Model PRO902C - User Manual
Contents
1. r 3 9 3 6 City Technology sensor alignment 3 10 3 7 Absolute pressure transducer checkout procedure 3 11 3 8 Remote probe controller interface board setup procedure 3 11 MAINTENANCE QS pagana 4 1 4 1 EE 4 42 Required maintenance 4 1 4 3 Heated filter replacelieib eo iiec 4 1 4 4 orifice Teplacemefit ooo eco 4 2 45 Probe bhead removal 4 2 4 6 Orifice holder assembly removal ate tede or tete 4 3 47 Eductor jet body c PERO Val 4 3 4 9 Probe head leak Tes 4 4 4 9 Probe Head pe o s do pt a A 4 5 2 10 Bd ctor vac uumifeSlu k e ade 4 5 August 16 2007 iii 902 MANUAL TFS 5 0 6 0 4 14 rouble Shooting sii 4 6 Zero dritt a o t S u Se 4 6 4 11 2 Span drift Tull eate d eei ad aer oi tod ce et 4 6 4 11 3 Low sample tactu 4 6 4 11 4 Hish sample How rate b ota dadas de 4 7 4 11 5 Low flow rate at the eductor2. 3 13 Probe head leak test configuration hao Ra d I poA uda 4 4 August 16 2007 iv 902 MANUAL TFS 49 Probe head flow test confipurdtion oie repente reete een renda 4 5 4 10 Eductor vacuum test configuration Cede euet e Ca Puta 4 6 LIST OF TABLES 142 Wiring umbilical table u terne etn es neuer tides 1 6 JI Setup menu parameters 5 b e ts Nd qo dons os aes 3 7 3 4 2 Operation setup mel iu ica aoreet OT V GS Gol a tob ted ritate 3 8 Rev 6 0 August 16 2007 902 MANUAL TFS 1 0 1 1 1 2 Rev 6 0 PRODUCT DESCRIPTION Introduction The Installation and Operation manual provides instruction for basic installation preventive maintenance corrective maintenance and trouble shooting procedures for the PRO902C dilution probe conditioning assembly and remote probe controller assembly This manual contains four sections Section 1 Product description Hardware description instrument operating parameters and physical characteristics Section 2 Theory of operation Complete functional description Section 3 Installation and operation Instructions for installation and operation of the dilution probe conditioning assembly Section 4 Maintenance Routine inspection troubleshooting corrective procedures and repair repla
3. En CC AAAA LT rj js olj I Figure 3 8 2 Remote probe controller assembly top view D At the Valve panel turn the cal valve and O2 span switches to ON then turn the O2 zero switch to AUTO and allow time for the reading to stabilize Adjust the O2 Rev 6 0 August 16 2007 3 12 902 MANUAL TFS span potentiometer on the front panel until the output signal is equal to the input signal Note steps B through D should be performed at least twice E Check the front panel O2 meter and adjust the meter adjust potentiometer R2 on the interface board if necessary to the correct meter reading please see Figure 3 8 3 below Use the following formula to calculate the correct meter reading mA reading 4 X 25 correct meter reading 16 where mA reading is the input milliamps at J1 pin 15 of the interface board F The oxygen system on the PRO902C is now calibrated and ready for an initial calibration METER ADJUST 899022299522 THE TIE 1 Bts PE zn SELECTOR SWITCH Figure 3 8 3 Remote Probe Controller Electronics Rev 6 0 August 16 2007 3 13 902 MANUAL TFS 4 0 4 1 4 2 4 3 Rev 6 0 MAINTENANCE General The following procedures are designed to allow the maintenance technician to accomplish all necessary maintenance procedures on the PRO902C dilution probe conditioning
4. 4 7 4 11 6 High flow rate at the eductor exhaust 4 8 4 117 Low one ee POR USE e OU eS OH 4 8 bow span reading es to dea ciues ies chad cons lao dub tva rad den ames 4 8 4 11 9 High span reading e o eive oe Redes ol det id e s 4 9 ASSEMBLY REPAIR aan 5 1 5 1 Obtaining replacement Parts OI Us M RI MN 5 5 2 spare parts Hist C TLIO C 5 1 5 3 Spare parts list PRO902C es te tu ee 5 2 5 4 Extended Parts List 92 5 3 5 5 Recommended 5 5 LIST ORE nies 6 1 LIST OF FIGURES Rev 6 0 1 3 2 2 3 1 3 3 3 4 3 8 1 3 8 2 3 8 3 4 8 Dil tton probe assembly 1 aqasha 1 4 Probe head flow diagram 2 3 Enclosure mounting 3 1 Probe barrel assemblbyo sce tesis xtate edited be quis neuen 3 4 Probe controller Tront panel uui ios eiat 3 6 Remote probe controller interface board setup 3 12 Remote probe controller assembly top view essen 3 12 Remote probe controller electronics
5. 4 90 VIEW A A FLANGE WELDED TO PIPE SPOOL IN THIS CONFIGURATION 1g 3 4 48 MINIMUM 72 MAXIMUM STACK WALL CATWALK OR FLOOR 1 is i RECOMMENDED MINIMUM NOTES 1 DO NOT ALLOW BURRS ON INSIDE DIAMETER OF 4 SCHEDULE 40 PIPE SUPPLIED BY CUSTOMER CUSTOMER SUPPLIED AND INSTALLED CUSTOMER IS TO ENSURE THE STRUCTURAL INTEGRITY ALLOW 24 CLEARANCE FOR DOOR OPENING ALLOW 30 CLEARANCE IN FRONT OF PROBE OF THE STACK OR DUCT AT ALL PENETRATIONS 10 CLEARANCE FOR MAINTENANCE 2 WELD PIPE TO STACK USING 1 4 FILLET WELD 3 A USE THESE FOUR HOLES FOR PROBE INSTALLATION BOX FOR ACCESS 4 PROBE LENGTH WILL MEET US EPA 1 METER PENETRATION REQUIREMENT MAY BE SHORTENED IF NECESSARY TO PLACE PROBE TIP AT CENTER OF GAS STREAM 5 ALLOW 6 CLEARANCE BETWEEN FLANGE AND WALL OR FLANGE AND INSULATION ea Figure3 1 Enclosure Mounting Diagram August 16 2007 3 1 902 MANUAL TFS 3 2 3 2 1 3 2 2 3 2 3 3 3 3 3 1 Rev 6 0 The dilution probe conditioning assembly should be installed in a location that will allow maintenance personnel access to the front of the enclosure All maintenance can be performed from the front of the unit Limitations at the probe site The placement of the PRO902C dilution probe conditioning assembly is important to achieve its maximum reliability Stack temperature extremes The
6. MANUAL TFS 5 3 Spare parts list PRO902C 00002968 17010069 22000009 22000010 25501002 25503002 25503003 25503011 25503012 25503021 25584012 26000501 26000502 26002001 26002018 26004056 26010019 26010021 43001011 43001033 43005014 43008023 45500006 45500007 53010036 53040007 Holder Assembly Orifice Quartz Torlon O2 Driver 2FO Citicell 0 25 Controller Assembly Watchdog Valve CONTROLLER ASSEMBLY HEATED FILTER GASKET EDUCTOR O RING 006 O RING 14 O RING EDUCTOR JET O RING FILTER BODY O RING PROBE Cell O2 2FO Type Citicell w connectors Heat Sink Assembly 902 903 Series Probe Cooler Assembly Thermoelectric FILTER 1 MIC NYLON FILTER 1 MICRON 2 5 STD Orifice Quartz O2 Pump 100CC Eductor Assembly 10L MIN System Specific Eductor Assembly 5L MIN System Specific FUSE 1 AMP DELAY MDL FUSE 10 AMP DELAY MDL FUSE 5 AMP DELAY MDL FUSE 2 AMP DELAY MDL VALVE ASSEMBLY 2 WAY VALVE ASSEMBLY 3 WAY HEATER ASSEMBLY CARTDRIDGE 150 WATT RTD ASSEMBLY SURFACE MOUNT 900 SERIES Check system drawings for flow rates Only choose one eductor Rev 6 0 August 16 2007 5 2 902 MANUAL TFS 5 4 Extended Parts List PRO902C 00300061 Support Heated Filter Aluminum 07020001 IFED Assy Dry w o Probe Barrel 26010016 Housing Filter Dry basis 26010009 Filter Body Dry basis 2 5 26010002 Eductor Cap side AFB 26010003 Eductor Ca
7. by trace levels of the measured gas in the dilution air supply Either obtain the dilution air from a different source or install suitable air cleanup devices to remove the gas of interest Check the analyzer location for large temperature changes or other changes in the analyzer utilities Please see the system manual for zero drift calculations 4 11 2 Span drift full system Span drift may be caused by many different variables throughout the monitoring system Most problems with the sampling system will be indicated by a failure to pass the daily span calibration Failure to pass the daily calibration is subdivided into several different problem areas that would cause a high or low indication on daily calibration For each possible problem a corrective action is listed Please see the system manual for span drift calculations 4 11 3 Low sample flow rate Possible problem Leak in sample line between filter body and orifice holder Corrective action check heated filter sample outlet eductor inlet heat exchanger inlet and outlet and sample line tee compression fittings Rev 6 0 August 16 2007 4 6 902 MANUAL TFS 4 11 4 4 11 5 Rev 6 0 Possible problem Plugged orifice Corrective action Change orifice Possible problem Leak around filter cap Corrective action Clean o ring and apply high vacuum grease Replace o ring Possible problem Leak at probe connection to filter body Corrective ac
8. the calibration gas passes through all system components at the same flow rates and conditions as the process sample gas August 16 2007 2 4 902 MANUAL TFS 3 0 3 1 Rev 6 0 INSTALLATION AND OPERATION Site location and preparation 40 CFR Performance Specification Two 2 provides a guide to proper site selection and lists several points that should be considered for most applications The most accurate readings will usually be obtained when Performance Specification Two 2 is followed The PRO902C dilution probe conditioning assembly is installed on a four 4 inch pipe flange The pipe flange must be installed on a pipe nipple extending six 6 inches from the outer wall of the stack The nipple is used to allow clearance behind the conditioning assembly for installation of the four 4 1 2 inch X 1 3 4 inch stainless steel mounting bolts Also allow a clear space at least the width of the probe enclosure in front of the enclosure door to allow the door to be opened The four 4 inch pipe flange must be aligned as shown in Figure 3 1 1 A slip type pipe flange is recommended to insure that the conditioning assembly can be leveled 52 T G TEFLON LINED PROBE EXTENDING INTO STACK 3 8 PIPE HASTELLOY C 276 MAINTENANCE SEE NOTE 4 SEE DETAIL A CLEARANCE SEE NOTE 9 z 477 SEE NOTE 4 SEE NOTE 5 4 25 SEE NOTE 2 ph He MAIN POWER DISCONNECT 35
