Method 5 – Isokinetic Metering Console Part # 0028 User Manual
Contents
1. JAYA ISHVOD 137N 3 ndWvS nd gt gt uve 1010320NM NOE a II lt x d T LY is 5 3 NN 3 Nw ad SAWA w LL LAONIONYI 95 U b SOI gt SIN 1014 4 1 FG 5 m NOI e B UALIWONYW 8 0 V i Oye UL uU Mi 2 NOS 4 Sod ah LI 7 0 un 62 3 H ON Woo T SSINdXI AVI 30 NO1SSIHN3d NALLIYM LNOHLIM JO SS3udX3 BVI 40 AlN3dOHd SI 9 SIKL o c O o i and c O o 2 o lt 2 Gar Diagram Wiring Diagram E x R E 5 5 Figure 9 eh aita CLEAN AIR EXPRESS FILTER PROBE DADATANDRAWINGS SCHEH 7 t 5 Meter Box WIRING DIAGRAM AUX mag ET Hu E71 AMP C B2. Isokinetic Control Console Method 5 x P R E s CLEAN AIR ENGINEERING PARTS LIST ISOKINETIC CONTROL CONSOLE PAGE 1 May 29 2008 Parent Part 0028 Type F COMPONENT DESCRIPTION QTY UM TYPE 0028F M 5 METER BOX FACE PLATE 1 0 EA A ASSEMBLY 0028D DRY GAS METER SUB ASSEMBLY 1 0 EA A M 5 METER BOX 0028C M 5 METER BOX CHASSIS ASSY 1 0 EA A 0028PMP M 5 METER BOX PUMP BOX ASSY 1 0 EA A 0028FB METER BOX FUSE BRACKET SUB 1 0 EA A ASSEMBLY Sub Part 0028C Type A M 5 Meter Box Chassis COMPONENT DESCRIPTION QTY TYPE 9512 MALE ELBOW 3 8 T 1 4 MNPT 2 0 EA BRASS 99312 METER BOX CHEST FRONT PANEL 1 0 EA 99313 METER BOX CHEST REAR PANEL 1 0 EA R 99314 METER BOX CHEST OUTER SHELL 1 0 EA 9721 RUBBER GROMMET 3 8 X 1 2 2 0 EA 9935 5 METER BOX CHEST HANDLES 20 EA 9927 METER BOX HANDLE 1 0 EA 9948 OIL FILTER JAR BRACKET 1 0 EA 9946 DRAFT GAUGE BRACKET 2 0 EA 9924 COMPRESSING SPRING 1 0 EA 00588 MANOMETER 8 DUAL INCLINE 1 0 EA 9952 CLAMP PINCH STYLE 1 0 EA 9100M QC MANOMETER MALE 5 0 EA 9100F FEMALE QC MANOMETER 4 0 EA R 9950 FINISHING PLUG 1 0 EA R 9511 INSERT 3 8 OD 1 4 ID X 1 16 4 0 EA R WALL SS 9524 RUBBER STOPPER 1 0 EA R 00028 MANOMETER ADJUSTMENT PLATES 1 0 EA R FOR METER BOX 060360 60ML NALGENE BOTTLE 1 0 EA R 99422 SERIES 50 SLIDE LATCH 4 0 EA R Isokinetic Control Console Method 5 x P R E s CLEAN AIR ENGINEERING SUMMARIZ
3. ET Principles of Operation d Connect the male thermocouple plugs into the thermocouple input bank Be sure to match the descriptions 2 3 3 Modular Sample Unit See Figure 4 1 Attach the probe onto the probe support arm 4 1 and tighten into place Connect the two Pitot lines 2 Connect the sample line onto the end or optional male fitting of the umbilical adapter 3 Connect the Amphenol cable to the green four pin socket 4 2 4 Insert the male thermocouple plug into the female socket marked filter 4 3 5 Connect the female thermocouple with the male plug labeled 4 4 5 on the impinger outlet 4 4 Figure 4 Modular Sample Unit 5 Impinger Outlet Thermocouple o 1 Probe Support 4 Impinger Arm Outlet Connection Check Valve Probe Heater 6 Impinger Outlet Sample Line 2 Umbilica Auxilary Drain Amphenol 3 Filter Oven Power Plug Connection Thermocouple Connection Connection Isokinetic Control Console Method 5 rs 7 r E x R 5 5 3 Routine Maintenance and Inspection Do NOT disassemble this product outside the specifications of this manual For internal maintenance and for the annual recalibration contact Clean Air Express 3 1 Pump Maintenance Materials needed Gast Model no 0523 V3 G21DX 1 4 HP motor Nonflammable flushing solvent A 3 8 inch socket A 3 16 inch hex key wrench Brass hammer Spark g
