CleanAIR SGC4000 Installation and Maintenance Manual Sample Gas Installation Guide

CleanAIR SGC4000 Installation and Maintenance Manual Sample Gas

Clean Air Engineering, Inc.

Clean Air Engineering designs and manufactures a variety of gas sampling systems and source testing accessories. This include sample gas conditioners, automatic and manually controlled flow panels, sample gas probes, and continuous moisture monitoring systems. Our products include the following

• Sample Gas Conditioners
• Computer Controlled and Manually Operated Flow Panels
• Sample Gas Probes
• Water Intrusion Monitors
• Continuous Moisture Monitoring Systems

Clean Air Engineering specializes in solving your environmental challenges by offering the following services

Mobile Emissions Source Testing Laboratory

• Analytical Services
• Diagnostic Services
• Consulting Services
• CEM System Services
• Air Toxics Testing
• Instrumental Rental
• Training Services

Call or Fax us today to find out how we can be of service to you. You can reach us by phone at 800-223-3977, or by Fax at 847-991-8924

INSTRUCTIONS

To Avoid Accidents

• Keep your work area clean and well lit.
• Keep bystanders away.
• Exercise common sense.

Electrical Safety

• Do not operate in combustible environments.
• DO NOT operate these products when wet or in water.
• ALWAYS be sure that the components of this system are running with the correct voltage (120V).
• Never remove a grounding prong or modify a plug.
• Do not abuse the power cord or plug. Remove by handling plug only.

Personal Safety

• Stay alert and watch what you are doing.
• Dress appropriately. Wear the appropriate personal safety devices.
• Calibration and/or flue gases can be hazardous to human health. Be sure that all lines are properly vented to an open area.
• Check the system for leaks after installation.

Equipment Maintenance

• Maintenance and repairs should be performed only by one of Clean Air Express’s trained technicians.

Customer Feedback

Clean Air Engineering takes pride in our quality products and services. We strive to provide the highest quality products and services in the industry. We realize the importance of end user input in the continual improvement of our products and services. Customer feedback is of paramount importance. We encourage your feedback with any suggestions or problems that can help us improve our performance. A customer feedback form is available online at http://www.cleanair.com/About/feedback.html. To emphasize our commitment to quality products and complete customer satisfaction, Clean Air Engineering’s manufacturing division, Clean Air Engineering Express, offers what we feel is the best and most comprehensive warranty in the environmental industry.

Safety
Safety should always be considered first, and proper safety procedures should be followed.

Weight and Bulk
The Sample Gas Conditioner – SGC 4000 weighs approximately 30 pounds (13.6 kg) and has dimensions of 15” x 17” x 6.5” (381mm x 431.8mm x 165.1mm). Remember to use good lifting technique in order to avoid injury. Two persons should be utilized if necessary. Do not attempt to carry the weight yourself if you do not feel comfortable doing so.

Pump Cleaning
When flushing the pumps, a nonflammable flushing solvent should be used.
WARNING!! Do NOT use kerosene, gasoline or any other flammable liquid to flush the pump!! Harmful vapors can result in personal injury or damage to the pump itself.

Electrical Shock
The system is powered by a standard 120 VAC line, meaning potentially fatal shocks are possible. It is no more dangerous than many household appliances in this regard; however, care must be taken to avoid shock. Before performing any maintenance or removing the back cover, turn off and unplug the console from the 120 VAC line. Be sure that the correct voltage is used in order to help prevent accidents.

Introduction

Clean Air Engineering Express’ Sample Gas Conditioners are positive pressure, thermoelectrically cooled conditioning units that remove condensed water from the sample gas stream without dilution or loss of sample gas pressure to the analyzer system. Sample Gas entering the conditioner passes through a corrosion resistant pump where it is compressed before entering the thermoelectrically cooled heat exchanger. After the sample gas passes through the pump, the remainder of the system is under positive pressure that eliminates the problems caused by negative pressure leaks. The heat exchanger removes water from the sample gas by condensation as it passes through a zigzag path in a thermoelectrically cooled corrosion resistant plate. Condensed water collects in small water sumps built into the bottom of the heat exchanger. The entire heat exchanger is under positive pressure so the water collected in the sumps can be discharged continuously without dilution of the sample gas, thus allowing continuous operation. The conditioned Sample Gas exits the unit under positive pressure allowing the low-dew-point conditioned sample gas to be directed to any flow distribution panel or directly to on or more instruments.

