GASS 2040 Manual.pmd
Contents
1. 1 2 J Enclosure Temperature Current enclosure air temperature in C Dryer Temperature Current dryer air exhaust temperature in C Drain Time Set Optional feature Coalescing filter drain cycle interval time setpoint Default cycle time is 8 0 hrs Drain time fixed at 6 sec Range 000 0 hrs Always on for testing purposes to 999 9 hrs Disabled Enclosure Temperature Set Enclosure temperature setpoint in C Range O to100 C Default 65 C Dryer Temperature Set Dryer temperature set point in C Range Enclosure Temperature to 110 C Default 70 C Blow Back Time Set Optional feature Probe filter blowback cycle interval time setpoint Default cycle time is 8 0 hrs Blowback time fixed at 2 sec Range 000 0 hrs Always on for testing purposes to 999 9 hrs Disabled Eriha Tia pa Sop paml By Back Cycla Tima fire Figure To use the operator interface simply press the select button until the indicating LED lights up next to the desired parameter If the parameter is either the enclosure or dryer temperature the current respective temperature is shown If the parameter is a setpoint value pressing the up arrow or down arrow button will adjust the setpoint value GASS 2040 User Manual Original Instructions 14 4 3 Systems Operation Monitoring The PLC monitors the system parameters for proper operation and can alert personnel of potential problems via an indicat2. GASS 2040 Gas Analysis Sampling System User Manual v1 20 8 Executive Drive Toms River N J 08755 ra Phone 800 337 3762 732 244 0010 PERMA PURE l Fax 732 244 8140 e mail info permapure com Web Site www permapure com TABLE OF CONTENTS I IrOdUu6t R u uuu E SR A A 6 MINI GASS Cormmponehis u LLULLU LL nate O ka Oa iai 7 2 1 Probe Probe Filter and Automatic Blowback Optional 2 2 Filtration 2 3 Automatic Filter Drain Optional 2 4 Sample Pump Optional 2 5 Nafion Dryer 2 6 Ammonia Scrubber Optional 2 1 Purge Air Dryer Optional 2 8 Purge Air Eductor Optional 2 9 Z Purge Optional l n Oise l D n E E E TER ce E EE 10 3 1 Mounting 32 Electrical Connection a Power Wiring b I O Wiring 3 3 Plumbing a Sample Connection b Purge Air Supply c Filter Drain Connection Optional d Purge Exhaust e Purge Eductor Inlet Connection Optional Control System Operation a a 13 4 1 General Information 4 2 Operator Interface 4 3 Systems Operation Monitoring a Alarm Output Operation b System Status Indicator Operation 4 4 Preheating the System 4 5 Automatic Filter Drain Control Optional 4 6 Automatic Probe and Filter Blowback Operation Optional NIQI ISGR8IICE oa ed l l AEE EA r R a 19 6 1 Filters 6 2 Dryers 6 3 Ammonia Scrubber 6 4 Fuse GASS 2040 User Manual Original Instructions APPENDIX
3. GL 0 0v0C S SASN Vd pue LyMcCOCAd 0VOCSO 9 Z GL 0 07072 SD L SASN ZV4 pue LVMOOZAd 010ZS9 J3gNL T13HS ANY avo Z GL 0 0702 SD L SASN ZV4 pue LVMOOLAd 010ZS9 L GL 0 0702 SD L SISN ZV3 pue LyMOSAd 0POZSO ONMdnod IvYNAa TIAHS AIS LH9IY NI LNIINITI TIVLSNI CHIAHA LNIINITA ATONIS V ONIGTING NSHM 2 APPENDIX C 1 Replacement Parts List for GASS 2040 Part Description GS2040 PLC Control Module GS2040 DTC J Type Thermocouple for dryer and enclosure or probe filter temperature GS2040 DPS Differential Pressure Switch GS2040 FM Flow Meter purge gas 0 50 L min GS2040 PR Pressure Regulator 30 psi GS VG 0 30 Vacuum Gage purge eductor 0 30 Hg GS SV K24 Safety Interlock Solenoid Valve Kynar 24V GS SV S24 Safety Interlock Solenoid Valve Stainless Steel 24V FF DCV Drain Check Valve Polypropylene for vacuum drain DVP S24 Drain Solenoid Valve Stainless Steel for vacuum drain 24V DVP K24 Drain Solenoid Valve Kynar for vacuum drain 24V MG DVT Drain Valve Timer MG DC Mounting Clamps for Dryer specify dryer model MG 1412 HB Backplate with Heater for Enclosure 1412 MG 2112 HB Backplate with Heater for Enclosure 2112 GS2040 PD 50E 50 Tube dryer replacement element 24 long includes o rings GS2040 PD 100E 100 Tube dryer replacement element 24 long includes o rings GS2040 PD 200E 200 Tube dryer replacement element 24 long includes o rings FF 250 E 2 5G Replacement filter element
4. DIMENSIONS OPERATING ENVIRONMENT O TO 10 LITER MIN 250 F W SST FILTER 230 F W KYNAR FILTER 70 26 F 4 C at 10 L MIN 12 F 12 C at 5 L MIN 12 F 25 C at 2 L MIN 36 F 2 C at 10 L MIN 26 F 4 C at 5 L MIN 6 F 15 C at 2 L MIN 42 F 5 C at 10 L MIN NO NO2 SO2 0 loss CO CO2 0 loss H2S HCI 0 loss 10 PSIG 5 H2O VACUUM 10 H2O VACUUM 1 4 or 3 8 TUBING FITTINGS 1 4 or 3 8 TUBING FITTINGS PURGE AIR 40 C DEW POINT MAXIMUM ONE 1 CFM MAXIMUM THREE 3 CFM 950 Watts 115V 10 or 230V 10 50 60Hz 10A 5A 1 25 X 0 25 GLASS FUSE 5mm X 20mm 1 0A FAST BLOW FUSE NEMA 4X STAINLESS STEEL 20 W x 40 H x 10 DEEP 20 C TO 40 C AMBIENT TEMP O TO 95 R H Altitude up to 2000m GASS 2040 User Manual Original Instructions 2 APPENDIX B 1 PD Dryer Disassembly Special tool needed for Assembly Disassembly included for item numbers refer to the dryer assembly drawing on page 25 1 Begin by loosening the four set screws item 11 Remove the four 1 4 NPT plugs item 10 in the end faces of the coupling fittings item 1 See Figure 10 3 Disconnect the differential pressure switch tubing from the compression fitting 4 Using the special dryer disassembly tool begin removing the coupling fittings by performing the following steps Single element dryer only one shell tube contains a membrane tube element a Look into the ports from which th
