QFM330 Installation and Operation Instructions Rev VER 1.0 Aug 2013

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CONTENTS 1

SAFETY WARNINGS ... 5

2

INTRODUCTION / PRODCUCT DESCRIPTION ... 8

3

INSTALLATION ... 9

4

5

3.1

MOUNTING / FIXING INTO POSITION ... 9

3.2

WIRING / CONNECTION OF OPTIONAL ACCESSORIES ... 11

3.3

CONFIGURATION / CALIBRATION / TESTING ... 11

OPERATION ... 13 4.1

GENERAL ... 13

4.2

SPECIAL CONTROLS AND INDICATORS ... 13

MAINTENANCE ... 14 5.1

SERVICING ... 14

5.2

BASIC FUNCTION TESTING / RECALIBARTION ... 15

5.3

REPLACING THE SENSOR-BATTERY PACK IN QFM330. ... 16

5.3.1

REMOVAL OF THE OLD SENSOR-BATTERY PACK. ... 18

5.3.2

FITTING THE NEW SENSOR-BATTERY PACK ... 18

5.3.3

CALIBRATING AFTER FITTING A NEW SENSOR-BATTERY PACK ... 18

5.3.4

TESTING AFTER FITTING AND CALIBRATING A NEW SENSOR-BATTERY PACK ... 19

5.3.5

FITTING THE NEW `REPLACE SENSOR-BATTERY PACK BY ...’ LABEL... 19

APPENDIX A ... 20 TECHNICAL SPECIFICATIONS ... 20 MECHANICAL... 20 ENVIRONMENTAL ... 20 ELECTRICAL... 20 APPENDIX B ... 21 QUICK REFERENCE GUIDE ... 21 APPENDIX C ... 22 TROUBLE SHOOTING GUIDE ... 22 APPENDIX D... 24 SPARES AND ACCESSORIES ... 24 APPENDIX F ... 26 WARRANTY STATEMENT ... 26 EC DECLARATION OF CONFORMITY (DOC) ... 27

QFM330 OXYGEN DEPLETION MONITOR & ALARM

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www.quantumcryogenics.com APPENDIX H... 28 END OF LIFE DISPOSAL ... 28

COPYRIGHT QAUNTUM CRYOGENICS. 2012 © THIS DOUMENT IS THE PROPERTY OF QUANTUM CRYOGENICS. NO PART OF THIS DOCUMENT MAY BE REPRODUCED TO A THIRD PARTY IN ANY FORM WITHOUT WRITTEN PERMISSION OF QUANTUM CRYOGENICS.

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1

SAFETY WARNINGS THESE INSTALLATION AND OPERATION INSTRUCTIONS SHOULD BE READ COMPLETELY BEFORE INSTALLING OR OPERATING THE UNIT.

THIS MANUAL ASSUMES YOU ARE ALREADY TRAINED AND COMPETENT IN THE SAFE USE AND HANDLING OF INDUSTRIAL GASES / CRYOGENIC FLUIDS AND CRYOGENIC / ELECTRICAL EQUIPMENT! YOU ARE FAMILIAR WITH THE RISK ASSOCIATED WITH ASPHYXIATION AND LOW OXYGEN ATMOSPHERES

Persons handling cryogenic liquids (liquid nitrogen, argon or carbon dioxide) should be aware of the dangers associated with their extreme cold and also the possibility of asphyxiation should large volumes of liquid or gas be discharged in confined or poorly ventilated areas. Persons handling liquid oxygen must also be aware of its potentially hazardous oxidising properties. Carbon Dioxide additionally has toxic properties. IMPORTANT – OXYGEN DEPLETION MONITORS SHOULD NOT BE USED FOR THE DETECTION CARBON DIOXIDE GAS. CARBON DIOXIDE CONCENTRATIONS CAN REACH TOXIC LEVELS BEFORE OXYGEN DEPLETION ALARMS WILL ACTIVATE.

USE APPROPRIATE PERSONAL GAS MONITORS WHEN WORKING ON PRIMARY GAS MONITOR ALARM SYSTEM

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Safety information provided by the suppliers of the industrial gas / cryogenic liquid must be read and understood before and followed during the installation and operation of this equipment. Failure to observe all safety precautions may result in property damage, personal injury, and/or death.