4. amp 212 N Woodwork Lane Palatine leanAir IL 60067 800 223 3977 E x R s S Method 5 Isokinetic Metering Console Part 0028 User Manual May 2008 Contact us at 800 223 3977 or online at http www cleanair com equipment Express main html Isokinetic Control Console Method 5 o mz Table of Contents Console Serial Number Isokinetic Control Console Method 5 s a Table of Contents R amp MER TANTEN 1 Customer FeedbaCk scrisese AA 2 EE 3 1 141 AVIA Bulk TD 3 12 Pump JEG user TERMS 3 ESCA OC etUm 3 2 Principles ot Operation 4 2 1 NN Egede 4 2 2 System 2 runke 5 23 System SE 7 2 3 1 Description OF Controls 7 2 3 2 Meter Control Console Initial Set up 9 2 3 3 Modular Sample PA ANAK AA 10 3 Routine Maintenance and Inspection 11 3 1 Pump 11 3 1 1 Pump Assembly Definitions 17 7 11 3 1 2 Preventative 12 3 1 3 Six month maintenancoce 13 3 2 Maintenance Outside the 15 3 3 Other Maintenan
5. 250 F will be displayed 2 Use the up and down buttons 3 1 to change the set point 3 Re autotune your equipment to the new set point 4 Press both the up and down controls 3 1 simultaneously until AUT appears 5 Press the select button 3 2 and hold NO will appear 6 Press the up and select buttons 3 1 3 2 simultaneously until YES appears Release 7 The controller will autotune to the new set point The display will flash TUNE 8 Autotuning is complete when the flashing stops 3 2 Select 2 3 2 Meter Control Console Initial Set up 1 Locate a level surface that can support the meter box console and pump box Adjust the manometer leveling wheel to zero the manometer 2 Connect the vacuum pump to the control console as follows a Plug the male power plug into the connection marked pump b Connect the vacuum and pressure hoses into the fitting marked vacuum and pressure The letters V and P are stamped into the fitting of each pump hose to differentiate them Be sure that the connections are snapped into place To check lightly tug on the connections they should not come apart 3 Connect the umbilical as follows a Connect the sample line into the fitting marked sample inlet b Connect the Pitot Lines into the fittings marked Pitot and Be sure to match the signs c Connect the Amphenol plug into the green 4 pin fittings Isokinetic Control Console Method 5
6. while the pump is running to flush the pump Continue to flush until it runs freely Squirt clean oil into the inlet to lubricate the vanes 7 2 Empty the exhaust jar of the muffler assembly 5 1 Reassemble jar assemblies Tapping sound from pump Insufficient clearance in The pump needs to be assembly the pump regapped See the six month maintenance section page 14 Pump motor is overheating Too much friction due to The rotor needs to be insufficient clearance regapped See the six month maintenance section An adequate substitute for a feeler gage is a piece of cellophane tape about 002 or 05 mm No oil getting to the pump for If the Take apart and reassemble lubrication pump is not properly the Oiler jar 5 2 making lubricated it can cause sure that the wick 6 1 is not damage to the pump too far in Be sure there is a Always be sure that there Sufficient amount of oil is a sufficient amount of oil Temperature can also affect in the Oiler jar the rate of lubrication Isokinetic Control Console Method 5 Troubleshooting E x P R E s Foreign matter in the pump Disconnect pump s pressure and vacuum lines from the meter console Remove pump intake filter assembly 5 1 Shoot a small amount of solvent Carbo sol into the air inlet while the pump is running to flush the pump Continue to flush until it runs freely Squirt clean oil into the inlet to lubric