5. GASS 2040 User Manual Original Instructions 10 3 2 Electrical Connection a Power Wiring The GASS 2040 system is intended to be hard wired via a customer supplied disconnect switch and wire capable of supplying 5A 10A at 115 230 VAC The external disconnect switch must meet IEC 60947 1 amp 60947 3 stds and must be installed in close proximity to the equipment within easy reach of the operator and shall be clearly marked as the disconnecting device for the GS 2040 Connect the system to an appropriate earth ground Adhere to all electrical code requirements in effect at the installation site Connect the power wiring as shown in Figure 4 below The fuse block is supplied with 1 25 x 0 25 glass fuses and if necessary should be replaced with one of similar rating A fuse block for PLC power located in the upper terminal strip is supplied with a 5mm x 20mm 1 0A fast blow fuse and should be re placed with one of GEN LOW TEMP ALARM O TB C011 O GRY Y11 0 TO PLC TERM Y11 similar rating LOW PURGE AIR FLOW ALARM O TB C012 O GRY Y12 O TO PLC TERM Y12 if necessary GENERAL ALARM O TB C013 O GRY Y13 O TO PLC TERM Y13 CUSTOMER I O MAN FILTER DRAIN O TB C101 O WHT X1 O TO PLC TERM X1 CONNECTIONS MAN FILTER BB O TB C102 O WHT X2 0 TO PLC TERM X2 REMOTE PUMP SHUT OFF O TB C104 O WHT X4 O TO PLC TERM X4 0 VOLTS DC O TB COV O BLK O TO TB 0V 2
6. A 1 Specifications APPENDIX B 1 PD Dryer Disassembly 2 PD Dryer Reassembly APPENDIX C 1 Replacement Parts List for GASS 2040 APPENDIX D 1 Stack Mount Systems 1 1 Flange Mounting 1 2 Support Installation APPENDIX E 1 Z Purge Operation 2 Troubleshooting 3 Helpful Hints GASS 2040 User Manual Original Instructions WARNING Thank you for purchasing sample gas conditioning equipment from Perma Pure LLC We want your new sample gas conditioning equipment to operate safely Anyone who installs or uses this equipment should read this publication before installing or operating this equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regu late the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify the equipment installation and operation is in compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious personal injury can result from the failure to follow a
7. Operation With the inert gas supply connected enclosure power deenergized and alarm system if utilized Follow steps to purge system Carefully read Start Up Instruction Nameplate on system 2 Check operation of the Enclosure Protection Vent EPV 1 if utilized opening it manually several times see helpful hints below 3 Seal protected enclosures 4 Open Enclosure Pressure Control Regulator but turning CW to set Enclosure Pressure Indicator at Safe pressure 5 Ensure the Protection System Enclosure Pressure Indicator maintains a Safe pressure for one minute 6 Standby for exchange time as specified on the Instruction Nameplate then energize the protected enclosure power 7 Ensure the Enclosure Pressure Indicator maintains a Safe pressure before leaving system unattended 2 Troubleshooting Problem or Fault Possible Causes Corrective Action Enclosure pressure control regulator will not hold a safe pressure Enclosure pressure indicator reading is difficult to stabilize Enclosure Pressure Indicator Drifts up or down from the Safe pressure setting Enclosure pressure loss alarm switch does not appear to be operating Leakage around gasketing covers seams piping and tubing connections conduit connections and electrical conduit seal of the enclosure Insufficient enclosure leakage or opening of the venture orifice is crimped too small Application involve
8. outlet to remote area if desired Line should not restrict purge flow 1 4 I D tubing can be used for runs up to 10 feet or larger D tubing for longer exhaust lines e Purge Eductor Inlet Connection Optional Connect air supply line to compression fitting labeled Compressed Air 4 Control System Operation 4 1 General Information The GASS 2040 system consists of an operator interface panel and a Koyo DLO6 PLC which serves a number of purposes The PLC controls two or three PID temperature control loops Two PID loops are standard on the wall mounted version Three PID loops are standard on the stack mounted version which contains an additional PID loop for control of the probe filter In addition to controlling the temperature of the system the PLC continually monitors the system temperatures and will initiate an alarm if any of the temperatures deviate too far from their respective set point temperatures More about this can be found in the System Operation Monitor section on page 15 The PLC also controls timing of the optional heated probe filter blow back air and the coalescing filter drain Clean display panel with soft cloth and mild detergent Do not use chlorinate cleaners on stainless steel housing GASS 2040 User Manual Original Instructions 13 4 2 Operator Interface The operator interface panel shown in Figure 7 below serves both as a temperature display and a time and temperature setpoint entry device
9. the mating flange on the stack nozzle If the probe pipe is less than two feet in length it can be installed and tightened If the probe is longer than two feet it may be necessary to slide the probe pipe into the stack nozzle first This depends on how wide the platform is or if there is physically enough space to be able to back the system away from the stack with the probe pipe attached At this point an appropriately sized flange gasket should be installed on the system flange Attaching the gasket to the flange with a small amount of tape at the edge of the gasket will hold it in place temporarily If space is limited slide the probe pipe into the stack nozzle and hold on tightly Lift the system up to the nozzle and install the probe pipe on the system and tighten Mate the two flanges install the mounting bolts and tighten 1 2 Support Installation Once the system has been mounted on the flange supports must be installed to prevent it from swinging on the hinged flange mount Two Unistrut compatible angle brackets are mounted to the lower corners of the enclosure to allow attachment Due to the wide variety of possible support configurations this is left up to the customer The supports can be placed vertically to the deck or horizontally to the stack wall or any other convenient angle as long as they are rigidly attached by welding or mechanical fastening GASS 2040 User Manual Original Instructions 28 APPENDIXE 1 Z Purge
