Micro-GASS™
Contents
1. User Manual Micro GASS Gas Analysis Samping System p PURE INC TOSIN GR Kia ore 8 Executive Drive Toms River N J 08755 Phone 800 337 3762 732 244 0010 Fax 732 244 8140 e mail info permapure com Web Site www permapure com PERMA PURE TABLE OF CONTENTS 1 Introduction 2 Micro GASS Components 2 1 Heated Filter 2 2 Perma Pure Dryer 2 3 Pump 2 4 Dry Sample as Purge Gas 2 5 Temperature Control a System Power b Pump Power c Temperature Control d Flow Control 3 Installation 3 1 Mounting 3 2 Electrical Connections 3 3 Plumbing a Sample Connection b Purge Connection c Sample Exhaust d Calibration Gas Connection 4 Start Up Shutdown Procedures 4 1 Start Up Procedure 4 2 Shutdown Procedure 5 Maintenance 5 1 Flow Rate 5 2 Coalescing Filter Element 5 3 Dryer Element Replacement a Element Removal b Element Installation APPENDIX A Specifications APPENDIX B Micro GASS System Spare Parts APPENDIX C CAL 3300 Temperature Controller Configuration Micro GASS User Manual 2 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 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 prov2. 9 1 vi A Ig A3SSV J IANDODWIIHI AdAL A avga 3119433 ALS ANNDAD T13NVd SyA NAD ONIA33 S NOTAN TALYONAAOI 8 S HILIMS EH 530 HILIMS Ep tH BE PIA ad d dW d BH LIA JOLIINNOI JIALS X3JIOW SANTINI N 3J9IldS LINE JOLJINNOI 3AVI amp 3 VW34 91 JOLIINNOI LAVING 3 1V433 JOLJINNOI 13 1108 JIYW GN 39341 AULOANNOO ANJA MU123NND9 3dAL JADA SI E gt tt Le teh Adee DJ AISIAJI o pron S3ITIJS Ling G3aav a opt TIV13A ONISIM 331713 QAMAY v oss was arva qa1238 NOISIAJY DNIENL ANISHS LV3H Ad 52V 18 T ddd DAVSI SI DONISIA TIV Q3lV INSNI NU 1331 delV Sdel SLIHM e amp 3HlIL HOv43 UL NUWWUY Ady Sal 129 JAT SIAIM 52V18 ANY daa JHL dOa Ld39X3 213 MSS WOas OV A3JI0AINOI SI MOVISA OV G3HOLIAS SI JONVAD JONVISNI eid JaAIM HOVE 30 NOILONMI SSLVNDISST SU 109 SATA JAIM ZOOT AdAL DAV 8T Ave MIE A18 JAA ve c LIA 034 dWNd 3JIAWYS T t IMD SNIVH Sa SYN SV JOVLTOA IWYS INIT G31V3H OL xvn vot Nag Vl SIMOd INVISNUO 3Sfid 3NIINI NAD 5 Pu ayy ZH 08 09 OvA022 02I Ng n JIMBDA SNIVW 940 1 O HILIMS IV TA TE d AVT38 ALVLS ANOS 6 4718 E A3LVIH 33A 6 CES C JYNDIS 30A6 Dar 5 A9 L E3 AVTIY 3JIVIS QOS v2 34189 E3 M3IV3H 31317113 HE 034 HOT S32V ld 8 ONIG AL NIJHS LY3H Ald AW 1 v 1 JVASIT M02 JILVIH AJLI CINEMA oce myin 9VASTI A02 JILVIH asl M4 9021 ddyl JILVIH ONILV 10538 4
3. controller Dry sample gas returns to the system at ambient conditions cooling the outlet end of the dryer As the purge gas passes through the dryer it is heated to the desired sample inlet temperature creating a temperature gradient along the dryer This gradient allows for both rapid water removal and decreased final dew point a System Power The system power switch controls power to the temperature controller and the filter dryer and heated line heaters System power is on a 2 Amp fuse located on the front panel b Pump Power The pump power is wired through the temperature controller In order for the pump to engage the system must be heated to 40 C and the pump power switch must be in the ON position Sample flow is controlled by the flow meter c Temperature Control The dryer heaters are controlled by a PID electronic temperature controller Set point adjustment is made by pressing the key and either the up arrow key or the down arrow key simultaneously When the desired temperature is displayed release both keys The allowed set point range and the pump cut off temperature are preset by Perma Pure LLC Refer to APPENDIX C for the temperature controller configuration or to the manual included with the documentation package d Flow Control System flow is measured after the analyzer in the dry sample at atmospheric pressure and temperature The flow meter should be adjusted to provide a flow of between 0
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5. 5 to 1 0 Ipm depending on the water content of the sample Lower flow rates result in dryer samples T FLOWMETER lt gt lt a NEEDLE e GAS O VALVE INLET ELECTRO CHEMICAL SENSOR SAMPLE O gt INLET MD DRYER FILTER Y TEMPERATURE COMPRESSE AIR p di m EXHAUST E P doc F PRESSURE SOLENOID REGULATOR VALVE EDUC TOR Oo Figure 2 Micro GASS User Manual 7 3 Installation 3 1 Mounting The Micro GASS enclosure is rated NEMA 4 but the system is intended for indoor installation For mounting choose a location to avoid exposure to direct sunlight as it may raise the internal temperature above the operating limits nor should the system be subjected to extreme cold temperatures lt 10 C Vertical orientation of the system is required for proper operation of the flow meter A set of four mounting feet are supplied for mounting the system on 12 4 centers 3 2 Electrical Connections Standard 110VAC receptacle is provided For 220 volt systems a pigtail cord is provided for
