5210 Classic Cooler Manual
Contents
1. musco enc ee S 9 Z 8 T JO TIYANSIALSAS ITSNIMONNPSN s 0350 NIHA SINIWAINOI 9176 5310 34 C 2 NI L 1 N W J V V NC m 37DHA NI ONIaQ12V J0NVW AO LNG 31 96 325 38 4 153 304 1 o D SENSE CASN 38 LON TWWHS 1 SIHL SNOISN3WIG ONIINNOW INNOW QS AIDS 0380 36 OL SI ONY AIVA AINDILIOND 3 ldWAVS C3LON SY NIMGTVE 14482530 1 Adv NOILYWAD INI SNIVIND SIHL NIMC 1Va NOLLYWAO ANI 20 61 90 701 ava 3189089 013130395 ISIMYIHLO 55319 011918253 114142530 A10 W311 S00 NISE CLINIVAA M LNAOW NIYA 3941 CP00 NISE 138094 LNAOW 3094 TIYWS NOI 19142534 ava naaa T JO TIVANSWALSAS ITSNIMONNPSN s 0350 NIHA SINIWAINOI AGLIWITIW 5310830 CO NIMOTYA INNON TIYA 91 6 S3HONI NI tle 11125 325 NI INIANLIVINNYW AO 1 3 SNOISN3WI 21530 01530 05 SY 350 38 10 TWHS LN3WN200 SIHL 112 72 RE a d S 0 NOU 1495302. 14 Sample Conditioning Systems w Classic Model 5210 Thermo Electric Cooler 14 Appendix Bs Cooler Drawings RR RR ERR ER A SEE RR E RR REA CE Ene RR No 16 Bi Model 5210 dimensional ecce BANNA 16 B2 Controller Wiring diagram ba a Ma MR Error Bookmark not defined Interconnect wiring 16 B4 Contact states pr E PE GAAN 16 B5 Relay board wiring diagram naaa NA Error Bookmark not defined Appendix Sample Conditioning System 65 17 Flow schernatic i REPRE n IHE DAA 17 C2 4S 9PA Piping and dimensional drawing 17 C3 Rack mounting plates dimensional drawing 17 Wall mounting plates dimensional 17 Appendix E Perma Pure Sample Pump Maintenance Instructions 18 Appendix G Warranty and 21 Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA PAN Page 3 of 21 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 e
3. Sample Conditioning Systems w Classic Model 5210 Thermo Electric Cooler Part No Description 3KFA 001 Filter Assembly Sample in line 2 micron 3FHG 001 Filter Bowl Glass 3FEC 002 Filter Element Ceramic 2 micron 3KPB 003 Peristaltic Pump Dual Kit 115V Complete w Enclosure 2PBM 003 Peristaltic Pump Head Only Standard 2PBM 001 Peristaltic Pump Motor Only 115V AC 60 Hz 2PBT 002PK Peristaltic Pump Tubing Norprene Size 17 10 feet 3KPA 001 Sample Pump Assembly Single Head w Check Valve 115V 2PAS 008 Sample Pump Single Head Mini Dia Vac 115V bare 2PAM 001 Sample Pump Repair Kit Single 3CWS 001 Water Slip Sensor Hastelloy SS Pins 3KCW 002 Water Slip Sensor SS Pins w Holder Assembly Recommended Spares Consumables Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 A HALMA COMPANY Page 15 of 21 Appendix A Installation of Peristaltic Pum NOTE Perma Pure peristaltic pumps are rated for a maximum pressure of 20 psi If supplied loading key is not available use a flat head screwdriver Single pump head loading a Separate the end bells the pump head halves Hold the end bell containing the rotor as shown with the tubing retainer grooves facing down b Place tubing in the right groove and against the first two rollers Hold tubing with thumb Near groove insert smaller prong of loading key between the top of the rotor and tubing Push key in as far as possibl
4. TVIYILYN AAV13IlddDdd NOILYWAD INI SNIVINOD LN3WNIOG SIHL NIMC 1Va NOLLYWAO ANI 20 61 90 ava 3189089 013130395 ISIMYIHLO 55319 011918253 01001 28 0128 ores 0128 0126 0119142531 410 311 cm sm 7300W 202 T3004 19 1300W 2 7300 1380948 100 425 200 4386 C4LV 1d 1911 LNAOW TIWA 39491 C4LV 1d 1913 INNON TIWA TIYWS Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 18 of 21 HALMA COMPANY Appendix Perma Pure Sample Pump Maintenance Instructions Item Description 1 VALVEBODY 2 BEARING 3 CAP 4 CWEIGHT 5 CAPACITOR 6 ECCENTRIC 7 FAN BLUE 8 FAN WHITE 9 HEAD STD SS 10 PLATE DIAPH 11 CONNECTING ROD 12 TOL RING 13 SCREW HEAD BASE AN 14 VALVE SCREW 15 PLATE SCREW 7 16 GROUND SCREW 17 SCREW gt 18 SCREW P d 19 SCREEN 20 7 01311 115v 60 60 20 SCREW NA NA 01312 220v 60 50 21 LOCK WASHER 22 DISC VALVE 23 DIAPHRAGM GASKET 08 07 09 5 WASHER 19 pa Disassembly of head section and service diaphragm 1 Remove head section by unscrewing the four large bolts A flat bladed screw driver may be needed to gently pry the head free of the service diaphragm If you have Teflon coating on the heads use caution not to scratch the s
