PERMA PURE LLC Baldwin™-Series Model M8B Tester’s Choice Portable Sample Conditioning System User’s Manual PERMA PURE LLC 8 Executive Drive ▪ P.O. Box 2105 ▪ Toms River, NJ 08754 (732) 244-0010 ▪ (800) 337-3762 ▪ fax (732) 244-8140 ▪ www.permapure.com ▪ [email protected] Model M8B User’s Manual PERMA PURE LLC Doc. #580: Revision: 000 Page 2 of 22 Contents Introduction......................................................................................................................3 General description............................................................................................................4 Specifications....................................................................................................................6 Connections...................................................................................................................6 Important Safety Warnings.................................................................................................7 Connection & Start-up........................................................................................................8 Sample and Drain Connections.........................................................................................8 LED Summary.............................................................................................................. 10 Start-up......................................................................................................................... 11 Set Points....................................................................................................................... 12 Shutdown.......................................................................................................................12 Replacement Parts........................................................................................................... 15 Appendix A: Installation of Peristaltic Pump........................................................................ 16 Appendix B: Drawings..................................................................................................... 17 B1: 4S-M8 flow diagram............................................................................................... 17 B2: Impinger schematic ............................................................................................... 17 B3: Relay board contact state ....................................................................................... 17 B4: Relay board field connections.................................................................................. 17 B5: Interconnect diagram............................................................................................. 17 Appendix C: Perma Pure Sample Pump Maintenance Instructions........................................... 18 Appendix D: Dual Stream Operation.................................................................................. 19 Appendix E: Conversion Tables......................................................................................... 20 Appendix F: Warranty and Disclaimer ................................................................................ 22 PERMA PURE LLC Model M8B User’s Manual Doc. #580: Revision: 000 Page 3 of 22 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 every 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. (cid:153) 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. (cid:153) 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 M8B – Testers’ Choice Portable Sample Conditioning System (1) Power cord (1) User’s manual 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 support, 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: [email protected] website: www.permapure.com The Testers Choice Portable Sample Conditioning System can be either used for intermittent or continuous operation. It is designed for accurate, repeatable and precise gas sample conditioning that can be effectively carried out nearly anyplace and at anytime. This unit is also designed to require only a minimum amount of maintenance to maximize its operation. 3 COPYRIGHT 2008, ALL RIGHTS RESERVED Model M8B User’s Manual PERMA PURE LLC Doc. #580: Revision: 000 Page 4 of 22 General description The Perma Pure/Baldwin Tester’s Choice Model M8 Thermo-Electric cooler features a complete gas conditioning system in one easy to manage enclosure. The unique design leaves additional space to install or access other sample conditioning system components. A unique drop-down door on the M8 cooler section, provides easy access to electronic boards and the power supply. All electronic boards (control, relay, and display) are mounted on the door of the cooler for easy access. Sample pump and peristaltic drain pump(s) are also mounted within the enclosure. The process of 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 components of interest. The Tester’s Choice M8 System is an ideal way to decrease the dew point of combustion gases to a repeatable, stable, constant low dew point. The Tester’s Choice M8 system prevents water condensation in sample pre-filters, sample pumps, and gas analyzers. For gas analyzers where water vapor is an interferent, a stable, repeatable, dew point, becomes a part of the gas analyzer performance specification. The Tester’s Choice system provides this constant low water concentration, resulting in an accurate component gas measurement. Figure 1: Thermo-electric element (Peltier) The Tester’s Choice M8 system removes the moisture from the sample gas by cooling the gas as it passes through a laminar impinger (heat exchanger). A diagram showing the gas flow path through an impinger is shown in the Appendix B2. The impinger, made of 316L stainless steel, Durinert® (a corrosion-resistant inert coating over 316L stainless steel), PVDF (Kynar®), or glass, is mounted within a thermally insulated heat transfer block bored to receive the impinger without a mechanical lock. This assembly allows the easy removal of any impinger 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 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 as a sensor. PERMA PURE LLC Model M8B User’s Manual Doc. #580: Revision: 000 Page 5 of 22 Figure 2: Heat Exchanger, Impinger and Heat Sink The Tester’s Choice M8 system will reduce the sample gas dew point to 5°C at a maximum flow of 8 Liters Per Minute (LPM). This is slightly above the temperature that the condensate removed from the gas stream will freeze. If the condensate freezes sample analysis and gas stream flow will be compromised. If a lower dew point is necessary, a Perma Pure LLC Supplemental Drying System (S.D.S.) may be necessary. A sample gas stream that contains significant amounts of SO3 may also be encountered. Perma Pure LLC/Baldwin can supply SO3 Aerosol Removal Systems, specifically for this purpose. Please contact Perma Pure LLC for suggestions on alternative devices. Perma Pure LLC has a system and expertise that can handle nearly any sample conditioning application. 