6. ELLER 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 Micro GASS User Manual 3 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 regulate 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
7. 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 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 information 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 publications 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 Trademarks Nafion and Teflon are registered trademarks of EI DuPont de Nemours Copyright 1996 2005 Perma Pure LLC All Rights Reserved Micro GASS User Manual 1 Introduction The Perma Pure Micro GASS is designed to reduce the h
8. at source heat the boot evenly until the sleeve shrinks into place Allow extra heating time to ensure that the adhesive melts and flows for proper adhesion 4 Keep the heat source 1 away from the heated line Keep the heat source moving do not concentrate the heat in one place If charring or burning occurs stop heating immediately Micro GASS User Manual 8 b Purge Connections 1 4 Bulkhead compression fittings located on the side of the enclosure are for the purge connections Connect the Dry Sample Outlet port on the Micro GASS enclosure to the inlet port of the sensor Connect the sensor exhaust outlet back to the Dry Sample Return on the Micro GASS No heated line is required for these connections unless the lines will be exposed to cool temperatures lt 10 C c Sample Exhaust The sample exhaust can either vent freely or can be piped away from the Micro GASS This gas is wet and condensation in the line is likely d Calibration Gas Connection 1 4 Bulkhead compression fitting is located on the enclosure bottom The port must be plugged when not in use A cap for this purpose is provided 4 Start Up Shutdown Procedures 41 StartUp Once all sample purge and electrical connections have been made the system is ready for operation Start with the sample flowmeter closed and system and pump power switches in the OFF position 1 Turn System Power switch to the ON positi
9. connection to the appropriate 220 volt plug not provided For connection to the heated line two female and one male bullet connectors for neutral line and ground connections respectively are provided An in line fuse holder is provided for a fuse not to exceed 10 amps See wiring diagram on page 16 3 3 Plumbing a Sample Connections To prevent condensation of the sample gas a heated line may be required The Micro GASS is Supplied HEATED SAMPLE with a heat shrink sealing heated line fitting sleeve or Ni MINI GASS boot Connect the boot to the enclosure with the SLEEVE fitting hub inside the enclosure and the o ring seal on SEAL U om the outside as shown in Figure 3 tighten to secure 6 ae The heated sample line passes through the sleeve HPN E i into the enclosure Remove the insulation from the heated line and connect the sample line to the 14 Figure 3 compression fitting at the inlet to the filter body Heat shrink the boot sleeve to the heated line 1 Before heat shrinking the boot connect the sample line to the filter and ensure that it is in its final and ultimate position The sleeve is adhesive lined and the heated line cannot be removed after shrinking 2 Provide adeguate ventilation Fumes from burning can cause eye skin nose and throat irritation 3 Using a low intensity heat source such as a hot air heat gun or infrared he
