MiniGASS Product Manual
Contents
1. 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 50cc of Berl Saddles tap housing to allow material to settle Pour 150cc 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 over tighten OANA WN 433 UW Fuse Fuse Replacement 1 Turn cap marked FUSE counter clockwise turn and the fuse holder will come out 2 Remove the blown fuse and replace with one of equal amperage rating The standard fuse is a BUSS type AGC or equivalent 3 After installing correct replacement fuse re install fuse holder by pressing inward and twisting 1 4 turn clockwise 16 Mini GASS User Manual Original Instructions Doc 212 Revision 00A n PERMA PURE LLC Mini GASS User s Manual 4 HALMA Page 17 of 32 3RPA 001 MG DTC MG TCS MG SSR MG FM MG PR MG DPS MG PG 0 30 MG VG 0 60 FF DCV DVV B10 DVV B20 DVP K10 DVP K20 MG DVT MG DC MG 1412 HB PD 50T 24EM PD 100T 24EM PD 200T 24EM FF 250 E 2 5G FF 350G FF 250 3 AS 200 08 EB Repl2. 1023 hours all switches on 1 Adjust purge air pressure regulator to about 15 psig Sample under vacuum Purge air regulator will control air pressure to educator of the automatic filter drain Regulator must be set to provide ample vacuum to remove filter condensate but not excessive enough to cause interruption in sample flow to analyzers Under positive pressure Condensate drain flow is directly controlled by solenoid valve When solenoid valve is actuated opened positive pressure in filter housing purges condensate out of system through drain line 2 Initially adjust DIP switches on drain timer to drain for 6 seconds every 24 hours Time on switches is additive Left switch should have only top 0 1 min switch in the ON position and right switch should have 8 and 16 hr switches in the ON position Time periods may need further adjustments after system has been in operation Temperature Control PI D Electronic Temperature Controller 1 Press and hold ok key on the CAL Controls temperature controller 2 Press either up or down key to adjust setpoint Setpoint temperature will change one C with each press of arrow key 3 When desired temperature is reached release both keys NOTE MG 1228 2812P and 1235 systems have a low temperature alarm that is programmed into controller Default temperature setting for alarm is 5 C below setpoint temperature Refer to CAL Controls temperature controller manual f
3. CONTROLLER POWER SWITCH OD POWER CONNECTION 1 2 CONDUIT HUB 110 220 VAC FUSE iM DRY SAMPLE OUTLET KYNAR 1 4 COMPRESBION PURGE AIR INLET 1 4 NPT FEMALE HEATLESS DRYER PURGE AIR EXHAUST 1 4 NPT FEMALE Figure 15 MG 1228 Style System 25 Mini GASS User Manual Original Instructions 4 PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A A HALMA COMPANY Page 26 of 32 SAMPLE INLET PURGE EXHAUST 1 4 FNPT FIBERGLASS ENCLOSURE W CLEAR POLY CARBONATE COVER HEATED BACKPLATE uo 1 1 CONTROL ENCLOSURE RH PRESSURE TEMPERATURE GAUGE CONTROLLER PURGE FLOW METER PURGE PRESSURE REGULATOR PURGE INLET F COMPRESSION TUBE FITTING PD SERIES 24 DRYER SAMPLE OUTLET 1 4 FNPT Figure 16 26 Mini GASS User Manual Original Instructions 4 PERMA PURE LLC A HALMA COMPANY Mini GASS User s Manual Doc 212 Revision 00A Page 27 of 32 PURGE GAS EXHAUST 1 4 NPT FEMALE B SAMPLE INLET 10 W C VACUUM 30 PSIG PRESSURE RANGE 1 4 NPT FEMALE 316 S8 OR KYNAR OR OPTIONAL SEALING FITTING FOR 1 57 HEATED BAMPLE LINE Fa RUBBER FEET MG 1220 Style System HINGE THERMOCOUPLE o oyo She Figure 17 HEATED BACKPLATE m HEATED FIBERGLASS ENCLOSURE W CLEAR POLYCARBONATE COVER MG 2812T Transportable System Mini GASS
4. ELEMENT 6 1 SHELL TUBE Mini GASS User Manual Original Instructions Doc 212 Revision 00A HALMA COMPANY Page 21 of 32 E PERMA PURE LLC Mini GASS User s Manual Figure 10 APPENDIX C Flange Mounted with Integral Sampling Probe and Filter Blowback I nstallation Flange mounted Mini GASS is designed to be stack mounted on 2 3 or 4 pipe flange The integral sample probe and filter eliminates need for a heated umbilical line to connect stack gas sampling probe to sample conditioning system The Mini GASS system is attached directly to sample port flange by following the steps below 1 Attach flange to sampling port using appropriate sized gasket and bolts 2 Align flange holes with turnbuckle anchor at bottom Install four appropriate sized bolts and hand tighten all four bolts evenly Tighten with wrench see Figure 11 3 Install sampling probe pipe into pipe flange by inserting non threaded end of probe pipe through flange see Figure 12 Probe should extend into the center of the stack and pointing slightly downward to allow any entrained liquid to drain back into the stack Tighten probe pipe into flange with wrench pipe Attach one end of turnbuckle to anchor at bottom of flange and fix pin in place with cotter pin Ua Probe Pipe Flange Turnbuckle Figure 11 Figure 12 6 If system is being installed with automatic filter blow back option install blow back