7. 7 VACUUM GAUGE 30 Hg 2 U CLAMP 1 0 EA R 1 8 FITTING 0316PMSI PANEL MOUNT THERMOCOUPLE 5 0 EA R 99381 BALL VALVE SS 3 8 TUBE ENDS 1 0 EA R 0419SNV NEEDLE VALVE 3 8 T S S 1 0 EA R 9110SR PLASTIC POWER CORD STRAIN 1 0 EA R RELIEF AND NUT BLACK 0418SBU BULKHEAD 1 4 T 1 4 T S S 1 0 EA R 9507 QUICK CONNECT 3 8 Q 3 8 T 2 0 EA R UMQCSS NON VALVED 9501 SS QUICK CONNECT 1 2 Q 1 2 T 1 0 EA R UMQC NON VALVED 9518 SS QUICK CONNECT 1 4 Q 1 4 T 2 0 EA R UMQCSS NON VALVED 0028P PLUMBING TUBE ASSY FOR METER 1 0 EA A BOX Isokinetic Control Console Method 5 x P R E s CLEAN AIR ENGINEERING SUMMARIZED BOM ISOKINETIC CONTROL CONSOLE PAGE 5 Sub Part 0028F Type A M 5 Meter Box Face Plate Assembly 2 COMPONENT DESCRIPTION QTY UM TYPE 9521 PORT CONNECTOR 1 4 T 3 8 F 55 1 0 EA 9510 PORT CONNECTOR 3 8 T 1 2 F SS 1 0 EA R 9508B UNION TEE 3 8 BRASS 3 0EAR 9511 INSERT 3 8 OD 1 4 ID X 1 16 9 0 EA R WALL SS 9129 SOLID STATE RELAY CRYDOM 2 0 EA R 9103 TOGGLE SWITCH SPST 125V 15A 1 0 EA R 9110 14 GAUGE POWER CORD 7 1 0 EA R 0316FM THERMOCOUPLE PLUG MINI FEM 1 0 EA R TYPEK 91031 TOGGLE SWITCH DPST 125V 15AMP 2 0 EA R 91301 FUJI 32ND DIN TEMP CONTROLLER 3 0 EA R PXR3 RCY 1 4VA01 0316MM THERMOCOUPLE PLUG MINI MALE 1 0 EA R TYPEK 9944 THERMOCOUPLE QUICK TIP 1 0 EA R 000021 BLACK PLASTIC CAP 1 X1 2 1 0 EA R 932511 3 8 OD 1 4 ID POLYETHYLENE 4 0 FT R LOW DENSITY TUBING 99311 M5 BASE PANEL 1 0 EA
8. CONNECT 3 8 1 4 2 EA R ss 9519 PUSH LOK 1 4 3 8 HOSE 4 0 EA R FITTING BRASS 9520 STREET ELBOW 1 4 1 4 2 0 EA R BRASS 9927P PUMP HANDLE 1 0 EA F 9932BASE PUMP BOX BASE 1 0 EA R 9932FRNT PUMP BOX FRONT PANEL 1 0 EA R 9973 FAN HOUSING BRACKET 1 0 EA R 0016 PUMP BOX BOLTS 5 8 4 0 EA R 1 4 20 HEX HEAD SS 9951 BUMPER STOP 4 0 EA R 99422 SERIES 50 SLIDE LATCH 2 0 EA R Isokinetic Control Console Method 5 x P R E s CLEAN AIR ENGINEERING SUMMARIZED BOM ISOKINETIC CONTROL CONSOLE PAGE 4 Sub Part 0028F M 5 Meter Box Face Plate Assembly 1 COMPONENT DESCRIPTION QTY UM TYPE 9133K TIMER MIN SEC WITHOUT AC DC 1 0 EA R ADAPTER 9325 FLEXIBLE PVC TUBING 5 16 OD X 15 0 FT R 3 16 ID 1 16 WALL CLEAR 9418 4 PIN BOX RECEPTICLE W FLANGE 1 0 EA BLACK COLOR 9127 SOLENOID VALVE 120 VOLT 3WAY 3 0 EA R NORMALLY CLOSED W MTG BRACKET 9135 30 AMP SWITCH WITHOUT CIRCUIT 2 0 EA R BREAKER 9444DBL6 DOUBLE 6 POSITION ROTARY SWIT 1 0 EA R 0757 FLOWMETER 100 1000CC MIN 1 0 EA RATE MASTER 9141A HUBBELL PLUG FOR OVEN COM 2 0 EA R 15 AMP 115 VAC RECEPTICLE 9101 TERMINAL STRIP 2 0 EA R 9515 MALE ELBOW 1 4 T 1 8 11 0 EA R MNPTBRAS 9139 WIRING HARNESS M 5 METER BOX 1 0 EA 9133A TIMER AC DC ADAPTER KAL 1 0 EA 9931F METER BOX FACE PLATE 1 0 EA 9939N 6 PANEL MOUNT NUT 1 0 EA R 9134 15 AMP CIRCUIT BREAKER SWITCH 1 0 EA R 9136 10 AMP CIRCUIT BREAKER SWITCH 1 0 EA R 001
9. ED BOM ISOKINETIC CONTROL CONSOLE PAGE 2 Sub Part 0028D Type A Dry Gas Meter Sub Assembly COMPONENT DESCRIPTION QTY UM TYPE 0026 I G S FLOW REDUCER 1 0 EA A 9006 CALIBRATION ORIFICE F DRY GAS 1 0 EA A METER 9922 DRY GAS METER S 275 ROCKWELL 1 0 EA R 9936 SS DGM BRACKET 1 0 EA R 9503 REDUCING BUSHING 3 4 M 3 8 FM 1 0 EA R BRASS 9504 MALE RUN TEE 3 8 T 3 8 MNPT 1 0 EA R BRASS 9505 TUBE END REDUCER W NUT 3 8 T 1 0 EA R 1 8 T 932511 3 8 OD 1 4 ID POLYETHYLENE 2 0 FT R LOW DENSITY TUBING 9502A DRY GAS METER THERMOCOUPLE 1 0 EA A ELBOW 0316FM THERMOCOUPLE PLUG MINIFEM 1 0 EA TYPE K 0316MM THERMOCOUPLE PLUG MINIMALE 1 0 EA R TYPE K Sub Part 0028FB Type A Meter Box Fuse Bracket COMPONENT DESCRIPTION QTY UM TYPE 9112 CIRCUIT BREAKER 8AMP 250 VOLT 1 0 EA R 99361 ALUMINUM FUSE BRACKET F METER1 0 EA R BOX 9114 CIRCUIT BREAKER 15AMP 250 V 1 0 EA R 9113 CIRCUIT BREAKER 3AMP 250 VOLT 1 0 EA Isokinetic Control Console Method 5 x P R E s CLEAN AIR ENGINEERING SUMMARIZED BOM ISOKINETIC CONTROL CONSOLE PAGE 3 Sub Part 0028PMP Type A M 5 Meter Box Pump Box Assembly COMPONENT DESCRIPTION QTY UM TYPE 9530 HOSE 63 DD X 3 8 ID BLACK 3 0 FT R 9940 FAN METER PUMP BOX 1 0 EA R 115V 9109 18 GAUGE POWER CORD 7 1 0 EA R 9935 M5 METER BOX CHEST HANDLES 2 0 EA R 9143 2 CONDUCTOR WIRE 2 0 FT R 9932 PUMP BOX ENCLOSURE 1 0 EA R 9937 PUMP GAST METER BOX 120V 240V 1 0 EA R 9509 QUICK
