Nuvair PRO HE Operating Instructions Manual

PRO HE HELIUM ANALYZER P/N He Rev 1 DANGER This instrument is designed to monitor the helium concentrations in a gas mixing process. When processing gas mixtures intended for breathing, the instrument must be calibrated and functioning properly. Suffocation or other fatal respiratory complications can result from improperly calibrated or malfunctioning equipment. Oxygen accelerates combustion. Do not use this instrument around open flames and combustible gases, liquids or solids. Only authorized personnel should conduct maintenance and/or servicing. Before conducting any maintenance or servicing, consult with authorized supervisor/manager. Pro He Manual Rev 08/01/07 P/N He - i

All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Nuvair, 2949 West 5th Street, Oxnard, CA 93030. Warranty This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction, and that our liability shall be limited to replacing or repairing at our factory (without charge, except for transportation), or at customer plant at our option, any material or construction in which defects become apparent within one year from the date of shipment, except in cases where quotations or acknowledgements provide for a shorter period. Components manufactured by others bear the warranty of their manufacturer. This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Nuvair or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage, which may result from its use or misuse. We reserve the right to employ any suitable material in the manufacture of our apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in so far as such alterations do not adversely affect our warranty. Important Notice This instrument provides measurement readings to its user, and serves as a tool by which valuable data can be gathered. The information provided by the instrument may assist the user in eliminating potential hazards caused by his process; however, it is essential that all personnel involved in the use of the instrument or its interface, with the process being measured, be properly trained in the process itself, as well as all instrumentation related to it. The safety of personnel is ultimately the responsibility of those who control process conditions. While this instrument may be able to provide early warning of imminent danger, it has no control over process conditions, and it can be misused. Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Nuvair at the time the order is placed. Therefore, the purchaser must be aware of the process conditions and the potential for misuse. The purchaser is responsible for the training of personnel, for providing hazard warning methods and instrumentation per the appropriate standards, and for ensuring that all devices and instrumentation are calibrated, maintained and operated properly. Nuvair, or the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the user’s process conditions. - ii

The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument. Commonly available options are listed below. � CE CONFORMITY: This Nuvair PRO HE Analyzer meets or exceeds all requirements of the Commonwealth of Europe (CE) for Radio Frequency Interference and Electromagnetic Interference (RFI/EMI) protection. � PRO HE MCWHE: Wall-mountable instrument with view window for helium analysis. � PRO HE MCWHEO2: Wall-mountable instrument with view window for helium analysis. � PRO HE MCPHE: Battery operated portable instrument for helium analysis. � Optional AC to DC Adapter: Power instrument directly from 115VAC US plug source. � Optional International Power Adapter: Powers instrument directly from an AC power source 100-240 VAC 50/60 Hz CE approved. Includes US and 3 international AC plugs. - iii

safety messages in this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The definition of these symbols is described below: GENERAL WARNING/CAUTION: Refer to the instructions for details on the specific danger. These cautions warn of specific procedures which if not followed could cause bodily Injury and/or damage the instrument. CAUTION: HOT SURFACE WARNING: This warning is specific to heated components within the instrument. Failure to heed the warning could result in serious burns to skin and underlying tissue. WARNING: ELECTRICAL SHOCK HAZARD: Dangerous voltages appear within this instrument. This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion. Failure to heed this warning could result in injury and/or death from electrocution. TECHNICIAN SYMBOL: All operations marked with this symbol are to be performed by qualified maintenance personnel only. NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form of a note. CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. No Symbol - iv

NOT ALLOW WATER INSIDE THE ENCLOSURE. IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED, UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES. This manual provides information designed to guide you through the installation, calibration and operation of your new analyzer. Please read this manual and keep it available. Occasionally, some instruments are customized for a particular application or features and/or options added per customer requests. Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information, procedures, cautions and warnings that may be peculiar to your instrument. Manuals do get lost. Additional manuals can be obtained from Nuvair at the address given in the Appendix. Some of our manuals are available in electronic form via the internet. Please visit our website at: www.nuvair.com. - v

Safety Messages .......................................................................... iv Table of Contents......................................................................... vi List of Figures............................................................................. viii Introduction ................................................................................. 11 1.1 Overview 11 1.2 Features 13 1.3 Options 13 1.4 Applications 13 Setup ............................................................................................ 14 2.1 Unpacking the Analyzer 14 2.2 Mounting the Analyzer (Wall-Mount Unit) 14 2.3 AC Power Connections 15 2.4 Battery Test (Portable Model Only) 16 2.5 Battery Installation (Portable Model Only) 16 2.6 Calibration 17 Operation ..................................................................................... 20 3.1 Operation/Start-up 20 3.1.1 Powering Up 20 3.1.2 Attaching the Sample Gas 20 Maintenance ................................................................................ 22 4.1 Battery Replacement 22 - vi