Theory of Operation

The theory governing the operation of a condensation type sample gas conditioning system has been in existence for a number of years, and therefore will not be discussed in detail. Basically, the following three areas of consideration apply to Clean Air Engineering Express Sample Gas Conditioners

1. Positive Pressure Sample Gas System (Optional)
2. Thermoelectric Cooling Modules
3. Flat Plate Heat Exchanger

Positive Pressure Option

Positive pressure operation is highly desirable to eliminate changes in sample gas concentration that may be caused by negative pressure leaks in the sampling system. Clean Air Engineering Express can supply an optional pressure pump, installed in the Sample Gas Conditioner for this purpose. In a positive pressure system, any leaks that do occur are outgoing and will not cause changes in the Sample Gas Concentration. When leaks do occur, they will be evident by a reduction in sample gas flow rate. Any leaks that cause prohibitive reduction in the flow rate may be easily detected by the application of bubble solutions at the suspected location of the leak.

Thermoelectric (Peltier) Coolers

Thermoelectric coolers provide the cooling for the single sided, flat plate sample gas heat exchanger. The solid state, Peltier coolers are arranged on one side of the corrosion resistant metal plate to transfer heat from the sample gas to a finned heat sink that is cooled by fan driven forced air convection. The temperature of the sample gas heat exchanger is controlled by a thermocouple, temperature controller and DC power supply connected to the Peltier coolers.

Sample Gas Heat Exchanger

The primary purpose of the heat exchanger is to lower the temperature of the sample gas so that water vapor contained in the gas sample will be condensed, separated and discharged from the sample gas stream, without absorbing the sample gas.

Heat Exchanger Plate

The heat exchanger plate transfers the majority of the heat contained in vaporized water that is condensed out of the sample gas. The plate must be capable of transferring the heat without reacting with or being corroded by the sample gas stream, regardless of its composition. Flow channels are available in a variety of corrosion resistant materials and are of an open channel design to minimize scrubbing of sample gas and to prevent clogging.

Water Sump/Discharge System:
The water separated from the sample gas is collected in a water sump built into the heat exchanger. This water is drained from the water sump by a Peristaltic pump that operates continuously, so long as power is applied to the conditioner.

Thermoelectric Cooler- Power Supply

The Thermoelectric Cooler (Peltier cells) is powered by a dual voltage power supply, controlled by a solid-state temperature controller. When the temperature controller calls for full power (“Heat”) pilot lamp is off. A double-pole, doublethrow relay located in the power supply is activated, causing the power supply to deliver maximum voltage to the Peltier cells until the cold plate temperature sensing thermocouple reaches the proper temperature. When the desired temperature (temperature controller set point) is reached, relay contacts in the controller open causing the relay in the power supply to open. This action lowers the power supply voltage by connecting one of the two transformer secondary windings (normally connected in series during maximum cooling) and also connects a high wattage resistor in series with the full wave bridge rectifier to provide the low voltage and current power supply output. The low power setting is required in order to prevent freezing up the heat exchanger and still not allow heat to transfer from the cooling fins back through the Peltier cells and into the heat exchanger as would be the case if the power to the Peltier cells were simple turned off.

High Temperature Manual Reset Thermostat
The high temperature thermostat is mounted on the thermoelectric cooler, finned heat sink. This device will operate to interrupt input power-to-power supply in the event that the heat sink temperature exceeds 175°F, to provide a safeguard for the Peltier Cells in case the cooling fan fails. In order to manually reset the high temperature thermostat a button accessible through a hole in the thermoelectric cooler fan shroud needs to be depressed.

Temperature Controller
The Watlow Series 965 Temperature Controller (Figure 2-1) is currently being installed in all Sample Gas Conditioners starting with serial number PL- 005910203. This controller has been up-graded from the previous type to provide additional features and greater reliability. The following tables show the default setup parameters for the Watlow Series 965 Temperature Controller (Table 2-1 and Table 2-2).

Table 2-1 Clean Air Engineering Express’ Default Settings

Table 2-2 Default Operating Parameters

Figure 2-1 Watlow Temperature Controller – Series 965

Unpacking

Unpacking

The Sample Gas Conditioner is shipped in a plastic bag, surrounded with Styrofoam packing material to prevent damage, and packed in a cardboard shipping container. To unpack, open the box and extract the unit from the packing material.