10. R 9951 BUMPER STOP 4 0 EA R 9517 BARB CONNECTOR 1 4 HOSE 1 8 1 0 EA R FNPT Isokinetic Control Console Method 5 R E 5 5 Oiler Jar Cover Gasket 9948SG Felt Filters 99481 99482 Oiler Jar 9948SJ Oil Wick 9948W Vanes 9937RV Pump Oil 99370 Muffler Jar Assembly 9973L Oiler Jar Assembly 99370 Cover Gasket 9948LG Felt Filters 99481 99482 Exhaust Jar 9948LJ Isokinetic Control Console Method 5 www 202 R E 5 5 Manometer 00588 Temperature Controllers 2 nA ir 91301 ear me Amphenol Manometer Oil Connection NE 0058R 0058Y 9418 Connections 91414 Isokinetic Control Console Method 5 26 R E 5 5 Dry Gas Meter 9922 m Clear polyethylene tubing 932511 Isokinetic Control Console Method 5 2T r 7 TITTEN E x P R E s Our Guarantee Clean Air Engineering warrants products to be free from defects and workmanship for a period of one year after delivery date The sole and exclusive remedy for defective goods shall be repair or replacement of defective parts or payment price of the goods for which damages are claimed at Clean Air Engineering s option Clean Air Engineering June 2008 Isokinetic Control Console Method 5
11. Turn the main power switch 3 on 4 Turn the valve switch 3 off and the leak check switch 3 on 5 Close the coarse valve 16 6 Remove the elbow fitting on the low side of the manometer yellow gauge oil column Replace with the extra fitting that is provided with the unit DO NOT attach tubing to the new fitting its purpose is simply to vent the manometer 7 Withdraw the tubing from the upper right hand corner of the console a white flow clamp should be attached 19 8 Blow into this tube to pressurize the dry gas meter The amount of pressure is registered on the manometer yellow gauge oil column The system should be pressurized to 17 5 cm on the manometer 1 mark this point with a piece of tape The white flow clamp should be closed If no leaks are present the manometer oil will remain steady If not leaks should be located and fixed before testing Timer 4 displays minutes and seconds A backup battery is provided in case of power failure Timer will not actuate unless the timer switch is turned on Isokinetic Control Console Method 5 Principles of Operation E X R E 5 5 Temperature Controllers 7 The programmable temperature controllers regulate the temperature of the sampling probe and the filter assembly oven The controllers are set to operate at 250 degrees Fahrenheit 120 C To change this set point use the following steps see Figure 3 1 Press the select button 3 2
12. ap feeler gage or 002 0 05 mm shim stock Teflon tape Clean rags Lubricating Oil o Ambient temperatures below freezing 5 parts SAE 10 to 1 part kerosene o Ambient temperatures from 32 F 100 F 0 38 SAE 10 o Ambient temperature above 100 F 38 Replacement parts as needed 3 1 1 Pump Assembly Definitions End Plate 5 3 See Figure 5 Metal plate attached to the end of the pump motor with six indented hex washer 20 screws Fittings Plumbing that connects the inlet and outlet jars to the body of the pump Intake Filter Assembly 5 2 99370 See Figures 5 and 6 o Jar 9948SJ Figure 6 o FeltFilters 6 2 99481 99482 o Oil Wick 6 1 9948W 6 2 o Cover Gasket 9948SG Felt o Attachment Bracket Filter o Brass Elbow o Motor Oil e Muffler Assembly 5 1 9973L See Figure 5 o 9948LJ o FeltFilter 99481 99482 o Cover Gasket 9948LG o Attachment Bracket and Arm 6 1 Oil Wick Isokinetic Control Console Method 5 7 NOT E R E 5 5 Figure 5 5 1 Muffler Assembly Pump Motor 5 2 Intake Filter Assembly Oiler Jar 5 3 End Plate e Body 7 3 See Figure 6 Metal plate that is attached to the front of the motor with two 20 socket cap screws Rotor 7 1 See Figure 6 Rotates and contains the four vanes Vane 7 2 9937RV See Figure 6 Moving pieces of molded fiber This is conjunction with the rotor causes the vac