9. 1 24 General sqa 2 2 2 Flow functional description e d 2 22 T Sampling mod ei credet edet be cae Rabat 2 2 22 2 PULSE TONE dcos oda ctas id as lav Nae entes 2 3 222 9 Callbrationi node S os any pha AN Da Da dira Mi 2 4 INSTALLATION AND 3 1 3 1 Site location and preparation dod 3 1 3 2 Limitations at the probe SIEG uoo aree ap pra or a Ua ded opa DRM AE RR RARUS 3 2 August 16 2007 ii 902 MANUAL TFS 4 0 Rev 6 0 3 2 1 Stack temperature extremes 3 2 3 2 2 Ambient temperature extremes 3 2 32 3 en s diae 3 2 3 3 Generalinstalatiom es ha Su sa B Ba 3 2 3 3 1 Dilution probe conditioning 3 2 3 5 3 3 3 Sample and calibration gas 3 5 Nue Dn US Debes DR d fare ta DM LU 3 5 3 3 3 detailed ue 3 5 3 3 6 Control and data 3 6 34 Dilution probe conditioning assembly Start up City Fechnology Ob 3 6 3 5 4 20 mADC current output calculation
10. 5 902 MANUAL analyzers in the analyzer rack with diluted sample 1 4 3 Wiring Umbilical Table 1 5 1 5 1 1 5 2 Interface printed circuit assembly and meter display Rev 6 0 TFS Pair Number Function Signal 1 Heat exchanger signal 4 20 milliamp 2 Heat exchanger control signal 0 24 VDC pulse modulation 3 Heated filter RTD signal 4 20 milliamp 4 Heated filter control signal 0 24 VDC pulse modulation 5 Spare 6 Spare 7 Absolute pressure 4 20 milliamp 8 Oxygen analyzer signal 4 20 milliamp 0 25 9 O2 span request 0 24 VDC contact closure 10 O2 zero request 0 24 VDC contact closure 11 Calibration valve control 0 24 VDC contact closure 12 Purge control 0 24 VDC contact closure Remote probe controller assembly The remote probe controller assembly monitors and controls temperatures of subassemblies in the dilution probe conditioning assembly Subassemblies of the remote probe controller assembly include OQ LD Remote probe controller enclosure 3 1 2 X 15 X 17 rack mount enclosure with optional slides Interface printed circuit assembly O meter display Probe heated filter temperature controller Heat exchanger temperature controller The enclosure total length is 15 inches and the enclosure will mount in a standard 19 inch rack excluding the additional space required on the back for connection ofthe two multiple
11. 5 also allows the moisture trapped by the heat exchanger to dump during the purge mode A thermoelectric TE cooler cools the heat exchanger block to its operational temperature of 45 F The heat exchanger control module contains an AC to DC bridge rectifier circuit to provide the necessary DC power for driving the TE cooler A shroud fan directs 100 CFM of air over a heat sink to dissipate the heat generated by the TE cooler 1 3 6 analysis system The oxygen analysis system includes Citicel fuel cell In the presence of 20 9 atmosphere the Citicel sensor produces a 9 13 mVDC signal and 0 00 mVDC when 0 00 is present This signal is amplified to produce a 4 20 mADC signal from a loop powered transmitter located on the cell holder the loop power is powered by the 24V power supply located in the probe controller assembly The signal travels down the wiring umbilical to the probe controller assembly and is input to the remote zero span printed circuit assembly At the zero span printed circuit assembly zero and span of the 4 20 mADC signal can be adjusted before the signal is sent to the DAHS or chart recorder and to the percent panel meter 1 3 6 1 eductor The eductor is the sample mover for the O analyzer and is located in the upper left hand corner of the dilution probe conditioning assembly The sample is drawn from the process stream through the cell under a vacuum
12. 9 When 30 psi instrument air is supplied to the eductor dilution air inlet port the meter flow rate at the sample inlet port should be approximately the same value as the value recorded on the system flow diagram EDUCTOR OUTLET FLOWMETER 2 CA ens TI DILUTION AIR IN 3 30 PSI DRY SAMPLE FLOWMETER Yi WET SAMPLE INLET LEE FLOWMETER SAMPLE OUTLET t TO HEAT EXCHANGER PLUG OR CAP CAL GAS PURGE PORT FITTING Figure 4 9 Eductor Flow Test Configuration Eductor vacuum test Connect the hand held vacuum pump to the eductor inlet port as shown in Figure 4 10 below The hand held vacuum pump is used for its vacuum gauge only With the instrument air pressure of 30 PSIG 200kPa supplied to the eductor air jet the eductor must pull a minimum of 17 inches Hg vacuum August 16 2007 4 5 902 MANUAL TFS EDUCTOR EXHAUST DILUTION AIR IN HAND VACUUM PUMP Figure 4 10 Eductor Vacuum Test Configuration 411 Trouble shooting 4 11 1 Zero drift full system Zero drift is independent of the dilution system as any dilution of a zero gas will still cause a zero indication on the analyzer Analyzer zero drift may be caused however
13. FILTER CONTROLLER HEATED EXCHANGER CONTROLLER Rev 6 0 O2 ZERO POTENTIOMETER O2 SPAN POTENTIOMETER Figure 3 4 Probe Controller Front Panel B Heated filter and heat exchanger temperature controller setup procedure August 16 2007 3 6 902 MANUAL TFS 1 Remove the Watlow controllers from the front panel and check the dip switches on the backs of the controllers both switches should be in the position 2 Reinstall the temperature controllers and apply power to the remote probe controller assembly via the power switch located at the rear of the chassis 3 Please refer to Table 3 4 1 below for parameter set points for each controller Enter the setup menu by pressing and holding the up and down arrows on the controller for three seconds The controller will enter the setup menu when LOC is displayed on the lower window 4 To proceed to the next parameter press the Advance key NOTE all outputs will be switched off while in the setup menu Parameter Function Heated Filter Heat Exchanger Settings Settings LOC Lockout security level 0 0 In Input type 420 420 dEC Decimal point placement 0 0 0 rL Low temperature range 32 0 rH High temperature range 626 176 Otl Output type 1 Ht CI HSC Hysterisis control 3 0 0 3 Ot2 Output type 72 dEA dEA HSA Alarm hysterisis dead band 2 22 LAt Alarm latching NLA NLA SiL Alarm silencin
14. PRO902C probe barrel was supplied using hastelloy C 276 Teflon lined hastelloy C 276 or other suitable material specific to the application The Teflon lined hastelloy probe barrel may be used at temperatures up to 190 5 C 375 F and lengths up to six 6 feet long Use the shortest possible probe barrel length less than six feet for proper response times and consistent sampling practice Ambient temperature extremes The PRO902C dilution probe conditioning assembly may be operated at a maximum ambient temperature of 20 C to 50 C 4 F to 122 F This upper temperature is selected to assure proper operation of the electronic circuitry and solenoid valves contained in the enclosure Optimum operation of the sampling system will always be achieved if a sampling location is selected with moderate temperatures Process pressure The sampling system should not be installed in sampling locations that have pressures that exceed 5 inches H O 1 2 or 10 inches H20 2 5kPa Positive pressure ducts are a special problem because process gases may escape into the area of maintenance personnel when the filter body is opened for maintenance Positive pressure stacks or ducts may be easily sampled if a small portion ofthe stream is vented to atmosphere and the probe installed to sample this atmospheric vent The probe typically pulls between 50 and 300 cc minute requiring only a small bypass flow General Installation Dilution probe condit
15. assembly With the exception of changing the heated filter element none of these procedures are to be considered as normal maintenance and should only be performed in the event ofa calibration failure other trouble shooting procedure or after disassembly of the Heated Filter Eductor Assembly Required Maintenance Equipment To perform maintenance on the sample system the following equipment is required A Vacuum gauge 0 30 inches Hg 0 100kPa B Flow meter 0 500 cc minute P N 29020006 or equivalent Flow meter 0 10 L minute P N 29020009 or equivalent D Temperature meter 0 260 C 0 500 F E Tweezers to remove quartz jet F 2 ea 1 4 tube cap Teflon G 2 ea 1 8 FPT pipe cap H Probe adapter 3 8 pipe to 1 4 tube P N 07990000 I Vacuum pump 20 inches Hg 70kPa P N 26006022 or equivalent J Standard hand tools K High vacuum silicone grease P N 16000003 or equivalent Heated filter replacement NOTE The existing heated filter must be replaced with a new one each time the filter cap is removed the filter is slightly crushed to seal Once a crushed filter is removed it will not seal properly and should not be used again A Turn off the dilution air regulator to prevent any contamination in the critical orifice while the filter cap is removed Remove the three nuts that secure the heated filter cap B Remove the main filter cap by pulling straight back on the filter cap tube fitting The filter is
