PRO903 - User Manual
Contents
1. Interface Printed Circuit Assembly The printed circuit assembly is manufactured by TFS The card has one channel with an on board 24 VDC power supply for the 4 20 mADC outputs and digital control signals Temperature Controllers Two Watlow Series 965 temperature controllers located in the front of the CTL903 Probe Controller Assembly provide readouts in degrees Fahrenheit F or degrees Celsius C as selected in the controller setup menu Each upper display is the actual temperature of the controlled device and each lower display is the temperature set point On the face of each controller located to the right of the temperature displays are two LED s labeled L1 and L2 L1 indicates that power is being applied to a heat element or to the TE cooler in the Heat Exchanger L2 indicates that the temperature has strayed past the alarm set point and if an alarm device is connected to the alarm output an alarm will be sounding The Watlow controllers monitor and control the Probe Heated Filter temperature 275 285 F and the Heat Exchanger temperature 35 45 F September 24 2001 1 6 PRO903 MANUAL 1 6 Specifications TFS The PRO903 Dilution Probe Conditioning Assembly was designed to operate within the following specifications Power Requirements Power Connection Operating Temperature Range Maximum Process Temperature Calibration Gas Flow Rate Enclosure Temperature Instrument Air Supply2. on position 2 Reinstall the temperature controllers and apply power to the remote probe controller assembly via the power switch located at the rear of the chassis 3 Please refer to Table 3 4 1 below for parameter set points for each controller Enter the setup menu by pressing and holding the up and down arrows on the controller for three seconds The controller will enter the setup menu when LOC is displayed on the lower window 4 To proceed to the next parameter press the M mode key NOTE all outputs will be switched off while in the setup menu Rev 3 0 September 24 2001 3 6 PRO903 MANUAL TFS Parameter Function Heated Filter Heat Exchanger Settings Settings LOC Lockout Security Level 0 0 In Input Type 420 420 dEC Decimal Point Placement 0 0 0 rL Low Temperature Range 32 0 rH High Temperature Range 626 176 Otl Output Type 1 Ht Cl HSC Hysterisis Control 3 0 0 3 Ot2 Output Type 2 dEA dEA HSA Alarm Hysterisis Dead Band 2 2 LAt Alarm Latching NLA NLA SiL Alarm Silencing OFF OFF rP Ramping not used OFF OFF PL Power Limiting 100 not used dSP Display Windows NOr NOr Table 3 4 1 Setup Menu Parameters 5 Please refer to Table 3 4 2 below for parameter set points for each controller Enter the operation menu by pressing the M mode key The controller is in the operation menu when Pb1 is displayed on the lower window To proceed to the next pa
3. Eductor Flow Rates Heated Eductor Assembly Sample Flow Dilution Flow Eductor Pump Assembly Sample Flow Dilution Flow Heat Exchanger Cooler Block Temperature Heated Eductor Filter Body Temperature Materials of Construction Enclosure Mounting Method Sample Orifice Eductor Jet Eductor Body Orifice Holder Body Heated Filter Body Probe Barrel Heat Exchanger Cooling Block Connecting Lines Sample Lines Weight Dilution Probe Conditioning 120 VAC 800 Watts CSA UL Approved screw terminal Terminal wire capacity up to 10 AWG 20 C to 50 C 4 F to 122 F 600 C 1112 F 2 0 L minute minimum 2 5 L minute maximum 37 7 C 3 C 100 F 5 F 60 PSIG 400 kPa minimum 80 PSIG 550 kPa maximum via 12 inch tubing 0 300 inch minimum I D approx 100 300 cc minute approx 5 10 L minute approx 100 cc minute approx 5 L minute 7 2 C 40 F 50 F 140 5 C 5 5 C 285 F 10 F Fiberglass 4 each 13 x 3 SS bolts mates to customer s 4 150 flange Quartz Torlon or suitable material Torlon Torlon or suitable material Stainless Steel or suitable material Hastelloy C276 Teflon or suitable material Teflon Rev 3 0 September 24 2001 1 7 PRO903 MANUAL TFS Assembly 73 Ibs 33 1 kg Rev 3 0 September 24 2001 1 8 PRO903 MANUAL TFS 2 0 2 1 2 2 Rev 3 0 THEORY OF OPERATION General The PRO903 Dilution Probe Conditioning A
4. OF THE STACK OR DUCT AT ALL PENETRATIONS CLEARANCE FOR MAINTENANCE 2 WELD PIPE TO STACK USING 1 4 FILLET WELD 3 A USE THESE FOUR HOLES FOR PROBE INSTALLATION BOX FOR ACCESS 4 PROBE LENGTH WILL MEET US EPA 1 METER PENETRATION REQUIREMENT MAY BE SHORTENED IF NECESSARY TO PLACE PROBE TIP AT CENTER OF GAS STREAM 5 ALLOW 6 CLEARANCE BETWEEN FLANGE AND WALL OR FLANGE AND INSULATION 6 7 8 9 Figure 3 1 Enclosure Mounting Diagram September 24 2001 3 1 PRO903 MANUAL TFS 3 2 3 2 1 3 2 2 3 2 3 3 3 3 3 1 Rev 3 0 The Dilution Probe Conditioning Assembly should be installed in a location that will allow maintenance personnel access to the front of the enclosure All maintenance can be performed from the front of the unit Limitations at the Probe Site The placement of the PRO903 Dilution Probe Conditioning Assembly is important to achieve its maximum reliability Stack Temperature Extremes The PRO903 Probe Barrel was supplied using Hastelloy C 276 Teflon Lined Hastelloy C 276 or other suitable material specific to the application The Teflon lined Hastelloy probe barrel may be used at temperatures up to 190 5 C 375 F and lengths up to six 6 feet long Use the shortest possible probe barrel length less than six feet for proper response times and consistent sampling Ambient Temperature Extremes The PRO903 Dilution Probe Conditioning Assembly may be operated at a maximum ambient
5. V 4 into the filter body and exiting into the process through the probe barrel The heated filter exchanger purge is used to remove particulate buildup from the inside surface of the heated filter When the particulate is dislodged it is carried out of the filter chamber and through the probe barrel with the blow back air The heated filter exchanger purge air enters the heated filter body through the sample gas outlet and simultaneously enters the Heat Exchanger cooling block inlet The purge air is introduced through the filter cap that houses the blow back calibration gas inlet Moisture is removed from the Heat Exchanger sample inlet line and the moisture Rev 3 0 September 24 2001 2 3 PRO903 MANUAL TFS 2 2 3 Rev 3 0 collection reservoir during the purge cycle The moisture reservoir drain valve V 3 opens to drain collected moisture from the Conditioning Assembly The high pressure purge air from the heated filter exchanger purge solenoid valve V 4 enters the cooling block inlet to force out the moisture from the block through the drain opening V 3 Calibration Mode The PRO903 Dilution Probe Conditioning Assembly is calibrated by passing a gas of known concentration through all the components in the sample analysis system and adjusting the response of the gas analysis system to reflect the known value of the calibration gas Calibrating in this manner compensates for total system losses in filter elements or other pneumati
6. in minute September 24 2001 4 4 PRO903 MANUAL TFS 4 9 4 10 Rev 3 0 Probe Head Flow Test The Dilution Probe may be supplied with various jets to accomplish different dilution ratios Please refer to the site specific system flow diagram to obtain the proper flow rates Connect a mass flow meter in line to the eductor exhaust outlet port eductor outlet flowmeter as shown in Figure 4 9 When 30 psi instrument air is supplied to the eductor dilution air inlet port the meter flow rate should be approximately the same value as the value recorded on the system flow diagram Repeat the flow test with a flow meter connected to the eductor sample inlet port dry sample flowmeter in figure 4 9 When 30 psi instrument air is supplied to the eductor dilution air inlet port the meter flow rate at the sample inlet port should be approximately the same value as the value recorded on the system flow diagram E Weg E E Ze SC RE i M Dei H DILUTION AIR IN d 30 PSI w m DRY SAMPLE FLOWMETER OZ WET SAMPLE INLET LZ FLOWMETER SAMPLE OUTLET TO HEAT EXCHANGER PLUG OR CAP CAL GAS PURGE PORT FITTING Figure 4 9 Probe Head Flow Test Configuration Eductor Vacuum Test Connect the hand held vacuum pump to t