5. FLOWMETER SUPPLY PRESSURE GAUGE DRY SAMPLE OUTLET 816 SS 4 NPT FEMALE PURGE AIR INLET 14 NPT FEMALE HEATLESS DRYER PURGE AIR EXHAUST 14 NPT FEMALE Figure 3 Mini GASS Sampling System Filter drain optional Connect the line from the eductor outlet to designated collection exhaust basin containing acid absorption media to prevent release of exhaust to surrounding 14 i d tubing can be Mini GASS User Manual Original Instructions n PERMA PURE LLC Mini GASS User s Manual l Doc 212 Revision 00A HALMA COMPANY Page 10 of 32 used for runs up to 10 feet or larger i d tubing for longer exhaust lines Line should not restrict purge flow Purge eductor inlet connection optional Connect air supply line to compression fitting labeled Instrument Air Steam connection optional Refer to figure 4 1 Insulate supply line to steam control valve 2 Insulate supply line between valve and steam coil 3 Supply low pressure steam 50 psig max to steam coil Do not exceed this pressure or overheating may occur Outlet end of steam coil located at lower left side of enclosure is connected to a thermostatic steam trap to allow condensed steam to drain in a controlled manner Condensate can be piped to a wastewater drain or to condensate recovery system PURGE EXHAUST 5 4 FEMALE NPT N SAMPLE FEM ALI
6. NEVER operate this equipment if it is visibly damaged or the possibility exists that it may have been damaged e The use of components that have not been purchased through an authorized Perma Pure dealer or directly from Perma Pure may compromise the safety of the operator Additionally use of non authorized components may change the operating characteristics of this equipment Any changes to the equipment that modify its operation in any way are dangerous and are strictly prohibited e Read the entire operating manual before attempting to set up or operate the equipment e Please heed all warning labels that are on the equipment They are there to remind you of possible hazardous conditions e Verify the integrity of any mechanical and or electrical connections that are made to the unit e Verify that the unit is connected to the proper rated power for the system e Verify that the unit is plumbed properly to operate effectively Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A A HALMA COMPANY Page 6 of 32 General description Proven tube in shell membrane technology is the basis of the Mini GASS Conditioning System which selectively removes water vapor from a gas stream The driving force is the vapor pressure differential between the sample gas and a purge gas counter flowing outside the tubing This difference quickly dries the gas stream The Mini GASS sta
7. PINE G89 EAH TH PORGE LATI HPT MAE Uu d COMPRESED AR MET WHT ARE DUETI Ft IPT FEMALE Bs V FEMALE NPT PARTEA fuk ERPE OMB LET FN RHME DE SPLE OUTLET V FEHALE IPT COL GAB ILITI HET FEMALE DHONE ORAN OR VUIM OPERATION M NPT MAE FER PRESSURE OPERATION A PPT FEALE NETE PRESSURE STUE SHONN ELI TIMER AND CHECK WALIE ARE NOT ED ENOO VLE ALY HEKLER DMR EXHAUET AR ET sweet ie UAE IPT ALTA PARRE DAS TT e FEMALE FT E Oth one a eus WE THER HIE CEVPONT OF BELOW PERMA PURE LLC B EXECUTIVE DRIVE TOME RIVER Nw DB754 JAPPROVED BY pue MINI GASS 1228P FLOW DIAGRAM SE ORMWNG NUMBER vasos B MG 1228 01 24 24 Mini GASS User Manual Original Instructions 4 PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A A HALMA COMPANY Page 25 of 32 Piping and Instrumentation Diagram AMPLE INLET SEALING FITTING FOR 1 6 0 D HEATED LINE PURGE EXHAUST PORT 1 4 NPT FEMALE NAFION MEMBRANE DRYER SAMPLE INLET FITTING MODEL PD 50T 24KA KYNAR 1 4 COMPRESSION PURGE EXHAUST SAMPLE FILTER TEMPERATURE SENSOR FF 260 FG 2 6d TEFLON COATED HEAD SAMPLE PUMP HEATED BACKPLATE BAMPLE PUMP MOTOR BELOW FRONT PANEL HEATLESS AIR DRYER BELOW FRONT PANEL OPTIONAL MEMBRANE DRYER PURGE AIR FLOWMETER FLOWMETER SUPPLY PRESSURE REGULATOR FLOWMETER SUPPLY PRESSURE GAUGE DIGITAL ELECTRONIC TEMPERATURE