26 A.3 Helium/Air Chart 27 A.4 Material Safety Data Sheet 30 Index............................................................................................. 31 - vii

Figure 1-1: Wall-mountable PRO HE ............................................ 12 Figure 1-2: PRO HE—Portable Configuration............................... 12 Figure 2-1: Mounting Dimensions ................................................. 15 Figure 2-2: Power Adapter Port (Wall Mount) ............................... 15 Figure 2-3: Power Adapter Port (Portable Model) ......................... 16 Figure 2-4: Battery Installation ...................................................... 17 Figure 2-5: Typical Sample System with Calibration ..................... 19 19 Figure 3-1: Typical Setup Flow Diagram ....................................... 21 Figure 4-1: Battery Disposition ...................................................... 23 - viii

WARNING This is a general-purpose instrument designed for use in a non-hazardous area. It is the customer's responsibility to ensure safety. Combustible gases should not be present in the immediate area nor should this instrument be used near an open flame or ignition source. Helium and nitrogen, while inert, can pose a suffocation risk. The customer must eliminate the possibility of displacing atmospheric air with helium or nitrogen at or near the instrument during the mixing or analysis process. The customer must also ensure that the principles of operating this equipment are well understood by the user. Misuse of this product in any manner, tampering with its components, or unauthorized substitution of any component may adversely affect the safety of this instrument. Since the use of this instrument is beyond the control of Nuvair, no responsibility by Nuvair, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed. - ix

of a gas during mixing or cylinder filling operations. A LCD mounted on the front panel of the instrument displays the percentage of helium during the mixing operation. There are two basic configurations available both of which offer oxygen analysis as an option. The wall-mountable unit is housed in an enclosure equipped with a window for viewing the helium displays. It is powered by a plug-in 6V DC adapter which uses a conventional 120VAC source (100- 240 VAC 50/60 Hz optional). The portable instrument is housed in a rugged high-impact plastic watertight enclosure. It has a molded-in handle for easily transporting the instrument to the mixing or process area. Both models, the standard wall-mount and the portable instrument, use corrosive-resistant materials where applicable for enhanced durability in salt air or spray environments. The wall-mount model is shown in Figure 1-1 and the portable instrument is shown in Figure 1-2. 1.1 Overview The PRO HE analyzes the helium concentrations in a gas mixture. The gas to be monitored is drawn into the analyzer and passed to the sensor network. The sample gas is then directed to a thermal conductivity sensor. This sensor provides a signal that is proportional to the difference in conductivities between the components of the gas mixture. A microprocessor compares the sensor output to data contained in an onboard chip and converts the raw data into a linearized signal that is sent to the helium LCD display. - 11

at constant temperature (25°C) at constant pressure (atmospheric). Figure 1-1: Wall-mountable PRO HE Figure 1-2: PRO HE— Portable Configuration - 12

Two independent easy to read LCD display for He • • • • • • • • • • • • • Low power consumption—up to 150 operational hours on 4 C-cell batteries (portable unit) Convenient front panel ON-OFF power switch with Battery Test Front panel mounted Span and Zero calibration potentiometers Linearized He channel output over the entire analysis range Accessible 1/8” NPT inlet and outlet gas connections for easy setup (wall mount unit) Microprocessor controlled electronics Long-life, low temperature solid state thermal conductivity sensor for accurate helium analysis ABS enclosure for wall-mounting—rugged water resistant plastic housing for portable model Low pressure power inflator hose sampling adapter 1.3 Options AC/DC adapter to power either unit using 120VAC power AC/DC adapter for universal power (100-240 VAC) with 4 interchangeable international AC power plugs (CE rated) 1.4 Applications The PRO HE is specifically offered to the diving industry where specific mixtures of Helium in air are required for technical diving. The PRO HE will allow on-site confirmation of gas mixtures prepared for divers. It is also useful in the gas mixing process during cylinder charging where adjustments to the gas composition can be made based on the real-time analysis of the gas mixture. Other applications include: Gas purification and air liquefaction process control - 13