10. 4 VOLTS DC O TB C24V O RED O TO TB 24V GROUND O TRG O SRN YEL O TO TB G 14 AWG CUSTOMER POWER lt NEUTRAL L2 O FUSE BLOCK F1 O BLU O TO TB AC N 14 AWG CONNECTIONS LINE L1 O O FBRN O TO POWER BUTTON 14 AWG Figure 4 b I O Wiring The PLC outputs operate at 24 VDC and are sourcing See Figure 5 This means that when commanded to turn on by the PLC logic the output terminal goes from 0 VDC to 24 VDC and supplies current to the device being signaled or powered The device must pull no more than 0 5A and must have a minimum load of 10 mA at 24 VDC A 0 VDC terminal connection is supplied as a current sink to complete the output circuit Sourcing Output Figure 5 The PLC inputs operate at 24 VDC and are sinking See Figure 6 This means that the input is to turn on and signal the PLC logic that an event has occurred or is desired 24 VDC must be applied to the input terminal A 24 VDC terminal is supplied as a current source to complete the input circuit Sinking Input Input Sensing Figure 6 GASS 2040 User Manual Original Instructions 11 3 3 Plumbing a Sample Connection GASS 2040 Probe version refer to Appendix D With Optional Heated Line 1 Install heated line sealing fitting by threading hub into sleeve 2 Ensure o ring seal is installed on outside of enclosure between sleeve and enclosure wall 3 Run heated sample line through entry seal and into enclosure 4 Co
11. EMPERATURE CONDENSATE DRA N 1 NPT MALE VACUUM 1 4 NPT FEM PRESSURE PURGE EDUCTOR VENTURI BUILT INTO DRYER HOUSING RGE AIR EXHAUST ae x NPT MALE NO CONNECTION RECYD PURGE AIR EXHAUST THERMOCOUPLE PURGE AIR EXITING SHELL TUBES HEATED ENCLOSURE MEMBRANE DRYER ASSEMBLY CAL GAS DRYER HEATERIS ne T YE PRESSURE REGULATOR DIFFERENTIAL MEATLESS AIR VACUUM mA PRESSURE SWITCH RYER ACLUM FLONMETER PURGE AIR ENTERING SHELL TUBES FIXED 30 PSIG NEEDLE VALVE PRESSURE J REGULATOR PR ia M DRY SAMPLE OUTLET l 3 1 COMPRESSION CONTROL ENCLOSURE ee de US AR ts ALARM OUTPUT SIGNALS LOW PURGE FLOW 24VDC INSTRUMENT AIR INLET 1M FEM NPT LOW TEMPERATURE 24VDC GENERAL ALARM 24VOC REQUIRED WHEN THE HEATLESS DRYER OPTION LEGEND o Sc sr nad IS NOT INSTALLED 30100 PSIG 2 SCFM INPUT SIGNALS GAL GAS INLET 4 6 FEM NET BLOWBACK CYCLE INITIATE 24VDC SAMPLEICALIBRATION GAS FILTER DRAIN CYCLE INITIATE 24 VDC HEATLESS DRYER VENT t FEM NPT N INSTRUMENTICOMPRESSED AIR REQUIRED WHEN THE KEATLESS DRYER OPTION S INSTALLED NO CONNECTION REQUIRED REQUIRED FOR THE FOLLOWING OPTIONS de p A 2 OR 3 CABLE ENTRY SEAL J LIQUID CONDENSATE BLOWBACK OPTION 0100 PSIG MINIMNAL USAGE HEAT SHRINK STYLE e PUMP OPTION VORTEX COOLER 80 100PEIG 8 SCFM CONDENSATECOMPRESSED AIR MIX HEATLESS DRYER OPTION 80 100 PSIG 2 SCFM PURGE EDUCTOR OPTION 60 100 PSIG 2 SCFM Figure 4
12. Element Replacement Refer to Figure 11 S DL ee Loosen bolt on bottom of filter Gently pull apart assembly and remove old element Place new element into grooves in top and bottom of housing When re assembling inspect for o rings on top and bottom caps and on center bolt Install glass shell onto bottom piece Place new element in groove in bottom piece Be sure that element is seated correctly and parallel to glass shell Carefully mate bottom assembly onto top piece Slight twisting motion may be required to allow shell to slip over o ring seal Visually make sure element is seated correctly in top groove Replace bolt through hole in bottom piece and screw clockwise into top piece Do not over tighten center bolt It should be just tight enough so it does not vibrate loose Over tightening will not help the filter to seal Shell Bottom Cap Bolt Figure 11 GASS 2040 User Manual Original Instructions 19 5 2 Dryers Under normal conditions Perma Pure dryers require little maintenance and can last for several years However if there is no pre filter and the tubing becomes clogged or saturated with water the dryer may require cleaning or repair Refer to Appendix B for PD dryer element replacement 3 Ammonia Scrubber Media Replacement When deposits are visible on 75 of the scrubber scrubbing media needs to be replaced
13. Unscrew thumbscrew on bottom of housing Swing yoke to one side Separate housing and bottom cap as an assembly from top cap Remove spring and top screen Remove old media and dispose of properly rinse housing with soapy water to clean Fill housing with 135cc of Berl Saddles tap housing to allow material to settle Pour 65cc of Scrubbing Media tap housing to allow material to settle Replace stainless steel screen on top of media Replace spring on top of screen 10 Clean o rings on shell and inside top manifold replace if necessary 11 Place center tube into o ring seal in top cap 12 Push and twist to seal housing around o ring 13 Replace yoke and finger tighten thumbscrew do not overtighten O eA ee Thumbscrew nt Housing Shell Spring Top Screen Botan Gap Figure 12 GASS 2040 User Manual Original Instructions 20 APPENDIX A Specifications MAXIMUM SAMPLE FLOW RATE MAXIMUM INLET SAMPLE TEMPERATURE MAXIMUM GAS SAMPLE WATER VAPOR CONTENT OUTLET SAMPLE DEW POINT With GS2040 PD200KA dryer With GS2040 PD100KA dryer With GS2040 50KA dryer SOLUBLE GAS REMOVAL RATES MAXIMUM GAS SAMPLE INLET PRESSURE MINIMUM GAS SAMPLE INLET PRESSURE WITHOUT PURGE EDUCTOR OPTION WITH PURGE EDUCTOR OPTION GAS SAMPLE INLET FITTINGS GAS SAMPLE OUTLET FITTINGS AIR REQUIREMENTS OPTIONAL PURGE EDUCTOR ELECTRICAL REQUIREMENTS FUSE FUSE BLOCK INLINE FUSE HOLDER PLC ENCLOSURE