DO NOT TOUCH COLD SURFACES OR LIQUID WITH BARE SKIN.

Cryogenic liquids are extremely cold and exposure of skin or eyes to liquid, cold gas or cooled objects may result in severe cold burn injury. The use of eye / face protection, insulated gloves, appropriate clothing and footwear is required. Take time to consider these and other safety precautions that must be observed.

Siren beacons can be extremely loud, >110dBA. Wear appropriate ear protection if working with or close to active siren beacons. Consider others working nearby. QFM330 OXYGEN DEPLETION MONITOR & ALARM

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www.quantumcryogenics.com Calibration The QFM330 has been designed to warn of a potentially lethal hazard. Failure to correctly maintain and calibrate the unit could result in the unit failing to operate correctly. Calibration should only be performed by persons trained and approved by Quantum Cryogenics. The equipment must be used only for the purpose and in the manner described in these instructions. If used for other purposes or in a manner not specified protection provided by this equipment may be impaired. The equipment must not be used as a critical component in life support devices or systems.

ELECTRICAL SHOCK CAN KILL Isolate all power supplies before opening enclosures or attempting to connect / disconnect equipment. Although the standard QFM330 is normally powered via the internal battery, auxiliary power may be supplied from repeater units or other ancillary items connected. All electrical installation must only be carried out by a qualified electrician or other suitably qualified and competent person.

Take extreme care if handling the PCB, THE ASSEMBLY IS EXTREMELY FRAGILE. Protect it from damage and electro static discharge.

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2 INTRODUCTION / PRODCUCT DESCRIPTION The QFM330 is a self-contained oxygen depletion monitor and alarm unit. The QFM330 continually monitors the air surrounding the sensor filter on its base. It provides visual and audible alarms when the monitored concentration of oxygen falls below the pre-set `Alarm’ thresholds. The default factory set alarm threshold levels are: ALARM 01 Low Oxygen Alarm

19.5% (since 2013)

ALARM 02 Critically Low Oxygen Alarm

18.2%

Alarm thresholds are derived from nationally recognised industry guidelines. Special thresholds are available upon request. Careful consideration should be given before specifying special thresholds. The unit is powered via a replaceable internal battery and sensor pack (QM330RS). It is necessary to replace the battery / sensor pack every 2 years. The unit may also be connected to a repeater panel (CryoPanel) and various other ancillary devices via the 9 way d-type connector socket on-top of the unit.

Figure 2-1 QFM330 OXYGEN DEPLETION MONITOR & ALARM UNIT

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3 INSTALLATION 3.1 MOUNTING / FIXING INTO POSITION The QFM330 is supplied fitted with a wall mounting bracket which should be used for securing the QFM330 firmly to a clean, dry, vertical surface. 2 fixings are required, spaced horizontally 128mm apart. A set of screws and masonry plugs are provided with the QFM330, these are suitable for most but not all surfaces. Ensure the fixings used are appropriate to the mounting surface. When deciding where to position the monitor, consideration should be given to 

Is the risk of asphyxia from a lighter than air or heavier than air gas? o For lighter than air gases such as He the unit should be positioned above nominal head height (approx. 2m AFFL). o For heavier than air gases such as N2 the unit should be positioned between knee and hip height (approx. 0.5 to 1m AFFL) o Can the alarm lights and audible alarm be easily seen and heard o Is the unit positioned so that it is monitoring the required area adequately?

The QFM330 monitors the surrounding air by natural convection and diffusion into the oxygen sensor through the sensor filter in its base. IT IS IMPORTANT TO ENSURE THAT THE SENSOR FILTER IS NEITHER COVERED NOR BLOCKED and that AIR CAN CIRCULATE FREELY AROUND THIS FILTER AND THE BASE OF THE UNIT. The QFM330 is not waterproof and must not be exposed to, immersed in, sprayed or washed with water, rain, solutions or other solvents.

Please note that a water resistant / weatherproof enclosure” W-PROOFBOX” is available where units are to be mounted outdoors.

