Watts Hf scientific air sentinel h-28136 User manual

Operations and Maintenance Manual

Air Sentinel™ Replacement Kit

Model H-28136

IOM-HF-Air Sentinel Replacement Kit 29207

WARNING

Read this Manual BEFORE using this equipment.

Failure to read and follow all safety and use information can

result in death, serious personal injury, property damage, or

damage to the equipment.

Keep this Manual for future reference.

IOM-HF-Air Sentinel Replacement Kit 29207 Rev 4

2.0 Overview

2.1 Kit Contents

The kit consists of all the hardware required to replace the Cyclops

Purge Controller with the Air Sentinel™ or for a direct replacement.

The complete kit consists of:

• The Air Sentinel

• This Guide

• The Bypass Key

• 10 washer/locknuts

• Cat # 25359 Hole Plug

• Information sticker

If this kit is used for to replace a defective Air Sentinel the hole plug Cat

# 25359 will not be required.

Table of Contents

1.0 Safety........................................................................................... 2

1.1 Understanding Safety Information............................................. 2

2.0 Overview ..................................................................................... 2

2.1 Kit Contents ............................................................................. 2

2.2 Understanding Safety Information

2.3 Hardware.................................................................................. 2

3.0 The Cyclops Purge Controller....................................................... 3

3.1 The Chassis Removal and Replacement .................................. 3

3.2 Temperature Controller Finger Guard........................................ 4

3.3 Cyclops Removal...................................................................... 4

3.4 Removing the Cyclops Vent...................................................... 4

3.5 The Information Sticker............................................................. 4

4.0 Installing the Air Sentinel™ ........................................................... 5

4.1 Installing the Top Hole Plug (25359).......................................... 5

4.2 Install the Air Sentinel ............................................................... 5

4.3 Air Vent Connection.................................................................. 5

4.4 Wiring the Air Sentinel .............................................................. 5

4.5 Chassis Replacement............................................................... 5

5.0 Replacement of a Defective Air Sentinel ....................................... 6

6.0 Warranty....................................................................................... 8

WARNING

Nothing is more important than personal safety. There is high

voltage connected to the instrument Make sure all voltage

has been removed. Disconnect or turn off the water and

Air supplies.

To prevent hand injury is recommended that safety gloves

be worn.

2.2 Safety

2.3 Hardware

As there will be quite a bit of hardware removed it may be handy

to have a small container to prevent losing any parts during the

service work.

This is a safety-alert symbol. The safety alert symbol

is shown alone or used with a signal word (DANGER,

WARNING, or CAUTION), a pictorial and/or a safety

message to identify hazards.

When you see this symbol alone or with a signal word

on your equipment or in this Manual, be alert to the

potential for death or serious personal injury.

This symbol identiﬁes hazards which, if not avoided,

could result in death or serious injury.

This symbol identiﬁes hazards which, if not avoided,

could result in minor or moderate injury.

This symbol identiﬁes practices, actions, or failure to

act which could result in property damage or damage

to the equipment.

This pictorial alerts you to the need to read the

manual.

This pictorial alerts you to electricity, electrocution, and

shock hazards.

1.1 Understanding Safety Information

This manual contains safety and use instructions that must be

followed during the installation, commissioning, operation, care and

maintenance and service of the Air Sentinel™ Replacement Kit. All

responsible personnel must read this manual prior to working with this

instrument and should familiarize themselves with the following safety

symbols, signals and pictorials.

1.0 Safety

3.0 The Cyclops Purge Controller

The purpose of the Purge controller

is to ensure the enclosure is in a safe

condition before applying line power. To

do this it monitors air pressure and air

ﬂow. If these two conditions meet the

control parameters this is considered

safe. To ensure that all potentially

explosive air has been purged when

power is ﬁrst applied, a ﬁve minute

times period must occur prior to power

allocation, under the safe condition

mentioned above.

The Cyclops system consists of the

Cyclops controller, the vent and the

external stainless steel interconnection

tube.

The controller is sealed and no repair

is possible. This manual will guide you

through removal of the Cyclops System

and the upgrade to The Air Sentinel.

The Air Sentinel is smaller, lighter and

includes the vent integral to the controller.

This system was designed speciﬁcally for

the CLX-Ex and CLX-Ex2.