5. IN3A 319 01 0 MO 19101 8 YIONIdWI M3L3AMOTH 31 vino dvd YISNIONOD NISNIONO M31VM SH3ZA IVNV JOSN3S LIINI IWNOILdO dis 9 15 915 01 35 3NWA 33 138 S 9 L 8 L JO 1 OMG WALSAS WVS SOMG WPS S OVI 0351 51 NIMGTYS 1936 0122 5 v 7 YILININ NOS MATA LNOd4 310HM NI INIINLIVINNYN YO LNIN SNOISNANI_NOISI OL 14Yd INMYYO a 0350 38 LON TIVHS 1 900 SIHL WILSAS ONINOILIGNOD 31dWVS 1936 0129 5 1300W NI NIMTVG NOU doS 18 AYYLJYdOYd NOILVN4OINI 0 SNIVINOO 1N3 n200 SIHL Z0 HI NIMQ1V8 NOIL VIASJO INI Ava 3 031112345 3SIMYIHLO SSIINN 8142530 NIVYd OILFIVISIN3d 1300W Qv3H 3NNYW NOIL dI8IS3Q ALO wat D MATA AdIS 1 a 431 14 45 431002 21410313 83 1 II YOSNAS 415 YILYM zanl 8 lt 1 31dWVS QV3H 319NIS JOWYL LV3IH 7 YILIWMO 14 131 0 paa 62418701 L3INI NOIL dIYIS3O 31 0
6. PERMA PURE LLG Doc 561 Revision 000 HALMA Page 21 of 21 Appendix G Warranty and Disclaimer 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
7. Wire the sample pump power leads to TB2 terminals 6 hot 7 neutral and 8 ground e Sample pump control water slip plus read slip power fail safe start a Jumper hot neutral and ground from the power supply line terminals to TB8 GNL on the relay board b Wire the sample pump power leads to TB2 7 neutral and 8 ground o Wire a jumper on TB1 from terminal 3 to terminal 4 and wire another jumper TB9 from terminal 1 to terminal 2 d Wire sample pump hot wire to TB9 terminal 5 Wire water slip sensor to TB1 terminals 1 and 2 Sample pump is now in series with water slip sensor and the ready slip power failure relay which will only allow the sample pump to start if both conditions are true ie No water slip and safe operating temperature of the sampling system NO COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 10 of 21 HALMA CO LED Summary The Classic Model 5210 has a single channel digital operating temperature front panel indicator and 3 LED status displays 2 green and 1 red These indicators are arranged vertically on the front of the cooler Ready Green LED comes on when output stream dew point is below 10 C Slip Green LED comes on when water is not present on water slip sensor Failure Red LED comes if the thermocouple failed NOTE Slip LED is connected
8. 0 031 13 55 1 48 34 30 0 025 12 54 1 38 36 34 0 019 11 52 1 29 38 37 0 016 10 50 1 21 40 40 0 013 9 48 1 13 42 44 0 011 8 46 1 03 44 47 0 008 7 45 0 988 46 51 0 006 6 43 0 922 48 54 0 005 5 41 0 861 550 58 0 004 4 39 0 803 52 62 0 003 3 37 0 751 54 65 0 002 19 COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 Page 20 of 21 5 PERMA PURE LLG HALMA MOISTURE CONVERSION TABLE DEW POINT DEW POINT VAPOR PRESSURE RELATIVEHUMIDITY m by WEIGHT oF C Mm Hg ppm by VOLUME 70F air 110 166 10000010 00132 10000053 0 00082 108 162 10000018 100237 10000096 0015 106 159 10000028 00368 1000015 0023 104 155 0000043 00566 000023 10035 102 152 0000065 100855 1000035 10053 100 148 10000099 0130 1000053 10081 98 144 1000015 0197 1000080 012 96 141 1000022 0289 00012 018 94 137 1000033 0434 00018 027 92 134 1000048 0623 00026 039 90 130 00007 0921 00037 1057 88 126 00010 132 100054 082 86 423 00014 184 00075 41 84 119 00020 263 100107 16 82 116 100029 382 100155 24 80 112 00040 562 00214 33 78 108 100056 737 00300 46 76 105 100077 1 01 00410 83 74 101
9. 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 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 COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions
10. 100105 1 38 100559 86 72 98 00143 1 88 00762 1 17 70 94 100194 2 55 0104 1 58 68 90 100261 3 43 0140 2 13 66 87 00349 4 59 0187 2 84 64 83 100464 6 11 10248 3 79 62 80 00614 8 08 10328 5 01 60 76 100808 10 6 043 6 59 58 72 0106 13 9 10565 8 63 56 69 0138 18 2 0735 11 3 54 65 0178 23 4 10948 14 5 52 62 0230 30 3 123 18 8 50 58 0295 38 8 157 24 1 48 54 10378 49 7 202 30 9 46 51 0481 63 3 257 39 3 44 47 0609 80 0 325 49 7 42 44 0768 101 A10 62 7 40 40 0966 127 516 78 9 38 36 1209 159 644 98 6 36 33 1507 198 804 122 9 34 29 1873 246 1 00 152 32 26 2318 305 1 24 189 30 222 2859 376 1 52 234 28 18 351 462 1 88 287 26 45 430 566 2 30 351 24 526 692 281 430 22 8 640 842 3 41 2 20 4 776 1020 4 13 633 18 0 939 1240 5 00 770 16 3 1 132 1490 6 03 925 a7 1 361 1790 7 25 1110 42 10 1 632 2150 8 69 1335 10 14 1 950 2570 10 4 1596 8 18 2 326 3060 12 4 1900 6 21 2 765 3640 147 2260 4 25 3 280 4230 17 5 2680 2 28 3 880 5100 20 7 3170 0 32 4 579 6020 24 4 3640 2 36 5 294 6970 28 2 4330 4 39 6 101 8030 32 5 4990 6 43 7 013 9230 37 4 4730 8 46 8 045 10590 42 9 6580 10 50 9 029 12120 49 1 7530 12 54 10 52 13840 56 1 8600 14 57 11 99 15780 63 9 9800 16 61 13 63 17930 72 6 11140 18 64 15 48 20370 82 5 12650 20 68 17 54 23080 93 5 14330 22 71 19 827 26088 16699 24 75 33 377 29443 18847 26 79 25 209 33169 21232 Model 5210 User s Manual
11. 31000 NOWdIdIS30 ONI NOILdi4 S3Q 9 1009 AlddNS 33MOd ZI 2 0 NIS LV3H STVNINY3L 3S3HL NO 1 353 SI Y3MOd IV NOILNVD TOMLNOD dWNd 04 SLOVLNOD ANO OL JAOWIY IANN 71 1 2 01 SALVLS MOI SLOVLNOD WHVlv Nav XOSNIS 416 YILYM SLIINNOI XIINO WINIWNOMIANI NIMOTYA YO NI INIINLIVINNYN YO LNIN N9IS30 INIYIINIINI YOI 0361 38 LON TIVHS LNIWNIOO SIHL SI LI HOIHM 303 3S0d4Nd 04 113105 0350 38 OL SI ANV WINJNNOSIAN3 NIMTTV8 NOLLVINSO NI SNIVINOO LN3WND00 SIHL 13 300 331005 4350 ALO wa S1N3W313 1002 2 1 od lOMINOO 33MOd dW d 3ldWVS 3043 LOH OV SNLVLS 403 SLOVLNOD dS YILVM 13534 IWANVW 304 NOIL23NNOO ANI 0 86 u S NOILdlJ2S3G YOLOSNNOD Qv3HX1n8 1 zd LI 8 ZHR SN 010 8226 0408 43TIOMLNOO OIL TIVISIM3d Wav FIN IN 64 ON LIVINOD 0
12. 35072 ATIYWYON 3LONSY OL 334Wnr L 3155 800 05 1 AlddNS MOGZ 90 y CRE x bag u w 5 Ba ing HUE dS ty cts T1 5 Ar te Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA COMPANY Page 17 of 21 Appendix C Sample Conditioning System Drawings C1 Flow schematic C2 4S 9PA Piping and dimensional drawing C3 Rack mounting plates dimensional drawing C4 Wall mounting plates dimensional drawing COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions 1 30 res oma maisas lt 5 av 035 N3HM SIN31VAInO3 INI NIKTIVB naang QS VIG MOTE WGISAS 9NINOUIQNOO Sonu eb sag 3AILOV 3AISSVd NOlLdl S30 LAYA RR M vid SNIVLNOD 1 380200 SIHL 0 T JNI avo NOILYWYO INI WITIHO 314485 30 38 TIVHS WLOL Z 031319395 3SIMY3HLO 531 NOLIA 530 1331 5519 ILVINISOYOA 13315 SSIINIVIS 38 TIVHS 0126 SZEW 13006 NOILdlJ2S3Q A10 Wal SISVI 2 FIdNVS 8 31134 SIN3NOdWOO I SILON 217151439 Qv3H 1
13. 7 pins 1 amp 2 and 3 amp 4 If loose then reseat connectors If no voltage or low reading replace relay board F1 on control board keeps blowing Impinger remains at ambient temperature Thermocouple failure LED is on Replace fuse 3A and disconnect P10 cable going to relay board Peltier current draw Should be between 6 and 8 amps Thermocouple connection TB1 If fuse does not blow replace relay board Replace Peltier element Ensure proper connection Try a good thermocouple in place of old one Replace thermocouple Impinger frozen and cooler indicates ambient temperature Thermocouple placement in heat exchanger block Peltier current draw gt 6A for both elements on that channel Ensure proper placement Replace bad peltier Impinger does not reach set temperature but is below ready temperature System loading Calibration and set temperature adjustment Ensure system loading is not exceeding cooler capacity Adjust as necessary Impinger temperature cycles up and down Peltier connections on control board Ferrite bead on thermocouple going into terminal TB1 Ensure a firm connection on flag connectors on control board Ensure system loading is not exceeding cooler capacity Wrap thermocouple wires around a Ferrite bead PERMA PURE LLG HALMA COMPANY Model 5210 User s Manual Doc 561 Revision 000 Page 13 of 21 Wa