10. ement package of 5 elements UG FE GASS Module with no drain on filter UG FE GASS Module with automatic drain on filter UG 1212 PUMP Vacuum pump for sample and purge Teflon coated UG FM Flow meter sample gas 0 1 5 L min UG HL Heated line assembly charge UG HL 10 Heated line Micro GASS User Manual 13 APPENDIX C CAL 3300 Temperature Controller Configuration 1 For all Micro GASS systems with the CAL3300 Temperature controller perform the following setup procedures a Power Up Apply power to the system and wait for the controller to perform its self test routine The display will then be alternately flashing nonE and inPt Input sensor type Press and hold key Press A key repeatedly to select the tc J option for J type thermocouple Release both keys Input unit type Press the A key once The display will then be alternately flashing unit and nonE Press and hold the key Press A key repeatedly to select the C unit Release both keys Input setpoint 1 type Press the A key once The display will then be alternately flashing SP1 d and nonE Press and hold the key Press A key once to select the output device SSd Release both keys Input the maximum temperature setpoint Press and hold the V key until LEVL appears Press and hold the key Press the V key to move to level 2 Release the two keys Press and hold the A key until hi SC appears Press and ho
11. es 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 responsibility 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 S
12. ld the key Press the V key until 65 appears Release the two keys Input the minimum temperature setpoint Press the A key once Lo SC appears Press and hold the key Press the A key until 45 appears Release the two keys 2 Configure the low temperature alarm a Configure SP2 relay as alarm Press and hold A and V keys simultaneously for 3 seconds to enter the program mode Release the two keys The display will then be alternately flashing tunE and oFF Press the V key once The display will then be alternately flashing LEVL and 1 Press and hold the key Press the A key once to move to level 2 Release the two keys Press and hold the A key until SP2 A appears Press and hold the key Press the A key until the display reads FS Lo Release the two keys The display will then be alternately flashing SP2 A and FS Lo Save configuration into memory Press and hold A and V keys simultaneously for 3 seconds The display will then be alternately flashing the process temperature and PArK indicating that no setpoint temperature has been entered Micro GASS User Manual 14 3 Setthe control setpoint and auto tune the controller a Input the control setpoint temperature Press and hold the key Hold the A key until the display goes from O to 55 Auto tune the controller Press and hold A and V keys simultaneously for 3 seconds to enter the program mode Release the two ke
13. on This supplies power to the heated line the filter dryer heaters and the temperature controller Allow 10 15 seconds for the system to start up The temperature controller will display the dryer temperature Adjust dryer set point temperature to 35 C or 10 C above the maximum anticipated dewpoint temperature whichever is higher Refer to section 2 5 and Appendix C for the temperature controller instructions Switch Pump Power switch to the ON position To prevent wet sample gas from entering the unheated dryer the sample pump is powered via the temperature controller A relay in the temperature controller remains open until the system reaches 40 C The system requires 10 15 minutes before the operating temperature is reached and the pump then becomes energized There will be a temperature spike associated with the start of sample flow This is acceptable provided the temperature stabilizes within a few minutes Open the flow meter adjust the flow to the desired rate 0 5 to 1 lpm Lower flows result in dryer gas samples Samples with a dewpoint of greater than 35 C should be run at no more than 0 5 lpm 4 2 Shutdown Do not permit wet gases to condense in the Nafion dryer Follow this procedure to purge wet sample gas from the system before shutting down 1 With system and pump power switches in the ON position remove the filter cap from the bottom of the enclosure Check condition of the filter element All
14. ow the pump to run for at least two minutes Turn the power switches to the OFF position and replace the filter cap Micro GASS User Manual 9 5 Maintenance 5 1 Flow Rate The system should be checked daily for proper flow rate 5 2 Coalescing Filter Element The filter element should be checked regularly to ensure that the element is in good condition If the filter is dirty or causing a flow restriction replace the filter element 1 Remove the filter cap and element 2 Inspect the o ring for damage and replace if necessary 3 Fit new filter element to raised portion of the filter cap and replace filter cap 4 Tighten until snug do not overtighten 5 3 Dryer Element Replacement Under the operating conditions specified the Nafion dryer element could last for several years If element becomes wet clogged or dirty it may require replacement a Element Removal Disconnect the system power source Remove four 4 screws from filter housing flange Open cover and lift control panel to gain access to the system components Remove two 2 nuts from the sample inlet tee fitting Rotate the tee fitting counterclockwise and remove it from the heater sleeve While holding the filter heater sleeve from the inside of the enclosure remove the Kynar filter housing from the outside by turning counterclockwise until it can be pulled out Remove nut and union from the outlet end of the dryer 8 From the outlet end carefully