Unpack unit • • • • • • Mount unit Install sensor Install batteries (portable unit only) Make gas and power connections Calibrate and test the installation Also covered in this section are battery issues, replacing the battery and replacing micro-fuel cells. 2.1 Unpacking the Analyzer The PRO HE is shipped fully functional and ready to install except for installing and batteries (portable unit only). Carefully unpack the analyzer and inspect it for damage. 2.2 Mounting the Analyzer (Wall-Mount Unit) The PRO HE is designed to mount and operate in a general-purpose area only. The instrument is not designed to accept or handle hazardous gases. CAUTION: USING OR MONITORING OXYGEN LEVELS ABOVE ATMOSPHERIC COMPOSITION (20.9%) CAN BE HAZARDOUS. WHILE OXYGEN IS NOT COMBUSTIBLE OR EXPLOSIVE, ITS PRESENCE ACCELERATES AND PROMOTES COMBUSTION. HIGH LEVELS OF OXYGEN WILL MAKE MOST MATERIALS COMBUSTIBLE INCLUDING METALS. DO NOT USE OXYGEN LEVELS ABOVE 20.9% IN THE PRESENCE OF ANY FLAME OR IGNITION SOURCE. Refer to Figure 2-1 and the Outline Drawing in the Appendix for mounting dimensions. The location should be close to the process line to avoid excessive run lengths of tubing. The plastic wall mount enclosure is not watertight. It should not be exposed to water or spray while in use due to the exposed external power adapter inlet. The AC adapter used on this instrument is not water resistant. Care must also be taken not to allow water entry into the power adapter inlet port. CAUTION: POTENTIAL WATER DAMAGE COULD OCCUR IF THE POWER ENTRY ACCESS PORT IS EXPOSED. - 14

return port must not be restricted and must be vented at atmospheric pressure. Figure 2-1: Mounting Dimensions 2.4 AC Power Connections Instrument power for the standard wall-mountable model is supplied by a 6VDC power adapter that is plugged into the side of the analyzer as shown in Figure 2-2. Figure 2-2: Power Adapter Port (Wall Mount) The portable model is powered from 4 C-cell batteries, which must be installed prior to placing the instrument in service. See Section 2.6. The portable unit can also be powered using the optional 6 - 15

port on the side of the front panel near the ON/OFF/ BATT TEST switch as shown in Figure 2-3. This figure also shows the internal pressure vent port which allows the instrument to vent and return to atmospheric pressure before the lid is opened. Figure 2-3: Power Adapter Port (Portable Model) 2.5 Battery Test (Portable Model Only) A battery test function is available from the front panel and should be used prior to using the instrument. To test the batteries, turn the OFF-ON switch to the BATT TEST position. A fresh set of batteries will show a reading of 120. If the reading is 100 or below, you must change the batteries to maintain the accuracy of this instrument. 2.6 Battery Installation (Portable Model Only) Before using the portable model for the first time, 4 C-cell batteries must be installed. Note: Do not use rechargeable batteries. This type of battery does not provide the required voltage to power the instrument. - 16

compartment cover and install the batteries noting the polarity indicated on the label molded into the battery holder. See Figure 2-4. When replacing batteries, for best results use only long-life alkaline batteries. The monitor can be run for up to 150 hours on a fresh set of batteries. Figure 2-4: Battery Installation 2.7 Calibration The analyzer is supplied fully calibrated from the factory but will require calibration checks and recalibration every 30 days or less to maintain the best accuracy. Zero Calibration (helium sensor) Note: To zero the helium sensor, there must be no residual gases other than air in the sample line of the instrument. Step 1 below is designed to purge the sample line using air. 1. With the air source still attached make sure the flow is adjusted between 0.2 and 2 SLPM. Flow air for at least 2 minutes to purge all other gases from the sample line. - 17

potentiometer on the front panel until a reading on the helium display reads slightly above zero, for instance, 4% helium. 3. Slowly rotate the potentiometer and watch the helium display as it slowly decreases toward zero. Once the helium reading changes from 0.2% to 0.1% stop the adjustment process. The analyzer is now properly zeroed. Note: This procedure is necessary to avoid producing “negative” readings. The display is incapable of displaying negative values and will read zero even if the potentiometer is turned additionally after the zero point is approached. Span Calibration (helium sensor) Note: The span is set using the helium display 1. Attach the 100% helium gas to the sample inlet and adjust the flow to between 0.2 and 2.0 SLPM. 2. While helium is purging the sample line, watch the oxygen display. When the oxygen concentration decreases to 0.2–0.0%, adjust the helium span potentiometer on the front panel to set the display (helium) to 100.0% ±0.2% helium. The instrument is now calibrated You should verify that the analyzer reads 20.9% O2 and 00.0 ±0.2% He with air flowing through the instrument and 0.00 ±0.2% O2 and 100.0% ±0.2% He when flowing 100% He. For additional calibration notes, see Section A.3 in the Appendix. The analyzer is now ready to be placed in service. - 18