8. TLET E NPT E AIR INLET L T AMPLE INLET MRES A FEMALE NPT N HEATED FIBERGLASS ENCLOSURE CLEA CARBONATE COVE A STEA IL MOUNTED BELO ENCLOSURE BACKPLATE Figure 4 Steam heated Mini GASS Electrical connections Mini GASS Model 1220 and 2812T Transportable have a power cord and plug for 115 VAC and power cord with pigtail wires for the 230 VAC version For Mini GASS model 1228 Mini GASS model 1228 is intended to be hard wired via a customer supplied disconnect switch and wire capable of supplying 5A 10A 115 230 VAC The external disconnect switch must meet IEC 60947 1 amp 60947 3 standards and must be installed in close proximity to 10 Mini GASS User Manual Original Instructions n PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A 4 HALMA COMPANY Page 11 of 32 the equipment within easy reach of the operator and shall be clearly marked as the disconnecting device for the Mini GASS Connect power supply line to terminal block located on the backplate of the control enclosure inside the 12 conduit hub Refer to figure 5 for color coding Connect the system to an appropriate earth ground Adhere to all electrical code requirements in effect at the installation site Connect power such that the protective earth conductor is the last to take the strain Green yellow Connect
9. safety procedures These procedures represent the MI NI MUM requirements to operate the equipment safely It is the ultimate responsibility of the operator to ensure proper safety practices are utilized at the point of operation e This equipment is NOT designed to operate in a wet environment e Condensate is potentially dangerous NEVER handle drain lines or any other item that may have come in contact with the gas stream or any hazardous material without adequate personal protective equipment ALWAYS assume that any liquid present is hazardous e Sample gas is potentially dangerous A leak test is recommended at initial startup and as often as necessary to maintain a safe working environment around the equipment The gas stream exhaust must exit away from all personnel to prevent dangerous exposure e NEVER operate the equipment with any part of the enclosure unsecured All operated doors and covers must be in place and secured prior to operation Electrical current may be present behind covers or doors even if tools are not necessary to access these components e NEVER attempt service on this equipment without first disconnecting all energy sources Repair of this equipment should only be done by properly trained personnel that are familiar with the potential risks involved with servicing of the equipment e NEVER replace fuses with types other then the sample specification of type and current Do not bypass this or any other safety device e
10. AT THI S TI ME Check purge air is flowing immediately after turning on AC power or steam If for any reason there is no purge air or flow is inadequate turn off AC power or steam before attempting to locate problem OPERATI NG SYSTEM WI TH LITTLE OR NO PURGE AIR CAN CAUSE DAMAGE TO MEMBRANE DRYER ASSEMBLY Set purge air pressure to 15 psig Adjust purge air flow to 20 L min Set purge air educator vacuum level to 5 in Hg if applicable Ensure purge air is exhausting from system pue Buon The temperature controller will be alternately displaying AL and actual purge air exhaust temperature until purge air temperature comes within 5 C of setpoint temperature 7 Allow 15 30 minutes of additional heating time after system has come to setpoint temperature Sample flow may be started For Mini GASS with a pump when set on AUTO mode pump will turn on when unit has reached temperature and purge gas is sensed 13 Mini GASS User Manual Original Instructions n PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A 4 HALMA COMPANY Page 14 of 32 System fine tuning Temperature adjustment Steam heated systems Steam control valve is factory set to 180 F and is normally not field adjustable This temperature is adequate for most applications in which sample gas water content is not in excess of 50 water vapor by volume Consult factory if condensation in sample tubing is detected Electrical
11. 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 responsibility for he 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 LIMITATION 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 ORDER AND OR PRODUCT DELIVERED ON ACCOUNT OF THIS ORDER FOR ANY AMOUNT GREATER THAN THAT PAID TO SELLER ON ACCOUNT OF THIS ORDER 19 Mini GASS User Manual Original Instructions Doc 212 Revision 00A HALMA COMPANY Page 20 of 32 E PERMA PURE LLC Mini GASS User s Manual APPENDIX B Dryer element replacement TO DISASSEMBLE DRYER Tools Needed Phillips head screwdriver unsharpened pencil wi