16. conditioning assembly Oxygen sensor Primary sensitivity Range Output signal Operating life in air at S T P Preconditioning requirements Storage life in CTL container under clean dry conditions at 0 20 C off load Operating temperature range continuous Operating pressure range Operating relative humidity range Full scale output drift at S T P continuous duty in air Output at 0 0 Response time step changes ambient air to using a 47W load resistor August 16 2007 TFS approx 100 300 cc minute approx 5 10 L minute approx 100 cc minute approx 5 L minute 7 2 C 5 C 45 F 50 F 140 5 C 5 5 285 F 10 F Fiberglass Quartz or suitable material Torlon Torlon or suitable material Stainless steel or suitable material Hastelloy C276 Torlon or suitable material Teflon 82 5 Ibs 37 4 kg Direct 0 25 O 5 200 20 9 100 000 hours minimum 1 hour on load 6 months 159 to 40 Ambient 10 0 99 RH non condensing 2 full scale month lt 200ppm equivalent gt 95 in 20 seconds 902 MANUAL TFS 2 0 2 1 2 2 Rev 6 0 THEORY OF OPERATION General The PRO902C dilution probe conditioning assembly extracts a continuous sample from a stack or duct removes entrained liquids and water vapor measures oxygen content of the sample gas and delivers a clean dry sample for transport to a
17. from the heated filter exchanger purge solenoid valve V 4 enters the cooling block inlet to force out the moisture from the block through the drain opening V 3 Calibration mode The PRO902C dilution probe conditioning assembly is calibrated by passing a gas of known concentration through all the components in the sample analysis system and adjusting the response of the gas analysis system to reflect the known value of the calibration gas Calibrating in this manner compensates for total system losses in filter elements or other pneumatic components changes in dilution air flow rates and changes in process gas flow rates A typical calibration gas flow path is as follows from the calibration gas cylinder the gas flows through a flow controlling device and calibration gas valve located in a remote or local gas analysis system through the calibration gas line to the PRO902C dilution probe conditioning assembly calibration gas inlet The gas enters the dilution probe through the calibration gas solenoid valve V 1 and then into the filter body through the purge calibration gas inlet The calibration gas solenoid valve allows the flow of calibration gas to be initiated remotely through a controller in the remote or local analysis system The calibration gas valve is located as close as possible to the purge calibration gas inlet to prevent process condensation from forming in the calibration line between calibrations From the heated filter body
18. gas analysis system The PRO902C delivers a 4 20 mADC oxygen output signal for data retrieval and produces a closure alarm for low system air pressure Gas flow functional description A regulated source of instrument air is connected to the dilution eductor jet through the pressure regulator PR 1 and pressure gauge PI 1 The pressure regulator precisely regulates the air pressure to within 0 04 PSI 3kPa for a 10 PSIG 70kPa change in input pressure The flow through the air jet creates a vacuum that pulls the sample gas through the dilution probe conditioning system and is also used to dilute the sample gas to lower concentrations therefore the air supply quality and pressure are vital for proper probe operation The dilution eductor air flow rate is set and controlled by a dilution critical orifice in the air jet operated at 30 PSIG 200kPa to provide the sample gas critical orifice pressure drop of 15 inches Hg 50kPa or greater The dilution air and sample gas flow rate may be set by selecting different orifice combinations Dilution flow rates between 5 and 10 liters minute may be chosen in combination with different process sample gas flow rates between 50 and 300 cc minute to yield dilution ratios between 16 1 and 100 1 The process sample gas and dilution air are combined within the eductor and the diluted sample gas exits the dilution eductor assembly through the eductor exhaust port In the primary sample path the dil
19. heater The heat element cycles on and off according to the temperature inside the enclosure The temperature of the enclosure is maintained at 100 F by the adjustable thermostat August 16 2007 1 2 902 MANUAL TFS 1 3 3 Valve manifold and dilution air regulator The air valve manifold provides distribution of the box purge and heated filter purge air and a place to conveniently mount the four valves for the Probe conditioning assembly The four valves include SV 1 the calibration valve used to inject calibration gas in the heated filter chamber SV 2 the 3 way purge valve and SV 3 and SV 4 used to purge the heat exchanger The dilution air regulator is located on the left side of the air valve manifold please refer to the 7000 series probe box assembly drawings The regulator is 0 60 PSI with a 0 60 PSI gauge The set point is 30 PSI 1 3 4 Heated filter dilution eductor and probe barrel assembly Rev 6 0 The dilution probe assembly consists of a hastelloy probe barrel and an eductor probe head as shown in Figure 1 3 An eductor assembly and a heated filter body make up the eductor probe head A heated high capacity sub micron filter is housed in a Teflon filter body located within the Probe Head and can be easily replaced during preventive maintenance The sampling probe barrel is typically a section of pipe with an outer diameter of 0 67 inches and an inner diameter of 0 50 inches Probe barrel material is sel
20. m 30 Reg Pres Al 0 60 PSI Manifold Valve 4 Port Pump Eductor 50 1 Fitting Tef 1 8 1 8 Fitting NY 1 8MPT 1 4T Fitting Tef 1 8FPT 1 8T Flange Probe Stop 1 5 Fitting SS 1 8MPT Close Nipple Fitting SS 1 8 1 8 Fitting SS 1 8MPT 1 4T Fitting SS 1 4 1 2 Fitting SS 1 8 1 4 Elbow August 16 2007 5 4 902 MANUAL 5 5 26232312 26246812 26262010 26346312 26346320 26413312 26711210 28254002 29010004 51010034 53010053 53010001 55000007 07990101 24600020 TFS Fitting SS 1 8MPT 1 4T Elbow Fitting SS 1 8 1 4 Tee Run Fitting 55 1 8 Plug Fitting Tef Tee 1 8T 1 4T 1 8T Fitting Tef 1 4TTT TEE Fitting KY 1 8T 1 4T TB Stub Fitting SS SW 1 8FPT 10x32MPT Nut Blind Rivet 10 32 Gauge Pres BR 0 60PSI Switch Disconnect 20A 3P NONIN Heater 800W 120V Hoffman w Fan Heater Cart 150W 1 4 Transducer Pressure 0 15PSIA Barrel Probe 3 8 Hastelloy specify length LAMP 60W 120V Recommended tools PROBE ADAPTER TEFLON 07990000 CHEMICAL HEAT SINK 16000007 CHEMICAL SILICONE GREASE 16000003 PUMP VACUUM HAND HELD 26006022 FLOWMETER SIERRA 5 L MIN 29020005 FLOWMETER SIERRA 500 CC MIN 29020006 Teflon is a registered trademark of E I duPont de Nemours amp Company Inc Torlon is a trademark of Amoco Chemical Company Rev 6 0 Printed in the U S A August 16 2007 5 5 XXXX71151 1 2 OF 2 SOURCE DIL
21. to the exact previous pressure Eductor jet body removal The eductor block may be removed as follows A B C D E F Remove the probe head as described in section 4 5 Remove the eductor assembly housing insulated cover Remove the four 4 spring screws and remove the flat washers and springs Remove the eductor assembly top cap Remove the eductor jet assembly and the jet cartridge assembly from the eductor assembly housing Gently break the modules apart at the gasket The eductor jet assembly can now be repaired or replaced Clean the sealing gasket by removing all hardened vacuum grease Lubricate the August 16 2007 4 3 902 MANUAL TFS 4 8 Rev 6 0 gasket with a fresh thin coat of silicone high vacuum grease Do no let any grease get in the gasket opening G Reassemble the eductor assembly in the reverse order of disassembly being sure to align the block passages with the gasket opening H The top plate springs measure inch uncompressed Tighten the nuts until the spring height is approximately 3 8 of an inch Reinstall the Probe Head J Return the air supply to the exact previous pressure Probe head leak test Cap the eductor air inlet dilution air and the eductor exhaust outlet ports then connect a hand held vacuum pump to the eductor sample inlet as shown in Figure 4 8 Pull minimum vacuum of 20 inches Hg 70kPa with the vacuum pump as shown on the vacuum gauge and
22. 3 7 3 Heated filter control module The heated filter control module interfaces with the Watlow controller in the remote probe controller assembly to control the A C heater for maintaining the factory set temperature of 285 F in the heated filter 1 3 7 4 Heat exchanger control module 1 3 8 1 4 1 4 1 Rev 6 0 The heat exchanger control module interfaces with the Watlow controller in the remote probe controller assembly to control a cartridge heater for cooling the heat exchanger block to a factory set temperature of 45 F Absolute pressure transducer The absolute pressure transducer is mounted on top of the purge valve SV2 and produces a 4 20 mA signal representing 0 15 psi absolute pressure Tubing and wiring umbilicals The tubing and wiring umbilicals are the main link between the dilution probe assembly and the analyzer rack Tubing umbilical The tubing umbilical supplies purge air dilution air calibration gas and the sample return line for the analyzers in the analyzer rack Purge air is supplied by the 1 2 black polyethylene tube at 60 PSI to the valve manifold Dilution air is supplied by the 1 4 black polyethylene tube at 60 PSI to the dilution air regulator Calibration gas is supplied by a 1 4 clear Teflon tube at 30 psi limited to 2500cc minute by flow orifice to the calibration gas inlet on the valve manifold The sample outlet is connected to a 1 4 clear Teflon tube to supply the August 16 2007 1