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Powering up the instrument • • Attach a sample gas 3.1.1 Powering Up Turn the instrument on using the power switch and allow it to operate for 30 seconds. 3.1.2 Attaching the Sample Gas See Figure 3-1. On the portable unit, attach the sample tube to the gas source and adjust the flow rate to 0.2—2.0 SLPM. For the wall mount unit, attach the sample gas to the sample in port and adjust the flow to 0.2—2.0 SLPM. The actual sample flow rate is not critical, but it is important that the flow rate does not exceed 2.0 SLPM. The instrument incorporates small gas passages inside the sample block. A high gas flow rate will pressurize the helium sensor and cause it to indicate an incorrect gas concentration. The analyzer display reading should become stable in less than a minute. Most of the time required for the analyzer’s reading to stabilize is caused by gas sampling propagation delays. This is the time required for the gas sample to purge through the regulators, gas lines and fittings. Depending on the sample system employed, it may require several minutes for the gas sample to reach the analyzer and become stable. - 20

Note: The wall-mounted version requires the tubing and a 1/8” NPT male barb fitting. - 21

batteries, and cleaning the plastic housing. Routine maintenance consists of periodic cleaning of the front panel and displays and leak checking the gas lines. Should any part of the instrument malfunction or fail to perform, the unit should be removed from service and returned for repair and calibration. This unit contains no user-serviceable parts except the batteries. 4.1 Battery Replacement Figure 4-1 shows the battery compartment and indicates the battery disposition as they are replaced. Refer to Section 2.6 and Figure 2-6 for battery replacement procedure. Note: Do not use rechargeable batteries. When replacing the batteries, replace all four at once. It is false economy to replace individual batteries. . - 22

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the Commonwealth of Europe (CE) for Radio Frequency Interference and Electromagnetic Interference (RFI/EMI) protection. Gas Concentrations: 1 SLPM nominal 2.5 SLPM maximum (0.5 psig/3.4 kPa max) Range: 0-100% helium in oxygen and/or nitrogen Accuracy: He: +1% at constant temp & press He: +4% at const press over operating temp range (0-50°C) equilibrated Resolution: He: 0.1-0.2% Response Time: 90% in less than 5 seconds Display: 3 1/2” Dual LCD AC Power: Standard: 6 VDC power adapter powered from 120 VAC 60 Hz. Optional: AC power adapter 100-240 VAC 50/60 Hz International CE version DC Power: 6V Nominal (5.2-10VDC) @ 50 mA max. Battery Power: 4 C-cell alkaline batteries ANSI-14A, IEC-LR14 Battery Life: Approximately 150 hr. continuous use (portable unit) Sensor Type: Solid state thermal conductivity (helium) Enclosure: Wall Mount: ABS plastic housing Portable: Water resistant polyethylene - 24

(157.5 x 149.9 x 94.0)mm Portable: (8.7 L x 7.5 W x 3.8 D)in (221 x 190.5 x 96.5) mm Storage Temp. 0 to +50°C Operating Temp: 0-40°C Humidity: Environmental, 95% non-condensing max. Pollution Degree: 2 Over Voltage Category: 1 - 25

QTY PART NO DESCRIPTION 1 C74069-R33D1 Micro-Fuel Cell R33D1 1 A558 6 VDC 115 VAC 60 Hz power adapter (US version) 4 B90 C-cell alkaline battery 1 A555 6VDC International Power Adapter 100-240 VAC 50/60 Hz (CE version) 1 B75401 Low pressure inflator hose sampling adapter (2 SLPM) 1 P1244 Trim Pot Tool 1 A75813 300DIN Tank Sampling Adapter Kit ____________________ A minimum charge is applicable to spare parts orders. Note: Orders for replacement parts should include the part number (if available) and the model and serial number of the instrument for which the parts are intended. Orders should be sent to: NUVAIR 2949 West 5th Street Oxnard, CA 93030 Phone 1-805-815-4044, Fax 1-805-815-4196 Web: www.nuvair.com or your local representative. - 26