3.1 The Chassis Removal and Replacement

To gain access to the Cyclops mounting hardware it is ﬁrst required to

remove the chassis

Tools Required:

A medium size Philips screwdriver

The Electronic PCB and Chassis assembly is the complete system

as shown to the right. This includes the LCD, keypad, power supplies

and cables.

Steps:

1. Remove electrical connectors to Optics PCB (2 places), the intake

solenoid, the purge solenoid and the reagent pump.

2. Remove 8 screws as shown in the photo on the next page. Please

note that two different sized screws are used. The five larger screws

go around the perimeter of the plastic frame.

3. Remove the entire chassis.

4. Replace the chassis and reverse the steps 1-3 above. Ensure

that the PCB is installed correctly in the enclosure before screwing

in place.

When properly located, the PCB and Chassis should have no wires or

tubing pushing against it.

Electronic PCB and Chassis Assembly

Chassis Screw Locations

To remove the PCB and Chassis assembly, ensure that water

and all electrical connections to the instrument are removed.

WARNING

3.4 Removing the Cyclops Vent

Tools and Supplies Required:

14mm (or 9⁄16") open end wrench

23mm (or 29⁄32") closed end wrench

Steps to remove the Vent:

1. Remove the connection to the external interconnection stainless

steel tube if this has not already been done. This requires a 14mm

(or 9⁄16") open end wrench.

2. From inside the enclosure use a 23mm (29⁄32") closed end wrench to

remove the nut and washer, then remove the vent.

3.5 The Information Sticker

When replacing the Cyclops with the Air Sentinel one of the four front

door yellow stickers will have incorrect information. The kit includes a

replacement sticker to be used. The stickers are exceedingly difﬁcult to

remove. To make this easier, we recommend that this sticker be placed

over the existing sticker that showed the Minimum and Maximum

Overpressure values.

3.2 Temperature Controller Finger Guard

To gain better access the back nuts the Temperature Controller Finger

Guard should be removed.

Tools Required:

A small size Philips screwdriver

Located above the Electronic PCB and chassis is a large ﬁnger guard

and Temperature Controller cover. This is easily removed by loosening

the four screws. Use care not to lose these screws as they are quite

small.

After replacement of the controller, be sure the reattached the cover

and ﬁnger guard.

Remove all power from the system before starting removal to

avoid risk of electrocution.

WARNING

3.3 Cyclops Removal

Tools Required:

14mm (or 9⁄16") open end wrench

11mm (or 7⁄16") combination wrench and socket wrenches

Small ﬂathead screwdriver 2.5 - 4mm (or 1⁄8- 5⁄32")

Steps:

1. Remove the power from the system.

2. Remove the wire connections at terminals 4, 5 and 6 of the Cyclops.

3. Remove the external interconnection stainless steel tube. Undo

the connection at both ends. This requires a 14mm (or 9⁄16") open

end wrench.

4. Remove the Chassis. See section 1.1 above.

5. Remove the 10 perimeter nuts flat washers and lock washers. This

will require 11mm (or 7⁄16") tools. Often a combination wrench and a

socket set work the best.

6. Once all the hardware is removed you may need to give small tug as

the rubber gasket can stick to the enclosure.

7. After the hardware is removed, there is a small safety cover and a

DIN rail containing a terminal. The safety cover can be discarded,

but the Din rail will need to be replaced when installing the

Air Sentinel.

Use care as the Cyclops weighs over 2.3 kg (5 lbs).

CAUTION

4.0 Installing the Air Sentinel

The kit includes the Air Sentinel, ten locking nuts and a top hole plug.

4.1 Installing the Top Hole Plug (25359)

Tools Required:

3⁄8" or 10mm nut-driver or socket wrench

As the Air Sentinel has an integral vent the Cyclops Vent was removed.

This hole must now be plugged. A stainless steel plug is provided.

This has rubber seal that goes on the outside and washer and nut

on the inside.

The plug needs to be sealed until there is no gap between the top cap

and the enclosure but do not over tighten.

4.2 Install the Air Sentinel

Tools Required:

11mm (or 7⁄16") combination wrench and socket wrenches

The Air Sentinel is sent with 10 Stainless Steel locking nuts. These are

a combination of a nut, washer and lock to make installation easier.

When installing the din rail needs to be installed at the top left side

tightened with two nuts.

After installing, check all 10 nuts one last time to ensure all are tight.