23. E Turn the zero request switch back to the Auto position and place the span request switch to the On position The span value of the 4 20 mADC output is calculated using the following formula span gas concentration of full scale full scale concentration of Full Scale 16 4 mADC output Example August 16 2007 3 10 902 MANUAL TFS 3 7 3 8 Rev 6 0 25 O full scale 20 9 span gas concentration 20 9 O gt mu G IG 0 836 or 83 6 of full scale 25 0 836 16 4 17 376 mADC output After the cell has stabilized adjust the span potentiometer R18 the remote O PCA to the calculated mADC output please refer to figure 3 7 1 for span potentiometer location G Now place the span request switch back to the Auto position Note Steps D through need to be accomplished at least twice Absolute pressure transducer checkout procedure A Obtain the current barometric pressure reading in inches of mercury The absolute pressure 15 the barometric pressure reading times 491154 B At the dilution probe assembly locate the stack pressure signal at VCM1 ofthe valve control watchdog module terminals 26 and 27 Place an ammeter in series with this signal to measure 4 20 mADC pressure transducer range is 0 15 psia C Remove the calibration gas inlet tube at the heated filter assembly to allow the
24. M system 4 20 mADC current output calculation The first step in calculating the current output for a given gas concentration is to specify the full scale value of oxygen The most widely used full scale value is 25 This value allows approximately 4 oxygen headroom when monitoring atmospheric oxygen levels The 25 full scale value prevents input circuit saturation when atmospheric levels are pulled into the PRO902C dilution probe conditioning assembly during periodic maintenance A full scale value of 1096 oxygen is used when lower levels of oxygen are typically present in the process The second step requires finding the calibration gas percentage of full scale For example ifa full scale value of 25 oxygen is selected and there is a calibration span gas of 20 9 oxygen then 20 9 divided by 25 equals 0 836 This shows that 20 9 oxygen is 83 6 ofthe full scale 2596 oxygen span gas concentration of full scale full scale concentration 20 9 Or 83 6 0 836 of full scale 25 Now that the gas concentration s percentage of full scale is determined calculate the current output by taking the percentage of full scale value in this example 83 6 or 0 836 and multiplying it by sixteen 16 then adding four 4 The total current change is 16 mA from Zero percent oxygen to the full scale value with four 4 added to give a baseline or reference in milliamps to equal 096 o
25. PRO902C Instruction Manual Dilution Probe Conditioning Assembly amp Remote Probe Controller Assembly Part Number 111981 00 16 02007 2011 Thermo Fisher Scientific Inc rights reserved Specifications terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermoscientific com aqi Thermo Fisher Scientific WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive are available at www thermoscientific com WEEERoHS WEEE Compliance 902 MANUAL TFS 1 0 2 0 3 0 6 0 PRODUCT DESCRIPTION 141 2 evs 1 3 Dilution p
26. Rev 6 0 August 16 2007 3 4 902 MANUAL TFS 3 3 2 3 3 3 3 3 4 3 3 5 6 0 3 Connect the eductor inlet tube 4 Connect the calibration purge tube 5 Connect the sample outlet tube 6 Connect the probe filter heater cartridge 7 Connect the RTD on top of the heated filter next to the eductor assembly 8 Check all connections and confirm that the cartridge heater and thermistor are installed to maximum depth Air supply NOTE Do NOT apply pressure to the conditioning assembly until start up Section 3 4 This section is for an air line connection only The air supply must have a dew point of at least 40 40 F A low dew point will prevent condensation in the unheated sample line and reduce sample loss The air supply should have a minimum pressure of 60 PSIG 400kPa to ensure an adequate purge The typical TFS air clean up assembly meets these requirements Connect a 1 2 O D minimum air supply line to the instrument air inlet of the conditioning assembly The instrument air supply inlet is accessed through a 1 2 inch stainless steel compression tube fitting located at the bottom of the conditioning assembly Sample and calibration gas lines Connect the Teflon sample and calibration gas lines to the appropriate 1 4 inch compression type tube fittings located at the bottom ofthe conditioning assembly The maximum length for the sample and calibration lines varies with individual applicat
27. T TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY STATEMENT SELLER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT Warranty Thermo Fisher Scientific
28. UTION PROBE ASSEMBLY 6 0 LIST OF DRAWINGS DRAWING REV SHEET DESCRIPTION NUMBER 07020001 1 1 2 ASSY DRY W O PROBE 26010019 1 1 OF 1 EDUCTOR ASSEMBLY 10L TORLON 26010021 1 1 OF 1 EDUCTOR ASSEMBLY 5L TORLON 00002968 1 1 OF 1 HOLDER ASSEMBLY ORIFICE QUARTZ DRY TORLON XXXX7131 0 1 OF2 SOURCE DILUTION PROBE WIRING DIAGRAM XXXX7132 1 2 SOURCE DILUTION PROBE WIRING DIAGRAM XXXX7141 3 1 OF1 SOURCE PROBE CONTROLLER WIRING DIAGRAM XXXX71151 3 1 OF2 SOURCE DILUTION PROBE ASSEMBLY XXXX71151 1 20F2 SOURCE DILUTION PROBE ASSEMBLY Rev 6 0 August 16 2007 5 1 Thermo Fisher Scientific Appendix A Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller s published specifications and be free from defects in material and workmanship when subjected to normal proper and intended usage by properly trained personnel for the period of time set forth in the product documentation published specifications or package inserts If a period of time is not specified in Seller s product documentation published specifications or package inserts the warranty period shall be one 1 year from the date of shipment to Buyer for equipment and ninety 90 days for all other products the Warranty Period Seller agrees during the Warranty Period to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with
29. actory supplied over the process end of the probe barrel for sealing process gases from the conditioning assembly enclosure Insert the probe barrel assembly through the flange porthole in the back of the conditioning assembly with the bend downward Align the three hole probe mounting flange and flange gasket to the three hole pattern of the conditioning assembly flange porthole Insert the three 3 supplied 1 4 20 X 1 3 4 inch bolts through the probe mounting flange into the threaded holes and tighten Coat the polished probe tip surface with a liberal amount of silicone based high vacuum grease This allows a proper o ring seal of the probe head August 16 2007 3 3 902 MANUAL TFS TOP CENTER MOUNTING GASKET Figure 3 3 Probe Barrel Assembly Probe head installation NOTE Before initial installation of the dilution probe assembly and after any probe head maintenance the tests described in Sections 4 9 and 4 10 of this manual should be performed The probe pre test verifies that the probe assembly is leak free and has the proper flow rates A Reinstall the probe head by sliding the probe head over the polished probe tip The rear of the probe head is usually tilted upward during installation to allow clearance for the sample outlet fitting B Reinstall all items removed during steps B and C of the probe head removal section 1 Connect the eductor dilution air 2 Connect the eductor exhaust tube
30. at Exchanger Assy Complete 00500055 Block Spacer Heat Exchanger Rev 6 0 August 16 2007 5 3 902 MANUAL Rev 6 0 00800029 00300009 15121509 17010072 21001164 21002032 21031000 21031003 21090010 25501018 28253100 48050004 48060001 56010025 53060008 21001021 21032001 26000505 21002033 21032001 26001501 21002033 21032001 26001004 26001007 26002058 28253007 28253200 28259001 45500005 45510006 26004005 26004007 26004029 26005025 26006036 26312311 26512312 26311311 26010007 26212217 26212311 26212312 26212324 26231312 TFS Shroud Fan Bracket Capacitor Mntg Cap 15Kmf 16V Radial PCA Controller TE Cooler Conn Flange MT Recp 16pin Male Conn Recpt 3 Pin Molex Terminal Socket Molex 18 22AWG Terminal Pin Crimp 16 18AWG Cable Clamp for 16 pin 453 Dia Cable Max Gasket Heat Sink Screw 10 32 x 2 SS Phillips Transistor N Mosfet Bridge Rectifier 50 PRV 25A Transfomer 115 12 96VA Dipped Thermostat Assy Conn Rept molex 2 pin ny Terminal pin molex 18 22 AWG Heat Exchanger Assy Block Conn Plug 3 pin molex Terminal Pin Molex 18 22AWG Fan Assy Conn Plug 3 pin Molex Terminal Pin Molex 18 22 AWG Fan Axial 4 100 115 Fan Axial Guard 4 Filter Air Fan Shroud Screw 10 32 x 75 SS Phillips Screw SS 325 x 500 Spring SS 325 x 500 Valve Assy Drain Valve Sol 2 Way 120V DRN Orifice Sap 10 000 cc m 64 Orifice Sap 2 500 cc