7. 508 520 0430 International We continue to support our customers with advanced online resources Our Air Quality Instruments Online Library allows our customer s access to product documents and information on a constant basis Available 24 hours a day and seven days a week the online library provides quick access to information regardless of time zone or office hours To register for an account or log in please visit www thermoscientific com aqilibrary Thermo Fisher Scientific Where to Get Help PRO903 MANUAL Claims for Damaged Shipments TFS A The PRO903 and Remote Probe Controller Assembly are shipped ready for operation Immediate inspection of the PRO903 and Remote Probe Controller Assembly should follow upon receipt Inventory of the container should be checked against the enclosed packing list If there is a shortage of items the operator should immediately contact TFS If the contents are damaged the carrier and TFS should be notified immediately B The following documents are necessary to support claims 1 Original freight bill and bill of lading 2 Original invoice or photo copy of original invoice 3 Copy of the packing list 4 Photographs of damaged equipment and container NOTICE Material contained in this manual is proprietary information of TFS The TFS manual is to be used only for the installation understanding and servicing of this product For further information or assistance contact TFS
8. All rights reserved No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of TFS REVISION HISTORY Revision Revision Made Pages Affected Revision Date No 2 0 Revise document to Word format incorporate AII September 24 ECN 99 013 for internal AL flange 2001 3 0 Changed Logo All September 24 2001 Rev 3 0 September 24 2001 li PRO903 MANUAL TFS 1 0 2 0 3 0 Rev 3 0 PRODUCT DESCRIPTION 1 1 1 1 tere eege 1 1 1 2 BRO903 Descriptio E 1 1 1 3 Dilution Probe Conditioning Assembly Hardware 1 2 1 3 5 Probe Ne E 1 2 1 3 2 Enelosure H dt r seser ao eene as eee kasaka 1 2 1 3 3 Valve Manifold and Dilution Air Regulator ssssssenseeesseeessresseessereseee 1 3 1 3 4 Heated Filter Dilution Eductor and Probe Barrel Assembly 1 3 1 3 5 Heat Exchanger and Drain Valve Assembly cccceescceeeseeceeereeeeeeeees 1 4 1 3 6 Probe Power Purge and Temperature Control 1 4 1 3 6 1 erte LUES ed 1 4 1 3 6 2 Valve Controller Watchdog Module 1 4 1 3 6 3 Heated Filter Control Mille Sedregergegege eegegeteeeeegege ege ededt et 1 4 1 3 6 4 Heat Exchanger Control Module 1 5 1 3 7 Absolute Pressure Transducer muska 1 5 1 4 Tubing and Wiring Umbilicals eent Zoe Seeerei oer aeta saal 1 5 1
9. Assembly is installed on a customer supplied four 4 inch pipe flange The pipe flange must be installed on a pipe nipple extending six 6 inches from the outer wall of the stack The nipple is used to allow clearance behind the Conditioning Assembly for installation of the four 4 13 x 3 stainless steel mounting bolts Also allow a clear space at least the width of the probe enclosure in front of the enclosure door to allow the door to be opened The four 4 inch pipe flange must be aligned as shown in Figure 3 1 A slip type pipe flange is recommended to insure that the Conditioning Assembly can be leveled nO 52 47 SEE NOTE 4 SEE NOTE 5 SEE NOTE 2 EAN Ka MAIN POWER DISCONNECT JA ga 7 dT li Zz 90 E SA SEE NOTE 1 A EE TEFLON LINED PROBE EXTENDING INTO STACK 3 8 PIPE HASTELLOY C 276 SEE NOTE 4 SEE DETAIL A MAINTENANCE CLEARANCE SEE NOTE 9 VIEW A A FLANGE WELDED TO PIPE SPOOL IN THIS CONFIGURATION 48 MINIMUM 72 MAXIMUM STACK WALL CATWALK OR FLOOR t 48 RECOMMENDED MINIMUM ll XX NOTES Rev 3 0 1 DO NOT ALLOW BURRS ON INSIDE DIAMETER OF 4 SCHEDULE 40 PIPE SUPPLIED BY CUSTOMER CUSTOMER SUPPLIED AND INSTALLED CUSTOMER IS TO ENSURE THE STRUCTURAL INTEGRITY ALLOW 24 CLEARANCE FOR DOOR OPENING ALLOW 30 CLEARANCE IN FRONT OF PROBE
10. Ee 4 1 4 2 Required Maintenance Equipment sssesssessessseeesseressressresseressetsseresseesseeeseesseee 4 1 4 3 Heated Filter Replacement daa maht kalakasvatajate 4 1 4 4 Quartz Orifice Replacement aastakasv 4 2 4 5 Probe Head Removal 3 26 is ace eop a Ee 4 2 4 6 Orifice Holder Assembly Removal intsdis mil paviakunvaeskve p e deer pai aasa 4 3 4 7 Eductor Jet en 4 3 4 8 Prob Head E e EE 4 4 4 9 Probe Head Plow Testi mammu Oe ee 4 5 4 10 Ed ctor Vacuum eege erte EE 4 5 AAT Trouble Shootin EE 4 6 411 1 Zero Drift Pull System eere ionen orian vs 4 6 4112 Span Drift Pull Sy stern isalt lt vt veli nese 4 6 4 11 3 Low Sample Flow EE 4 6 4 11 4 High Sample Please e 4 7 4 11 5 Low Flow Rate at the Eductor Bxvbaust 4 7 4 11 6 High Flow Rate at the Eductor Exhaust A 4 8 4 11 7 Low Ed ctor Vac n eae i a 4 8 September 24 2001 iii PRO903 MANUAL TFS 411 68 L w Spam AE 4 8 4119 High Span Kerger dee eege ugeet 4 9 940 ASSEMBLY A EE 5 1 5 1 Obtaining Replacement P TS EE 5 1 5 2 Spare EE 5 1 5 3 Recommended a 5 2 LIST OF FIGURES 1 3 Dilution Probe Assembly E 1 3 22 Probe Head Flow Krater 2 3 3 1 Enclosure Mounting Diagram ssseseeessesessereseressressrrsseerssersseressresseeeseeessersseees 3 1 3 3 Probe Barrel Assemb uereg oorsese an a arn o a e i ariei 3 4 34 Probe Controller Front Panel getetuteieestbeteste ustakviuvakastvlunl hulul ee 3 6 4 8 Probe Head Leak Test Confeurapon een een 4 4 4 9 Probe H
11. TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMENT TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY STATEMENT SELLER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT Warranty Thermo Fisher Scientific
12. TFS EDUCTOR EXHAUST DILUTED SAMPLE OUT HH TID EDUCTORAIR DRIVE INLET EDUCTOR INLET i DRIED SAMPLE IN ja e SAMPLE wl SE J Gas PARTICLES 5 MICRON AND LARGER FILTER ELEMENT UNDILUTED SAMPLE GAS OUTLET TO HEAT EXCHANGER Figure 2 2 Probe Head Flow Diagram 2 2 2 Purge Mode A purge cycle occurs periodically to clear various sections of the Dilution Probe Assembly and Heat Exchanger from moisture and particulate matter The purge solenoid valves are operated automatically through a controller in the remote or local analysis system The filter body and probe barrel are purged in a simultaneous two part process while the moisture collection reservoir is dumped to clear the Heat Exchanger Purge frequencies may vary from every 15 minutes for applications with extremely heavy particulate concentrations to several hours for cleaner applications The blow back pulse lasts approximately 10 seconds Longer purge times could result in dilution probe cooling Particulate matter is removed from the probe barrel and the heated filter by the periodic introduction of high pressure blow back air from the blow back solenoid valve V 2 and the heated filter exchanger purge solenoid valve