• At this time, check each item against the packing slip and inspect for any physical damage. Report all Physical Damage to the freight company.
• Spare parts, optional equipment and/or manuals will be in the shipping container along with the conditioner.
• Do not discard packing until all items on the packing slip have been accounted for. Report all shortages to Clean Air Engineering Express.
• All claims for shortages must be reported within 10 days after receipt of shipment.

Installation

The Sample Gas Conditioner is contained in a single enclosure measuring 15” x 17” x 6 ½” (W x H x D). The unit is designed for bulkhead (wall) mounting in a location protected from the weather. Ideally, this location should be close to the emission stack. When mounting the unit, provide sufficient clearance for access to all cover mounting screws. Electrical power required to operate the unit should be provided using grounded duplex outlet box located within six feet of the unit if AC Power cord installation is used. The unit requires 120 VAC – 50/60 Hz at 5A.

Note: For maximum cooling efficiency, the Sample Gas Conditioner should not be installed in locations where the ambient case temperature will exceed 100°F.

Sample Gas Connection
Sample gas enters the conditioner through a ¼” Nylon bulkhead Swagelok tube fitting (sample gas inlet), located on the upper left side of the unit as shown in Figure 3-1. Conditioned Sample Gas exits the conditioner through a second ¼” bulkhead fitting (sample gas outlet), also located on the left side of the unit.

Heat Exchanger Water Sump Drain Connection
The collected sump water is discharged through a drain fitting that exits the conditioner case on the bottom as shown in Figure 3-1. This fitting should not be restricted or blocked.

Figure 3-1 Sample Gas Conditioner Component Location

Operation

Initial Parameter Setup
In order for this conditioner to function as designed, the operator must understand the consequences of various control actions. Please read Section II Theory of Operation. The explanation will greatly assist in the initial parameter setup.

Note: This conditioner has been operated at Clean Air Engineering Express’ facility for a minimum of 72 continuous hours before it was packaged for shipment; all control functions have been tested by Express to assure that the unit is ready for immediate use by the customer.

Sample Gas Conditioner Operational Test

Note: The conditioner must be installed as described in Section III before proceeding with the following instructions.

Steps

1. On Sample Gas Conditioner, Turn Main Power switch, located on the lower left side of unit to ON
2. Verify Cooling Fan is operating
3. Verify that the Peristaltic drain pump is operating
4. Observe that PROCESS temperature and current Set Point temperature are displayed on the digital temperature controller
5. On Temperature Controller, use Up-Down arrow keys to change Set Point to 035°F
6. After 10 minutes have elapsed, turn PUMP POWER switch to ON
7. After an additional 10 minutes has elapsed, perform the following steps to establish the Optimum Set Point* (OSP)
8. Using the UP-DOWN arrow keys, change the displayed Set Point temperature to 5°F above the displayed PROCESS temperature
9. Verify that the LD indicator lamp (on the left side of the temperature controller) cycles on and off and the displayed PROCESS temperature remains within +-3°F of Set Point

Note: The Optimum Set Point (OSP) is based on three interrelated fa ctors;

1. The temperature of the sample gas at the conditioner’s Sample Gas Inlet
2. Flow Rate of the Sample Gas
3. The conditioner’s Cooling Capacity

Setting Specific Sample Gas Temperature
If a specific sample gas temperature laving the conditioner is required, the following procedure should be performed

Steps

1. Insert a temperature reading thermocouple device in the sample gas outlet line. A street “T” with thermocouple extending into the gas stream works well.
2. On Temperature Controller, reset the “Set Point” to 020°F
3. Observe temperature reading on temperature reading thermocouple device and determine that desired sample gas outlet temperature can be obtained. If the desired temperature can be obtained, proceed to step (4). If the desired temperature cannot be reached, the thermoelectric cooler/heat exchanger combination does not have sufficient power to cool the sample gas to the required temperature.
4. If the sample gas outlet gas flow rate is above the minimum required, it can be reduced to lower the temperature.
5. If the minimum acceptable flow rate does not produce the temperature desired, it may be advisable to install a free convection pre-cooler consisting of 5 to 10 feet of coiled stainless steel tubing to reduce sample gas temperature before it enters the gas conditioner sample gas inlet. If the desired sample gas outlet temperature still cannot be obtained, contact Clean Air Engineering Express regarding possible modifications to achieve the desired temperature.
6. If a stable temperature at or below the desired temperature can be achieved using the above procedures, the temperature controller Set Point can be adjusted to the desired sample gas outlet temperature (LED cycles ON and OFF).