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15. allows condensate to be directly expelled through a solenoid valve See Figure 9 When the drain timer in the PLC times out a solenoid valve energizes and allows the pressure in the filter to push the condensate out of the filter DL ETC H FILTER SAMPLE ES Ed PLE as ER ET CHITLET Ea Era VALVE ms SOMDEMIAT MIE THA AT Figure 9 The filter drain event can be triggered externally via the Manual Filter Drain input to the PLC Refer to the I O Wiring section for connection details on page 11 4 6 Automatic Probe and Filter Blowback Operation Optional Adjust the Blowback Time as described in the Operator interface section on page 14 Dust in the probe filter needs to be removed periodically to extend the life of the element This is accomplished by passing compressed air backwards through the filter See Figure 10 The blowback system consists of an accumulator tank and solenoid valve to accomplish this task When the blowback timer in the PLC expires a solenoid valve is energized for two seconds This allows compressed air to flow from the accumulator tank directly into the probe filter causing collected dust on the filter element to be forced back into the stack through the probe pipe The timer then resets to the user selected cycle time and begins counting down to the next blowback The cycle repeats indefinitely unless the timer is turned off When calibration gas flow is de tected the blowback timer is temporarily paused This preve
16. c replacement See section 6 3 for replacement instructions 2 7 Purge Heatless Air Dryer optional If 40 C dewpoint purge air is not available a heatless air dryer can be installed in the GASS 2040 to dry the compressed air supply Outlet of heatless dryer will be connected to standard purge gas flow controls Operation of heatless dryer is fully automatic and continuous and should not require any maintenance as long as oil free compressed air is used 2 8 Purge Air Eductor optional When the sample is under more than five inches of water vacuum a purge air eductor is required Eductor generates a vacuum to drop pressure of purge gas to prevent collapsing of Nafion tubing 2 9 Z Purge optional For hazardous environments to meet Class I Division Il specifications Refer to Appendix E GASS 2040 User Manual Original Instructions 9 3 Installation Refer to Figure 4 for reference 3 1 Mounting Unit should be shielded from direct rain and snow Do not install outdoors if temperature will fall below 10 C Probe refer to Appendix D Automatic Blowback refer to Appendix D Z Purge refer to Appendix E General flow schematic refer to Figure 4 1 Install GASS 2040 system on vertical surface with dryer filter compartment on top and control compartment on bottom 2 Attach and tighten to sturdy surface w ET SAMPLE INLET NET PROBE PIPE CONNECTION O FILTER HEATED BACKPLATF MAINTAINS ENCLOSURE T
17. e plugs were just removed and determine which one contains the dryer element The membrane tube ends will be visible See Figure 11 b Thread the tool into this port and tighten by hand Turn the handle until resistance is felt c Then slowly turn the handle until the coupling fitting is free of the shell tubes Some manual adjustment of the assembly will be required to keep the coupling fittings parallel with each other while pressing See Figure 12 d Repeat steps a c for the other coupling fitting e Atthis point the dryer element shells should be free of the coupling fittings and the header plugs item 5 on the unused shell tube side should still be in the coupling fitting bore Figure 12 f Remove an o ring item 8 from one of the element headers See Figure 13 g Slip the element from the opposite end of the shell tube See Figure 14 Figure 13 Figure 14 GASS 2040 User Manual Original Instructions 92 Dual element dryer a OAP 2 PD Dryer Reassembly 1 Insert a membrane element into the heated shell tube and install o rings item 8 into the grooves on each header See Figure 15 The membrane element should now be constrained to the shell by the o rings 2 If this is a dual membrane element dryer repeat step 1 for the other membrane element shell tube assembly 3 Perform the following steps to complete the reassembly a b Thread the tool into one of the ports from which the plugs were
18. erature Controller Ammonia Scrubber s Dryer Purge Flow Controls Purge Air Eductor Z Purge Probe and Automatic Blowback Probe Filter and Hatelloy Heat Exchanger Optional Lifting Ring Standard on probe model Heated Probe Filter amp Heated Backplate Hastelloy Heat Exchanger Optional Blow back Optional Sample Probe Accumulator io To purge probe filter Particulate Coalescing Filter For removal of parboulates and acid mist Optional Ammonia Scrubber 2 Shawn Required when gas Nafion Gas Dryers stream contains ammonia Singh or Double Optional Heated Head Dryer Heater Sample Pump PLC Controller Optional Heatless Dryer for Purge Gas Required when instrument air is not available Stabilizing Braces For Probe System Purge Eductor Regulator and Gauge Purge Gas Flowmeter Electrical Connectors Heated Umbilical Connection Figure 1 GASS 2040 User Manual Original Instructions 6 2 GASS 2040 Components 2 1 Probe Probe Filter and Automatic Blowback optional The GASS 2040 system with integral probe filter eliminates the need for a high temperature heated line by conditioning the gas sample at the sample gas extraction point on the stack When sample gas is drawn from the stack itis passed through a 2 micron ceramic filter to remove oil and acid aerosols The sample gas is dried and cooled immediately after removal from stack to minimize chan