12. P MG 1220 Operating environment 0 to 10 Ipm 250 F 121 C max with stainless steel filter 230 F 110 C max with Kynar filter 30 by volume maximum maximum 20 psig minimum 5 H20 vacuum minimum 10 H20 vacuum Maximum 1 cfm of oil free instrument air or nitrogen with less than 40 C dew point 2 CFM clean dry air 80PSIG 26 F 49 C at 10 Ipm 12 F 12 C at 5 Ipm 12 F 25 C at 2 Ipm 36 F 2 C at 10 Ipm 26 F 4 C at 5 Ipm 6 F 15 C at 2 Ipm 42 F 5 C at 10 Ipm 34 F 1 C at 5 Ipm 22 F 6 C at 2 Ipm V4 or 3 8 tubing fittings 115V 10 or 230V 10 50 60Hz 8 0A 4 0A up to 900 Watts depending on options 8A 4A BUSS type AGC or equivalent NEMA 4X Fiberglass with polycarbonate cover 12 W x 28 H x 7 Deep 28 W x 12 H x 7 Deep 12 W x 20 H x 7 Deep 20 C to 40 C ambient temperature 0 95 RH Altitude up to 2000m Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A HALMA COMPANY Page 8 of 32 Installation Mounting 1 Install Mini GASS system on vertical surface with dryer filter compartment on top and control compartment on bottom 2 Place mounting feet on each corner of enclosure with slotted end protruding at a 45 angle 3 Drop mounting screw in from top and tighten into foot Connections Refer to figure 2 Heated sample line _HUB a FITTING 1 Instal
13. PERMA PURE LLC Mini GASS Sample Conditioning System User s Manual PERMA PURE LLC HALMA COMPANY 8 Executive Drive P O Box 2105 Toms River NJ 08754 732 244 0010 800 337 3762 fax 732 244 8140 www permapure com info permapure com Doc 212 Revision 00A n PERMA PURE LLC Mini GASS User s Manual 4 HALMA COMPANY Page 2 of 32 Contents WM igler te diy RPM 3 Important safety Warnings usissestkenuada wa kk dat or RR ER V ka vea oV Va Dx VA RAE Rad FEE Ea Aa E ROS VENE a 5 General descrip zaaxxyade duxi aad rid iba a xcd RH UE RN b c ER i a E aA d RR 6 Specifications and Feat reS Juaxss sux dq ua Eu3 dial d Rau d au ea YOUR EROR A Ya RR KM I a RE ARM dtl 7 nstallati MONET 8 edis eer sd Pe OUTRE 10 Start Up DrOCed Ure RT 11 Preheating the SVSEBITI ca iode nudi eR VR vd aaa x KE TRAE RANA EE ER X RV MER Via AU NR a Ra DES a ER e a dares 13 Systemi file TUNING cuaesesuae2usud pha dad e ERG dE a Eau E a ri aar Fac aa PEE RU a a dl DAS M DA 14 Mies 14 Replacement Bal S asczesieekvsaduasutssak ones eresctonbenid EEN EENE vxd Devi TTE da Dp Sw E ENERE icd wt nds vUa 17 APPENDIX A Warranty and disclaimers eeeseeeesseeeee enean 19 APPENDIX B Dryer element replacement eeeseeeesseeseseee esee nennen nan nn 20 APPENDIX C Flange Mounted with Integral Sampling Probe and Filter Blowback 21 APPENDIX D DiBOr
14. SS User s Manual Doc 212 Revision 00A HALMA COMPANY Page 31 of 32 APPENDIX F Safety Interlock System Control system safety interlock The interlock system is present to provide an output signal that can be used internally to stop sample flow via the optional internal sample pump This system can also be used to provide an external output to a PLC or other control monitoring system so that the status of the Mini GASS can be monitored Two relays are used to perform this function e Low purge flow relay A differential pressure switch across the purge air ports of the PD dryer senses the flow of purge air and energizes this relay when flow is present A minimum purge flow rate of about 10 Ipm is required Below this flow the alarm relay will de energize e Low temperature relay The CAL 3300 temperature controller has an alarm function that is used to energize this relay when the system is operating at normal temperature The actual point at which a low temperature alarm is triggered is Set point minus 5C For instance if the temperature controller is set at 90C the alarm relay will de energize at 85C The interlock system is used in the Mini GASS to control the optional internal sample pump by simply supplying power to the sample pump motor via the alarm relays Each of the relays is of a DPDT or double pole double throw design This just means that there are two sets of normally open normally closed N O N C contac
15. SS User s Manual Probe Accumulator E a L Outlet Figure 19 MG 1228 with Probe and Blowback 29 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A A HALMA COMPANY Page 30 of 32 APPENDIX E Z Purge Operation With the inert gas supply connected enclosure power de energized and alarm system if utilized Follow steps to purge system 1 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 Z Purge Troubleshooting Problem or Fault Possible Causes Corrective Action Enclosure pressure control regulator will Leakage around gasketing covers Tighten enclosure latches silicone not hold a safe pressure seams piping and tubing connections sealant can be applied from inside the conduit connections and electrical protecte