5 COPYRIGHT 2008, ALL RIGHTS RESERVED Model M8B User’s Manual PERMA PURE LLC Doc. #580: Revision: 000 Page 6 of 22 Physical Description • Two channel system • 2 x 10” heat exchangers connected in series or parallel • 2 Active (cooled to 5°C) heat exchangers • LCD temperature display and LED status indicators • Dimensions: 14.5” x 11” x 10.5” HWD (37 x 28 x 26.5 cm) • Weight: 53 lbs (24 kg) Specifications Sample gas flow range Up to 8 LPM (17 scfh) Water content 20% H O (60°C DP) 2 Maximum cooling rate 440 BTU/ht (464 kJ/hr) Maximum inlet sample temp. 400°F (205°C) for SS or glass impingers 280°F (138°C) for Kynar™ impingers Maximum inlet pressure 15 psig (1 bar) Maximum pressure drop <+1 in H2O Ambient temperature range 33-114°F (0.6-43°C) Outlet sample gas dew point 41°F (5°C) Voltage 115VAC (230VAC optional) 50/60 Hz Power supply 1000W Cooling down time Less than 10 minutes Connections • Sample gas inlet: Kynar, 1/4” tube compression fitting • Sample gas outlet: Kynar, 1/4” tube compression fitting • Drain tubing connection: Kynar, 1/4” barbed tube fitting PERMA PURE LLC Model M8B User’s Manual Doc. #580: Revision: 000 Page 7 of 22 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. • 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. • Sample gas is potentially dangerous. A leak test is recommended 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. • 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. • 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 this equipment. • NEVER replace fuses with types other then the same specification of type and current. Do not bypass this, or any, safety device. • NEVER operate this equipment if it is visibly damaged or the possibility exists that it may have been damaged. • The use of components that have not been purchased through an authorized Perma Pure LLC dealer or directly from Perma Pure LLC 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. • Please heed all warning labels that are on the equipment. They are there to remind you of possible hazardous conditions. • Verify the integrity of any mechanical and/or electrical connections that are made to the Testers Choice Portable Sample Conditioning System. o Verify that the unit is connected to the proper rated power for the system o Verify that the unit is plumbed properly to operate effectively o Do not block either the cooling air inlet or outlet on the rear of the cabinet. The efficiency of the unit will be compromised and long term use in this condition could permanently damage the cooling system. 7 COPYRIGHT 2008, ALL RIGHTS RESERVED Model M8B User’s Manual PERMA PURE LLC Doc. #580: Revision: 000 Page 8 of 22 Connection & Start-up The Classic Tester’s Choice portable sample conditioning system should be set up away from any heat sources in a well vented area. The system can only be operated in an upright position. The conditioning system must not be set up at an angle greater than 30° from vertical. 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. The Tester’s Choice portable sample conditioning system can be either used for intermittent or continuous operation. It is designed for accurate, repeatable and precise gas sample conditioning that can be effectively carried out nearly anyplace and at anytime. This unit is also designed to require only a minimum amount of maintenance to maximize its operation. Sample and Drain Connections 1. Connect a suitable condensate drain line to the connector on bottom of unit. NOTE: Do not reduce the size of the condensate tubing since doing so restricts water flow resulting in water carryover into the sample. 2. Run the external drain line to appropriate drain receptacle. Drain condensate can be potentially hazardous. Always make sure that proper precautions are taken regarding personal protective equipment when handling condensate. 3. Connect the sample line to the stainless steel sample inlet compression fittings on the rear of the unit. See figure 3. NOTE: If using stainless steel sample line, place 2 inches of Teflon tubing in between the exchanger 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. Figure 3 - Gas connections PERMA PURE LLC Model M8B User’s Manual Doc. #580: Revision: 000 Page 9 of 22 The Tester’s Choice M8 will condition a single gas stream in its standard configuration only. A second, parallel gas stream connection and the associated hardware are available as an option. If this option was purchased, see Appendix D for instructions. 4. Connect the conditioned sample outlet connector to the sample gas line leading to the analyzer. 5. Connect the supplied power cord to the receptacle on the rear of the unit. See figure 4. Figure 4 - Power connection Do not power up the unit at this time. Verify that the proper supply voltage is available to power the Tester’s Choice M8. 9 COPYRIGHT 2008, ALL RIGHTS RESERVED Model M8B User’s Manual PERMA PURE LLC Doc. #580: Revision: 000 Page 10 of 22 LED Summary The controls for the M8 cooler are visible through the main door’s window. The M8 is a two channel cooler that can flow up to 8 LPM of a gas stream, reducing the dew point to 5°C or less. There are several indicators and a display to provide operational information on the status of the cooler. The temperature of either channel can be selected and viewed on the LCD display. Simply move the toggle switch on the front panel in the direction of the channel, to display the temperature on the LCD. Figure 5 - Front display panel There are 2 sets (one for each impinger) of 3 LED status displays, 1 red and 2 green. These indicators are arranged vertically on the front of the cooler. See figure 5. ● “Failure” Red LED comes on if the thermocouple or an electronic controller component has failed. ● “Slip” Green LED comes on when powered up. ● “Ready” Green LED comes on when the ready set-point temperature (+10°C) is reached. NOTE: “Slip” LED is connected 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. The sample pump will begin operating once the green READY indicators are both lit.