19. ges in sample composition Refer to Appendix D for Installation Instructions The optional blowback assembly minimizes maintenance of the probe filter by periodically pass ing compressed air back through the element This action dislodges captured particles and forces them back into the stack Included with the blowback system is a calibration gas flow sensor which prevents blowback from occurring while calibration gas is flowing 2 2 Filtration The sample is passed through a 1u filter to remove particulates and aerosols The standard filter in the GASS 2040 system has a borosilicate glass filter element with a fluorocarbon binder This element is disposable and will withstand high sample temperatures In addition to removing particulates it coalesces liquid aerosols and droplets Two flow patterns are possible with this filter 1 Particulate Filter Filter installed with flow passing from outside to the inside of the element With this Installation collected particulates will build up on outside surface of the element allowing visual inspection of its condition 2 Coalescing and Particulate Filter See Figure 2 Filter is installed with flow passing from inside of element to the outside An automatic drain is usually Installed to remove the condensate Figure 2 2 3 Automatic Filter Drain optional If coalescing is anticipated system should be fitted with automatic filter drain to periodically remove collected liquid mist
20. gure 19 GASS 2040 User Manual Original Instructions 23 Insert the free shell tubes ends of the partially completed assembly into the bores of the other coupling fitting Important Be sure to have the set screw holes in each cou pling fitting facing in the same direction See Figure 20 Press the tubes into the coupling This step can be done by hand with some rocking of the coupling fitting while pressing Rocking the fitting helps get the shell tube ends past the o rings Light tapping with a rubber mallet or pressing lightly in an arbor press will facilitate the assembly See Figure 21 Lay the dryer assembly on a flat surface with the set screw holes facing up Check that both coupling fittings are flat against the surface and there is no twist in the dryer assembly Gently tighten all four shell set screws item 11 by turning until resistance if felt and turning an additional 1 4 turn Do not over tighten See Figure 22 Reinstall all four pipe plugs item 10 Reconnect the purge pressure switch tubing to the compression fittings in each coupling fitting Set screws Figure 20 Figure 21 Figure 22 GASS 2040 User Manual Original Instructions 24 cire0 0r0Z SS O emo meses z ron oR Ev pani epee O q31ON SY Ld32X39 SIDNVHITOL ZYM LVMOOLAd 010ZS9 6 A l19NA4SSY JIAHA AdS9 ZY LVM0SGd 0F0ZS9 YAAYC AO UNI S NO4 dad 6 LALLNO ITIdNVS Q 25 VS280 N HIAIS SWOL SAINA JALLNDI
21. hip under normal use and service Seller s sole obligation and liability under this warranty is limited to the repair or replacement at its factory at Seller s option of any such product which proves defective within one year after the date of original shipment from seller s factory or for a normal usable lifetime if the product is a disposable or expendable item and is found to be defective in material or workmanship by Seller s inspection Buyer agrees that 1 any technical advice information suggestions or recommendations given to Buyer by Seller or any representative of Seller with respect to the product or the suitability or desirability of the product for any particular use or application are based solely on the general knowledge of Seller are intended for information guidance only and do not constitute any representation or warranty by Seller that the product shall in fact be suitable or desirable for any particular use or application 2 Buyer takes sole responsibility for the use and applications to which the product is put and Buyer shall conduct all testing and analysis necessary to validate the use and application to which Buyer puts the product for which Buyer may recommend the use or application of the product by others and 3 the characteristics specifications and or properties of the product may be affected by the processing treatment handling and or manufacturing of the product by Buyer or others and Seller takes no responsib
22. ility for the nature or consequence of such operations or as to the suitability of the product for the purposes intended to be used by Buyer or others after being subjected to such operations SELLER MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED OF THE PRODUCT SUPPLIED HEREUNDER INCLUDING WITHOUT LIMITATIONS IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY EXCLUDED SELLER SHALL HAVE NO LIABILITY FOR LOSS OF PROFITS OR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES OR LEGAL THEORY WHETHER BASED ON NEGLIGENCE BREACH OF WARRANTY STRICT LIABILITY TORT CONTRACT OR OTHERWISE SELLER SHALL IN NO EVENT BE LIABLE IN RESPECT OF THIS OR DER AND OR PRODUCT DELIVERED ON ACCOUNT OF THIS ORDER FOR ANY AMOUNT GREATER THAN THAT PAID TO SELLER ON ACCOUNT OF THIS ORDER GASS 2040 User Manual Original Instructions 5 1 Introduction Perma Pure GASS 2040 sample pre conditioning systems are designed to prepare gas samples for analysis The GASS 2040 system will condition high flow high moisture sample eliminating acid mists or ammonia if present without removing the compounds being monitored Figure 1 below gives a general overview of a GASS 2040 system Standard Features Include Options Heated Enclosure Purge Air Heatless Dryer Filter s Particulate and or Coalescing Heated Head Sample Pump Perma Pure Nafion Gas Dryer s Filter Drain Temp