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3.2 WIRING / CONNECTION OF OPTIONAL ACCESSORIES When used as a stand-alone unit there is no wiring required. The QFM330 can be linked to a number of ancillary units by means of a QM330CC interconnecting cable which plugs into the 9-way female D-connector socket on the top face of the unit. This allows repeat alarms, displays and the switching of external electrical circuits to be controlled by the QFM330. A brief summary of these ancillary units is given in Appendix B. When running cabling ensure appropriate containment is used to support and protect the cabling from damage. Route cabling away from high voltage or other power cables. Keep cable runs as short as possible. Unit can suffer from RF interference from a number of sources including high voltage cabling, WiFi and other wireless technologies. The connection cable has a heavy braided wire screen to minimise the effects of interference. The screen must be correctly terminated. WARNING - Do not allow the screen of the cable to touch any of the other terminals or any other electronic components on the circuit board. Quantum Cryogenics recommend cable to MIL-STD 7-2-8C Die-cast metal hoods are recommended for connectors due to superior screening properties. Please refer to drawing A4-00020 QM330CC & QM330CC-CRYOPAN on the next page for cable construction details.

3.3 CONFIGURATION / CALIBRATION / TESTING For full calibration information please refer to section 5 Maintenance.

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4

OPERATION

4.1 GENERAL The QFM330 is normally powered by an internal (non-rechargeable) battery. It operates continually and has no ON / OFF switch. The normal operation of the QFM330 is summarised in the table below:

Condition

Audible Alarm

Low Oxygen Red LED

Critically Low Oxygen Red LED

Low Battery Red LED

Normal (Monitored oxygen level above the `ALARM 1 - Low OFF OFF OFF OFF Oxygen’ threshold and battery voltage satisfactory. Low Oxygen Alarm (Monitored oxygen level below the `ALARM 1 - Low BLEEPING FLASHING OFF OFF Oxygen’ but above the `ALARM 2 - Critically Low Oxygen’ thresholds. Critically Low Oxygen Alarm (Monitored oxygen level below the BLEEPING FLASHING FLASHING OFF ‘ALARM 2 - Critically Low Oxygen’ threshold. Low Battery (Battery CONSTANT ON OFF OFF voltage unsatisfactory) TONE (CONSTANT) In the `Normal’ condition (monitored oxygen concentration is above the `ALARM 1 - Low Oxygen Alarm’ threshold and the internal battery voltage is satisfactory) the QFM330 is silent and shows no active visual indications. If the Low Battery condition is observed the QFM330 should be withdrawn from service immediately as it may no longer operate correctly. A replacement Sensor Battery Pack (Part number QM330RS) should then be fitted. The Sensor-Battery pack within the QFM330 must be replaced on or before the date shown on the label which is found on the side of the QFM330.

4.2 SPECIAL CONTROLS AND INDICATORS In addition to the above there is the calibration button, calibration lights and calibration pot. These are used to adjust the calibration / balance of the unit. Please refer to section 5.2 Basic Function Testing for further details.

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5 MAINTENANCE 5.1 SERVICING Other than the QM330RS Sensor & Battery Pack there are no operator serviceable or replaceable parts. Important maintenance practices are the testing and recalibration procedures described in this section. The sensor and battery pack have a nominal operational lifespan of 2 years under typical operating conditions. The sensor and battery pack should be replaced by the date indicated on the side of the QFM330. Please note that battery and sensor packs may require replacement within 2 years under extraordinary operating conditions. The outer case of the QFM330 may be wiped with a damp cloth. Care should be taken not to get the filter element wet. Do not use solvents or abrasive cleaning products. Check the filter element is not clogged with dust. Gently blowing with dry compressed air and or use of a small dry paint brush to remove any dust or debris.