13. ate the vanes 6 2 Empty the exhaust jar of the muffler assembly 5 1 Reassemble The pump head may have to be removed in order to dispose of foreign matter Manometer cannot be zeroed Not enough oil in the Add more oil to the manometer manometer as needed 0058R 0058Y Manometer rises instead of Pressure and vacuum Check the hoses Switch if falling when pump is turned on hoses are most likely necessary switched Heated probe or filter does not Bad connection Check all connections warm Bad relay Replace relay 9129 Isokinetic Control Console Method 5 5 amp a 5 5 E E 3155 gas 4 YN YN 26 06 EE YN assy sad Aol 3216 ET pum MIN c 914 DILVWSHOS ONIANA wu aa NYYOYIG ONISAN Td YILIW 5 00 1 SWaokadv 37105302 YALINW 22009 AMANG ins bar N lz S dus SO ka pus BIG xog dANd Gage paa gt FONVS KANIYA 0 0 i At 4 ALAA
14. ce 1 15 Troubleshooting mE Ec 16 Isokinetic Control Console Method 5 ona x P R E s IMPORTANT BEFORE YOU BEGIN READ THIS A READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE USING THIS SYSTEM To Avoid Accidents v Keep your work area clean and well lit v Keep bystanders away v Exercise common sense Electrical Safety v Do not operate in combustible environments v DO NOT operate these products when wet or in water v ALWAYS be sure that the components of this system are running with the correct voltage 120V v Never remove a grounding prong or modify a plug v Do not abuse the power cord or plug Personal Safety v The parts of this system are heated in excess of 500 degrees Fahrenheit Use caution when handling your equipment during and after a test v Stay alert and watch what you are doing Y Dress appropriately Wear the appropriate personal safety devices Equipment Maintenance Y Clean Air Express can not ensure that our Method 5 meter is compatible with any other systems See http www cleanair com or call 800 223 3977 for more information v Maintenance and repairs should be performed by one of Clean Air Express s trained technicians Isokinetic Control Console Method 5 Customer Feedback E x P R E s Customer Feedback Clean Air Engineering takes pride in our quality products and services We strive to
15. ch the curve of the rotor Gapping the Rotor o Place the body over the rotor Tighten the screws in such way that the body can still be moved with light taps from brass hammer o Adjust the gap by placing a 002 0 05mm shim between the rotor and body Tighten the screws o Turn the rotor to be sure the clearance is uniform Make adjustments if necessary Reassembly o Putthe lightly oiled body back on the pump motor and tighten o Inspect and check inlet and outlet fittings Replace Teflon tape as needed o Clean or replace the oil wick 6 1 and felt filter 6 2 Be sure the wick is bent slightly in the direction of the arrow on the top of the oiler jar at 3 8 of an inch o Check and replace the cover gasket 9948SG of the Oiler jar as needed o Fill the jar to the oil line with the correct oil To ensure a good seal put a layer of Teflon tape around the threads on the jar Put the intake filter assembly jar back on the pump o Empty the muffler filter assembly Clean or replace the muffler filter 99481 99482 and jar 9948LJ if necessary The filter should be replaced after one year of weekly use o Check and replace the muffler assembly jar cover gasket as needed 9948L G o Letthe pump run to allow any traces of flushing solvent to evaporate o Clean the muffler jar assembly To ensure a good seal put a layer of Teflon tape around the threads on the jar o Replace the pump cover Isokinetic Control Consol