14. PERMA PURE LLG Baldwin Series Model 5210 Thermo Electric Cooler User s Manual PERMA PURE LLG HALMA COMPANY 8 Executive Drive Box 2105 Toms River NJ 08754 732 244 0010 800 337 3762 fax 732 244 8140 www permapure com info permapure com Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 2 of 21 HALMA CO N Contents IMtHOGUCTION 3 General description aad neve pendula 4 6 Wii ri 6 Important Safety Warnings 11 0 4 6 7 Dp 8 Tools and hardware required for 8 GA AA AA AA AA NA 8 eeu 8 Sample 2 ee RTI 8 Electrical Relay Board c ccccccccccsssssssececececeesenssececeecceesessssesecececeeseessaaesesescesenenesasseeeceesesesensaaeeeseeeens 9 LED SUMMARY 10 AA 10 uc 11 Troubleshooting and Maintenance 12 Replacement CHR ERA AR UR 14 Classic Model
15. ad only standard 2PTB 002PK Peristaltic pump tubing Norprene size 17 10 feet 2PBM 015 Single head hardware kit 2PBM 006 Dual head hardware kit 15 COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 16 of 21 HALMA COMPANY Appendix B Cooler Drawings Model 5210 dimensional drawing 4C 5210 01 01 B2 Interconnect wiring diagram B3 Contact states diagram L JO 1 133 5 531035 1005 FINSIMONWPS S OVI 0350 N3HM SLNIIWAINOS NALIWITIIN S310N30 NIMGTVE 0166 1380O0N S3HONI NI WO WSNUIMPIDG 31 96 325 TIOHM NI ONIINLIVINNYW YO LUVd 9NIMVYO SNOISN3IWIG N9IS30 JNNOOYd 1530 INISIINIONI 303 ORLON Shia kam o3 401 Y71009 0125 1300 sv NP NING NOlLdIM2S30 1 4 NOLLVNYO INI 1494 1 2 13112345 5531 04 v 1 130W 0350 13uno NOlLdls2S3Q ALO Wali MATA AQIS LHOIY LNOdJ 4331000 OlMIO3T13 OWH3HL S3lJ3S ALNA AAV3H NAYYON S avd 01041 yas TON LYYd INMYYO wos 375 IWWOIdAL WVYOVIG 4
16. be fitting shown in figure 1 NOTE If using stainless steel sample line place 2 Sample Inlet S mls inches of Teflon tubing in between the exchanger TYP Outlet inlet fitting and the heated line This prevents the sample cooler from heat sinking the incoming heated line which adds undue load to the cooler THERMOELECTRIC COOLER 2 Connect the sample outlet to the 1 4 tube fitting 13 shown in figure 1 3 Connect the peristaltic pumps to the barbed tube fittings shown in figure 1 NOTE Do not reduce the size of the condensate tubing since doing so restricts water flow resulting till f water carryover into the sample sl Drain Port For instructions on installing a Perma Pure peristaltic pump see appendix 1 Note that the rating on this pump tubing is 20 psi 1 7 bar Figure 1 Model 5210 Cooler Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 COMPANY 9 of 21 Electrical Relay Board Make the following connections while referring to Appendix B3 Interconnect wiring diagram e Computer status alarms wire to TB2 a Terminals 1 and 3 for water slip alarms b Terminals 4 and 6 for ready slip alarm status e Sample pump control water slip only a Jumper line neutral and ground from the power supply line terminals to TB8 GNL on the relay board b
17. e c Push down and turn key counterclockwise completely around the rotor The key will push the tubing uniformly into the end bell assembly Hold the second end of the tubing Remove key d Position the other end bell on top and press the end bells together Be careful not to pinch the tubing If end bells do not snap tightly together reload tubing If necessary turn key in slot on rotor shaft to adjust tubing as in step e e With key in slot on rotor shaft turn key to align tang on rotor shaft with slot in motor drive shaft Point tubing retainer grooves up Shift the pump head slightly till it snaps on the alignment pins if present Secure with four provided screws Tighten with fingers only Multi channel mounting a Load the pump heads with tubing b Install the four correct length mounting screws in drive c Slide the first pump head into the mounting screws d Place key in slot on mounting shaft Twist to align tang on rotor shaft with slot in motor drive shaft Shift the pump housing around till it drops over the alignment pins if present e Repeat for each additional pump head aligning pump head tang with slot on previously mounted pump head f Slide the flow flat washers onto screws and secure with the four wingnuts Tighten with fingers only Replacement parts 2PBM 001 Peristaltic pump motor only 115 VAC 60 Hz 2PBM 002 Peristaltic pump motor only 230 50 Hz 2PBM 003 Peristaltic pump he