13. assembly Eductor air pressure set too low Adjust regulator Plugged eductor air jet Replace jet September 24 2001 4 9 PRO903 MANUAL TFS 5 0 RETURNING ASSEMBLIES FOR REPAIR Should it become necessary to return any assembly sub assembly or component for repair or replacement contact the factory prior to shipment for specific information such as return authorization number shipping instructions price time to repair etc Also include pertinent facts describing the nature of the problem Ship all components to the following address TEI P O BOX 2470 45 EIR STREET WALDRON AR 72958 U S A 5 1 Obtaining Replacement Parts The following information must be included in all purchase orders for parts A TFS Model and S N of major assembly B Part Number found in parts tables C Description of part 5 2 Spare Parts List PRO903 CHEMICAL HEAT SINK 16000007 CHEMICAL SILICONE GREASE 16000003 CONTROLLER ASSEMBLY WATCHDOG VALVE 22000009 CONTROLLER ASSEMBLY HEATED FILTER 22000010 CONTROLLER TEMP 965 22110019 EDUCTOR ASSY L MIN SYSTEM SPECIFIC katete FILTER 1 MICRON 2 5 STD 26002018 FILTER 1 MIC NYLON 26002001 FUSE 1 AMP DELAY MDL 43001011 FUSE 2 AMP DELAY MDL 43008023 FUSE 5 AMP DELAY MDL 43005025 GASKET EDUCTOR 25501002 HEAT EXCHANGER ASSEMBLY COMPLETE 26000551 HEATER ASSEMBLY CARTDRIDGE 150 WATT 53010036 LAMP 60W 120V 24600020 O RINGS VITON 25503015 O RING EDUCTOR JET 25503011 O RING F
14. 4 1 Tubing Bi E EE 1 5 14 25 Marine Etuden dereen edd 1 5 1 5 Remote Probe Controller Assembly si wcwatesacay Sege eege Seege 1 6 1 5 1 Remote Probe Controller Enclosure ccccscccsssseseseresesencsssescsesnneses 1 6 1 5 2 Interface Printed Circuit AssSembIK LASILA aal 1 6 1 5 3 Temperature ControllerS sssssiiesisnrie renn a 1 6 1 6 e ERT SEN 1 7 THEORY OF OPERA TION EE 2 1 2 1 6157 0155 EE EE 2 1 2 2 Gas Flow Functional Description 00vvovonvevevanevenanevenavovenatovennvoeruneveenne e 2 1 DA Sampin Mode istide a taak alam kaukaasia 2 2 22 24 Purge MOGAE E 2 3 22 3 Calibration hee adiantum 2 4 INSTALLATION AND OPERATTON gege elatada iial vill lt e 3 1 3 1 Site Location and WEE TEE 3 1 32 Limitations at the Erobe Zife etueg geed eeh 3 2 3 2 1 St ck Temperature EIER e na ana a E N 3 2 3 2 2 Ambient Temperature Extremes ys scsconcesusentasarerencetdy ohtocsaanameatapongeaczaneeas 3 2 September 24 2001 ii PRO903 MANUAL TFS 4 0 Rev 3 0 GE BTOGBSS E Ett EE ahela taa 3 2 3 3 General Installation sansen IS IS STT 3 2 3 3 1 Dilution Probe Conditioning Assembly 3 2 3 3 2 AIT SUD PUY TAA M MASS SA SSE Ad 3 5 3 3 3 Sample and Calibration Gas Lmmes 3 5 3 34 Vent Lihen kaal v idaks ETE E EEEE E E Es 3 5 E EE WE 3 5 3 3 6 el Eu Data E EE 3 6 3 5 Dilution Probe Conditioning Assembly Start up een 3 6 3 5 Absolute Pressure Transducer Checkout Brocedure 3 8 MAINTENANCE EE 4 1 4 1 E a anda ara A hee
15. ILTER BODY 25503012 O RING PROBE 25503021 HOLDER ASSEMBLY QUARTZ SITE SPECIFIC seek ORIFICE QUARTZ SYSTEM SPECIFIC sede eek Rev 3 0 September 24 2001 5 1 PRO903 5 3 Teflon is a registered trademark of E I duPont de Nemours amp Company Inc MANUAL PCA CONTROLLER 900 SERIES RTD ASSEMBLY SURFACE MOUNT 900 SERIES TRANSDUCER ASSY PRESSURE 16 32 HG VALVE ASSEMBLY 2 WAY VALVE ASSEMBLY 3 WAY 17010074 53040007 55010000 45500006 45500008 TFS tekk Site specific check system drawings for dilution ratios and flow rates Recommended Tools PROBE ADAPTER TEFLON CHEMICAL HEAT SINK CHEMICAL SILICONE GREASE PUMP VACUUM HAND HELD FLOWMETER SIERRA 5 L MIN FLOWMETER SIERRA 500 CC MIN Torlon is a trademark of Amoco Chemical Company Rev 3 0 Printed in the U S A September 24 2001 07990000 16000007 16000003 26006022 29020005 29020006 5 2 Thermo Fisher Scientific Appendix A Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller s published specifications and be free from defects in material and workmanship when subjected to normal proper and intended usage by properly trained personnel for the period of time set forth in the product documentation published specifications or package inserts Ifa period of time is not specified in Seller s product documentation published specifications or package inserts the warran
16. MBER SAMPLE EDUCTOR JET CRITICAL EDUCTOR EXHAUST ORIFICE SURFACE MOUNT RTD DILUTED SAMPLE OUTLET 3 EDUCTOR AIR DRIVE INLET EDUCTOR INLET A CHAMBER DRIED SAMPLE IN A PROBE BARREL MOUNTING FLANGE ORIFICE HOLDER VD Z A YY PURGE CAL il H GAS PORT LI i PROBE FILTER CAP Ze BARREL FILTER ELEMENT PROBE STOP FLANGE UNDILUTED SAMPLE GAS OUTLET Figure 1 3 Dilution Probe Assembly September 24 2001 1 3 PRO903 MANUAL TFS 1 3 5 Heat Exchanger and Drain Valve Assembly 1 3 6 The Heat Exchanger and Drain Valve are located on the left wall of the Dilution Probe Assembly A thermoelectric cooled Teflon block a moisture collection reservoir an ambient exposed aluminum heat sink and purge valve comprise the Heat Exchanger system The Heat Exchanger system removes moisture from the filtered sample immediately before dilution The drain valve SV 5 also allows the moisture trapped by the Heat Exchanger to dump during the blow back purge mode A thermoelectric TE cooler cools the Heat Exchanger block to its operational temperature of 45 F The Heat Exchanger control module contains an AC to DC br
17. PR0903 Instruction Manual Dilution Probe Conditioning Assembly amp Remote Probe Controller Assembly Part Number 111984 00 24Sep2001 2011 Thermo Fisher Scientific Inc All rights reserved Specifications terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermoscientific com aqi Thermo Fisher Scientific WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive are available at www thermoscientific com WEEERoHS WEEE Compliance Where to Get Help Service is available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information or visit us on the web at www thermoscientific com aqi 1 866 282 0430 Toll Free 1
18. c components changes in dilution air flow rates and changes in process gas flow rates A typical calibration gas flow path is as follows from the calibration gas cylinder the gas flows through a flow controlling device and calibration gas valve located in a remote or local gas analysis system through the calibration gas line to the PRO903 Dilution Probe Conditioning Assembly calibration gas inlet The gas enters the Dilution Probe through the calibration gas solenoid valve V 1 and then into the filter body through the blow back calibration gas inlet The calibration gas solenoid valve allows the flow of calibration gas to be initiated remotely through a controller in the remote or local analysis system The calibration gas valve is located as close as possible to the blow back calibration gas inlet to prevent process condensation from forming in the calibration line between calibrations From the heated filter body the calibration gas passes through all system components at the same flow rates and conditions as the process sample gas September 24 2001 2 4 PRO903 MANUAL TFS 3 0 INSTALLATION AND OPERATION 3 1 Site Location and Preparation 40 CFR Performance Specification Two 2 provides a guide to proper site selection and lists several points that should be considered for most applications The most accurate readings will usually be obtained when Performance Specification Two 2 is followed The PRO903 Dilution Probe Conditioning
19. cuum Pump 20 inches Hg 70kPa P N 26006022 or equivalent J Standard Hand Tools K High Vacuum Silicone Grease P N 16000003 or equivalent Heated Filter Replacement NOTE The existing heated filter must be replaced with a new one each time the filter cap is removed the filter is slightly crushed to seal Once a crushed filter is removed it will not seal properly and should not be used again A Turn off the Dilution Air Regulator to prevent any contamination in the critical orifice while the filter cap is removed Remove the three nuts that secure the heated filter cap B Remove the main filter cap by pulling straight back on the filter cap tube fitting The filter is snugly fit with an O Ring seal C Remove the filter from the mandrel of the heated filter cap September 24 2001 4 1 PRO903 MANUAL TFS 4 4 4 5 Rev 3 0 D E F G Inspect the filter body and cap for particulate accumulation around the filter seats Clean the filter body and seat by wiping with a soft cloth Lubricate the cap O Ring with a light coating of silicone based high vacuum grease Install the new filter element onto the cap mandrel and insert the cap and filter into the filter body Align the screw holes in the cap with the screw holes in the body and press the cap into the filter body Reinstall the nuts Hand tighten the nuts only Quartz Orifice Replacement The quartz orifice may be changed by removing the eductor