16. User Manual Original Instructions CARRYING HANDLE PERMA PURE MEMBRANE DRYER SAMPLE OUTLET p LOCATED BELOW FRONT PANEL 3168S 1 4 NPT FEMALE 2 OR KYNAR 1 4 COMPRESSION FITTING TO SAMPLE PUMP COMPRESSED AIR INLET 1 4 NPT FEMALE 60 100 PSIG HEATLESS DRYER PURGE AIR EXHAUST 1 4 NPT FEMALE 14 x 12 FIBERGLASS ENCLOSURE W CLEAR POLYCARBONATE COVER MEMBRANE DRYER PURGE AIR CONTROLS ELECTRONIC TEMPERATURE CONTROLLER ELECTRICAL 110 OR 220 VAC OPTIONAL PURGE AIR HEATLESS DRYER LOCATED BELOW FRONT PANEL 21 4 PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A A HALMA COMPANY Page 28 of 32 SAMPLE INLET FITTING FOR HEATED LINE PURGE EXHAUST X FEMALE NPT SAMPLE INLET TTING 316 SS COMPRESSION SAMPLE FILTER ae J 250 S6 2 56 STEAM INLET zzzzzzz 3X COMPRESSION 15 50 PSIG 2 DIAL THERMOMETER batty weed s INDICATES PURGE AIR RE BACKPLATE EXHAUST TEMPERATURE IIzz HEATED FIBERGLASS ENCLOSURE WITH CLEAR POLYCARBONATE COVER THERMOSTATIC STEAM TRAP PD SERIES MEMBRANE DRYER E DRAIN PORT COMPRESSION PURGE FLOW METER PURGE PRESSURE REGULATOR PURGE PRESSURE GAUGE INSTRUMENT AIR INLET SAMPLE OUTLET A FEMALE NPT M FEMALE Figure 18 MG 1228 Steam System 28 Mini GASS User Manual Original Instructions Doc 212 Revision 00A A HALMA COMPANY Page 29 of 32 E PERMA PURE LLC Mini GA
17. acement parts Replacement instrument air regulator Digital temperature controller single channel J Type thermocouple Solid state relay Flow meter purge gas 0 60 Ipm Pressure regulator purge gas or educator Differential pressure switch for purge flow detection Pressure gage purge gas 0 30 psi Vacuum gage purge educator 0 30 Hg Drain check valve polypropylene for vacuum drain Drain solenoid valve brass for vacuum drain 110V 60Hz Drain solenoid valve brass for vacuum drain 220V 50Hz Drain solenoid valve kynar for pressure drain 110V 60Hz Drain solenoid valve kynar for pressure drain 220V 50Hz Drain valve timer Mounting clamps for dryer specify dryer model Backplate with heater for enclosure 1412 50 tube dryer replacement element 24 long includes O rings 100 tube dryer replacement element 24 long includes O rings 200 tube dryer replacement element 24 long includes O rings Replacement filter element Replacement glass shell for filter Replacement O ring set set of 3 rings Media replacement for ammonia scrubber bulk supply 5 17 Mini GASS User Manual Original Instructions PERMA PURE LLC HALMA COMPANY Mini GASS User s Manual Doc 212 Revision 00A Page 18 of 32 fillings MG PUMPKIT Pump repair kit Teflon diaphragm SP 270E Ceramic filter element for MG 1228P Mini GASS User Manual Original Instructions 18 b PERMA PURE LLC Mini GASS User s Manual Doc 212 Rev
18. afiSs iiit vesica ad ERO EXE E A E QU S Ia PU AE ADEPKECSAQIE SERE EDI RUE Tdad pad aad 24 APPENDIX E Z P rge i ecese ee eene re En ER o pe XERXEE RR E ERR Y FEXEENEEKE RRRXYY RN FRE FEE ER ER 30 APPENDIX F Safety Interlock System ous es cgo a e b ERG E M ROO D o EH OY e e Y EE E 31 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A HALMA COMPANY Page 3 of 32 Unpacking Perma Pure has made every effort to ship you a high quality product that has been thoroughly inspected and tested It has been carefully packed to ensure that it arrives at your facility in good condition Even though every effort has been made to prevent damage during transportation damage can occur by the carrier This is out of Perma Pure s control and is the responsibility of the carrier to ensure that your equipment arrives intact and undamaged Inspect outside packaging If there is any visible damage inform the carrier at the time of delivery This inspection is important Once the package is signed for responsibility for any visible damage then transfers to the consignee Unpack your equipment Visually inspect the outside of your equipment for any damage If there is any damage contact the carrier immediately Generally a carrier must be notified within 24 hours of the delivery to make a hidden damage claim Save the packing material in the event a damage claim must be verified by t
19. can result from the failure to follow all 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 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A 4 HALMA COMPANY Page 5 of 32 I mportant safety warnings Please be sure to review the following basic
20. d correctly and parallel to glass shell 7 Carefully mate bottom assembly onto top piece Slight twisting motion may be required to allow shell to slip over o ring seal 8 Visually make sure element is seated correctly in top groove 9 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 rali d IEEE I i MMI O T Ron p Cap 4 M A IN Figure 7 Filter Element Replacement Bolt 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 When disassembling the dryer note that the end fittings on the PD SERIES dryer can be easily rotated on the shell tube This rotation should be avoided to prevent twisting the membrane tubes inside the shell Refer to Appendix B for PD dryer element replacement Ammonia Scrubber Media Replacement When deposits are visible on 75 of the scrubber scrubbing media needs to be replaced 1 Unscrew thumbscrew on bottom of housing 2 Swing yoke to one side 15 Mini GASS User Manual Original Instructions 4 PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A HALMA COMPANY Page 16 of 32