16. e Method 5 7 NT E R E 5 5 3 2 Maintenance Outside the Pump General cleanliness will extend the life of your equipment The outside of the console can be safely cleaned with window cleaner or soapy water Always check the inside for oil leaks tubing damage and wire damage It is also recommended that the unit is returned to CleanAir Express annually for recalibration and maintenance All tubing will be replaced 932511 a full electrical test will be performed and the system will be recalibrated Yearly recalibration is necessary 3 3 Other Maintenance Issues For any other maintenance issues concerns or questions please contact Clean Air Express at 800 223 3977 Clean Air Express can also be reached by mail at 212 Woodwork Lane Palatine IL 60067 by fax at 847 991 8924 or on the web at http www cleanair com equipment Express main html Isokinetic Control Console Method 5 Troubleshooting R E 5 5 4 Troubleshooting Pump motor fails to start or Tripped circuit breaker Reset circuit breaker slows down when load is Bad wires Examine wires present Incorrect power Check for correct voltage Unit is too cold Bring unit to room temp Pump stalls Pump is dirty or foreign Disconnect pump s pressure matter has entered the and vacuum lines from the pump meter console Remove pump intake filter assembly 5 2 Shoot a small amount of solvent Carbo sol into the air inlet
17. er 18 IGS 9 Power Connections Connection 2 Manometer 11 Vacuum leveling wheel 20 Power Cord Pump Connections KA ow 12 Pitot Tube 13 Umbilical Connections Connection 10 Umbilical Amphenol Connections Isokinetic Control Console Method 5 6 I Principles of Operation R E 5 5 2 3 System Operation 2 3 1 Description of Controls AC Power Connections 9 transfer power to the vacuum pump and an auxiliary device The vacuum pump must be connected to the pump outlet Amphenol Connection 10 provides power to the probe heater and filter oven Coarse Control Adjustment 16 opens and closes the sample line Dry Gas Meter 5 displays the volume of gas flowing through the internal diaphragm pump one revolution equal 0 1 cubic feet of gas The index indicator accumulates and displays the total gas volume see Figure 2 Fine Control Adjustment 15 When coarse control is open this is used to fine tune the gas flow rate through the system Turn clockwise 08 ONEREV 1Cu FT 02 to open IGS Collection 18 sample collection system designed to simultaneously collect representative gas sample for the analysis of O2 CO2 and CO Connect the sample collection bag to the 14 fitting beneath the flow meter and ue to the desired setting The IGS system works off the orifice exhaust Some agencies may not allow this type of sampling for com
18. ic Acid Mist Method 13 Fluoride Method 17 In stack particulate Method 23 Dioxin and Furan Method 26 Halides and Halogens Method 29 Metals Emissions Isokinetic Control Console Method 5 Principles of Operation E x P R E 5 2 2 System Components Requires 120 V See Figure 1 on the following page Dual 8 incline manometer Manometer leveling wheel 3 Circuit breaker switches Timer 6 6 channel temperature indicator 7 Temperature controllers for probe and filter 8 Thermocouple plug input bank 9 5 Dry gas meter index Power connections 10 Umbilical Amphenol connection 12 i pe 11 Vacuum pump connections Pitot tube connections 13 Umbilical connection 14 Vacuum gauge 16 Coarse flow adjustment knob Power connections 17 IGS rotometer 18 19 Flow clamp positive leak check tube J 15 Fine flow adjustment knob IGS sample connection 20 Power cord Isokinetic Control Console Method 5 Ce Ar Principles of Operation R E 5 5 1 Dual Incline Manometer 19 Flow Clamp 3 Switches 4 Timer 6 6 Channel Temp Indicator 5 Dry Gas Meter Index 7 Temperature 15 Fine Controllers Control Adjustment 14 16 Coarse Vacuum Control Gauge Adjustment Thermocouple 17 IGS Inputs Rotomet
