensions (w x h x d) overall Weight (overall) Measurement time Sample weight Range Sensitivity Accuracy PERFORMANCE Refer to manufacturers manual 5 min 230V, 50Hz, 1 ph, 110V, 50/60Hz, 1 ph, 600 x 1070 x 710 mm (approx inc. handle) 120 Kg 5 min 100g Up to 1.00cm3/100g 0.01cm3/100g Less than 5% difference between instrument method and vacuum sub-fusion method Printer (serial via RS232) Spares kit or individual items available

Optional accessories Spares

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8. ENVIRONMENT SPECIFICATIONS Temperature Operation 12 to + 40C Temperature Storage -30 to +70C Humidity Operation 5 to 90% RH (non condensing) Protection IP22

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INSTALLATION AND OPERATION MANUAL Hyscan II

9. SCHEMATICS

9.1 Figure 1: Schematic of component layout

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9.2 Table 4: Schematic and logic diagrams

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9.3 Figure 2: Operation stage 1

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9.4 Figure 3: Operation stage 2

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9.5 Figure 4: Operation stage 3

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9.6 Figure 5: Operation stage 4

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9.7 Figure 6: Pipette filling and use of calibration lid

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INSTALLATION AND OPERATION MANUAL Hyscan II 10. CHART 10.1 Function chart

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INSTALLATION AND OPERATION MANUAL Hyscan II 11. HYSCAN II PRINTER OPTION The printer is an optional accessory that is factory fitted if required. Manufacturers instructions for the printer are included with this manual. The printer will provide data on time, date, test number and hydrogen content. The procedure for changing the printout of time (hour only) is given below. 1. Move front panel switches to the following positions: LEFT HAND SWITCH Up (between tests) MIDDLE SWITCH Down (test)

2. Depress the AUTO ZERO button until all three front panel LEDs illuminate (approximately 2 seconds). Release the AUTO ZERO button immediately after the LEDs illuminate. The internal clock will then advance by exactly 1 hour and the new time will be printed. All future print outs given after completion of a test will display the new time. Repeat (2) as necessary until the desired time is obtained.

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INSTALLATION AND OPERATION MANUAL Hyscan II

12. HYSCAN II SPARES

Part no QRP-03C QRP-13 QRP-14 QRP-15 QRP-16 QRP-21 QRP-24 QRP-25C QRP-27 QRP-50 QRP-51 QRP-56 QRP-58 QRP-59 QRP-60 QRP-62A QRP-68 QRP-69 QRP-81 QRP-82

Description V2 modified PV25EKA valve 220-240V 1 PH 50/60HZ KF25 O rings KF10 O rings KF25 Clamp KF10 Clamp Alumina desiccant envelopes Sample Pot O Rings Ultragrade 19 Oil O rings, Carrier and Filter Sample pot Ladles Band heater Set of Rods KF25 blanking plate KF10 blanking plate Calibration pipette Hyscan II digital display Active pirani gauge head Hyscan II toggle switch (Between Tests/Open Chamber) pk 1 Hyscan II toggle switch for Auto Zero

No per pack 1 Pack of 5 Pack of 5 1 1 Pack of 5 Pack of 5 2 x 1 litre Pack of 5 1 Pack of 5 1 Pack of 25 Pack of 5 Pack of 5 1 1 1 1 1

Supplier

MechaTech Systems Ltd Unit 9 Brunel Way Thornbury Bristol BS35 3UR +44 (0)1454 414723 enquiries@mechatechsystems.co.uk www.mechatechsystems.co.uk

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