23. just removed and tighten by hand Turn the handle until resistance is felt Then slowly turn the handle 2 3 turns The coupling fitting will begin to move away from the shell tubes Remove the tool and thread it into the other port on the same coupling fitting and tighten by hand Slowly turn the handle 2 3 turns Repeat steps a b until the coupling fitting is free of the shell tubes Repeat steps a c for the other coupling fitting At this point the dryer element shells should be free of the coupling Remove an o ring item 8 from one of the membrane element headers and slip the ele ment from the opposite end of the shell tube Repeat step f for the other membrane element shell tube assembly Locate one of the coupling fittings and place it on a hard surface with the shell tube bores facing up Install o rings item 6 in the grooves See Figure 16 Skip this step for dual element dryers For a single element dryer Insert the end of the empty shell into the bore of the coupling fitting that has the header plug residing in it Important Position the purge air holes as shown on the drawing Press the assembly into place in the coupling fitting See Figure 17 Insert the shell element assembly into the other bore and press Figure 16 into place Important Position the purge air holes as shown on the drawing Repeat for the second shell element assembly See Figure 18 19 Purge air holes P Figure 17 Figure 18 Fi
24. ll applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your system design installation or operation This product should not be operated in any manner that is inconsistent with its intended use If you have any questions concerning the installation or operation of this equipment or you need additional informa tion please call us at 1 800 337 3762 This publication is based on information that was available at the time it was printed At Perma Pure we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publica tions at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product This equipment is to be installed and operated by trained personnel with sufficient command of the English language to clearly understand the instructions and safety warnings Trademarks Nafion and Teflon are registered trademarks of El DuPont de Nemours Copyright 1996 2005 Perma Pure LLC All Rights Reserved GASS 2040 User Manual Original Instructions 4 WARRANTY AND DISCLAIMERS Seller warrants that product supplied hereunder shall at the time of delivery to Buyer conform to the published specifications of Seller and be free from defects in material and workmans
25. nnect sample line to compression fitting labeled Wet Sample In 5 Shrink entry seal tubing around heated sample line with heat gun 6 Connect sample outlet port of system to sample line running to analyzers High temperature heated line is not necessary for this connection If sample line will be exposed to freezing temperatures freeze protected line is suggested b Purge Air Supply Instrument Air Purge gas must be of instrument grade with dew point no higher than 40 C 1 Connect regulated purge gas supply line to 1 4 female NPT purge inlet port of membrane dryer labeled Instrument Air Pressure maximum is 100 psig Heatless Dryer Optional 1 Connect oil free compressed air line to port labeled Purge Gas Inlet An oil coalescing pre filter is recommended 2 A 1 4 female NPT bulkhead fitting on bottom of enclosure is provided for heatless dryer purge air exhaust Humid air can be vented to atmosphere or piped to remote location c Filter Drain Connection Optional Connect line from eductor outlet to designated collection exhaust basin containing acid absorption media to prevent release of exhaust to surrounding 1 4 D tubing can be used for runs up to 10 feet or larger I D tubing for longer exhaust lines Line should not restrict purge flow GASS 2040 User Manual Original Instructions 12 d Purge Exhaust Purge exhaust may contain liquid water A line can be connected from purge
26. nts the blowback valve from activat ing while a system calibration cycle is in process SAMPLE Gass SAMPLE GAs MLET Ca TLE BLY AZIE A IF SOLENCHD VALVE COMPRESSED AIR INLET B BLOVEACK AIR AOL POR Figure 10 The filter blowback event can be triggered externally via the Manual Filter Blowback input to the PLC Refer to the I O Wiring section for connection details on page 11 and the electrical wiring diagram in the appendix GASS 2040 User Manual Original Instructions 17 4 7 Electrically Heated Systems 1 Check that no condensate is present in sample line between filter and dryer 2 If water droplets are visible increase temperature of filter dryer compartment by 5 C 3 Allow about 1 2 hour for system to stabilize and then check again for condensate 4 If necessary continue to increase temperature at 5 C intervals until condensate is no longer visible Do not exceed 100 C Maximum system temperature is 100 C Operation above this temperature can cause damage to Nafion dryer It is essential that purge gas flows continuously and setpoint temperature is not above 100 C to prevent damage to dryer GASS 2040 User Manual Original Instructions 18 5 Maintenance 5 1 Filters If system is fitted with a pre filter it should be checked regularly to ensure that the element is in good condition If element appears to be dirty or begins to cause flow restriction in system it should be replaced Filter