31. between the probe assembly and the remote analyzer is 50 feet or less Typical transport flow rates from the conditioning assembly to an external analysis system range from 1 5 to 3 0 liters per minute This gives the analytical instruments a response time of 2 to 5 minutes depending upon application which is adequate for most process control and environmental monitoring requirements System response time requirements have been met with the PRO902C dilution probe conditioning assembly by a three step process Upon extraction from the stack the process sample gas is filtered dried via the heat exchanger and diluted In the secondary sample path the oxygen path the Eductor Pump Assembly pulls the dry undiluted sample gas from the heat exchanger through an in line filter F2 into the oxygen analyzer sample inlet The sample gas passes through the oxygen analyzer into the eductor pump inlet and is then transported to vent To further simplify the gas conditioning system the process stream is immediately diluted at the sample source using dry air with dew points in the range of 40 0 C to 73 C 40 F to 100 F The dew point of the gas stream leaving the PRO902 probe is primarily a function of the dilution air dew point Dilution ratios of 16 1 to 100 1 are easily achieved The exit sample dew point of 7 8 C to 37 2 C 0 to 35 F allows use of unheated sample lines in all but the most extreme environments Operation of the dilu
32. cement for major assemblies PRO902C description The PRO902C dilution probe conditioning assembly is a three part package Part one is the stack or duct mounted dilution probe conditioning assembly part two is the wiring and tubing umbilicals and Part three is the remote controller assembly The dilution probe conditioning assembly draws conditions and dilutes the process emissions to be transported for analysis The tubing and wiring umbilical connects the dilution probe conditioning assembly to the analyzers calibration gas supply purge instrument air supply dilution air supply and the remote probe controller assembly Part three the remote probe controller assembly monitors and controls temperatures of subassemblies in the probe conditioning assembly displays the City Technology output and connects the dilution probe s alarm and control contact closures with the customer s control system PRO902C dilution probe conditioning assembly please refer to the 7000 series probe box assembly drawings 24 24 x 9 3 4 NEMA 4X enclosure Enclosure heater Dilution air regulator Heated filter dilution eductor and probe barrel assembly Heat exchanger and drain valve assembly TEI O analysis system a City Technology cell Citicel b pump eductor ON UC August 16 2007 1 1 902 MANUAL TFS 153 7 Heated filter control module 8 Valve control module Watchdog 9 Valve manif
33. d equipment and container NOTICE Material contained in this manual is proprietary information of TFS The TFS manual is to be used only for the installation understanding and servicing of this product For further information or assistance contact Thermo Fisher Scientific All rights reserved No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of TFS REVISION HISTORY Revision Revision Made Pages Affected Revision Date No 1 1 Revise document to Word format update All June 25 1999 2 0 Revised document All October 13 2000 3 0 Changed Logo amp TEI All April 12 2001 4 0 Changed O2 analyzer All Sept 28 2006 5 0 Changed List of Drawings 6 1 Aug 16 2007 6 Added Schematics 6 1 6 9 Jan 4 2008 Rev 6 0 August 16 2007 i 902 MANUAL TFS 1 0 2 0 3 0 6 0 PRODUCT DESCRIPTION 141 1 1 2 evs 1 1 1 3 Dilution probe conditioning assembly hardware 1 2 ProbeenclosSurer uuu saa pa te distat cae ania eae 1 2 1 3 2 Bmelosure Heater NR RR 1 2 1 3 3 Valve manifold and
34. dilution air 1 3 1 3 4 Heated filter dilution eductor and probe barrel assembly 1 3 1 3 5 Heat exchanger and drain valve assembly 1 4 1 3 6 Cb analysis SVSIGPW s AURI CAP AR RR 1 4 12 6 D 1 5 1 3 7 Power purge and temperature 1 2 1 5 1 3 L1 Poseer isteiDUCI ss sooo e Doe 1 5 1 3 7 2 Valve controller watchdog module 1 5 1 3 7 3 Heated filter control module 1 5 1 3 7 4 Heat exchanger control module 1 6 1 3 8 Absolute pressure transducer uoce ci ento tes tt ena Code d aus 1 6 1 4 Tubing and wiring umbilicals a 1 6 IET Turbine mbilical suscrito a c err sex asua 1 6 1 4 2 Wiring umbilical eoe onte nte tee cer D etie sien asha asua 1 6 1 5 Remote probe controller assembly 2 1 6 1 5 1 Remote probe controller enclosure 1 7 1 5 2 Interface printed circuit assembly and meter display 1 7 1 5 3 Temperature controllers 1 7 1 6 Specifications ve ve order everti NO Geo Qa 1 8 THEORY OE OPERATION unu nanan sun Peas eed 2
35. e raw sample outlet tubing from the bottom ofthe filter body Loosen the filter body wing nut Remove the heater and RTD from the rear of the filter body Remove the probe head from the probe barrel Prior to reinstalling the probe head coat the polished probe tip surface with a liberal amount of silicone based high vacuum grease This allows a proper o ring seal of the probe head Install the probe head in the reverse order of removal August 16 2007 4 2 902 MANUAL TFS 4 6 4 7 Rev 6 0 Orifice holder assembly removal A B C D E F G H J Remove the probe head as described in section 4 5 Remove the eductor assembly housing insulated cover Remove the four 4 spring screws and remove the flat washers and springs Remove the eductor assembly top cap Remove the eductor jet assembly and orifice holder assembly from the eductor assembly housing Gently break the modules apart at the gasket Clean the sealing gasket by removing all hardened vacuum grease Lubricate the gasket with a fresh thin coat of silicone high vacuum grease Do no let any grease get in the gasket opening Reassemble the eductor assembly in the reverse order of disassembly being sure to align the block passages with the gasket opening The top plate springs measure inch uncompressed Tighten the nuts until the spring height is approximately 3 8 of an inch Re install the probe head Return the air supply
36. ected for compatibility with the process stream and is supplied in hastelloy C 276 The standard four 4 foot probe barrel has an approximate 5 bend to prevent excess water buildup within the probe barrel in saturated processes EDUCTOR HOUSING ASSEMBLY DILUTION CHAMBER SAMPLE EDUCTOR J CRITICAL EDUCTOR EXHAUST ORIFICE SURFACE MOUNT RTD DILUTED SAMPLE QUTLET 2 2 PROBE BARREL MOUNTING FLANGE EDUCTOR AIR DRIVE INLET EDUCTOR INLET g m CHAMBER DRIED SAMPLE IN ORIFICE HOLDER PURGE CAL GAS PORT FILTER CAP FILTER ELEMENT PROBE BARREL cy A PROBE STOP FLANGE UNDILUTED SAMPLE GAS OUTLET Figure 1 3 Dilution Probe Assembly August 16 2007 1 3 902 MANUAL TFS 1 3 5 Heat exchanger and drain valve assembly The heat exchanger and drain valve are located on the left wall of the dilution probe Assembly A thermoelectric cooled Teflon block a moisture collection reservoir an ambient exposed aluminum heat sink and purge valve comprise the heat exchanger system The heat exchanger system removes moisture from the filtered sample immediately before dilution The drain valve SV
37. ed liquids are condensed and collected in the liquid reservoir at the lower extreme of the cooling block The heat from the cooling block is removed using a thermoelectric cooler and then transferred to the externally mounted aluminum heat sink The temperature of the block is maintained by the heat exchanger controlling the electronics 8 8 DILUTED SAMPLE OUT 4 H EDUCTOR AIR DRIVE INLET DRIED SAMPLE IN 1 EDUCTOR INLET Hi m 2 2 2 Rev 6 0 SAMPLE TE a NEC GAS PARTICLES 5 MICRON AND LARGER FILTER ELEMENT UNDILUTED SAMPLE GAS OUTLET TO HEAT EXCHANGER Figure 2 2 Probe Head Flow Diagram At the outlet of the heat exchanger the dry sample gas is separated into two sample lines One sample path is for dilution and transportation to a remote or local analysis system and the other sample path is for oxygen analysis Purge mode A purge cycle occurs periodically to clear various sections of the dilution probe Assembly and heat exchanger from moisture and particulate matter The purge solenoid valves are operated automatically through a controller in the remote or local analysis system The filter body and probe barrel are purged in a simultaneous tw
38. eller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear and tear ii accident disaster or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which Warranty they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage and handling of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty Buyer shall pay Seller therefor at Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMEN
39. emperature controllers 1 6 Specifications ve ve order everti NO Geo Qa THEORY OE OPERATION unu nanan sun Peas eed 2 1 General sqa 2 2 Flow functional description e d 22 T Sampling mod ei credet edet be cae Rabat 22 2 PULSE TONE dcos oda ctas id as lav Nae entes 222 9 Callbrationi node S os any pha AN Da Da dira Mi INSTALLATION AND 3 1 Site location and preparation dod 3 2 Limitations at the probe SIEG uoo aree ap pra or a Ua ded opa DRM AE RR RARUS August 16 2007 ii 902 MANUAL TFS Claims for Damaged Shipments A The PRO902C and remote probe controller assembly are shipped ready for operation Immediate inspection ofthe PRO902C and remote probe controller assembly should follow upon receipt Inventory ofthe container should be checked against the enclosed packing list Ifthere is a shortage of items the operator should immediately contact TFS If the contents are damaged the carrier and the project manager at TFS should be notified immediately B The following documents are necessary to support claims l Original freight bill and bill of lading 2 Original invoice or photocopy of original invoice 3 Copy of the packing list 4 Photographs of damage