19. personal injury or damage to the pump itself 1 3 Electrical Shock The system is powered by a standard 120 VAC line meaning potentially fatal shocks are possible It is no more dangerous than many household appliances in this regard however care must be taken to avoid shock Before performing any maintenance or removing the back cover turn off and unplug the console from the 120 VAC line Be sure that the correct voltage is used in order to help prevent accidents Isokinetic Control Console Method 5 Principles of Operation E X R E 5 5 2 Principles of Operation The Isokinetic Control Console is designed to sample a gas stream The system should be set up to extract the sample at the same rate that the gas flows from the stack The gases are extracted through a probe and then through a heated filter chamber where a majority of the particulate is removed The hot gases then travel through a series of chilled impingers where condensates are removed and the gases are cooled and dried before pumping This console is suitable for EPA methods 4 5 51 6 8 8A 13 17 23 26 29 and many more with proper accessories Access to the wiring and other components of the control box is achieved by removing the back panel of the unit Access to the pump box is gained by removing the front panel 2 1 Gases Analyzed e Method 4 Water vapor content Method 5 Particulate matter e Method 6 Sulfur Dioxide e Method 8 Sulfur
20. pliance testing Temperature Indicator 6 displays the temperature of each point on the selector switch Manometer 1 indicates the DP red oil and DH yellow oil The DP gauge measures the differential stack pressure from O to 8 of water via the S Type Pitot tube from the probe The DH gauge measures the pressure drop across the outlet side of the dry gas meter Pitot Line Connections 12 the connections to the positive and negative side of the Pitot tube lines in the umbilical cable assembly Be certain to match the sample probe positive and negative with the meter console s positive and negative Isokinetic Control Console Method 5 Principles of Operation E x R E 5 5 Switches 3 o Power Switch The 15 Amp double pole circuit breaker switch provides power to the control unit o Pump Switch the 10 Amp circuit breaker switch provides power to the vacuum pump o Valve Switch Activates the solenoid that bypasses the DH column on the incline manometer Useful for zeroing DH while running the pump At high flow rates the switch will help prevent oil from discharging from the manometer o Leak Check Switch Activates solenoid that makes it possible to leak check the positive side of the meter console To perform a leak check do the following 1 Unplug the unit Remove rear door 2 Slide copper elbow off of the orifice and plug orifice with the rubber stopper supplied 3 Plug the unit in
21. provide the highest quality products and services in the industry We realize the importance of end user input in the continual improvement of our products and services Customer feedback is of paramount importance We encourage your feedback with any suggestions or problems that can help us improve our performance A customer feedback form is available online at http www cleanair com About feedback html To emphasize our commitment to quality products and complete customer satisfaction Clean Air Engineering s manufacturing division CAE Express offers