18. ic TE Cooler is best illustrated as a small heat pump with no moving parts The Peltier operates on direct current and may be used for heating or cooling by reversing the direction of current flow This is achieved by moving heat from one side of the module to the other with current flow and the laws of thermodynamics A typical single stage Peltier Figure 1 consists of two ceramic plates with p and n type semiconductor material bismuth telluride between the M plates The elements of semiconductor material are connected electrically in series and thermally in parallel Figure 1 Thermo electric element Peltier When a positive DC voltage is applied to the n type thermo electric element electrons pass from the p to the n type thermo electric element and the cold side temperature will decrease as heat is absorbed The heat absorption cooling is proportional to the current and the number of thermo electric couples This heat is transferred to the hot side of the Peltier element where it is dissipated into the heat sink and surrounding environment The Classic Cooler removes the moisture from the sample gas by cooling it as it passes through a laminar impinger heat exchanger A diagram showing the gas flow path through an impinger is shown in the Appendix The heat exchanger made of 316L stainless steel Durinert a corrosion resistant inert coating over 316L stainless steel PVDF Kynar or glass is mo
19. located just above terminal TB1 where the control thermocouple terminates TP1 is the thermocouple zero span adjustment test points and should not be adjusted by the user TP2 is the control set point temperature set point 2 is the ready relay set point temperature set point 3 To adjust either set point open the cooler front door attach the DVM and adjust the labeled potentiometer on the control card NOTE These set point potentiometers are factory set and sealed for proper cooler operation Please consult the factory before making any changes to these set point adjustments SET POINT 2 is factory adjusted to 5 C 500 VDC SET POINT 3 is factory adjusted to 10 C 1 00 VDC COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 5 PERMA PURE LLG Page 12 of 21 HALMA Troubleshooting and Maintenance Guide Symptom Diagnostic Fix No LED s and no fan AC power input Ensure that AC power is connected No LED s and no fan DC 3A fuse F1 on control Bd AC 15A fuse on power supply Check for 15VDC at P1 amp P11 of control bd Replace fuse as necessary Replace fuse as necessary If low reading remove wires from P1 amp P11 measure at power supply and replace supply if voltage still is low LED s on and no fan Wire harness at P10 on control board over to P1 on relay boards Relay Board for 12VDC at TB
20. mmended for water removal Perma Pure part number 3KPB 003 size 17 tubing Always use factory supplied fittings Perma Pure cannot warrantee against damage to the Peltier elements or heat exchangers if our fittings are not used Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA PAN Page 7 of 21 Important Safety Warnings Please be sure to review the following basic safety procedures These procedures represent the MINIMUM 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 NEVER attempt to operate this equipment in an explosive or otherwise hazardous area NEVER exceed any specified rating for the equipment Voltage temperature and pressure ratings must be closely observed and not exceeded Voltage rating of the equipment MUST match the rating on the data label Please make sure that it matches before powering up the equipment This equipment is NOT designed to be used in an explosive environment This equipment is NOT designed to operate in a wet environment Condensate is potentially dangerous NEVER handle drain lines impingers 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 recomme