40. g OFF OFF rP Ramping not used OFF OFF PL Power limiting 100 not used dSP Display windows NOr NOr Table 3 4 1 Setup Menu Parameters Rev 6 0 August 16 2007 3 7 902 MANUAL TFS 5 Please refer to Table 3 4 2 below for parameter set points for each controller Enter the operation menu by pressing the gt Advance key The controller is in the operation menu when is displayed on the lower window To proceed to the next parameter press the Advance key These parameters will be automatically entered after the Auto tune 15 complete Parameter Function Heated Filter Heat Exchanger Settings Settings Pbl Power band 1 6 15 rE1 dE1 Reset 1 17 0 15 1 4 1 Rate 1 A 0 1 Ctl Cycle Time 1 1 0 1 0 ALO Low alarm set point 10 0 5 0 AHI High alarm set point 10 0 5 0 Calibration offset 0 0 0 0 Aut Autotune function Do Not Autotune Do Not Autotune Table 3 4 2 Operation Setup Menu Autotune will be engaged when a value other than 0 is entered into the Aut Parameter When the Autotune is complete the value will automatically revert back to 0 C D E F G 6 0 Go to the dilution probe assembly and verify that the dilution air regulator has been turned off This will keep moisture from contaminating the system until temperature set points are reached Apply power to the dilution probe assembly by turning on the rotary power switc
41. h Using a digital thermometer check the temperature ofthe heated filter assembly and the heat exchanger assembly via the thermocouple port drilled into each assembly Make sure that both temperatures are approaching their set points When both temperatures have stabilized return to the probe controller assembly for the next step At the controller check that both temperature controllers show a temperature within 10 F of the set point On the heated filter temperature controller push the gt Advance key until Aut is on the display and use the up key to enter a 2 controller will begin an autotune and the Heated Filter temperature will cycle up and down until the controller has set autotune parameters Do not perform the autotune on the heat exchanger temperature controller Using a digital thermometer verify the heat exchanger temperature is 45 5 F Using a digital thermometer verify the heated filter temperature is 285 10 Verify that the probe enclosure temperature is 100 F August 16 2007 3 8 902 MANUAL TFS 3 5 Rev 6 0 D Turn on the main air supply from the air clean up assembly and adjust the dilution air supply regulator PR1 to 30 PSI 200kPa J Complete the leak flow and vacuum tests outlined in sections 4 8 4 9 and 4 10 K Complete a purge cycle on the dilution probe conditioning assembly L The dilution probe is now ready to be calibrated with the complete CE
42. ioning assembly The dilution probe conditioning assembly is shipped in two separate containers The conditioning assembly is installed first and then the probe barrel is installed through the back of the conditioning assembly into the stack To install the dilution probe conditioning assembly perform the steps outlined in the following three sections August 16 2007 3 2 902 MANUAL TFS A B C D E A B C D E Rev 6 0 Conditioning assembly installation Install the conditioning assembly on the four 4 inch flange using a proper flange gasket and four 1 2 inch X 1 3 4 inch stainless steel bolts please see Figure 3 1 Probe head removal Open the conditioning assembly door and locate the dilution probe head Carefully cut and remove the shipping tie wrap from the probe head and support bracket Note the placement of all five 5 Teflon tubes connected to the probe head Loosen each of the Teflon tube connection fittings and remove the tubes Disconnect the cartridge heater and the RTD from the probe box wiring Loosen the probe head securing wing nut located underneath the support bracket Remove the probe head from the bracket and place in a safe clean area during probe barrel installation Probe barrel installation Inspect the probe barrel assembly for proper flange spacing and orientation factory set please see Figure 3 3 on the following page Install the probe flange gasket f
43. ions Please refer to the specific installation drawings for each application Vent line inch rubber grommet and Teflon tube are supplied for the vent NOTE The sample vent eductor exhaust should never be restricted or pressurized Power A standard 115VAC 15 service is required to operate the PRO902C dilution probe conditioning assembly Service must be supplied using 12 AWG minimum For long runs August 16 2007 3 5 902 MANUAL TFS 3 3 6 3 4 where voltage drops may occur 10 AWG may be used Connect the power to disconnect switch DC1 TB 1 and the grounding screws please refer to the site specific wiring drawings is a UL and CSA approved disconnect switch rated for 10 AWG wire 20 Amps AC A power cable entry to the conditioning assembly is supplied through 3 4 inch conduit hub Control and data lines Connect signal lines using specified shielded cable for oxygen data acquisition and control lines for calibration and purge valves A cable entry to the conditioning assembly is supplied through a 2 inch CGB Please refer to specific installation drawings for each application site Dilution probe conditioning assembly start up City Technology O A The dilution probe conditioning assembly start up procedure may be performed only after the installation procedure outlined above has been completed and all wiring and tubing connections have been rechecked for accurate hook ups HEATED
44. o part process while the moisture collection reservoir is dumped to clear the heat exchanger Purge frequencies may vary from every 15 minutes for applications with extremely heavy particulate concentrations to several hours for cleaner applications The pulse lasts approximately 10 seconds Longer purge times could result in dilution probe cooling Particulate matter is removed from the probe barrel and the heated filter by the periodic introduction of high pressure air from the purge solenoid valve V 2 and the heated filter exchanger purge solenoid valve V 4 into the filter body and exiting into the August 16 2007 2 3 902 MANUAL TFS 2 2 3 Rev 6 0 process through the probe barrel The heated filter exchanger purge is used to remove particulate buildup from the inside surface of the heated filter When the particulate is dislodged it is carried out of the filter chamber and through the probe barrel with purge air The heated filter exchanger purge air enters the heated filter body through the sample gas outlet and simultaneously enters the heat exchanger cooling block inlet The purge air is introduced through the filter cap that houses the purge calibration gas inlet Moisture is removed from the heat exchanger sample inlet line and the moisture collection reservoir during the purge cycle The moisture reservoir drain valve V 3 opens to drain collected moisture from the conditioning assembly The high pressure purge air
45. oblem Corrective action Regulator pressure set too high Reduce regulator pressure Leak around sample orifice Replace orifice o ring quartz orifices or orifice holder stainless steel Leak between orifice holder and eductor body Clean and lubricate gasket with high vacuum grease or replace gasket Low eductor vacuum Possible problem Corrective action Leak between orifice holder and eductor body Clean lubricate and tighten compression springs to specification please see Section 4 7 step H or replace gasket Possible problem Corrective action Possible problem Corrective action Low span reading Possible problem Eductor exhaust restricted Check internal and external exhaust vent tubing for restrictions Defective eductor air jet Replace jet Dirty main filter element August 16 2007 4 8 902 MANUAL 4 11 9 6 0 Corrective action Possible problem Corrective action Possible problem Corrective action filter Possible problem Corrective action Possible problem Corrective action step H Possible problem Corrective action Possible problem Corrective action High span reading Possible problem Corrective action Possible problem Corrective action Possible problem Corrective action TFS Replace filter element Sample jet plugged Replace je
46. old Tubing and wiring umbilical please refer to the 1200 series Umbilical Drawings 1 Tubing umbilical 2 Wiring umbilicals paired wiring umbilical 12 shielded pairs 20 AWG in PVC jacket Remote probe controller assembly please refer to the 7000 series probe controller drawings Dilution probe conditioning assembly hardware The PRO902C dilution probe conditioning assembly consists of eight subassemblies used to condition analyze and transport the sample 1 Probe enclosure 2 Enclosure heater 3 Valve manifold and dilution air regulator 4 Heated filter dilution eductor and probe barrel assembly 5 Heat exchanger and drain valve assembly 6 TEI analysis system 7 Probe power purge and temperature control 8 Absolute pressure transducer 1 3 1 Probe enclosure The dilution probe and conditioning assembly is housed in a fiberglass enclosure that measures approximately 24 inches H by 24 inches W by 9 75 inches D The enclosure is designed to protect the instruments and electrical controls from highly corrosive atmospheres 1 3 2 Enclosure heater Rev 6 0 The enclosure heater 15 located on the bottom right hand side ofthe enclosure please refer to the 7000 series probe box assembly drawing item 17 The assembly consists of one 400 watt heat element a 30 CFM fan and an adjustable thermostat switch The fan motor runs continuously when power is supplied to the probe conditioning enclosure