20. distribution of the box purge and heated filter purge air September 24 2001 1 2 PRO903 MANUAL TFS 1 3 4 Rev 3 0 and a place to conveniently mount the four valves for the Probe Conditioning Assembly The four valves include SV 1 the calibration valve used to inject calibration gas in the heated filter chamber SV 2 the 3 way purge valve and SV 3 and SV 4 used to purge the heat exchanger The dilution air regulator is located on the left side of the Air Valve Manifold please refer to the 7000 series Probe Box Assembly Drawings The regulator is 0 60 PSI set at 30 PSI with a 0 60 PSI gauge Heated Filter Dilution Eductor and Probe Barrel Assembly The Dilution Probe Assembly consists of a Hastelloy Probe Barrel and an Eductor Probe Head as shown in Figure 1 3 An Eductor Assembly and a Heated Filter Body make up the Eductor Probe Head A heated high capacity sub micron filter is housed in a Teflon filter body located within the Probe Head and can be easily replaced during preventive maintenance The sampling probe barrel is typically a section of pipe with an outer diameter of 0 67 inches and an inner diameter of 0 50 inches Probe barrel material is selected for compatibility with the process stream and is supplied in Hastelloy C 276 The standard four 4 foot probe barrel has an approximate 5 bend to prevent excess water buildup within the probe barrel in saturated processes EDUCTOR HOUSING ASSEMBLY DILUTION CHA
21. e power to Disconnect Switch DC1 TB 1 and the grounding screws please refer to the site specific wiring drawings DC1 is a UL and CSA approved disconnect switch rated for 10 AWG wire 20 Amps AC A power cable entry to the Conditioning Assembly is supplied through a 34 inch conduit hub Control and Data Lines September 24 2001 3 5 PRO903 MANUAL TFS Connect signal lines using specified shielded cable for control lines for calibration blow back and purge valves A cable entry to the Conditioning Assembly is supplied through a 1 2 inch CGB Please refer to specific installation drawings for each application site 3 4 Dilution Probe Conditioning Assembly Start up A The Dilution Probe Conditioning Assembly start up procedure may be performed only after the installation procedure outlined above has been completed and all wiring and tubing connections have been rechecked for accurate hook ups JT HEATED FILTER CONTROLLER FILTER ASSEMBLY SERIES 9 SERIES 965 TEMP CONTROLLER TEMP CONTROLLER HEAT EXCHANGER CUNTR ER Figure 3 4 Probe Controller Front Panel B Heated Filter and Heat Exchanger temperature controller setup procedure 1 Remove the Watlow controllers from the front panel and check the dip switches on the backs of the controllers both switches should be in the
22. ead Flow Test Configuration ssssssessseessseressresseesseresseesseresseesseeeseesseee 4 5 4 10 Eductor Vacuum Test Configuration onne 4 6 LIST OF TABLES 1 42 Wiring Umbilical Tables a amaan 1 5 34 11 Setup Meni Parameters Lisette iluaed amt all 3 7 3 4 2 Operation Setup EE 3 7 Rev 3 0 September 24 2001 iv PRO903 MANUAL TFS 1 0 1 1 1 2 Rev 3 0 PRODUCT DESCRIPTION Introduction The Installation and Operation Manual provides instruction for basic installation preventive maintenance corrective maintenance and trouble shooting procedures for the PRO903 Dilution Probe Conditioning Assembly and Remote Probe Controller Assembly This manual contains four sections Section 1 Product Description Hardware description instrument operating parameters and physical characteristics Section 2 Theory of Operation Complete functional description Section 3 Installation and Operation Instructions for installation and operation of the Dilution Probe Conditioning Assembly Section 4 Maintenance Routine inspection trouble shooting corrective procedures and repair replacement for major assemblies PRO903 Description The PRO903 Dilution Probe Conditioning Assembly is a three part package Part one is the stack or duct mounted Dilution Probe Conditioning Assembly Part two is the Wiring and Tubing Umbilicals and Part three is the Remote Controller Assembly The Dilution Probe Conditioning Assembly draws condition
23. erature controllers show a temperature within 10 F of the set point On the Heated Filter temperature controller push the M mode key until Aut is on the display and use the up key to enter a 2 The controller will begin an autotune and the Heated Filter temperature will cycle up and down until the controller has set autotune parameters Do not perform the autotune on the Heat Exchanger temperature controller Using a digital thermometer verify the Heat Exchanger temperature is 40 45 F Using a digital thermometer verify the Heated Filter temperature is 275 295 F Verify that the probe enclosure temperature is 100 F Turn on the main air supply from the Air Clean up Assembly and adjust the dilution air supply regulator PR1 to 30 PSI 200kPa Complete the leak flow and vacuum tests outlined in sections 4 8 4 9 and 4 10 Complete a purge cycle on the Dilution Probe Conditioning Assembly The Dilution Probe is now ready to be calibrated with the complete CEM system Absolute Pressure Transducer Checkout Procedure A B C Obtain the current Barometric pressure reading in inches of Hg At the Dilution Probe Assembly locate the Stack Pressure Signal at VCM1 of the Valve Control Watchdog Module terminals 26 and 27 Place an ammeter in series with this signal to measure 4 20 mADC The pressure transducer range is 16 32 Hg Remove the calibration gas inlet tube at the Heated Filter Assembly to al
24. etween the probe assembly and the remote analyzer is 50 feet or less Typical transport flow rates from the Conditioning Assembly to an external analysis system range from 1 5 to 3 0 liters per minute This gives the analytical instruments a response time of 2 to 5 minutes depending upon application which is adequate for most process control and environmental monitoring requirements System response time requirements have been met with the PRO903 Dilution Probe Conditioning Assembly by a three step process Upon extraction from the stack the process sample gas is filtered dried via the heat exchanger and diluted To further simplify the gas conditioning system the process stream is immediately diluted at the sample source using dry air with dew points in the range of 40 0 C to 73 C 40 F to 100 F The dew point of the gas stream leaving the PRO903 Probe is primarily a function of the dilution air dew point Dilution ratios of 16 1 to 100 1 are easily achieved The exit sample dew point of 7 8 C to 37 2 C 0 F to 35 F allows use of unheated sample lines in all but the most extreme environments Operation of the Dilution Probe Conditioning Assembly consists of three modes Sampling Blow back Purge and Calibration Sampling Mode Process gas enters the sampling system at the probe tip and flows down the probe at a low flow rate of 50 300 cc min Particles larger than 5 microns settle out on the probe walls due to the low samp