The helium/air chart allows the user to verify the proper functioning and calibration of a helium analyzer. This chart provides the helium and oxygen percentages for a gas mixture containing helium and air only. To use the chart, the user must have a flowing source of helium and air. It is preferred to have a gas cylinder of helium and a separate cylinder of compressed air. The gas cylinders must be equipped with regulators, and control valves. Fittings, tubing and connectors are also required. The cylinders need to share a common manifold or delivery line so that the air and the helium can be mixed together and supplied to the analyzer at a low flow rate and pressure. It is best to have a separate control valve or gas flow restrictor between the analyzer and the gas mixing system. After the oxygen section is calibrated, it will become the standard for checking the helium section. The only concern is that the flow rate does not exceed 2SCFH. Low flow rates do not typically cause an issue. To check the helium section, adjust the helium and the air to a low flow rate. Connect the gas to the analyzer. Note the helium readings. Use the chart to look up the oxygen reading. The helium reading from the analyzer should match the chart within +/-2% or better. Readjust the gas mixture and repeat the process. Typically, it is adequate to check one high helium reading, and one low reading on a PRO HE analyzer (these analyzers use two point calibration). Helium concentrations of 10% and 90% are good targets to shoot for. The actual concentrations are not important. A more practical and portable helium analyzer validation system can be made by using two small gas cylinders of mixed gas—one with a mixture of approximately 10% helium and air, and the other with approximately 90% helium and air. The gas cylinder can be kept on hand to validate the analyzer at any time. The mixed gas cylinder do not need to be very large. This method will require a regulator and a gas flow control and sampling device. Scuba equipment can be used to build this system. Pony tanks are suitable, and a standard primary regulator can be used as well. A power inflator sample adapter is a convent method to sample the gas cylinders at the correct flow rate. The next step is to sample each of the other cylinders. The results are compared to the Air /Helium chart. The most important issues are: Ensuring that the other cylinders contain a mixture of air and helium only. • The use of the power inflator sample adapter will ensure that the sample flow rate is correct. - 27

Percent Helium Percent Oxygen Percent Helium Percent Oxygen 100 0.00 50 10.45 99 0.21 49 10.66 98 0.42 48 10.87 97 0.63 47 11.08 96 0.84 46 11.29 95 1.05 45 11.50 94 1.25 44 11.70 93 1.46 43 11.91 92 1.67 42 12.12 91 1.88 41 12.33 90 2.09 40 12.54 89 2.30 39 12.75 88 2.51 38 12.96 87 2.72 37 13.17 86 2.93 36 13.38 85 3.14 35 13.59 84 3.34 34 13.79 83 3.55 33 14.00 82 3.76 32 14.21 81 3.97 31 14.42 80 4.18 30 14.63 79 4.39 29 14.84 78 4.60 28 15.05 77 4.81 27 15.26 76 5.02 26 15.47 75 5.23 25 15.68 74 5.43 24 15.88 - 28

Pro He Appendix Percent Helium Percent Oxygen Percent Helium Percent Oxygen 73 5.64 23 16.09 72 5.85 22 16.30 71 6.06 21 16.51 70 6.27 20 16.72 69 6.48 19 16.93 68 6.69 18 17.14 67 6.90 17 17.35 66 7.11 16 17.56 65 7.32 15 17.77 64 7.52 14 17.97 63 7.73 13 18.18 62 7.94 12 18.39 61 8.15 11 18.60 60 8.36 10 18.81 59 8.57 9 19.02 58 8.78 8 19.23 57 8.99 7 19.44 56 9.20 6 19.65 55 9.41 5 19.86 54 9.61 4 20.06 53 9.82 3 20.27 52 10.03 2 20.48 51 10.24 1 20.69 - 29

Consult Nuvair for a copy of the MSDS sheet for this product or visit our website at www.nuvair.com. - 30

applications, 13 BATT TEST, 16 batteries, 16 lifetime, 24 rechargeable, 22 battery compartment lid, 16 battery installation, 16 calibration, 17 required items, 18 span (helium), 17 CAUTION SIGN, iv CE mark, 24 combustible gas warning, ix control valve, 27 copyright, ii enclosure, 13, 26 error in readout, 20 ESD warning, 14 features, 13 flow rate, 20 gas connection, 13 general-purpose area, 14 helium/air chart, 27 installation, 14 LCD display, 13 maintenance, 22 manuals, additional, v microprocessor, 11, 13 Pro He, 12 Pro He-portable, 12 model information, iii mounting dimensions, 15 MSDS, 30 negative readings, 18 operation, 20 power adapter, 11, 13, 15, 16, 24 power requirements, 24 power switch, 13 pressure vent port, 16 propagation delays gas sampling, 21 purge, 18 regulator, 27 response, 24 safety information, iv sample system, 18 serial number, iii span potentiometer, 13, 18 spare parts listing, 26 Nuvair address, 31 warning sign, iv warranty, ii, 22 website address, v, 26 window, 11 zero potentiometer, 13, 18 - 31

Oxnard, CA 93030 Ph. 1-805-815-4044 Fax 1-108-815-4196 www.nuvair.com Revision 08-01-2007