what we feel is the best and most comprehensive warranty in the environmental industry Isokinetic Control Console Method 5 o W r mm E x P R E 5 5 1 Safety Safety should always be considered first and proper safety procedures should be followed 1 1 Weight and Bulk The Isokinetic Control Console weighs approximately 70 pounds 32 kg and has dimensions of 17 5 x 12 x 27 445mm x 305mm x 686mm It includes handles to make the system easier to lift and carry However remember to use good lifting technique in order to avoid injury Two persons should be utilized if necessary Do not attempt to carry the weight yourself if you do not feel comfortable doing so 1 2 Pump Cleaning r flushing the pump a nonflammable flushing solvent should be used an Do NOT use kerosene gasoline or any other flammable liquid to pump Harmful vapors can result in
22. uum action of the pump Figure 7 3 1 2 Preventative Maintenance Periodic checks of the oil and muffler jars are mandatory When air testing is complete the pump should be flushed with a nonflammable flushing solvent Use the following procedure e Take apart and flush the pump o Remove the pump cover o Remove the oiler jar 5 2 o Remove the felt filter and oil wick PA 7 2 Vanes o Connect the outlet hose to a KA 7 3 Body 7 1 Rptor waste container Isokinetic Control Console Method 5 7 NOT E x R 5 5 o While the pump is running squirt flushing solvent into the hole the inlet jars cap o Let the pump run for 1 3 minutes or until 1 inch 25 mm of dirty flushing solvent accumulates in the muffler jar 5 1 Lubrication o Squirt a small amount of clean pump oil into the inlet opening after the cleaning Run the pump to circulate the new oil and allow any remaining solvent to evaporate Reassembly o Clean the oil wick and felt filter Be sure the wick is bent slightly in the direction of the arrow on the top of the oiler jar o Check and replace the cover gasket 9948SG of the Oiler jar as needed o Fill the jar to the oil line with the correct oil To ensure a good seal put a layer of Teflon tape around the threads on the jar Put the intake filter assembly jar back on the pump o Empty and clean the muffler assembly jar o Check and replace the muffler assembly jar co
23. ver gasket as needed 9948LG o Clean or replace the muffler filter 99481 99482 and jar 9948LJ o To ensure good seal put layer of Teflon tape around the threads on the jar o Replace the pump cover 3 1 3 Six month maintenance e Take apart and flush the pump o Remove the pump cover o Remove the oiler jar 5 2 o Remove the felt filter and oil wick o Remove the muffler jar 5 1 Take out the felt filter for cleaning Replace the jar Clean the felt filter with flushing solvent and set aside o Connect the outlet hose to waste container Tip the pump on its side o While the pump is running squirt flushing solvent into the hole in the inlet jars cap o Let the pump run for 1 3 minutes or until 1 inch 25 mm of dirty flushing solvent accumulates in the muffler jar Empty and clean the muffler jar o Remove the end plate 5 3 Isokinetic Control Console Method 5 w air E x P R E 5 5 Cleaning o Clean the end plate o Take off the pump body 7 3 and clean o Examine the parts for wear replace as needed o Slide the vanes 7 2 out of the rotor 7 1 Clean and replace if needed It is recommended that if one vane needs a replacement that they should all be replaced Lubrication o When the parts are all clean or replace a thin sheet of oil is placed before reassembly o Reinsert the vanes Be sure they are properly positioned The curved edge of the vane will be placed to mat
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