25. he Conditioning Assembly on the four 4 inch flange using a proper flange gasket and four 2 13 x 3 stainless steel bolts please see Figure 3 1 Probe Head Removal Open the Conditioning Assembly door and locate the Dilution Probe Head Carefully cut and remove the shipping tie wrap from the probe head and support bracket Note the placement of all five 5 Teflon tubes connected to the probe head Loosen each of the Teflon tube connection fittings and remove the tubes Disconnect the cartridge heater and the RTD from the probe box wiring Loosen the probe head securing wing nut located underneath the support bracket Remove the probe head from the bracket and place in a safe clean area during probe barrel installation Probe Barrel Installation Inspect the Probe Barrel Assembly for proper flange spacing and orientation factory set please see Figure 3 3 on the following page Install the probe flange gasket factory supplied over the process end of the probe barrel for sealing process gases from the Conditioning Assembly enclosure Insert the Probe Barrel Assembly through the flange porthole in the back of the Conditioning Assembly with the bend downward Align the three hole probe mounting flange and flange gasket to the three hole pattern of the Conditioning Assembly flange porthole Insert the three 3 supplied 1 4 20 X 1 3 4 inch bolts through the probe mounting flange into the threaded holes and tighten Coat t
26. he eductor inlet port as shown in Figure 4 10 below The hand held vacuum pump is used for its vacuum gauge only With the instrument air pressure of 30 PSIG 200kPa supplied to the eductor air jet the eductor must pull a minimum of 17 inches Hg vacuum September 24 2001 4 5 PRO903 MANUAL EDUCTOR EXHAUST SCH a E TFS C y i LA DILUTION AIR IN 30 PSI a SA HAND VACUUM PUMP ue Figure 4 10 Eductor Vacuum Test Configuration 4 11 Trouble Shooting 4 11 1 Zero Drift Full System Zero drift is independent of the dilution system as any dilution of a zero gas will still cause a zero indication on the analyzer Analyzer zero drift may be caused however by trace levels of the measured gas in the dilution air supply Either obtain the dilution air from a different source or install suitable air cleanup devices to remove the gas of interest Check the analyzer location for large temperature changes or other changes in the analyzer utilities Please see the system manual for zero drift calculations 4 11 2 Span Drift Full System Span drift may be caused by many different variables throughout the monitoring system Most problems with
27. he polished probe tip surface with a liberal amount of silicone based high vacuum grease This allows a proper O Ring seal of the probe head September 24 2001 3 3 PRO903 MANUAL TFS Top Center A CH Mounting Gasket KE va E I j Figure 3 3 Probe Barrel Assembly Probe Head Installation NOTE Before initial installation of the Dilution Probe Assembly and after any probe head maintenance the tests described in Sections 4 9 and 4 10 of this manual should be performed The probe pre test verifies that the Probe Assembly is leak free and has the proper flow rates A B Rev 3 0 Reinstall the probe head by sliding the probe head over the polished probe tip The rear of the probe head is usually tilted upward during installation to allow clearance for the sample outlet fitting Reinstall all items removed during steps B and C of the Probe Head Removal Section 1 Connect the eductor dilution air 2 Connect the eductor exhaust tube 3 Connect the eductor inlet tube 4 Connect the calibration purge tube 5 Connect the sample outlet tube September 24 2001 3 4 PRO903 MANUAL TFS 3 3 2 3 3 3 3 3 4 3 3 5 3 3 6 Rev 3 0 6 Connect the probe filter heater cartridge 7 Connect the RTD on top of the heated filter next to the eductor assembly 8 Check all connections and confirm that the cartridge heater and thermistor are installed to maximum depth Air Supply NOTE Do NOT app
28. ical Table Pair Number Function Signal 1 Heat Exchanger RTD Signal 4 20 milliamp 2 Heat Exchanger Control Signal 0 24 VDC Pulse Modulation 3 Heated Filter RTD Signal 4 20 milliamp 4 Heated Filter Control Signal 0 24 VDC Pulse Modulation 5 Spare 6 Spare 7 Absolute Pressure 4 20 milliamp 8 Spare 9 Spare 10 Spare 11 Calibration Valve Control 0 24 VDC Contact Closure 12 Purge Control 0 24 VDC Contact Closure September 24 2001 1 5 PRO903 MANUAL TFS 1 5 1 5 1 1 5 2 1 5 3 Rev 3 0 Remote Probe Controller Assembly The Remote Probe Controller Assembly monitors and controls temperatures of subassemblies in the Dilution Probe Conditioning Assembly Subassemblies of the Remote Probe Controller Assembly include 1 3 1 2 X 15 X 17 Rack Mount Enclosure with Optional Slides 2 Interface Printed Circuit Assembly 3 Probe Heated Filter Temperature Controller 4 Heat Exchanger Temperature Controller Remote Probe Controller Enclosure The enclosure total length is 15 inches and the enclosure will mount in a standard 19 inch rack excluding the additional space required on the back for connection of the two multiple pin plugs Connection clearances require the rack to be at least 24 inches deep Cannon plug 1 connects to the Dilution Probe Conditioning Assembly and cannon plug 2 connects to the rack controller A power entry module for a standard 115VAC cord connection is also on the back of the enclosure
29. idge rectifier circuit to provide the necessary DC power for driving the TE cooler A shroud fan directs 100 CFM of air over a heat sink to dissipate the heat generated by the TE cooler Probe Power Purge and Temperature Control Probe power purge and temperature control are maintained by three sections a power distribution section a valve controller Watchdog module section and a heated filter control module section These three sections handle all power distribution and the digital interface from the Probe Controller Assembly please refer to the 7000 series Probe Assembly drawings 1 3 6 1 Power Distribution The power requirement is 120VAC 800 watts 60 Hz AC hot is supplied to Disconnect DC1 From DC1 AC hot is distributed to the Valve Controller Watchdog Module the Heat Exchanger Control Module the Enclosure Heater and the Enclosure utility light and outlet TB 2 supplies power and control for the heat exchanger temperature control Please refer to the 7000 series drawings for the fuse schedule 1 3 6 2 Valve Controller Watchdog Module The Valve Controller Watchdog Module controls all valves and contains an internal timer for watchdog functions Purge watchdog control is jumper selectable for intervals of 8 16 32 or 64 minutes 1 3 6 3 Heated Filter Control Module Rev 3 0 The Heated Filter Control Module interfaces with the Watlow controller in the remote probe controller assembly to control the A C heater for mai
30. inlet tube The orifice is sealed in the bore by an O Ring and may be removed by grasping the orifice with tweezers and pulling straight back If the O Ring does not come out with the orifice remove the O Ring with the tweezers Install a new orifice by placing the orifice O Ring on the orifice and inserting the smaller end of the orifice into the orifice bore Probe Head Removal A B C D E F G H D Note the dilution air pressure setting then turn off the power and air supplies Disconnect the air supply tubing to the eductor air jet Disconnect the sample tubing from the eductor exhaust Disconnect the purge calibration tubing from the filter cap Disconnect the raw sample outlet tubing from the bottom of the filter body Loosen the filter body wing nut Remove the heater and RTD from the rear of the filter body Remove the Probe Head from the Probe Barrel Prior to reinstalling the Probe Head coat the polished probe tip surface with a liberal amount of silicone based high vacuum grease This allows a proper O ring seal of the Probe Head Install the Probe Head in the reverse order of removal September 24 2001 4 2 PRO903 MANUAL TFS 4 6 4 7 Rev 3 0 Orifice Holder Assembly Removal A B C D E F G H D J Remove the Probe Head as described in section 4 5 Remove the eductor assembly housing insulated cover Remove the four 4 spring screws and remove the flat washers and s