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5.2 BASIC FUNCTION TESTING / RECALIBARTION The QFM330 should be regularly tested for functionality at intervals of no-longer than 3 months. Units operating under more demanding conditions should be tested more frequently. If the QFM330 fails a properly constituted functionality test it should be withdrawn from service immediately. A functionality test involves admitting gas having an oxygen concentration marginally below the `Critically Low Alarm’ threshold to the sensor and checking that both the `Low Oxygen’ and ‘Critically low Oxygen’ red LEDs flash and that the audible alarm bleeps. This can be carried out using an appropriate test gas. The alarms should activate within 30 seconds. The QFM330 should return to the normal (non-alarm) state within 60 seconds of fresh air being readmitted to the sensor. The QFM330 should be optimised at intervals of no longer than six months. Full formal recalibration should take place as indicated by the attached service label and/or each time the sensor/battery pack (QM330RS) is replaced, but at a period no greater than 12 months from the last service/calibration, a formal certificate with statement of gas bottle, actual concentration and the operation of all alarms should be issued to cover this visit. To perform a sensor optimisation, first, fresh dry air (or test gas with a concentration of 20.8% oxygen in balance of nitrogen) must be admitted to the sensor filter for at least 60 seconds and whilst still subject to this, the calibration button on the top face of the QFM330 should be held down. A fine blade instrument screwdriver (or trim-tool) should be used to adjust the brass coloured calibration screw (20 turn potentiometer) which is recessed beneath the top plate of the QFM330 to the left hand side of the socket. The calibration screw should be adjusted until both of the green lights are out (off) when the calibration button is pressed. If the upper `Cal High’ green LED is lit, rotate the screw Clockwise. If the lower `Cal Low’ green LED is lit, rotate the screw Anti-clockwise. (If both green LEDs are off when the calibrate button is first pressed, rotate the screw one way to make one of the green LEDs light and then rotate it back to turn the LED off again – this checks that the green LEDs are functioning.) Second, a test gas of 18.0% oxygen (balance nitrogen) should be admitted to the sensor filter (ideally at a flow rate of 0.5 litres per minute). The `Low Oxygen’ and `Critically Low Oxygen’ red LEDs should both flash and the audible alarm bleep within 30 seconds. When fresh air is admitted again to the sensor filter, the alarm indications should cancel within 60 seconds.

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5.3 REPLACING THE SENSOR-BATTERY PACK IN QFM330.

THIS UNIT IS DESIGNED PROTECT LIFE. PLEASE NOTE THAT ONLY QUANTUM CRYOGENICS APPROVED / TRAINED OPERATIVES SHOULD ATTEMPT TO REPLACE A SENSOR PACK AND RECALIBRATE THE UNIT. INCORRECT REPLACEMENT/RECALIBRATION COULD LEAD TO FAILURE OF THE UNT TO OPERATE AS INTENDED. LEADING TO A DANGER TO LIFE. WHEN REPLACING QM330RS SENSOR AND BATTERY PACK ENSURE ONLY GENUINE QUANTUM PARTS ARE USED. DO NOT ATTEMPT TO MODIFY OR REPAIR QM330RS SENSOR AND BATTERY PACKS. USE OF NON-GENUINE PARTS OR UNAUTHORISED THIRD PARTY MODIFIED / REPAIRED PARTS COULD LEAD TO THE FAILURE OF THE UNIT TO OPERATE AS INTENDED, LEADING TO A DANGER TO LIFE. When replacing a Sensor-Battery Pack, five steps must be taken: 1] The old Sensor-Battery Pack must be removed 2] The new Sensor-Battery Pack must be fitted 3] The QFM330 monitor must be calibrated 4] The QFM330 monitor must be tested. 5] The new `Replace Sensor-Battery Pack by:... ‘ label must be fitted.

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5.3.1 REMOVAL OF THE OLD SENSOR-BATTERY PACK. The four corner screws retaining the base panel of the QFM330 must be unscrewed carefully (posidrive screwdriver No.1) and the panel removed. Take care to prevent the old Sensor-Battery pack from falling out. When the base panel has been removed the Sensor-Battery pack will slide out of the bottom of the QFM330. The lead must now be carefully disconnected from the Pack by separating the metal clips and pulling gently on the top part of the connection. Do NOT pull on the wires of the lead.

Please note that the QM330RS battery sensor pack must not be disposed of in general waste. They can be disposed of in battery recycling bins. Alternatively they can be returned to Quantum Cryogenics for safe disposal and recycling (please contact QPL for returns authorisation number).