21. d enclosure where tightening is conduit seal of the enclosure not feasible Enclosure pressure indicator reading is In sufficient enclosure leakage or Remove the orifice cut off crimped end difficult to stabilize opening of the venturi orifice is crimped and ream tube then recrimp and too small reinstall tube As tube is shortened sensitivity decreases allowing easier setpoint on the enclosure Enclosure pressure Indicator Drifts up Application involves a small tightly Pre regulate gas supply upstream of the or down from the Safe pressure setting sealed enclosure and or a fluctuating enclosure protection system to 5 psi protective gas supply maximum Enclosure pressure loss alarm switch Pressure switch is out of calibration Calibrate by slowly adjusting does not appear to be operating counterclockwise to decrease setpoint and clockwise to increase setpoint 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 Il 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 30 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GA
22. g MINI GASS MRING DIAGRAM FOR ALL SYSTEMS m mn g vemen Mini GASS User Manual Original Instructions 32
23. ge Gas Inlet 2 A 4 FNPT bulkhead fitting on bottom of enclosure is the heatless dryer purge air exhaust see figure 3 Humid air can be vented to atmosphere or piped to a remote location Purge air exhaust optional To vent the purge gas exhaust to a remote location connect a line to the 1 4 FNPT fitting labeled Purge Exhaust Port This is suggested for gas samples that are toxic flammable or otherwise hazardous In case of failure of seal integrity the sample will be vented to the remote location For runs under 10 ft 14 OD tubing is acceptable For runs 10 40 ft 3 8 OD tubing is recommended SAMPLE INLET SEALING FITTING FOR 1 O D HEATED LINE SAMPLE INLET FITTING 316 SS 14 COMPRESSION SAMPLE FILTER FF 250 SG 2 5G HEATED BACKPLATE DRAIN VALVE OPTION DRAIN VALVE EXHAUST PORT 14 NPT HEATLESS DRYER OPTION 5 125 12g PURGE EXHAUST PORT M NPT FEMALE Sw 3X l BELOW FRONT PANEL N DIGITAL ELECTRONIC TEMPERATURE CONTROLLER POWER SWITCH POWER CONNECTION 12 CONDUIT HUB 110 220 VAC FUSE NAFION MEMBRANE J DRYER MODEL PD 200T 24SA PURGE EXHAUST TEMPERATURE SENSOR MEMBRANE DRYER PURGE AIR FLOWMETER FLOWMETER SUPPLY PRESSURE REGULATOR
24. ground earth here Brown Connect Line L1 here Blue Connect neutral or Line L2 here Figure 5 Electrical Connections Alarm Relays The SIVS2 has a 6 pole terminal block that will allow for field wiring of alarm relays for connection of external alarm equipment refer to Figure 6 Relay contacts are rated at 250 VAC 3A resistive See Appendix F for additional information Low Purge Low Dryer Air Flow Temperature Alarm Relay Alarm Relay VR A M Of Of b r 4 jJOlololo o 02662 6G z82z22z282 Figure 6 Alarm Relays Start up procedure Setup Check 1 Check that electrical sample purge drain and or steam connections have been made 2 Turn on compressed or instrument air to system 11 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A 4 HALMA COMPANY Page 12 of 32 Automatic Filter Drain Control Optional Automatic filter drain is controlled by a repeat cycle timer that operates a solenoid valve Two DIP switches are located on timing device to control drain and cycle times located on backside of control panel Standard factory setting is to drain for 0 1 minute once every 24 hours 0 1 minutes 1 switch on all others off Drain Time left DIP switch To 102 3 minutes all switches on 1 hour 1 switch on all others off Cycle Time right DIP switch To
25. he carrier Items in the carton include 1 Mini GASS sampling system 1 Heated line seal fitting 1 User s Manual If any of the above parts are missing or damaged call the helpline at 800 337 3762 ext 145 Mini GASS User Manual Original Instructions 4 PERMA PURE LLC Mini GASS User s Manual i Doc 212 Revision 00A A HALMA COMPANY Page 4 of 32 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
26. ision 00A HALMA COMPANY Page 19 of 32 APPENDIX A Warranty and disclaimers Perma Pure LLC Perma Pure 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 workmanship 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 an 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