31. le velocity From the sampling probe the gas enters the heated filter chamber shown in the cross section in Figure 2 2 below The filter body is heated and controlled by an external temperature controller and cartridge heating element between 135 C 146 1 C 275 F 295 F The sample gas then flows from the heated filter chamber through the heated filter and exits from the heated filter body through the filter chamber outlet The glass fiber filter element with a Teflon binder having a 0 1 micron efficiency rating is selected for its inertness to the process gas The filter element may be replaced by removing the filter cap and O Ring The filtered sample gas is then conditioned by the heat exchanger The sample gas is extracted using two precision low flow Eductor Assemblies that are driven by instrument quality air The Heated Eductor Assembly and the Eductor Pump Assembly pull a portion of the total sample flow through the heated filter and the heat exchanger Once the filtered sample gas enters the Teflon heat exchanger cooling block any condensable or entrained liquids are condensed and collected in the liquid reservoir at the lower extreme of the cooling block The heat from the cooling block is removed using a thermoelectric cooler and then transferred to the externally mounted aluminum heat sink The temperature of the block is maintained by the heat exchanger controlling the electronics September 24 2001 2 2 PRO903 MANUAL
32. low the pressure transducer to measure the current Barometric pressure The 4 20 mADC signal should be equal to Barometric pressure in inches Hg minus 12 equals output September 24 2001 3 8 PRO903 MANUAL TFS in MADC Hg 12 mADC Tolerance is 5 0 There are no field repairs or alignment procedures for this component D Reconnect the calibration gas tube to the Heated Filter Assembly Rev 3 0 September 24 2001 3 9 PRO903 MANUAL TFS 4 0 4 1 4 2 4 3 Rev 3 0 MAINTENANCE General The following procedures are designed to allow the maintenance technician to accomplish all necessary maintenance procedures on the PRO903 Dilution Probe Conditioning Assembly With the exception of changing the heated filter element none of these procedures are to be considered as normal maintenance and should only be performed in the event of a calibration failure other trouble shooting procedure or after disassembly of the Heated Filter Eductor Assembly Required Maintenance Equipment To perform maintenance on the sample system the following equipment is required A Vacuum gauge 0 30 inches Hg 0 100kPa B Flow meter 0 500 cc minute P N 29020006 or equivalent C Flow Meter 0 10 L minute P N 29020009 or equivalent D Temperature meter 0 260 C 0 500 F E Tweezers to remove guartz jet F 2 ea 1 4 tube cap Teflon G 2 ea 1 8 FPT pipe cap H Probe Adapter 3 8 pipe to 1 4 tube P N 07990000 I Va
33. ly pressure to the Conditioning Assembly until Start up Section 3 4 This section is for air line connection only The air supply must have a dew point of at least 40 C 40 F A low dew point will prevent condensation in the unheated sample line and reduce sample loss The air supply should have a minimum pressure of 60 PSIG 400kPa to ensure an adequate blow back The typical TFS Air Clean up Assembly meets these requirements Connect a 1 2 inch O D minimum air supply line to the instrument air inlet of the Conditioning Assembly The instrument air supply inlet is accessed through a 1 2 inch stainless steel compression tube fitting located at the bottom of the Conditioning Assembly Sample and Calibration Gas Lines Connect the Teflon sample and calibration gas lines to the appropriate 1 4 inch compression type tube fittings located at the bottom of the Conditioning Assembly The maximum length for the sample and calibration lines varies with individual applications Please refer to the specific installation drawings for each application Vent Line A inch rubber grommet and Teflon tube are supplied for the vent NOTE Fhe sample vent eductor exhaust should never be restricted or pressurized Power A standard 120VAC 15A service is required to operate the PRO903 Dilution Probe Conditioning Assembly Service must be supplied using 12 AWG minimum For long runs where voltage drops may occur 10 AWG may be used Connect th
34. mple path the dilution path the Heated Eductor Assembly pulls a portion of the dry undiluted sample gas from the heat exchanger into the heated eductor sample inlet Please see Figure 2 2 Probe Head Flow Diagram It is then carried through a protection filter and sample critical orifice into the dilution chamber for dilution The protection filter protects against particulate matter that may be dislodged during the heated filter replacement Installed immediately downstream of the heat exchanger this one micron filter protects the heated eductor assembly The filter does not normally require maintenance but visual inspection will reveal when contamination may be present The eductor sample critical orifice contained within the filter jet cartridge is fabricated from quartz The orifice temperature is maintained at 140 5 C 5 5 C 285 F 10 F From the orifice the process gas passes to the vacuum cavity of the dilution eductor The Dilution Eductor Assembly is heated by an extension of the heated aluminum housing From the eductor exhaust port the diluted process gas passes to a vent bulkhead on the Conditioning Assembly enclosure A portion of the diluted sample is pulled through a sample bulkhead and the unheated Teflon sample line by a sample transport pump to the remote analysis system In some cases the Sample Transport Assembly may be eliminated if September 24 2001 2 1 PRO903 MANUAL TFS 2 2 1 Rev 3 0 the distance b
35. ntaining the factory set temperature of 285 F in the heated filter September 24 2001 1 4 PRO903 MANUAL TFS 1 3 6 4 Heat Exchanger Control Module 1 3 7 1 4 1 4 1 1 4 2 Rev 3 0 The Heat Exchanger Control Module interfaces with the Watlow controller in the remote probe controller assembly to control a cartridge heater for cooling the heat exchanger block to a factory set temperature of 45 F Absolute Pressure Transducer The Absolute Pressure Transducer is mounted on top of the purge valve SV2 and produces a 4 20 mA signal representing 16 32 inches Hg absolute pressure Tubing and Wiring Umbilicals The tubing and wiring umbilicals are the main link between the Dilution Probe Assembly and the analyzer rack Tubing Umbilical The tubing umbilical supplies purge and blow back air dilution air calibration gas and the sample return line for the analyzers in the analyzer rack Purge and blow back air is supplied by the 1 2 black polyethylene tube at 60 PSI to the Valve Manifold Dilution air is supplied by the 1 4 black polyethylene tube at 60 PSI to the dilution air regulator Calibration gas is supplied by a 1 4 clear Teflon tube at 30 psi limited to 2500cc minute by flow orifice to the calibration gas inlet on the Valve Manifold The sample outlet is connected to a 1 4 clear Teflon tube to supply the analyzers in the analyzer rack with diluted sample Wiring Umbil
36. o let any grease get in the gasket opening G Reassemble the eductor assembly in the reverse order of disassembly being sure to align the block passages with the gasket opening H The top plate springs measure 2 inch uncompressed Tighten the nuts until the spring height is approximately 3 8 of an inch D Reinstall the Probe Head J Return the air supply to the exact previous pressure Probe Head Leak Test Cap the eductor air inlet dilution air and the eductor exhaust outlet ports then connect a hand held vacuum pump to the eductor sample inlet as shown in Figure 4 8 Pull a minimum vacuum of 20 inches Hg 70kPa with the vacuum pump as shown on the vacuum gauge and record this value The vacuum reading must not drop by more than 0 5 inches Hg 1 7kPa in 1 minute EDUCTOR INLET AND OUTLET N CAPPED OR PLUGGED HAND VACUUM PUMP d dE 2 A HAND VACUUM PUMP gt LS PROBE ADAPTER CAPPED OR PLUGGED SAMPLE OUTLET CAPPED OR PLUGGED Figure 4 8 Probe Head Leak Test Configuration Remove the hand held vacuum pump from the eductor sample inlet port and connect it to the purge calibration inlet heated filter cap Install a probe adapter fitting into the sample probe barrel port as shown in Figure 4 8 Pull a minimum vacuum of 20 inches Hg 70kPa with the vacuum pump as shown on the vacuum gauge and record this value The vacuum reading must not drop by more than 0 5 inches Hg 1 7kPa
37. ompression springs to specification please see Section 4 7 step H or replace gasket Possible Problem Corrective Action Possible Problem Corrective Action Eductor exhaust restricted Check internal and external exhaust vent tubing for restrictions Defective Eductor Air Jet Replace Jet September 24 2001 4 8 PRO903 MANUAL 4 11 9 Rev 3 0 Possible Problem Corrective Action Possible Problem Corrective Action Possible Problem Corrective Action filter Possible Problem Corrective Action Possible Problem Corrective Action 4 7 step H Possible Problem Corrective Action Possible Problem Corrective Action High Span Reading Possible Problem Corrective Action Possible Problem Corrective Action Possible Problem Corrective Action TFS Dirty Main Filter element Replace filter element Sample jet plugged Replace jet Leak at filter body cap Clean or replace filter cap O Ring Check purge calibration gas inlet Leak at probe filter connections Clean probe and O Ring area Apply silicone grease Replace O Rings Leak at orifice holder or eductor gaskets Clean or replace gaskets Check Spring Setting Please see Section Eductor air pressure too high Adjust regulator Defective Regulator Replace Regulator Leak around sample jet Replace orifice O Ring on the orifice holder
38. or third party supplier are not warranted by Seller but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier to the extent such assignment is allowed by such original manufacturer or third party supplier In no event shall Seller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear and tear ii accident disaster or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which Warranty they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage and handling of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty Buyer shall pay Seller therefor at Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER
39. prings Remove the eductor assembly top cap Remove the eductor jet assembly and orifice holder assembly from the eductor assembly housing Gently break the modules apart at the gasket Clean the sealing gasket by removing all hardened vacuum grease Lubricate the gasket with a fresh thin coat of silicone high vacuum grease Do no let any grease get in the gasket opening Reassemble the eductor assembly in the reverse order of disassembly being sure to align the block passages with the gasket opening The top plate springs measure 12 inch uncompressed Tighten the nuts until the spring height is approximately 3 8 of an inch Reinstall the Probe Head Return the air supply to the exact previous pressure Eductor Jet Body Removal The eductor block may be removed as follows A B C D E F Remove the Probe Head as described in section 4 5 Remove the eductor assembly housing insulated cover Remove the four 4 spring screws and remove the flat washers and springs Remove the eductor assembly top cap Remove the eductor jet assembly and the jet cartridge assembly from the eductor assembly housing Gently break the modules apart at the gasket The eductor jet assembly can now be repaired or replaced Clean the sealing gasket by removing all hardened vacuum grease Lubricate the September 24 2001 4 3 PRO903 4 8 Rev 3 0 MANUAL TFS gasket with a fresh thin coat of silicone high vacuum grease Do n
40. rameter press the M mode key These parameters will be automatically entered after the Auto tune is complete Parameter Function Heated Filter Heat Exchanger Settings Settings Pb1 Power Band 1 6 15 rE1 dE1 Reset 1 17 0 15 Ra1 dE1 Rate 1 29 0 1 Ctl Cycle Time 1 1 0 1 0 ALO Low Alarm Setpoint 10 0 5 0 AHI High Alarm Setpoint 10 0 5 0 CAL Calibration Offset 0 0 0 0 Aut AutoTune Function Do Not Autotune Do Not Autotune Table 3 4 2 Operation Setup Menu Auto Tune will be engaged when a value other than 0 is entered into the Aut Parameter When the Auto Tune is complete the value will automatically revert back to 0 C Rev 3 0 September 24 2001 Go to the Dilution Probe Assembly and verify that the dilution air regulator has been 3 7 PRO903 MANUAL TFS 3 5 Rev 3 0 D E F G H D J K L turned off This will keep moisture from contaminating the system until temperature set points are reached Apply power to the Dilution Probe Assembly by turning on the rotary power switch Using a digital thermometer check the temperature of the Heated Filter Assembly and the Heat Exchanger Assembly via the thermocouple port drilled into each assembly Make sure that both temperatures are approaching their set points When both temperatures have stabilized return to the Probe Controller Assembly for the next step At the controller check that both temp
41. rnal components connected to blow back calibration port Corrective Action Check external fittings for leaks Check external valves for port to port leaks High Sample Flow Rate Possible Problem Leak around orifice Corrective Action Either replace 1 Orifice O Ring or 2 Exchange the orifice holder assembly Low Flow Rate at the Eductor Exhaust Possible Problem Eductor air jet plugged September 24 2001 4 7 PRO903 MANUAL 4 11 6 4 11 7 4 11 8 Low Span Reading Rev 3 0 Corrective Action Possible Problem Corrective Action Possible Problem Corrective Action TFS Replace air jet Restricted eductor exhaust tubing Check internal and external exhaust vent tubing for restrictions Pressure Regulator not adjusted correctly or defective Adjust or replace regulator High Flow Rate at the Eductor Exhaust Possible Problem Corrective Action Possible Problem Corrective Action steel jets Possible Problem Corrective Action Regulator pressure set too high Reduce Regulator Pressure Leak around sample orifice Replace Orifice O Ring quartz orifices or orifice holder stainless Leak between orifice holder and eductor body Clean and lubricate gasket with high vacuum grease or replace gasket Low Eductor Vacuum Possible Problem Corrective Action Leak between orifice holder and eductor body Clean lubricate and tighten c
42. robe Enclosure Enclosure Heater Valve Manifold and Dilution Air Regulator Heated Filter Dilution Eductor and Probe Barrel Assembly Heat Exchanger and Drain Valve Assembly Probe Power Purge and Temperature Control Absolute Pressure Transducer NYDN PS L HA ra 1 3 1 Probe Enclosure The Dilution Probe and Conditioning Assembly is housed in a fiberglass enclosure that measures approximately 24 inches H by 24 inches W by 9 75 inches D The enclosure is designed to protect the instruments and electrical controls from highly corrosive atmospheres The PRO903 enclosure has an internal 2 inch aluminum mounting plate with 4 holes that match to standard 4 inch 150 ASI pipe flanges The threaded holes accept 2 13 studs please refer to Figure 3 1 Enclosure Mounting Diagram 1 3 2 Enclosure Heater 1 3 3 Rev 3 0 The enclosure heater is located on the bottom right hand side of the enclosure please refer to the 7000 series Probe Box Assembly Drawing item 17 The assembly consists of one 400 watt heat element a 30 CFM fan and an adjustable thermostat switch The fan motor runs continuously when power is supplied to the probe conditioning enclosure heater The heat element cycles on and off according to the temperature inside the enclosure and the temperature of the enclosure is maintained at 100 F by the adjustable thermostat Valve Manifold and Dilution Air Regulator The Air Valve Manifold provides
43. s and dilutes the process emissions to be transported for analysis The Tubing and Wiring Umbilical connects the Dilution Probe Conditioning Assembly to the analyzers calibration gas supply purge instrument air supply dilution air supply and the Remote Probe Controller Assembly Part three the Remote Probe Controller Assembly monitors and controls temperatures of subassemblies in the probe conditioning assembly and connects the Dilution Probe s alarm and control contact closures with the customer s control system PRO903 Dilution Probe Conditioning Assembly please refer to the 7000 series Probe Box Assembly Drawings 24 x 24 x 9 3 4 Nema 4X Enclosure Enclosure Heater Dilution Air Regulator Heated Filter Dilution Eductor and Probe Barrel Assembly Heat Exchanger and Drain Valve Assembly Heated filter control module Valve control module Watchdog Valve Manifold GO JC LN P Ga H ra September 24 2001 1 1 PRO903 MANUAL TFS 1 3 Tubing and Wiring Umbilical please refer to the 1200 series Umbilical Drawings 1 Tubing Umbilical 2 Wiring umbilicals Paired Wiring Umbilical 12 Shielded Pairs 20 AWG in PVC Jacket Remote Probe Controller Assembly please refer to the 7000 series Probe Controller Drawings Dilution Probe Conditioning Assembly Hardware The PRO903 Dilution Probe Conditioning Assembly consists of seven subassemblies used to condition analyze and transport the sample P
44. ssembly extracts a continuous sample from a stack or duct removes entrained liquids and water vapor and delivers a clean dry sample for transport to a gas analysis system Gas Flow Functional Description A regulated source of instrument air is connected to the dilution eductor jet through the pressure regulator PR 1 and pressure gauge PI 1 The pressure regulator precisely regulates the air pressure to within 0 04 PSI 3kPa for a 10 PSIG 70kPa change in input pressure The flow through the air jet creates a vacuum that pulls the sample gas through the Dilution Probe Conditioning System and is also used to dilute the sample gas to lower concentrations therefore the air supply quality and pressure are vital for proper probe operation The dilution eductor air flow rate is set and controlled by a dilution critical orifice in the air jet operated at 30 PSIG 200kPa to provide the sample gas critical orifice pressure drop of 15 inches Hg 50kPa or greater The dilution air and sample gas flow rate may be set by selecting different orifice combinations Dilution flow rates between 5 and 10 liters minute may be chosen in combination with different process sample gas flow rates between 50 and 300 cc minute to yield dilution ratios between 16 1 and 100 1 The process sample gas and dilution air are combined within the eductor and the diluted sample gas exits the Dilution Eductor Assembly through the eductor exhaust port In the primary sa
45. temperature of 20 C to 50 C 4 F to 122 F This upper temperature is selected to assure proper operation of the electronic circuitry and solenoid valves contained in the enclosure Optimum operation of the sampling system will always be achieved if a sampling location is selected with moderate temperatures Process Pressure The sampling system should not be installed in sampling locations that have pressures which exceed 5 inches H20 1 2kPa or 10 inches H20 2 5kPa Positive pressure ducts are a special problem because process gases may escape into the area of maintenance personnel when the filter body is opened for maintenance Positive pressure stacks or ducts may be easily sampled if a small portion of the stream is vented to atmosphere and the probe installed to sample this atmospheric vent The probe typically pulls between 50 and 300 cc minute requiring only a small bypass flow General Installation Dilution Probe Conditioning Assembly The Dilution Probe Conditioning Assembly is shipped in two separate containers The Conditioning Assembly is installed first and then the probe barrel is installed through the back of the Conditioning Assembly into the stack To install the Dilution Probe Conditioning Assembly perform the steps outlined in the following three sections September 24 2001 3 2 PRO903 MANUAL TFS A B C D E A B C D E Rev 3 0 Conditioning Assembly Installation Install t
46. the sampling system will be indicated by a failure to pass the daily span calibration Failure to pass the daily calibration is subdivided into several different problem areas that would cause a high or low indication on daily calibration For each possible problem a corrective action is listed Please see the system manual for span drift calculations 4 11 3 Low Sample Flow Rate Possible Problem Leak in sample line between filter body and orifice holder Corrective Action check heated filter sample outlet eductor inlet Heat Exchanger inlet Rev 3 0 September 24 2001 4 6 PRO903 MANUAL TFS 4 11 4 4 11 5 Rev 3 0 and outlet and sample line tee compression fittings Possible Problem Plugged Orifice Corrective Action Change Orifice Possible Problem Leak around filter cap Corrective Action Clean O Ring and apply high vacuum grease Replace O Ring Possible Problem Leak at probe connection to filter body Corrective Action Clean probe tip and O Rings area Apply silicone grease to probe and O Rings Replace O Rings Possible Problem Leak between orifice holder and eductor body Corrective Action Tighten compression springs to specification Please see Section 4 6 step H Clean gasket and apply high vacuum grease Possible Problem Low sample vacuum Corrective Action Check probe assembly for leaks Check eductor exhaust line for restriction Possible Problem Leak in exte
47. ty period shall be one 1 year from the date of shipment to Buyer for equipment and ninety 90 days for all other products the Warranty Period Seller agrees during the Warranty Period to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with said published specifications provided that a Buyer shall promptly notify Seller in writing upon the discovery of any defect which notice shall include the product model and serial number if applicable and details of the warranty claim b after Seller s review Seller will provide Buyer with service data and or a Return Material Authorization RMA which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replacement Products shall be made in accordance with the Delivery provisions of the Seller s Terms and Conditions of Sale Consumables including but not limited to lamps fuses batteries bulbs and other such expendable items are expressly excluded from the warranty under this warranty Notwithstanding the foregoing Products supplied by Seller that are obtained by Seller from an original manufacturer
Download Pdf Manuals
Related Search