27. or light or signal an external control system via digital outputs a Alarm Output Operation The system has three digital alarm outputs that can be used to signal an external control system that a problem has been detected Refer to the I O Wiring section for connection details on page 11 The definition of an active alarm is that the related output will be OFF During normal operation i e no active alarms all alarm outputs will be ON In the event of a power failure to the system all alarms will be in the active or OFF state Low Dryer Purge Air Flow alarm This alarm is initiated when the airflow that is used to purge the dryer is too low The airflow is sensed by a differential pressure switch located in the lower enclosure and connected to the dryer purge gas inlet and outlet At any time while the dryer purge air is too low this alarm will be active Low Temperature alarm This alarm is initiated when any of the system temperatures fall below the respective setpoint by 5 C as sensed by the thermocouples At any time the system temperatures is too low this alarm will be active General alarm This is an alarm that is initiated by either of the two alarms above At any time while the system power is on and either of the two alarms above is active this alarm will also be active b System Status Indicator Operation The system power pushbutton light serves as a basic system status indicator and is located at the lowe
28. particulate coalescer FF 250 G Replacement glass shell FF 250 3 Replacement O ring set set of 3 AS 200 08 EB Media replacement for ammonia scrubber bulk supply 5 fillings GS2040P FE Replacement 10 micron ceramic filter element for prode filter includes gasket GASS 2040 User Manual Original Instructions 26 APPENDIX D 1 Stack Mount Systems The GASS 2040 stack mount system is intended to be mounted on a 2 to 4 flanged nozzle has been welded directly to the stack It will accommodate a nozzle flange angle of 0 to 10 degrees Mounting of the system is relatively simple but will require a three person team as the system weighs approximately 110 pounds and will need to be supported temporarily during Installation See Figure 23 tes Lifting plate System mounting flange Stack nozzle flange Included Unistrut mounting angles Customer supplied supports Figure 23 GASS 2040 User Manual Original Instructions 27 1 1 Flange Mounting a f g h Once the system has been lifted up to the platform set the system down on blocks Short lengths of 2x4 studs or equivalent The blocks will protect the utility connections from damage and allow the system to be positioned upright on the platform deck Install the mounting flange on the system by threading it on to the protruding nipple that exits the back of the system and tighten Be sure to align the bolt hole pattern with that of
29. r left hand side of the control panel Based on the status of the alarm outputs and whether the system has reached operating temperature or not the indicator light will either remain lit or flash at one of two different rates There are three modes of operation Start up Heat up mode In this mode the indicator lamp will flash slowly at approximately 1Hz The system will stay in this mode until all of the system temperatures achieve their respective setpoints Normal Operation mode In this mode the indicator lamp will remain lit and will not flash Alarm mode In this mode the indicator lamp will flash quickly at approximately 4Hz Two different system conditions can initiate this mode 1 The system detects a low purge flow condition at any time For example power to dryer heaters is interrupted to prevent damage due to overheating 2 The system temperatures have all reached their respective setpoints Normal Operation mode attained and one or more of the temperatures then falls below the setpoint by more than 5 C GASS 2040 User Manual Original Instructions 15 4 4 Preheating the System 1 Turn on AC power to the system 2 Adjust purge air flow to 20 30 liters per minute 3 Set purge air eductor vacuum level to 5 in Hg This is necessary only if the sample gas pres sure upstream of the GASS2040 is below atmosphere and more than 10 in H2O vacuum 4 Allow 15 30 minutes of additional heating time after sys
30. s In most cases these mists will be acid mists Automatic drain is available in vacuum or pressurized style 1 Vacuum Configuration Collected liquid is withdrawn from filter drain port by a vacuum created by an eductor expanding compressed air through a venturi This is done in cycles and controlled by adjustable digital timer that switches a solenoid valve controlling compressed air supply GASS 2040 User Manual Original Instructions 7 2 Pressurized Configuration An eductor is not required since a vacuum is not needed to withdraw the sample Therefore condensate withdraw is directly controlled by the solenoid valve Cycle times can be varied and will be dependent on the amount of liquid present in sample 2 4 Sample Pump optional The sample pump draws the sample gas and supplies it to the analyzer It supplies up to 10 liters per minute of sample gas flow The pump is typically plumbed between the coalescing filter and membrane dryer or between the coalescing filter and the ammonia scrubber if present The head of the pump is located in the heated section of the system while the motor is located in the control section This configuration keeps pump head at a temperature above dew point of the sample preventing condensation from forming Included with the optional sample pump is a vortex cooling tube that helps keep the control enclosure at an acceptable temperature The PLC controls the valve that supplies air to the vortex t