21. nded 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 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 Read the entire operating manual before attempting to set up or operate the equipment e Please heed all warning labels tha
22. port please contact your purchasing dealer or contact Perma Pure directly Perma Pure LLC Tel 732 244 0010 P O Box 2105 Tel 800 337 3762 toll free US 8 Executive Drive Fax 732 244 8140 Toms River NJ 08754 e mail info permapure com website www permapure com 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 95 COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 4 of 21 HALMA General description Sampling combustion product stack gas or exhaust from internal combustion engines requires a method to remove the moisture from the sample without removing the gas compounds of interest The Baldwin Series Classic TE Cooler is an ideal way to decrease the dew point of combustion gases to a repeatable stable constant low dew point The Classic cooler prevents water condensation in sample pre filters pumps and analyzers For gas analyzers where water vapor is an interferent a stable repeatable dew point becomes a part of the gas analyzer performance specification Classic coolers provide this constant low water concentration resulting in an accurate gas measurement All Classic coolers use thermo electric elements Peltiers to cool the sample gas to the desired dew point temperature A Classic Thermo Electr
23. re the part is clamped in place Be sure the diaphragm plate is firmly replaced with its center screw Replacement parts 2PAM 001 Sample pump repair kit single head 2PAS 001 Sample pump single head 15 50Hz 2PAS 002 Sample pump single head 230 60Hz Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA 19 of 21 Appendix F Conversion Tables CHART OF VOLUME PERCENT WATER CONCENTRATIONS AT SATURATION FOR VARIOUS TEMPERATURES AT STANDARD PRESSURE ATMOSPHERIC PRESSURE DEGREES C DEGREES F VOLUME DEGREES DEGREES F VOLUME 100 212 100 00 2 36 0 696 90 194 69 20 1 34 0 649 80 176 46 70 0 32 0 602 75 167 38 70 1 30 555 20 158 30 70 2 28 0 510 65 149 25 20 3 27 0 469 60 140 19 70 4 25 0 431 55 131 15 50 5 23 0 396 50 122 12 20 6 21 0 363 45 113 9 45 7 19 0 333 40 104 7 25 8 18 0 305 35 95 5 55 9 16 0 281 30 86 4 19 10 14 0 256 29 84 3 95 11 12 0 234 28 82 3 73 12 10 0 214 27 81 3 62 13 9 0 196 26 79 3 32 14 7 0 179 25 77 3 13 15 5 0 163 24 75 2 94 16 3 0 148 23 73 2 77 17 1 0 135 22 72 2 61 18 0 0 123 21 70 2 46 19 2 0 112 20 68 3 21 20 4 0 102 19 66 2 17 22 8 0 084 18 64 2 04 24 11 0 069 17 63 1 91 26 15 0 057 16 61 1 79 28 18 0 046 15 59 1 68 30 22 0 038 14 57 1 58 32 26
24. stream from the cooler along with an optional water slip sensor The conditioned sample gas can then be directed to the gas analyzers COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 Page 6 of 21 UJ PERMA PURE LLC HALMA CO Physical Description Single channel system LCD temperature display e Weight 27 165 12 kg Specifications Sample gas flow range Avg inlet dew point at rated flow Maximum cooling rate Maximum inlet sample temp Maximum inlet pressure Maximum pressure drop Ambient temperature range Outlet sample gas dew point Voltage Power supply Cooling down time Connections 2 x 10 heat exchangers connected in series only 1 Passive cooled to ambient 1 Active cooled to 4 C heat exchangers Dimensions 14 5 x 11 x 10 5 HWD 37 x 28 x 26 5 cm Up to 8 LPM Up to 17 SCFH 20 60 C DP 5 LPM 440 BTU ht 464 kJ hr 400 F 205 C for SS or glass impingers 280 F 138 C for Kynar impingers 15 psig 1 bar 760 mmHg lt 1 H20 33 110 F 0 6 43 C 41 F 5 C 115 230 VAC 50 60 Hz 250W Less than 6 minutes e Sample gas inlet Kynar 3 8 tube compression fitting e Sample gas outlet Kynar 1 4 tube compression fitting Drain tubing connection Kynar 3 8 tube compression 14 barbed tube fitting An automatic condensate drain dual head peristaltic drain pump is reco