47. ontrollers monitor and control the probe heated filter temperature 275 285 F and the heat exchanger temperature 35 45 F Caution The controllers are hooked to three wire RTDs The internal dip switch settings determine the type of temperature sensor used For more information please refer to the Watlow Series 93 User s Manual 1 6 Specifications The PRO902C dilution probe conditioning assembly was designed to operate within the following specifications Power requirements 115 VAC 800 Watts Power connection CSA UL Approved screw terminal Terminal wire capacity up to 10 AWG Operating temperature range 209 to 50 4 F to 122 F Maximum process temperature 600 C 1112 F Calibration gas flow rate 2 0 L minute minimum 2 5 L minute maximum Enclosure temperature 37 7 C 3 C 100 F 5 F Instrument air supply 60 PSIG 400 kPa minimum 80 PSIG 550 kPa maximum via 12 inch tubing 0 300 inch minimum I D Eductor flow rates Heated eductor assembly Rev 6 0 August 16 2007 1 7 902 MANUAL Sample flow Dilution flow Eductor pump assembly Sample flow Dilution flow Heat Exchanger Cooler block temperature Heated eductor filter Body temperature Materials of Construction Enclosure Sample orifice Eductor jet Eductor body Orifice holder body Heated filter body Probe barrel Heat exchanger cooling block Connecting lines sample lines Weight Dilution probe
48. p top 26010012 Holder Orifice Quartz Dry Torlon 26010018 Nut Filter Cap 1 2 Torlon 26010025 Block Eductor Body 5L Torlon 26312312 Fitting Teflon 1 8 1 4 26332312 Fitting Teflon 1 5MPT 1 4T Elbow 26131312 Fitting Teflon 1 8FPT 1 4T Elbow 26312211 Fitting Teflon 1 8 X 2 Nipple 28259001 Spring SS 325 x 500 26010011 Filter Cap 2 5 26010004 End Cap Filter HSG 1 8 26010005 End Plate 0 125 Aluminum 2 45 dia 21010222 Terminal Fused AB 12A max neon 21001020 Conn Plug Molex 2 pin NY 21002032 Conn Recpt 3 pin molex 21002163 Conn Plug 16 pin female 21004007 Conn use with P N 55000007 21070000 Term Phoenix 5 2mm 14 26 AWG 21070001 Term Phoenix End Plate 5 2mm 21070002 Term Phoenix 6 2mm 10 26AWG 21070005 Terminal Phoenix End Bracket 21020033 Jumper Bar AB Fuse 10pt Non Interlaced 21020034 Term End Cover AB Fuse 21070004 Term Phoenix 10pt Jumper 6 2mm 21030005 Term Socket Crimp 16 18AWG 21031000 Term Socket Molex 18 22AWG 21090011 Cable Clamp for 16 703Dia Cable max 24600018 Light Rack Manual SW Hoffman 25595004 Analyzer Assy Retro O2 Cell 0 25 02 14030060 Enclosure NEMA 4 4 5 H x 2 88 W x 2 62 D 21002041 Conn 2 pos rept molex 156 21002044 Conn 2 Pos Rept Molex 100 21031004 Terminal Pin 100 21031005 Terminal Pin 156 Molex 25502008 Grommett Rubber 5 8 OD x Hole 1 8 Panel 25569035 Mount Manifold for AO2 Cell 26000551 He
49. pin plugs Connection clearances require the rack to be at least 24 inches deep Connector 1 and 2 are for connection to the dilution probe conditioning assembly and connector 3 is for connection to the rack controller A power entry module for a standard 115VAC cord connection is also on the back of the enclosure August 16 2007 902 MANUAL TFS The printed circuit assembly is manufactured by TFS and allows remote span and zero alignment of the 4 20 mADC signal generated by sensor The card has one channel with an on board power supply for the 4 20 mADC outputs and digital control signals The meter outputs are 0 200 uADC for meter display from 0 199 9 1 5 3 Temperature controllers Two Watlow series 93 temperature controllers located in the front of the CTL902C probe controller assembly provide readouts in degrees Fahrenheit F or degrees Celsius C as selected in the controller setup menu Each upper display is the actual temperature of the controlled device and each lower display is the temperature set point On the face of each controller located to the right of the temperature displays are two LED s labeled L1 and L2 L1 indicates that power is being applied to a heat element or to the TE cooler in the heat exchanger L2 indicates that the temperature has strayed past the alarm set point and if an alarm device is connected to the alarm output an alarm will be sounding The Watlow c
50. pressure transducer to measure the current Barometric pressure The 4 20 mADC signal should be equal to absolute pressure divided by 15 multiplied by 16 4 equals output in mADC Tolerance is 5 0 There are no field repairs or alignment procedures for this component D Reconnect the calibration gas tube to the heated Filter Assembly Remote probe controller interface board setup procedure A Pull the remote probe controller assembly to the extended position and remove the top cover Locate S1 on the interface board and set up the switches according to Figure 3 8 1 below August 16 2007 3 11 902 MANUAL 8 25 4 Figure 3 8 1 Remote Probe Controller Interface Board Setup B At the analyzer rack valve panel turn the cal valve and the O2 zero switches to ON Locate the interface printed circuit card and connect an ammeter in series with connector J1 pin 15 O2 input signal and another ammeter in series with connector J5 pin 2 O2 output signal C After the O2 reading has stabilized 4 mA at the input adjust the O2 zero potentiometer on the front panel please see Figure 3 8 2 until the output signal is equal to the input signal HEATED FILTER TEMP CONTROLLER O2 ZERO POTENTIOMETER O2 METER O2 SPAN POTENTIOMETER HEATED EXCHANGER TEMP CONTROLLER
51. produced by regulated instrument air passing through the O eductor the flow through the air jet stream creates the vacuum 1 3 7 Probe power purge and temperature control Probe power purge and temperature control are maintained by three sections a power distribution section a valve controller watchdog module section and a heated filter control module section These three sections handle all power distribution and the digital interface from the probe controller assembly please refer to the 7000 series probe assembly drawings 1 3 7 1 Power Distribution Rev 6 0 August 16 2007 1 4 902 MANUAL TFS The power requirement is 120VAC 800 watts 60 Hz AC hot is supplied to disconnect DC1 From AC hot is distributed to the valve controller watchdog module the heat exchanger control module the enclosure heater and the enclosure utility light and outlet TB 2 supplies power and control for the heat exchanger temperature control Please refer to the 7000 series drawings for the fuse schedule 1 3 7 2 Valve controller watchdog module The valve controller watchdog module controls all valves and contains an internal timer for watchdog functions Purge watchdog control is jumper selectable for intervals of 8 16 32 or 64 minutes The valve control module also houses the O2 zero and span request switches which allow maintenance crews to apply O2 zero and O2 span gasses while working at the dilution probe assembly 1
52. record this value The vacuum reading must not drop by more than 0 5 inches Hg 1 7kPa in 1 minute EDUCTOR INLET AND OUTLET CAPPED OR PLUGGED HAND VACUUM PUMP 7 HAND VACUUM PUMP PA PROBE ADAPTER CAPPED OR PLUGGED SAMPLE OUTLET CAPPED OR PLUGGED Figure 4 8 Probe Head Leak Test Configuration Remove the hand held vacuum pump from the eductor sample inlet port and connect it to the purge calibration inlet heated filter cap Install a probe adapter fitting into the sample probe barrel port as shown in Figure 4 8 Pull a minimum vacuum of 20 inches Hg 70kPa with the vacuum pump as shown on the vacuum gauge and record this value The vacuum reading must not drop by more than 0 5 inches Hg 1 7kPa in 1 minute August 16 2007 4 4 902 MANUAL TFS 4 9 4 10 Rev 6 0 Probe head flow test The dilution probe may be supplied with various jets to accomplish different dilution ratios Please refer to the site specific system flow diagram to obtain the proper flow rates Connect a mass flow meter in line to the eductor exhaust outlet port eductor outlet flowmeter as shown in Figure 4 9 When 30 psi instrument air is supplied to the eductor dilution air inlet port the meter flow rate should be approximately the same value as the value recorded on the system flow diagram Repeat the flow test with a flow meter connected to the eductor sample inlet port dry sample flowmeter in figure 4
53. robe conditioning assembly hardware ProbeenclosSurer uuu saa pa te distat cae ania eae 1 3 2 Bmelosure Heater NR RR 1 3 3 Valve manifold and dilution air 1 3 4 Heated filter dilution eductor and probe barrel assembly 1 3 5 Heat exchanger and drain valve assembly 1 3 6 TELO atialysis System oed di Hor ER CU MU 13 6 1 XO educ lol uso 1 3 7 Power purge and temperature control 13 71 o 1 3 7 2 Valve controller watchdog module 1 3 7 3 Heated filter control module 1 3 7 4 Heat exchanger control module 1 3 8 Absolute pressure transducer uoce ci ento tes tt ena Code d aus 1 4 Tubing and wiring umbilicals a IET Turbine mbilical suscrito a c err sex asua 1 4 2 Wiring umbilical eoe onte nte tee cer D etie sien asha asua 1 5 Remote probe controller assembly 2 1 5 1 Remote probe controller enclosure 1 5 2 Interface printed circuit assembly and meter display 1 5 3 T