15. push the element into the housing until the end of the element clears the o ring l Remove the o ring and replace with new o ring 10 Grab element from filter end of the dryer and gently pull until element is free of the housing 11 Remove o ring from housing with the element Or ha U NT N Micro GASS User Manual 10 b Element Installation 1 zoo M 11 12 13 Always wear gloves when handling the element to prevent skin oils from contaminating membrane surface Remove nut from tee fitting at the outlet end of the dryer Remove bend clips from dryer housing tube and straighten tube to allow element to slip in easily Slip two new o rings onto one end of the new element Install other end of the element into the filter side of the dryer housing by gently pushing element into the housing Be careful not to kink tubing Allow about 4 to protrude from end of the tee fitting Install third o ring seal around end of the element and gently push it into the recess of the tee fitting Install union and hand tighten followed by a va turn with a 5 8 wrench Install two 2 nuts on tee fitting and tighten by hand Replace tube bend clips Install filter housing by holding filter heater sleeve from the inside of the enclosure and lining up the union threads with the element and tee fitting end of the dryer Some flexing of the dryer heater sleeve may be necessary to line up the threads Do not cross thread the union When
16. the threads are lined up properly virtually no resistance will be felt until union contacts the o ring seal Turn the filter housing until tight and the purge port is visible through the hole in the heater sleeve Apply new Teflon tape to the tee fitting and thread it into the purge port Do not cross thread the port Install two 2 nuts on the tee fitting and tighten by hand Install four 4 screw in the mounting flange Micro GASS User Manual 11 APPENDIX A Specifications TEMPERATURE PRESSURE SAMPLE FLOW RATE ELECTRICAL REQUIREMENTS Watts GAS INLET OUTLET FITTINGS OPERATING ENVIRONMENT NAFION TUBE INNER DIAMETER WATER VAPOR CONTENT by SAMPLE DEW POINT WATER VAPOR CONTENT by PERCENT SAMPLE GAS RELATIVE HUMIDITY O 5 Ipm SOLUABLE GAS REMOVAL RATES 65 1509 Max 30 PSIG Max 5 in Hg Min 0 5 to 1 0 LPM 110VAC 0 6A 60 Watts220VAC 0 3A 60 4 TUBECompression Fittings 10 C to 40 C AmbientO to 95 R H 0 060 10 55 130 F Max 15 by Volume Max INLET Dew Point OUTLET R H 20 C 35 C 27 40 C 29 45 C 33 GAS LOSS NO 0 NO2 0 SO2 0 CO 0 CO2 0 H2S 0 HCI 0 Micro GASS User Manual 12 APPENDIX B Micro GASS System Spare Parts Part Description MD 070 24E F Nafion dryer 0 070 O D 24 length replacement element only UM DA 070 24F Dryer assembly includes dryer heater insulation thermocouple connectors UM F Micro GASS filter assembly UG FE Micro GASS filter el
17. triction in the flow 2 3 Pump The system pump draws sample from the source through the dryer and analyzer and recirculates the sample through the purge side of the dryer under vacuum Pump has capacity up to 1 lpm and is made from materials highly resistant to chemical attack Pump power is controlled by the temperature controller in order to prevent drawing the wet sample into the system when the system is cold 2 4 Dry Sample as Purge Gas Dry sample is piped to the sensor and back to the Micro GASS for use as the purge gas It is expanded through a needle valve in the flow meter and placed under slight vacuum The vacuum increases the difference in partial water vapor pressure between the sample and purge gas and enhances the drying efficiency of the system The purge flow enters the dryer at the sample outlet end of the dryer and performs two functions First it provides a medium for the water vapor to be carried away Second the cool gas creates temperature gradient along the length of the dryer The purge gas is heated as it traverses the heated section of the dryer reaching its maximum temperature at the purge exhaust port The dryer temperature is monitored and controlled through the purge exhaust Micro GASS User Manual 6 2 5 Temperature Control The operating range of the Micro GASS is from 45 C to 65 C To maintain the proper operating temperature the purge gas exhaust is monitored and controlled by the electronic temperature