27. l heated line sealing fitting by threading hub into sleeve 7 SEAL O RING 2 Ensure o ring seal is installed on outside of enclosure between SLEEVE sleeve amp enclosure wall LINE HEATED SAMPLE 3 Run heated sample line through entry seal and into enclosure Figure 2 4 Connect 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 Mini GASS 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 recommended Purge air supply Instrument air Purge gas must be of instrument grade with dew point no higher than 40 C 1 On model MG 1214 the purge gas should be supplied to dryer via a 0 30 slpm flow meter and a regulator capable of supplying 0 50 psig All other models come with a control panel that includes a flow meter and regulator 2 For all other models connect a 30 100 psig purge gas supply line to the 1 4 female NPT purge inlet port of membrane dryer labeled Instrument Air Mini GASS User Manual Original Instructions 4 PERMA PURE LLC 4 HALMA COMPANY Mini GASS User s Manual Doc 212 Revision 00A Page 9 of 32 Heatless air dryer optional 1 Connect oil free compressed air line to port labeled Pur
28. ly 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 59 C 3 Allow about hour for system to stabilize and then check again for condensate 4 If necessary continue to increase temperature in 5 C increments 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 Maintenance 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 Element Replacement Refer to Figure 7 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 U1 4 U0NPN HR 14 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A HALMA COMPANY Page 15 of 32 6 Place new element in groove in bottom piece Be sure that element is seate
29. ndard features include a heated enclosure particulate and or coalescing filter Nafion gas dryer temperature controller and dryer purge flow controls There are also a number of options which may have been included in your system See Figure 1 PURG AS EXHAUST q HEATED CLOSUI d CONTROL CLOSUF AN AN i ve ZA AN WET SAMPLE INLET NC LE OUTI v c OALESCING MEMBRANE DRYER FILTER L BACKPLATE HEATER ES EDLE VALVE FLO ETER Pp ee 4 CUT E 4 DIGITAL DRAIN PA IEATLESS DRYER VALVE TIMER x EN ow EXHAUST AIR VENT x lt SOLENOID VALVE PRESSURE PRE d GAUGE A4 DUCTOR HEATLESS AIR DRYER L du E OPTIONAL DRAIN OPTIONAL HEATLESS VALVE ASSEMBLY DRYER ASSEMBLY L d CONDENSATE DRAIN Figure 1 Mini GASS flow diagram Mini GASS User Manual Original Instructions PERMA PURE LLC HALMA COMPANY Mini GASS User s Manual Doc 212 Revision 00A Page 7 of 32 Specifications and Features Sample flow rate Sample inlet temperature Sample inlet water vapor Sample inlet pressure Without purge eductor option With purge eductor option Purge air requirements Vortex cooler w sample pump Outlet sample dew point With PD 200T 24SS dryer With PD 100T 24SS dryer With PD 50T 24SS dryer Gas sample inlet and outlet fittings Electrical requirements Fuse Enclosure Dimensions MG 1228 MG 2812
30. or more information 12 Mini GASS User Manual Original Instructions b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A 4 HALMA COMPANY Page 13 of 32 Steam Temperature Control Steam heated systems are regulated by a thermostatic steam control valve located in the purge air exhaust stream This valve is preset at the factory to an appropriate temperature determined by sample conditions A typical setpoint temperature is 180 F which is the approximate temperature of the purge air exhaust indicated by analog thermometer located in the purge air exhaust stream Safety I nterlocks Systems equipped with the SIVS2 interlock option automatically shuts off the sample pump in the event of low purge airflow or low temperature in the system To accomplish this a differential pressure switch in the purge air inlet senses the flow of purge air and energizes arelay This relay then sends power to the contacts of a second relay which will energize only when temperature set point has been reached Under normal operating conditions both safety relays will remain energized When the system is operating normally open contacts will close and remain closed Alarm relays may be field wired to initiate an external alarm See Appendix F for additional information Preheating the system 1 Turn on AC power or steam to system WARNING On AC powered units temperature control display should light DO NOT BEGIN SAMPLE FLOW
31. provides power to the filter in the probe Blow Back Operation The blow back option includes a timer circuit which will initiate the blow back cycle based on a regular adjustable time period The time cycle control turned to the far left will cycle the blow back every 15 minutes At the far right side the period of time between cycles is about 24 hours The period of time between blow back cycles should be calculated to occur as often as when the filter has trapped one gram of particulates but no less frequently than once per day A jumper placed between AUTO OFF and COM will disarm the timer A contact closure between terminals labeled MAN B B and COM will initiate a blow back cycle The blow back solenoid valve will be opened for 2 seconds when the blow back cycle is started Maintenance Changing the Filter in Blow Back Probe Assembly 1 2 Unscrew black filter cap inside Mini GASS system use gloves if hot to touch Filter is now exposed With a pair of pliers pull out the old filter Inspect o rings which are at each end of filter Replace if they are charred or deformed Place new filter element using pliers Ensure it is centered and in contact with o ring Screw cap back on the filter body Mini GASS User Manual Original Instructions 23 b PERMA PURE LLC Mini GASS User s Manual Doc 212 Revision 00A HALMA PANY Page 24 of 32 APPENDIX D Diagrams m ae wo FIRE G85