54. said published specifications provided that a Buyer shall promptly notify Seller in writing upon the discovery of any defect which notice shall include the product model and serial number if applicable and details of the warranty claim b after Seller s review Seller will provide Buyer with service data and or a Return Material Authorization which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller replaced parts shall become the property of Seller Shipment to Buyer of repaired or replacement Products shall be made in accordance with the Delivery provisions of the Seller s Terms and Conditions of Sale Consumables including but not limited to lamps fuses batteries bulbs and other such expendable items are expressly excluded from the warranty under this warranty Notwithstanding the foregoing Products supplied by Seller that are obtained by Seller from an original manufacturer or third party supplier are not warranted by Seller but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier to the extent such assignment is allowed by such original manufacturer or third party supplier In no event shall S
55. snugly fit with an o ring seal C Remove the filter from the mandrel of the heated filter cap August 16 2007 4 1 902 MANUAL TFS 4 4 4 5 Rev 6 0 D E F G Inspect the filter body and cap for particulate accumulation around the filter seats Clean the filter body and seat by wiping with a soft cloth Lubricate the cap o ring with a light coating of silicone based high vacuum grease Install the new filter element onto the cap mandrel and insert the cap and filter into the filter body Align the screw holes in the cap with the screw holes in the body and press the cap into the filter body Reinstall the nuts Hand tighten the nuts only Quartz orifice replacement The quartz orifice may be changed by removing the eductor inlet tube The orifice is sealed in the bore by an o ring and may be removed by grasping the orifice with tweezers and pulling straight back If the o ring does not come out with the orifice remove the or with the tweezers Install a new orifice by placing the orifice o ring on the orifice and inserting the smaller end of the orifice into the orifice bore Probe head removal A B C D E F G Note the dilution air pressure setting then turn off the power and air supplies Disconnect the air supply tubing to the eductor air jet Disconnect the sample tubing from the eductor exhaust Disconnect the purge calibration tubing from the filter cap Disconnect th
56. t Leak at filter body cap Clean or replace filter cap o ring Check purge calibration gas inlet Leak at probe filter connections Clean probe and o ring area Apply silicone grease Replace o rings Leak at orifice holder or eductor gaskets Clean or replace gaskets Check spring setting Please see Section 4 7 Eductor air pressure too high Adjust regulator Defective regulator Replace regulator Leak around sample jet Replace orifice o ring on the orifice holder assembly Eductor air pressure set too low Adjust regulator Plugged eductor air jet Replace jet August 16 2007 4 9 902 MANUAL TFS 5 0 RETURNING ASSEMBLIES FOR REPAIR Should it become necessary to return any assembly sub assembly or component for repair or replacement contact the factory prior to shipment for specific information such as return authorization number shipping instructions price time to repair etc Also include pertinent facts describing the nature of the problem Ship all components to the following Thermo Fisher Scientific 5 1 Obtaining replacement parts The following information must be included in all purchase orders for parts A TFS Model and S N of major assembly B Part Number found in parts tables Description of part 5 2 Spare Parts List CTL902C 22110019 Controller Temperature Watlow 93 17010078 PCA Controller 29500003 Meter Panel Digital 0 2000 Rev 6 0 August 16 2007 5 1 902
57. tion Clean probe tip and o rings area Apply silicone grease to probe and o rings Replace o rings Possible problem Leak between orifice holder and eductor body Corrective action Tighten compression springs to specification Please see Section 4 6 step H Clean gasket and apply high vacuum grease Possible problem Low sample vacuum Corrective action Check probe assembly for leaks Check eductor exhaust line for restriction Possible problem Leak in external components connected to purge calibration port Corrective action Check external fittings for leaks Check external valves for port to port leaks High sample flow rate Possible problem Leak around orifice Corrective action Either replace 1 Orifice o ring or 2 Exchange the orifice holder assembly Low flow rate at the eductor exhaust Possible problem air jet plugged Corrective action Replace air jet August 16 2007 4 7 902 MANUAL 4 11 6 4 11 7 4 11 8 Rev 6 0 Possible problem Corrective action Possible problem Corrective action TFS Restricted eductor exhaust tubing Check internal and external exhaust vent tubing for restrictions Pressure Regulator not adjusted correctly or defective Adjust or replace regulator High flow rate at the eductor exhaust Possible problem Corrective action Possible problem Corrective action jets Possible pr
58. tion probe conditioning assembly consists of three modes Sampling Purge and Calibration Sampling mode Process gas enters the sampling system at the probe tip and flows down the probe at a low flow rate of 50 300 cc min Particles larger than 5 microns settle out on the probe walls due to the low sample velocity From the sampling probe the gas enters the heated filter chamber shown in the cross section in Figure 2 2 below The filter body is heated and controlled by an external temperature controller and cartridge heating element between 135 C 146 1 C 275 F 295 F The sample gas then flows from the heated filter chamber through the heated filter and exits from the heated filter body through the filter chamber outlet The glass fiber filter element with a Teflon binder having a 0 1 micron efficiency rating is selected for its inertness to the process gas The filter element may be replaced by removing the filter cap and 0 Ring The filtered sample gas is then conditioned by the heat exchanger The sample gas is extracted using two precision low flow Eductor Assemblies that are driven by instrument quality air The heated eductor assembly and the eductor ump assembly pull portion of the total sample flow through the heated filter and the heat exchanger August 16 2007 2 2 902 MANUAL TFS EDUCTOR EXHAUST Once the filtered sample gas enters the Teflon heat exchanger cooling block any condensable or entrain
59. ution path the heated eductor assembly pulls a portion of the dry undiluted sample gas from the heat exchanger into the heated eductor sample inlet Please see Figure 2 2 probe head flow diagram It is then carried through a protection filter and sample critical orifice into the dilution chamber for dilution The protection filter protects against particulate matter that may be dislodged during the heated filter replacement Installed immediately downstream of the heat exchanger this one micron filter protects both the O2 eductor pump and the heated eductor assembly The filter does not normally require maintenance but visibly indicates when contamination may be present The eductor sample critical orifice contained within the filter jet cartridge is fabricated from quartz The orifice temperature is maintained at 140 5 5 5 C 285 F 10 F From the orifice the process gas passes to the vacuum cavity of the dilution eductor The dilution eductor assembly is heated by an extension of the heated aluminum housing From the eductor exhaust port the diluted process gas passes to a vent bulkhead on the conditioning assembly enclosure A portion of the diluted sample is pulled through a sample August 16 2007 2 1 902 MANUAL TFS 2 2 1 Rev 6 0 bulkhead and the unheated Teflon sample line by a sample transport pump to the remote analysis system In some cases the sample transport assembly may be eliminated if the distance
60. xygen of Full Scale 16 4 mADC output August 16 2007 3 9 902 MANUAL TFS 3 6 Rev 6 0 In this example 17 376 mA equals 20 9 oxygen 0 836 16 4 17 376 mADC output Four 4 mA has been set to equal 0 oxygen and 20 mA has been set to equal 25 oxygen full scale Therefore 12 mA is the midpoint between 4 and 20 mA and equals 12 5 oxygen which is half the full scale value 2596 in our example City Technology sensor alignment NOTE ALLOW ONE 1 HOUR MINIMUM INITIAL RUN TIME ON CELL BEFORE PROCEEDING A At the dilution probe conditioning assembly locate the O cell holder and remove the two wire jack attached to the red and black leads Attach a DC volt meter to the leads B Locate the two switches on the right hand side wall of the enclosure Select the O zero request position In this position the cell output will drop to 0 0 mV DC only if there are no leaks in the system Let the system run zero gas for approximately 5 minutes or until the cell output stabilizes C Verify that the cell s output is acceptable 0 0 mV DC then disconnect the DC volt meter and plug the jack back into its socket Attach a DC ammeter in series with terminal 22 of the valve controller watchdog module VCMI D Verify that the O2 zero switch is in the position and that the cell s output has stabilized Adjust the output if required to 4 mADC using the zero potentiometer
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