25. t 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 Verify that the unit is connected to the proper rated power for the system Verify that the unit is plumbed properly to operate effectively COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Model 5210 User s Manual Doc 561 Revision 000 PERMA PURE LLG Page 8 of 21 HALMA Installation Hardware required for installation 4 14 20 mounting screws e For stainless steel sample lines 2 inches of 3 8 Teflon tube Peristaltic drain pump dual head Mounting The Classic Model 5210 Thermo Electric Cooler should be installed away from heat sources a well vented area NOTE The operational stability of the cooler dew point is influenced by the stability of the ambient temperature For proper operation the ambient temperature cannot exceed 43 C 110 F At or close to the maximum ambient temperature the cooler will not be able to control the temperature to reduce the dew point of the sample gas to the 5 C set point This will result in compromised operation and water slip or carryover possibly into the analyzer Also at or near this temperature the cooler will be running full on and Peltier life will be greatly reduced Connections Sample and Drain 1 Connect the sample inlet to the 3 8 tu
26. ter carryover in system Impinger temperature Should be below 6 C Ensure system loading is not exceeding cooler capacity Slip LED does not come on Water carryover in system Water slip sensor connections Ensure system loading is not exceeding cooler capacity Ensure that all water slip sensor connections are made Disconnect sensor at base of unit Clean tip of sensor Replace alarm relay water slip board Pump does not start Ready and slip LED s are on Pump electrical connections Ensure proper connections Replace board COPYRIGHT 2008 ALL RIGHTS RESERVED Original Instructions Doc 561 Revision 000 HALMA CO Model 5210 User s Manual 8 PERMA PURE LLC Page 14 of 21 Replacement Parts Classic Model 5210 Part No Description 3CCB 010 Control Board Single Channel 2FAN 005 Fan Muffin 4 x 1 12 VDC 2FAN 004 Fan Muffin 4 x 172 12 VDC 3CXD 022 Impinger 10 EZ clean twist apart Durinert 3CXD 024 Impinger 10 NJ EZ clean twist apart Durinert coated 3CXG 002 Impinger 10 Glass threaded w fittings 3CXK 003 Impinger 10 Kynar 3CXS 022 Impinger 10 Stainless Steel EZ clean twist apart 3CXS 024 Impinger 10 NJ Stainless Steel EZ clean twist apart 3KPE 004 Peltier Element Kit 40 mm 1PSD 008 Power Supply 250 W 15 VDC 3CCB 004 Relay Board Single Channel 1TTC 001 Thermocouple Temperature Control Type K 24 Recommended Spares
27. to the water slip sensor which is normally dry on start up If the Slip Green LED goes out this indicates water is slipping past the heat exchanger The relay then shuts off the sample pump so that water is not allowed to reach the analyzers preventing damage to the analytical instruments Steps need to be taken at this time to determine the cause of the moisture and correct the situation Classic Model 5210 is operating properly when both Green LED s are lit Start up 1 Plug power cord into a properly grounded main circuit Green Slip LED will come on 2 Wait for the green Ready LED light to come on approx 6 minutes This will indicate the impinger temperature is below 10 C and the sample gas flow can begin 3 After approx 3 more minutes the factory set point of 5 C 41 F will be reached The SLIP Green LED is always on unless e Moisture is detected by the water slip sensor e There is a malfunction eg Shorted water slip sensor leads or a bad relay board NOTE All voltages can be read at the PCB terminal strip Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA COMPANY Page 11 of 21 Set Points Both the operating control temperature and ready relay set points are adjusted by 20 turn potentiometers located on the control board Using a digital voltmeter DVM attach the black lead to P1 for ground reference point and attach the red lead to test points 1 2 or 3
