Operation, Maintenance, Troubleshooting And Repair Of 6V4135 Automatic Halogen Gas Leak Detector{0774} Caterpillar

Specifications

Size - 203mm × 76mm × 46mm (8" × 3" × 1.8")

Weight - 0.8 kg (1.75 lbs.)

Sensing Probe Length - 320mm (12.5")

Operating Temperature Range - 0°C to 38°C (32°F to 100°F)

Duty Cycle - Continuous (No limit)

Sensitivity - Will detect gas leak rate as small as 14 grams (1/2 ounce) per year, 3ppm concentration.

General Description

The 6V4135 Automatic Halogen Leak Detector is a battery operated instrument used to find any halogen family gas leaks, such as any type of Freon air conditioning systems or refrigerant systems, and halon charged fire suppression systems. When a leak is found in a system, the detector makes a beeping sound. The speed and frequency of the sound increases as the detector moves toward the leak.

The 6V4135 Halogen Leak Detector has the following characteristics.

1. No calibration is necessary.

2. The instrument is ready for use immediately when turned on.

3. A constant red LED light shows POWER ON indication.

4. Internal, automatic controls set the instrument sensitivity to start at any ambient refrigerant level present when the unit is turned on. Sensitivity is reset when the switch is turned OFF and ON again.

5. Operates on two C-size alkaline batteries (6 Volts). Approximate battery life under normal use is 70 hours.

6. Finds very small leaks, even in areas of high contamination.

7. Activated by very small amounts of halogen gas (3ppm); 1/2 ounce per year leak rate.

8. Has a 320mm (12.5") flexible stainless steel probe with 180° rotation for checks in areas of difficult access.

9. After contact with a large concentration of refrigerant the probe sensor may become contaminated for a few seconds before it returns to its original operating tone frequency.

Component Parts

1. Flexible Probe

2. Leak Detector Case

3. Batteries C-Cell Alkaline (2)

4. Sensing Tip Protector^*

5. Sensing Tip^*

6. Filter Cloths (6)^*

All of the parts shown come with the 6V4135 Leak Detector. An optional earphone (not shown - T.I.F. Part No. 446) and a replacement case (2) [T.I.F. Part No. 447] are available from T.I.F. Instruments, Inc.

6V4134 Circuit Board (7) is available for repair of the unit; see the topic REPAIR PROCEDURE. 6V4078 Maintenance Kit (8) has extra sensing tip (A), tip protectors (B) and filter cloths (C) as well as a test leak source bottle (D) in plastic case (E).

Operation

The 6V4135 Automatic Halogen Leak Detector has the ability to find the location of very small leaks, even in areas with a large concentration of halogen gas. An automatic sensitivity adjustment is controlled completely by the ON/OFF power switch. When the switch is turned on, sensitivity is automatically set to start from the gas level existing at the tip. When there is a small leak in an area of high contamination, turn the power switch OFF and then ON again to reduce the sensitivity of the detector. As the detector moves toward the source of the leak, the higher gas concentration will make the beeps come more often, and have a higher frequency tone. Turn the switch OFF and ON as often as necessary until the source of the leak is found. In areas where air is flowing rapidly, a large leak can be difficult to find because the gas is carried away from the leak source too fast. For this condition, it may be necessary to use a shield to decrease air flow in the leak area.

When a number of gas leaks are present, the large leaks can often make it difficult to find small leaks. First find and stop the larger leaks; then it is easier to find the smaller leaks.

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Always use eye protection during service work on systems that use halogen gas. Sudden release of gas can cause serious injury to the eyes, or cause blindness.

1 Loosen screw (1) and remove cover (2). Put two C-size alkaline batteries in, with the polarity as shown in the detector. (Do not use regular carbon zinc batteries. The unit requires high current that affects battery life.) Replace cover (2).

2 Put power switch (1) in the ON position. The red LED power light should be on. If the LED power light is not on, this indicates weak batteries or poor battery connection. Turn off the unit and replace the batteries.