4.3 Air Vent Connection

Tools Required:

Knife or Scissors

The vent from the top of the optics assembly previously had no final

connection. A check valve was used to prevent water from entering

the enclosure.

This vent must now connect to a fitting on the Air Sentinel through the

same check valve. The tube is shortened by about 50-60mm. This tube

will be placed on the output of the check valve to allow for the optics to

vent through Air Sentinel.

Installed Air Sentinel

4.4 Wiring the Air Sentinel

Tools Required:

Small flat blade screwdriver

Each of the power terminal

blocks can be removed

for ease of use. Be sure to

tighten these locks after

connections are finished.

As stated on the label, Mains

power is applied to the upper

set of terminals and the

connection to the DIN rail

must be made to the lower

set of terminals.

4.5 Chassis Replacement

Refer to section 1.1 and reverse all the electrical connections. When

replacing the chassis, ensure there are no interferences, that the finger

guards are in place and there no pinched wires.

This completes the installation. Refer to the Air Sentinel for operation.

5.0 Replacement of a Defective

Air Sentinel

In this application the instrument should look exactly the same after

replacement. It would be wise to take a few photos before disassembly.

Be sure to note problems and mark these on the defective unit. In most

instances you can contact HF scientiﬁc for an RMA number to return

the defective controller.

Tools Required:

11mm (or 7⁄16") combination wrench and socket wrenches

Small flathead screwdriver 2.5 - 4mm (or 1⁄8- 5⁄32")

Steps:

1. Remove the chassis Assembly as shown in section 2.1.

2. Remove the Temperature Controller Finger Guard as described in

section 2.2.

3. Remove the existing air vent connection. See section 3.3

4. Remove the Mains and Power Out connections terminal blocks

using the flat blade screwdriver. It is not necessary to wires from the

terminal blocks unless these terminal blocks have been damaged.

See section 3.4

5. Remove the 10 Washer/Locknuts.

6. Remove the defective Air Sentinel.

7. Replace in the reverse order of steps 1-6. Ensure all hardware

is tight. Also make certain that the terminal blocks have been

tightened into place.

To remove the PCB and Chassis assembly, ensure that water

and all electrical connections to the instrument are removed.

WARNING

Notes

______________________________________________________________________________________________________________________________________________________________________________________________________________

USA: T: (239) 337-2116 • Toll-Free (888) 203-7248 • F: (239) 454-0694 • HFscientific.com

Latin America: T: (52) 55-4122-0138 • HFscientific.com

6.0 Warranty

Watts Regulator Co. (the “Company”) warrants each product to be free from defects in material and workmanship under normal usage for a period

of two (2) years from ﬁrst use or three (3) years from date of invoice, whichever occurs ﬁrst. In the event of such defects within the warranty period,

the Company will, at its option, replace or recondition the product without charge. Parts, which by their nature are normally required to be replaced

periodically, consistent with normal maintenance, speciﬁcally reagents, desiccant, sensors, electrodes and fuses are excluded. Also excluded are

accessories and supply type items.

Proof of purchase (invoice or paid order conﬁrmation) and/or ﬁrst use (commissioning) must be provided when making a product warranty claim.

THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY WARRANTY GIVEN BY THE COMPANY WITH

RESPECT TO THE PRODUCT. THE COMPANY MAKES NO OTHER WARRANTIES, EXPRESSED OR IMPLIED. THE COMPANY HEREBY

SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED

WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

The remedy described in the ﬁrst paragraph of this warranty shall constitute the sole and exclusive remedy for breach of warranty, and the Company

shall not be responsible for any incidental, special or consequential damages, including without limitation, lost proﬁts or the cost of repairing or

replacing other property which is damaged if this product does not work properly, other costs resulting from labor charges, delays, vandalism,

negligence, fouling caused by foreign material, damage from adverse water conditions, chemical, or any other circumstances over which the

Company has no control. In addition, the Company shall not be responsible for any costs incidental to the Company’s warranty response efforts,

including, without limitation, costs associated with the removal and replacement of systems, structures or other parts of facilities, de-installation,

decontamination and re-installation of products, or transportation of products to and from the Company. This warranty shall be invalidated by any

abuse, misuse, misapplication, improper installation or improper maintenance, alteration of the product, or use of any parts or accessories (including

but not limited to reagents) not provided by the Company.