28. unted within a thermally insulated heat transfer block bored to receive the heat exchanger without a mechanical lock This assembly allows the easy removal of any heat exchanger simply by slipping it out of the cooling block by hand The heat transfer block cools the heat exchanger through the heat pumping action of the Peltier element The heat transfer block is on the cold side of the thermo electric element and the heat sink is on the hot side of the thermo electric element The heat from the heat transfer block is pumped to the heat sink where it is then dissipated into the air by the heat sink fan See Figure 2 The desired temperature is maintained by a closed loop control system which is implemented through an analog proportional controller The controller uses a type K thermocouple in the heat transfer block located very close to the cold side of the peltier element as the input sensor Model 5210 User s Manual PERMA PURE LLG Doc 561 Revision 000 HALMA COMPANY Page 5 of 21 Figure 2 Heat Exchanger Impinger and Heat Sink The sample gas is passed to the cooler via the heated filter sample probe and heated sample line The cooler lowers the sample dew point to 5 41 F As the gas cools and the moisture vapor condenses the condensate exits the heat exchanger through the bottom drain connection Particulate matter passing through the sample cooler can be removed by an optional Baldwin Series pre filter located down
29. urface The valve body can then be removed by unscrewing the two smaller screws also accessible on the top of the head section This part may be freed by gently tapping on these two screws after they have been loosened about 3 or 4 turns When the valve body is removed check all internal surfaces fro an accumulation of dirt The two valve discs can be wiped clean and replaced as long as they appear unaffected by usage The valve gasket can be easily removed and should be inspected As a matter of good practice the valve discs and valve gasket should be replaced during any routine maintenance check of the head section A once a year routing procedure is recommended The service diaphragm is secured by the single screw in its center Remove this screw with a 5 32 Allen wrench The diaphragm and its clamping plate should be easily lifted off Some slight adherence to the metal may occur if the diaphragm has been in use for a long period When replacing the service diaphragm a Teflon washer should be inserted under the head of the diaphragm cap screw This is added insurance against small gas leaks through screw heads and may be essential in vacuum applications where outside air contamination cannot be tolerated After tightening the screw the excess Teflon should be trimmed away NOTE When replacing the service diaphragm be sure the four projection studs of the base casting are properly located in the four outer holes provided in the diaphragm befo
30. very effort has been made to prevent damage during the transportation process damage can occur by the carrier This is out of control of Perma Pure 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 deliver 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 Items in the carton include 1 Model 5210 thermo electric cooler 1 User s Manual Optional glass impingers will ship separately If any of the above parts are missing or damaged call the helpline at 800 337 3762 ext 145 Introduction Thank you for purchasing this product from Perma Pure LLC This manual has been assembled so that it can answer all questions regarding operation Please keep the operators manual near the equipment for future reference There may also be optional equipment available that was not ordered at the time of original purchase which may be described and or illustrated in this manual If you still have any questions regarding your equipment s operation available options or technical sup
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