5.3.2 FITTING THE NEW SENSOR-BATTERY PACK Check that the `Replace by..’ date of the new Pack being inserted has not expired. Carefully insert the connector attached to the red, white and blue wires of the QFM330 into the black connector of the Pack. The connector is polarised and so can only be fitted one way round. Do NOT force the two halves of the connector together. When correctly fitted the two halves of the connector are held together by the metal clips which are both sides of the black connector of the Pack. The Pack should carefully be inserted into the QFM330 in the direction indicated by the arrows on the pack (i.e. connector first). The edges of the board of the pack slide into slots in the QFM330 housing. The pack is then held in place by fitting the base panel to the QFM330. When fitting the panel IT IS IMPORTANT TO ENSURE THAT THE PANEL IS THE CORRECT WAY ROUND AND THE CORRECT WAY UP. When viewed from below and facing the QFM330, the white sensor filter should be visible on the outside and should be on the left side of the panel. (The sensor filter should coincide with the sensor on the Pack).

5.3.3 CALIBRATING AFTER FITTING A NEW SENSOR-BATTERY PACK After fitting a new Sensor-Battery Pack (or after reconnecting any Sensor-Battery Pack) the QFM330 must be left for a minimum period of 2 hours before an accurate calibration can be performed. To perform a calibration:

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www.quantumcryogenics.com First, fresh dry air (or test gas with a concentration of 20.8% oxygen in balance of nitrogen) must be admitted to the sensor filter for at least 60 seconds and whilst still subject to this, the calibration button on the top face of the QFM330 should be held down. A fine blade instrument screwdriver (or trim tool) should be used to adjust the brass coloured calibration screw (20 turn potentiometer) which is recessed beneath the top plate of the QFM330 to the left hand side of the socket. The calibration screw should be adjusted until both of the green lights are out (off) when the calibration button is pressed. If the upper `Cal High’ green LED is lit, rotate the screw Clockwise. If the lower `Cal Low’ green LED is lit, rotate the screw Anti-clockwise. (If both green LEDs are off when the calibrate button is first pressed, rotate the screw one way to make one of the green LEDs light and then rotate it back to turn the LED off again – this checks that the green LEDs are functioning.)

5.3.4 TESTING AFTER FITTING AND CALIBRATING A NEW SENSOR-BATTERY PACK This must be performed following the calibration of the QFM330 described in the section above. A test gas of 18.0% oxygen (balance nitrogen) should be admitted to the sensor filter (ideally at a flow rate of 0.5 litre per minute). The `Low Oxygen’ and `Critically Low Oxygen’ red LEDs should both flash and the audible alarm bleep within 30 seconds. When fresh air is admitted again to the sensor filter, the alarm indications should cancel within 60 seconds.

5.3.5 FITTING THE NEW `REPLACE SENSOR-BATTERY PACK BY ...’ LABEL This label is supplied loose with the replacement Sensor-Battery Pack. The backing paper should be removed and the self-adhesive label fitted should be fitted directly over the previous label (so that previous label is completely covered).

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APPENDIX A TECHNICAL SPECIFICATIONS Refer to table in operating section Standard Alarm Thresholds Low Oxygen 19.2% oxygen Critically Low Oxygen 18.2% oxygen (Special thresholds available upon request) Response time (for correctly calibrated QFM330) typically less than 10 seconds for alarms to activate when sensor subject to 18% oxygen test gas Working Lifetime of QM330RS Sensor-Battery Pack must be replaced by date shown on label on the side of the QFM330 (The sensor has an expected operating life of two years in air whilst the battery lifetime depends on the proportion of its life the QFM330 spends in an alarm state. For a battery life of two years of normal operation the QFM330 typically can spend 26 days in continuous `Low Oxygen’ alarm state or 22 days in continuous `Critically Low’ alarm state.)

MECHANICAL Dimensions (excluding probe) Weight Material

(excl. bracket) 165 (H) x 90 (W) x 55 (D) mm. Approx. 550 gms (0.55 Kg). Black anodised aluminium with GRP front panel.

ENVIRONMENTAL Temperature Humidity IP rating Pressure Range

-5 to + 45°C (-20 to +50 at lower accuracy). 0 to 99% RH non-condensing IP?? AS STANDARD IPXX INSIDE W-PROOFBOX Atmospheric ±10%

ELECTRICAL Power source Read-out Sounder Output Output Voltage Signal & Power cable

5 LEDs and Audible Alarm 85 dBa

Electrical Connection Socket on top face for connection only to approved dedicated units.

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