31. s a small tightly sealed enclosure and ora fluctuating protective gas supply Pressure switch is out of calibration Tighten enclosure latches silicone sealant can be applied from inside the protected enclosure where tightening is not feasible Remove the orifice cut off crimped end and ream tube then recrimp and reinstall tube As tube is shortened sensitivity decreases allowing easier setpoint on the enclosure Pre regulate gas supply upstream of the enclosure protection system to 5 psi maximum Calibrate by slowly adjusting counterclockwise to decrease setpoint and clockwise to increase setpoint 3 Helpful Hints The term Safe pressure for purposes of this manual is defined as follows Class a minimum 0 25 inch of water column pressure Class a minimum 1 0 inch of water column pressure Regulator may be in the locked position upon arrival To adjust regulator pull handle to outward position To test the vent s operation gently prod the vent flapper open with a soft pointed object i e eraser end of pencil ensuring that the vent works freely GASS 2040 User Manual Original Instructions 29
32. tem has come to set point tempera ture 5 Sample flow may now be started For GASS 2040 systems that include a sample pump the pump will turn on if the pump switch is in the AUTO position The sample pump can be turned off externally via the Remote Pump Shut off input to the PLC Refer to the I O Wiring section for connection details on page 11 and the electrical wiring diagram in the appendix 4 5 Automatic Filter Drain Operation Optional Adjust the drain cycle time as described in the Operator interface section on page 14 When the sample gas is under a vacuum an eductor is used to generate enough vacuum to remove condensate in the filter See Figure 8 This is the most common configuration as the sample pump is most typically located downstream of the sample conditioning system Since the sample gas is being pulled through the system some amount of vacuum will be present in the filter and a higher vacuum will be required to expel condensate from the filter When the drain timer in the PLC times out a solenoid valve energizes and allows compressed air to flow to the drain eductor for 6 seconds In turn the eductor generates vacuum to expel condensate LE SaaS FILTER SAMPLE GAS SEAMS S FLET i EMPTLET CHECK F ADE qa OH DEMSATENIA EXHAUST DAS ELEL F OR SOLENOID VALUE ah F a A BURT Figure 8 GASS 2040 User Manual Original Instructions 16 When the sample gas is under positive pressure it
33. ube Compressed air requirements are approximately 4 scfm 80psi 2 5 Nafion Dryer The Perma Pure Nafion membrane dryer is installed downstream of the filter As sample enters the dryer flow splits into a number of small diameter Nafion tubes arranged in a parallel bundle as shown in Figure 3 below After sample enters one of these tubes it comes in contact with the Nafion membrane walls The membrane selectively removes water vapor from the sample by a process of permeation distillation Water vapor travels through the tubing walls driven by the difference in partial water vapor pressure on the opposing sides of the membrane As the sample flows from inlet to outlet water is continually removed reducing the sample dew point as it travels through the dryer Wet purge M rt z a x i gas inlet Figure 3 Dry purge gas enters the dryer at the sample outlet end and performs two functions 1 Provides a medium for water vapor from the sample to be carried away 2 Creates a temperature gradient along length of dryer Ambient purge air enters the dryer at sample outlet keeping that portion of dryer cooled This counter current flow is required to produce a temperature gradient along the length of the dryer To effectively maintain the gradient the temperature of purge gas exhaust is monitored and controlled by an electronic temperature controller As purge gas passes through the dryer it is heated to the desired sample inlet temperat
34. ure This gradient allows for both rapid vapor removal and decreased final dew point If the purge gas temperature begins to fall below the programmed temperature the system s backplate will heat An aluminum heating block will conduct energy from the backplate to the dryer s shell tube Purge gas traveling through the dryer s shell acquires heat from the shell This process allows final temperature of the purge gas to be closely controlled and a consistent temperature gradient will be maintained GASS 2040 User Manual Original Instructions 8 It is important that the dryer removes water in vapor state only If liquid water is introduced into the dryer efficiency will decline and the dryer could fail to perform altogether Tubing elongates approximately 10 over its dry length when saturated with liquid water causing tubing to kink inside housing Nafion dryers will operate most efficiently when a portion of the dryer is heated to prevent sample from condensing 2 6 Ammonia Scrubber optional The optional ammonia scrubbing canister must be used when ammonia or urea is used for the purpose of lowering NO levels or any time ammonia is present in sample stream Ammonia salts can deposit in dryer tubes and cause permanent loss of drying efficiency if not removed from the sample stream An ammonia scrubber consists of a polysulfone and 316 SS housing filled with a phosphoric acid based media and inert ceramic saddles This media will require periodi
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