18. umidity of gas samples to 20 to 80 RH the optimal humidity for Electrochemical Sensors The Micro GASS system will remove particulate matter and water vapor from a gas stream without removing the compounds being monitored The system consists of a heated particulate filter a partially heated Perma Pure Nafion gas dryer a sample pump and controls for temperature and sample flow assembled in a 12 x 12 x 7 NEMA3R enclosure 1 _ lt N i Micro GASS Gas Analysis Sampling System O PERMA PURE INC T TOMS RIVER NJ 08754 PURGE AIR POWER Figure 1 2 Micro GASS Components 2 1 Heated Filter The first step in conditioning the sample is filtering out particulate The filter is a disposable 1micron encapsulated micro fiber filter element housed in a Kynar filter body for corrosion resistance Surrounding the filter body is a heated aluminum shell The filter is thermostatically controlled at 95 C to prevent aerosols from forming in the sample stream Micro GASS User Manual 5 2 2 Perma Pure Dryer A Nafion tube is housed inside a dryer shell As wet compressed air flows through the tube water vapor is absorbed through the membrane and carried off by a counter c
19. urrent purge air flow at a reduced pressure The driving force for this process is the difference in partial vapor pressure of water between the product and purge gas flows In this system a portion of the dried air is expanded and used as the purge gas The sample inlet portion of the dryer is heated to provide rapid removal of the water and to prevent condensation Nafion transfers water vapor with a higher efficiency at elevated temperatures Yet not all of the water of hydration molecules can be removed and the Nafion always retains some water The amount of water retained is greater at higher temperatures Since water is removed only to the extent that the membrane is dry the dryer should be kept at the lowest temperature possible without causing the sample to condense As the sample dew point constantly drops as it travels through the dryer a temperature gradient that is just above the sample dew point is the most desirable This is achieved by heating only the sample inlet where the sample dew point is highest and cooling the sample outlet with purge air where the sample dew point is the lowest Efficiency throughout the dryer is achieved by using this process If liquid water is introduced into the dryer efficiency will decline and the dryer could fail to perform altogether The Nafion tube when wet will elongate approximately 10 over its dry length This elongation will cause the element to kink inside the dryer housing creating a res
20. ys The display will then be alternately flashing tunE and OFF Press and hold the key Press the A key until At SP appears Release the two keys Press and hold A and V keys simultaneously for 3 seconds to exit the program mode The display will then be alternately flashing tunE At SP and the actual process temperature Allow the controller time to auto tune When tuning is complete the display will show only the actual process temperature This process may take up to an hour 4 Enable low temperature alarm a Input the alarm setpoint Press and hold the V key until LEVL appears Press and hold the key Press the V key to move to level 1 Release the two keys Press and hold the A key until Set 2 appears Press and hold the key Press the A key until 40 appears Release the two keys This alarm will control the sample pump so that it will automatically turn off at any time that the temperature is below 40 C Micro GASS User Manual 15 9 L0 pO cLcL ON A 66 S l Adsl JJIAWNN ONIMVAC 3ZIS ILVC 439 40r 2 1 7 INVeHOVIGO ONIHIM SSVO OMSMOIIN V INSNY 49 17 ILVA A8 TIADNddy NNIILOVAJ d S00 7 31V A8 NAVA 3193s 39N333 433 TWNI23G VSGZ80 PN YANG SWOL JAIHAO 3AILLOOS3X3 8 JALVSOJSONNI JANd VlwNedd TILON SV 1d39X3 S3ONV3H IDOL TINLS ANNDAD T3NVd S Nam av3g 3119433 JI VIOILNOI JINLVAIAWNIL 00EE 199 aamod ov ING 318vN3 a3 Dd dWnd TALNOD ASS ITA e
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