32. system on right flange bolt refer to Figures 13 and 19 7 Attach pre bent SS tubing to Mini GASS and to blowback assembly 8 Lift Mini GASS system into place so union fitting on back of system can be attached to probe pipe This is most easily accomplished with help of an assistant 9 While holding system in place tighten union hand tight 21 Mini GASS User Manual Original Instructions i Doc 212 Revision 00A A HALMA COMPANY Page 22 of 32 E PERMA PURE LLC Mini GASS User s Manual 10 Connect free end of turnbuckle to anchor point at middle back of system refer to Figure 14 11 Attach with stainless clevis pin 12 Snap keeper wire into place 13 Adjust turnbuckle by turning it out to increase length until union fitting is straight Turnbuckle is used only to relieve torsional load from union fitting 14 Tighten union fitting with a wrench 15 Install insulation between flange and back of Mini GASS SS Tubing Figure 13 Right Flange Bolt Blowback Air Supply Connection 110VAC Insulation Figure 14 Anchor Point Plumbing 1 Connect blowback air line to blow back inlet port on the Mini GASS 22 Mini GASS User Manual Original Instructions 4 Mini GASS User s Manual PERMA PURE LLC Doc 212 Revision 00A HALMA COMPANY Page 23 of 32 2 Connect cal gas line to fitting labeled Cal Gas Inlet 3 Connect 110VAC power to blow back timer Note This also
33. th eraser m Loosen locking screws on both ends of dryer 2 Insert eraser end of pencil into one sample port until it rests on tube header face Refer to Figure 8 3 Hold dryer vertically and place other end of pencil down onto a hard slip resistant surface 4 While supporting shell tube push lower end fitting down with consistent pressure until it slips off shell tube Tube Header Do not attempt to pull fitting from shell tube doing this is likely to damage dryer element tubing 5 Repeat steps 2 4 for other end 6 Remove one o ring from tube header 7 Pull tube element from opposite end of dryer Figure 8 TO ASSEMBLE DRYER Refer to Figure 10 Tool Needed Phillips head screwdriver 1 Install one thick o ring onto grooved tube header 2 Slip opposite tube header into dryer shell Check for Alignment Sample Install other thick o ring onto groove Port Push one thin o ring into groove inside coupling for SS and AL shells slip o ring on shell across two holes Firmly push coupling over tube header Figure 9 Align purge port with hole in shell tube Refer to Figure 9 Tighten locking screws until underside of screw head contacts top of boss Repeat steps 4 7 for opposite end Aw Check for Alignment Co OY UI PARTS LIST ITEM QUANTITY DESCRIPTION 1 2 SCREW 10 24 x 3 8 SS 2 COUPLING WIN 2 ELEMENT HEADER SEAL VITON 4 2 SHELL TUBE SEAL VITON 5 1 DRYER
34. ts in each relay One set of contacts is used internally and one set of contacts is provided to allow connection to an external system e Refer the drawing MG 1228 04 12 Internally these relays are wired in series to supply power to the sample pump To accomplish this switched line voltage 115 230VAC Orange wire is supplied to the common term 5 connection of the low purge flow relay From the normally open term 3 connection of the low purge flow relay a brown wire connects to the common term 3 connection of the low temperature relay From the normally open term 3 connection of the low temperature relay a gray wire connects to the sample pump This allows the pump to start only if both relays are energized Refer to Figure 20 For external connection the second Low Purge Low Dryer set of contacts in each relay is dry No power is AlrFlow Temperature applied This allows the user to determine the control Alarm Relay Alarm Relay voltage that will be used A typical use of the alarm j e signal as described above is to control sample flow The actual use is left up to the customer Figure 20 N O COM N C N O COM N C 31 Mini GASS User Manual Original Instructions P PERMA PURE LLC HALMA COMPANY Mini GASS User s Manual Doc 212 Revision 00A Page 32 of 32 Ls ume PERMA PURE INCORPORATED wow iw 8 EXECUTIVE DRIVE TOMS RIVER Nw 08734 E Ai me
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