NOTE: After replacement of batteries, if the LED power light is not on and there is no beeping sound, see the TROUBLESHOOTING and/or REPAIR PROCEDURE sections of this instruction for more information.

3 If the unit operates correctly, loosen probe knob (2), adjust flexible probe (3) and start to look for halogen gas leaks in the system. When a leak is found, the tone frequency becomes higher, and the beeping sound rate increases.

Maintenance

Show/hide table

Before the sensing tip, batteries or filters are changed, turn off the 6V4135 Leak Detector. Personal injury could result from a hazardous shock caused by very high voltage.

Batteries

If the red LED power light is not on or the detector is not operating correctly, turn the detector off and replace the batteries. Should the detector still not operate, see the TROUBLESHOOTING section of this instruction.

NOTE: Cold temperatures will decrease battery strength.

Sensing Tip Replacement

1 Carefully remove sensing tip protector (1) and filter cloth (2) from sensing tip (3).

2 Remove sensing tip (3) from flexible probe (4).

3 Connect a new sensing tip to the flexible probe; tighten finger tight only.

4 Put a new filter cloth over the sensing tip and install the tip protector back on the sensing tip.

Troubleshooting

Detector Beeping (At Erratic Rates)

If the 6V4135 Halogen Leak Detector should start to beep at irregular rates, check the following:

1. Read and follow the directions carefully.

2. The red LED power light should be on. If not, replace batteries.

3. Look for a source of tip contamination.

4. Change the sensing tip and filter if necessary.

NOTE: If after the above inspection the unit does not operate correctly, see the REPAIR PROCEDURE section for further information.

Detector Beeping (At Constant Rates or Not at All)

If the 6V4135 Halogen Leak Detector does not beep or starts to beep at a constant rate but does not find a leak source, check the following:

1. The red LED power light should be on. If it is not, replace the batteries.

2. Change the sensing tip and filter.

If the detector still does not operate correctly after the above inspection, see the REPAIR PROCEDURE section for further information.

Repair Procedure

Flexible Probe Check

1 Remove screw (1) and battery cover (2).

2 Remove two batteries (3), extra parts (4), knob (5), four screws (6), cover (7), and sensing tip (8).

3 Check for continuity between socket (9) of the sensing probe and point (W). (The white wire is fastened with solder to the PC board at point (W).

4 Check for continuity between probe chassis (10) and point (B). (The black wire is fastened with solder to the PC board at point (B).) Make sure there is not a short circuit between probe socket (9) and probe chassis (10).

NOTE: If the sensing probe does not pass the preceding tests, a new probe should be installed. To order a new probe from T.I.F. Instruments request a fixed flexible probe including wire and elbow knob.

6V4134 PC Board Replacement

1 Use a sharp knife and remove five tabs (11) that connect the PC board to the front cover.

2 Use a soldering iron to remove battery negative wire (12) from the ON/OFF switch, sensing tip white wire (W) from the PC board, battery positive wire (13) from the PC board and sensing tip black wire (B) from the PC board.

3 Remove speaker wire (13) and (14) from the component side of PC board. Remove old PC board.

4 Install a new 6V4134 PC Board; use the REPAIR PROCEDURE instructions in reverse order. Use epoxy glue to connect the PC board to the five support posts on the inside of the front cover.

Warranty

The 6V4135 Halogen Leak Detector is designed to give unlimited service. Should a new unit not operate correctly after the recommended maintenance is done, a "no charge" repair or replacement will be made to the original purchaser. This Warranty applies to all instruments that can be repaired, which have not been tampered with or damaged. The claim must be made within one year from the date of purchase. Repairable instruments, out-of-warranty, will be repaired or replaced for a nominal service charge. All returned units, out of warranty, serviced F.O.B. Miami. An extra 90-day warranty will cover the repaired or replaced unit.

Units returned for repair should be sent to: