Micro-GASS™ Model UG-1212 Gas Analysis

Micro-GASS™ Model UG-1212 Gas Analysis
PERMA PURE LLC
Micro-GASS™ Model UG-1212
Gas Analysis Sampling System
User Manual
www.permapure.com
10/2010
2
TABLE OF CONTENTS
Warranty and Disclaimer: ............................................................................................. 5
Warnings........................................................................................................................ 7
Trademarks.................................................................................................................... 7
1.0 System and Component Description .................................................................. 9
MicroGASS™ System..................................................................................................... 9
Particulate Filter............................................................................................................... 9
Nafion® Membrane Dryer ................................................................................................ 9
Sample Gas Pump .......................................................................................................... 10
2.0 Control System.................................................................................................... 10
System Power................................................................................................................. 10
Pump Power ................................................................................................................... 10
Filter Temperature Control ............................................................................................ 10
Dryer Temperature Control............................................................................................ 10
Flow Control .................................................................................................................. 10
3.0 Installation ........................................................................................................... 11
Mounting........................................................................................................................ 11
Electrical Connections ................................................................................................... 11
Electrical conduit connection - ................................................................................ 11
Electrical conductor connections -........................................................................... 11
Heated Line connection – ........................................................................................ 11
Mechanical Connections................................................................................................ 12
Wet Sample Gas Inlet - ............................................................................................ 12
Calibration Gas Inlet -.............................................................................................. 12
Dry Sample Gas Outlet -.......................................................................................... 12
Dry Sample Gas Return -......................................................................................... 13
Exhaust - .................................................................................................................. 13
4.0 Operation ............................................................................................................. 13
Start-Up/Shutdown Procedures...................................................................................... 13
Start-Up.................................................................................................................... 13
Shutdown ................................................................................................................. 14
5.0 Maintenance and Repair ..................................................................................... 14
Periodic checks .............................................................................................................. 14
Sample Gas Flow Rate............................................................................................. 14
Sample Gas Filter..................................................................................................... 14
Coalescing Filter Element Replacement........................................................................ 14
Dryer Element Replacement .......................................................................................... 15
Sample Pump Replacement ........................................................................................... 16
6.0 Appendices.......................................................................................................... 17
Appendix A – Specifications ......................................................................................... 17
Appendix B - Micro-GASS System Spare/Repair Parts................................................ 19
Appendix C – CAL 3300 Temperature Controller Configuration................................. 21
Appendix D – Drawings ................................................................................................ 23
Cutsheet Drawing..................................................................................................... 25
Electrical Diagram ................................................................................................... 27
Flow Diagram .......................................................................................................... 29
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4
Warranty and Disclaimer:
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 any particular use or application are based solely on the general
knowledge of Seller, are intended for information guidance only, and do not constitute any
representation or warranty by Seller that the product shall in fact be suitable or desirable for any
particular use or application; (2) Buyer takes sole responsibility for the use and applications to
which the product is put and Buyer shall conduct all testing and analysis necessary to validate
the use and application to which Buyer puts the product for which Buyer may recommend the
use or application of the product by others; and (3) the characteristics, specifications, and/or
properties of the product may be affected by the processing, treatment, handling, and/or
manufacturing of the product by Buyer or others and Seller takes no responsibility for the nature
or consequence of such operations or as to the suitability of the product for the purposes
intended to be used by Buyer or others after being subjected to such operations.
SELLER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, OF THE PRODUCT
SUPPLIED HEREUNDER, INCLUDING, WITHOUT LIMITATIONS, IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE, AND ALL SUCH
WARRANTIES ARE HEREBY EXPRESSLY EXCLUDED. SELLER SHALL HAVE NO
LIABILITY FOR LOSS OF PROFITS, OR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES UNDER ANY CIRCUMSTANCES OR LEGAL THEORY, WHETHER BASED ON
NEGLIGENCE, BREACH OF WARRANTY, STRICT LIABILITY, TORT, CONTRACT, OR
OTHERWISE. SELLER SHALL IN NO EVENT BE LIABLE IN RESPECT OF THIS ORDER
AND OR PRODUCT DELIVERED ON ACCOUNT OF THIS ORDER FOR ANY AMOUNT
GREATER THAN THAT PAID TO SELLER ON ACCOUNT OF THIS ORDER.
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6
Warnings
WARNING
Thank you for purchasing sample gas conditioning equipment from Perma Pure LLC. We want
your new sample gas conditioning equipment to operate safely. Anyone who installs or uses
this equipment should read this publication before installing or operating this equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and
national codes that regulate the installation and operation of your equipment. These codes
vary from area to area and usually change with time. It is your responsibility to determine
which codes should be followed and to verify the equipment, installation and operation is in
compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National
Electrical Code, and the codes of the National Electrical Manufacturer’s Association (NEMA).
There may be local regulatory or government offices that can also help determine which codes
and standards are necessary for safe installation and operation.
Equipment damage or serious personal injury can result from the failure to follow all applicable
codes and standards. We do not guarantee the products described in this publication are
suitable for your particular application, nor do we assume any responsibility for your system
design, installation or operation. This product should not be operated in any manner that is
inconsistent with its intended use.
If you have any questions concerning the installation or operation of this equipment, or you
need additional information, please call us at 1-800-337-3762.
TRADEMARKS
This publication is based on information that was available at the time it was printed. At Perma
Pure we constantly strive to improve our products and services, so we reserve the right to
make changes to the products and/or publications at any time without notice and without any
obligation. This publication may also discuss features that may not be available in certain
revisions of the product.
Trademarks
Trademarks
Nafion®, Viton® and Teflon® are registered trademarks of EI DuPont de Nemours
Copyright 1996-2010, Perma Pure LLC All Rights Reserved
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1.0 System and Component Description
MicroGASS™ System
The Perma Pure MicroGASS™ system prepares gas samples for analysis by electrochemical
sensor (ECS) and other analyzers when the sample is too humid for analysis but not
condensing at ambient temperature. ECS analyzers suffer reliability problems when the sample
is either too wet or too dry. MicroGASS systems reduce sample humidity to the ideal range for
ECS (typically 20-80%RH), while also removing dust or dirt particles. MicroGASS sampling
systems offer full corrosion resistance and very high selectivity to water vapor, so complex
samples can be processed without loss of analyte gases. Nafion® dryer technology is the
driving force behind this system. Operating as a self-contained unit, the MicroGASS
incorporates a built-in pump to draw the sample gas through a filter and MD-Series™ Nafion®
dryer. Clean sample gas then flows to the sensor where the measurement is made. After
exhausting from the analyzer and returning to the system, the gas passes through a needle
valve and expands, causing a reduction in vapor pressure. It then re-enters the dryer to be used
as a purge gas. Because the purge gas is generated from the sample gas exhaust stream of the
sensor, the MicroGASS gas conditioning process is self-regenerating. No maintenance, other
than regular replacement of the particulate filter element, is required. System power is supplied
by a standard 115 or 220 VAC circuit
Particulate Filter
The particulate filter’s function is to remove small amounts of particulate matter from the sample
stream that could, over time, contaminate the system and degrade performance of the system.
High levels of particulate matter should be removed by alternate means upstream of the
MicroGASS system. This is typically accomplished with a heated filter at the point of sample gas
extraction.
Nafion® Membrane Dryer
The dryer consists of a Nafion® membrane tube housed inside a tubular shell. The sample inlet
portion of the dryer is heated to provide rapid removal of the water and to prevent condensation.
Nafion transfers water vapor with a higher efficiency at elevated temperatures yet will allow for
drying to lower water concentration at lower temperatures. For this reason, only the inlet portion
is heated. As wet sample gas enters the Nafion® tube, water vapor is transferred through the
membrane and carried off by a counter-current gas flow at a reduced pressure. The driving
force for this process is the difference in partial vapor pressure of water between the sample
and purge gas flows. In the MicroGASS system, the dried sample gas flow is returned from the
gas sensor or analyzer, expanded to about 1/2 atm pressure and then passed through the shell
portion of the dryer as the purge gas. While all of this may be confusing and sounds like black
magic, it’s not. The sample gas leaves the system with the same water content that it entered
with. What is important to note is that the majority of the water vapor is essentially shortcircuited inside the dryer. The sample gas flow from the system to the sensor and back is the
only section of the plumbing where the humidity of the sample gas is low and condensation
cannot occur. Some of the water vapor will condense as the sample gas exits the system
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Sample Gas Pump
The sample gas pump draws sample gas from the source, through the dryer and analyzer. By
generating a vacuum in the process, it serves to create the proper conditions for the sample gas
to be used as the purge gas. The pump has a capacity up to 1 lpm and is made from materials
highly resistant to chemical attack.
2.0 Control System
System Power
The system power switch controls power to the temperature controller, filter heaters, and dryer
heaters, System power is on a 2 Amp fuse, located on the control panel. The heated-line
connector is directly connected to the AC power input terminal bock. As a result, the power
switch does not interrupt power to this circuit. There is a 10A inline fuse in this circuit.
Pump Power
Pump power is enabled by the temperature controller when the system reaches the operating
temperature setpoint. With the switch in the ON position, the pump will automatically turn on
when the dryer temperature reaches setpoint. This allows the pump to draw the wet sample into
the system only when the system is ready.
Filter Temperature Control
The particulate filter is thermostatically controlled via a solid state relay and pad style heaters
that are attached to the aluminum housing that surrounds the filter. The setpoint is fixed at 100C
and does not require adjustment.
Dryer Temperature Control
The Nafion® membrane dryer temperature is monitored and controlled by an electronic
temperature controller via a solid state relay and pad style heaters. A type K thermocouple is
used to sense the temperature. The setpoint temperature range is from 35OC to 65OC.
Flow Control – Sample gas flow is measured and controlled by a float type rotameter after
it returns to the MicroGASS. The flow meter should be adjusted to provide a flow of between 0.5
to 1.0 lpm for optimal performance of the system.
Figure 1- Flow Diagram
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3.0 Installation
Mounting
The Micro-GASS enclosure is rated NEMA-4 however, the system is intended for indoor
installation. When choosing a mounting location, choose a location that avoids exposure to
direct sunlight as it may raise the internal temperature beyond the system operating limits. The
system should also not be subjected to extremely cold temperatures. Wall mounting of the
system is required for proper operation of the flow meter. A set of four mounting feet are
supplied for mounting the system on 12.4” centers.
Figure 2 – Mounting Dimensions
Electrical Connections
Confirm the operating voltage on the system nameplate before connecting power.
Electrical conduit connection - The system is supplied via the ½” electrical hub that can
be used to attach sealtite™ flexible conduit or rigid metal or plastic conduit.
Electrical conductor connections - Made at a terminal block located inside the
enclosure near the conduit hub. The MicroGASS system is factory configured for either 115 or
220VAC operation.
Heated Line connection – A three pole Molex style inline connector is provided to supply
10A fused power to a heated line if desired. Voltage will be present at this connector whenever
power is connected to the system. For this reason, it is recommended that the system power be
supplied via a fused disconnect switch.
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Figure 3 – Electrical Connections
Mechanical Connections
All connections to the MicroGASS system are intended to be made with Teflon or
other suitable plastic tubing
Wet Sample Gas Inlet - Compression fitting for ¼″ OD Tubing. To be connected to the
sample gas source via a heat traced line to prevent condensation of the sample gas. Once
the heated sample line is installed, the heated line inlet fitting can be shrunk into place
permanently.
Heat shrink
sealing fitting
Figure 4 – Heated Line Connection
Calibration Gas Inlet - Compression fitting for ¼″ OD Tubing. To be connected to the
sample calibration gas source. Do not exceed 30 psi. Port must be capped when not in use
Dry Sample Gas Outlet - Compression fitting for ¼″ OD Tubing. To be connected to
analyzer’s inlet port
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Dry Sample Gas Return - Compression fitting for ¼″ OD Tubing. To be connected to
analyzer’s outlet port
Exhaust - Compression fitting for ¼″ OD Tubing. This port may be left open to
atmosphere if the gas being sample is non-toxic and non-corrosive or piped to an outside
location or vent/drain. If the port is connected to a remote drain or vent, do not exceed 10 ft
of ¼” tubing or 30 ft of 3/8” tubing to avoid restriction of the flow.
Figure 5 - Mechanical Connection
4.0 Operation
Start-Up/Shutdown Procedures
Start-Up
1. Once all sample, purge, and electrical connections have been made, the system is ready
for operation. Start with the sample flow meter closed and system and pump power
switches in the “OFF” position.
2. Apply power to the system. This supplies power to the heated line if the heated line
power connector included with the MicroGASS system was used. If the heated line
power was supplied otherwise, turn on power to the heated line.
3. Allow adequate time for the heated line to come up to temperature.
4. Turn on the “System Power” switch. This supplies power to the filter heaters and the
dryer heater temperature controller. After a short amount of time, the temperature
controller will display the dryer temperature.
5. Adjust the system (dryer) set-point temperature to 35°C, or 10°C above the maximum
anticipated dew point temperature, whichever is higher. Refer to the Appendix for the
temperature controller instructions.
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6. Switch “Pump Power” switch to the “ON” position. To prevent wet sample gas from
entering the unheated dryer, the sample pump is powered via the temperature controller.
A relay in the temperature controller remains open until the system temperature comes
to within 5°C of the setpoint at which point, the pump will turn on. The system will require
less than 5 minutes before the operating temperature is reached but pleas allow about
15 minutes for the balance of the system to come to a stable temperature.
7. Slowly open the valve on the flow meter by turning counterclockwise, adjust the flow to
the desired rate (0.5 to 1 lpm). Lower flows result in dryer gas samples. Samples with a
dew point of greater than 35°C should be run at no more than 0.5 lpm.
Shutdown
1. To prevent wet gases from condensing in the Nafion dryer, follow this procedure to
purge wet sample gas from the system before shutting down.
2. With system and pump power switches both in the “ON” position remove the filter cap
from the bottom of the enclosure (Check condition of the filter element.)
3. Allow the pump to run for about two minutes.
4. Turn the power switches to the “OFF” position and replace the filter cap.
5.0 Maintenance and Repair
Periodic checks
Sample Gas Flow Rate
Check daily for proper flow rate in the range of 0.5 to 1.0 lpm
Sample Gas Filter
Check frequently for excessive buildup if particles on the outside of the element or if a
noticeable loss of gas flow is detected and can not be adjusted with the flow meter needle valve.
Coalescing Filter Element Replacement
The filter element should be checked regularly to ensure that the element is in good condition. If
the filter is dirty or causing a flow restriction, replace the filter element.
1. Remove the filter cap and element.
2. Inspect the o-ring for damage and replace if necessary.
3. Fit new filter element to raised portion of the filter cap and replace filter cap.
4. Tighten until snug, do not overtighten.
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Dryer Element Replacement
Under the operating conditions specified, the Nafion® dryer element should last for several
years. However, if the element becomes wet, clogged, or dirty it may require replacement.
Disconnect the system power source before continuing
1. Remove four (4) screws from filter housing flange.
Remove these screws
2. Open cover and lift control panel to gain access to the system components.
3. Disconnect the tube running from the pump to the dryer exhaust at the dryer end.
Remove tube at
this location
4. Using a 3/32” Allen wrench, remove the dryer exhaust fitting from the dryer
3/32” Allen socket for
fitting removal
5. Disconnect both tubes from the opposite end of the dryer.
6. Using a 3/32” Allen wrench, remove the side fitting at the opposite end of the dryer to
allow it to slip through the heated section.
15
Remove this fitting
7. Cut the wire tie that holds the dryer in a loop.
8. Pull gently on the filter housing flange and slip the entire filter/dryer assembly out of the
system.
9. Refer to the MD dryer element replacement instructions and replace the dryer element.
Sample Pump Replacement
Under the operating conditions specified, the sample should last for more than a year under
typical conditions.
Remove the four mounting screws, disconnect the electrical connector and tubing from the
pump. Remove pump.
Remove these
four screws
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6.0 Appendices
Appendix A – Specifications
SAMPLE GAS INLET TEMPERATURE
65°C (150°F) MAX.
30 PSIG MAX.
SAMPLE GAS PRESSURE/VACUUM
-1 in. Hg MIN.
SAMPLE FLOW RATE
0.5 to 1.0 LPM
ELECTRICAL REQUIREMENTS
(Not including heated line power of 10A max.)
115VAC, 1.2A
220VAC, 0.6A
GAS INLET/OUTLET FITTINGS
¼” TUBE COMPRESSION FITTINGS
OPERATING ENVIRONMENT
10°C to 40°C AMBIENT, 0 to 95% R.H.
NAFION TUBE INNER DIAMETER
0.060" +/- 10%
SAMPLE GAS INLET HUMIDITY (DEW POINT, ºC)
SAMPLE GAS INLET HUMIDITY (% BY VOL.)
SOLUABLE GAS REMOVAL RATES
55°C (130°F) MAX.
15% MAX.
GAS
% LOSS
NO
0
NO2
0
SO2
0
CO
0
CO2
0
H2S
0
HCl
0
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Appendix B - Micro-GASS System Spare/Repair Parts
Part #
Description
UG-0000-02-01
100018
MD-070-24E-F
MD-070-24F-R
UG-FE
UG-1212-PUMP
UG-FM
100396
101212
100403
Filter cap/element holder
O-Ring, Viton® for filter cap
Nafion® dryer element only, 0.070" O.D., 24" length
Nafion® dryer assembly, 0.070" O.D., 24" length element
Micro-GASS filter element (package of 5 elements)
Pump, 24VDC
Flow meter, sample gas (0-1.2 L/min)
Solid state relay, dryer or filter
Power supply, 24VDC
Temperature Controller
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Appendix C – CAL 3300 Temperature Controller Configuration
1
For all Micro-GASS systems with the CAL3300 Temperature controller, perform the following
setup procedures.
a
Power Up - Apply power to the system and wait for the controller to perform its self test
routine. The display will then be alternately flashing “nonE” and “inPt”.
b
Input sensor type - Press and hold º key. Press S key repeatedly to select the “tc K”
option for K type thermocouple. Release both keys.
c
Input unit type - Press the S key once. The display will then be alternately flashing “unit”
and “nonE”. Press and hold the º key. Press S key repeatedly to select the “OC” unit.
Release both keys.
d
Input setpoint 1 type - Press the S key once. The display will then be alternately
flashing “SP1.d” and “nonE“. Press and hold the º key. Press S key once to select the
output device ”SSd”. Release both keys.
e
Input the maximum temperature setpoint - Press and hold the T key until “LEVL”
appears. Press and hold the º key. Press the T key to move to level 2. Release the two
keys. Press and hold the S key until “hi.SC” appears. Press and hold the º key. Press
the T key until “65” appears. Release the two keys.
Input the minimum temperature setpoint Press the S key once. “Lo.SC” appears.
Press and hold the º key. Press the S key until “45” appears. Release the two keys.
f
2
3
Configure the low temperature alarm.
a
Configure SP2 relay as alarm - Press and hold S and T keys simultaneously for 3
seconds to enter the program mode. Release the two keys. The display will then be
alternately flashing “tunE” and “oFF”. Press the T key once. The display will then be
alternately flashing “LEVL” and “1”. Press and hold the º key. Press the S key once to
move to level 2. Release the two keys. Press and hold the S key until “SP2.A” appears.
Press and hold the º key. Press the S key until the display reads FS.Lo. Release the two
keys. The display will then be alternately flashing “SP2.A” and “FS.Lo”.
b
Save configuration into memory - Press and hold S and T keys simultaneously for 3
seconds. The display will then be alternately flashing the process temperature and “PArK”
indicating that no setpoint temperature has been entered.
Set the control setpoint and auto-tune the controller.
a
Input the control setpoint temperature - Press and hold the º key. Hold the S key until
the display goes from 0 to 65.
b
Auto-tune the controller - Press and hold S and T keys simultaneously for 3 seconds to
enter the program mode. Release the two keys. The display will then be alternately
flashing “tunE” and “oFF. Press and hold the º key. Press the S key until “At.SP”
appears. Release the two keys. Press and hold S and T keys simultaneously for 3
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seconds to exit the program mode. The display will then be alternately flashing “tunE”,
“At.SP” and the actual process temperature. Allow the controller time to auto-tune. When
tuning is complete the display will show only the actual process temperature. This process
may take up to an hour.
4
Enable low temperature alarm.
a
Input the alarm setpoint - Press and hold the T key until “LEVL” appears. Press and
hold the º key. Press the T key to move to level 1. Release the two keys. Press and hold
the S key until “Set.2” appears. Press and hold the º key. Press the S key until “32”
appears. Release the two keys. This alarm will control the sample pump so that it will
automatically turn off at any time that the temperature is below 32OC.
22
Appendix D – Drawings
23
24
Cutsheet Drawing
25
26
Electrical Diagram
27
28
Flow Diagram
29
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