Note: Setting the Sample Gas Outlet Temperature too low may require the cooler plate in the heat exchanger to operate below 32°F. This will probably result in freeze up of the heat exchanger.

Setting Low Power Level for Thermoelectric Cooler
The Thermoelectric Cooler is temperature controlled by cycling between a maximum/minimum power applied to the Peltier cells. The minimum power setting was adjusted for normal operation before shipment and should need no further adjustment unless the following conditions are observed.

• If the temperature controller does not cycle between high and low power (LED cycles ON and OFF), with LED ON at least 10% of the time, the low power setting may require adjustment.
• Note: The ideal cycle time is 25% ON and 75% OFF with the unit operating under normal conditions.

To adjust the low power setting perform the following procedure

Steps

1. Disconnect power to the Sample Gas Conditioner
2. Remove cover from the conditioner and locate the adjustable power resistor mounted above the power supply on the right side of the conditioner.
3. Loosen screw securing the adjustment band and slide the band to increase the resistance (Move adjustment band towards the end of the resistor that has no wire connected).
4. Reconnect power to the conditioner and operate the conditioner under normal gas sampling conditions.
5. Wait for temperature controller to cycle ON and OFF and observe the ON/OFF cycle times. If not close to 25% ON and 75% OFF, repeat steps 1 through 4.
6. When adjustment is complete disconnect power and reinstall cover.
7. Operate Sample Gas Conditioner as required.

Routine Maintenance and Inspection

CAUTION!! – Do NOT disassemble this product! For internal maintenance contact Clean Air Express.

Maintenance Issues
For any other maintenance issues, concerns, or questions, please contact Clean Air Express at (800)-223-3977. Clean Air Express can also be reached by mail at 212 N. Woodwork Lane Palatine, IL 60067; by fax at (847)-991-8924 or on the web at http://www.express.cleanair.com

Maintenance
Clean Air Engineering Express Series 4000 Sample Gas Conditioners are designed for maintenance free operation for extended periods of time, however routine preventative maintenance is recommended to insure maximum efficiency and to avoid unexpected future problems.

Optional Pressure Pump Maintenance
The pump motor, bearing assembly, and diaphragm head, should not require any maintenance. Bearings are long life, oversized aircraft bearings, lubricated for the life of the bearing. The pump valves can become inefficient due to particulate buildup under the seals. It is recommended that the following maintenance be performed at the intervals specified.

• Every Month: Disconnect Sample Gas Inlet and Outlet lines from the conditioner and flush tap water through the pump (up to one pint), using a squirt bottle. The rate should not exceed on half once per minute (15 cc/min). This procedure will also assist in flushing out any particulate buildup on the heat exchanger plate as well. Observe that the Peristaltic drain pump functions adequately. Once the system has been flushed and all sump water has drained, reconnect the Sample Gas Inlet and Outlet line and resume normal operation.
• Every Six Months: Remove the pump head and disassemble. Inspect the valves and diaphragm. Clean or replace if defective.
• Note: Replacement parts for pressure pumps are stocked and available from Clean Air Engineering Express.

Heat Exchanger Maintenance
The heat exchanger will require little or no maintenance, if the sampling probe removes sufficient particulate from the sampling gas stream. Flushing tap water through the unit once a month should wash the heat exchanger. Refer to pressure pump monthly maintenance.

Warning: Attempting to repair the heat exchanger is not recommended. Contact Clean Air Engineering Express at (800) 223- 3977 for further instructions regarding any problems with the unit.

Sump Drain Peristaltic Pump Maintenance

The pump used for this purpose is specifically designed to operate without any attention for long periods, however Monthly inspection of the pump tubing should be performed to insure trouble free operation. To replace the tubing, perform the following steps

Steps

1. Disconnect power to the pump motor
2. Disconnect the suction and discharge tubing from the pump tubing
3. Remove (4) screw retaining the pump cover
4. Remove old pump tubing and discard
5. Clean roller race, removing any particles that could damage tubing
6. Position roller bracket assembly as shown in Figure 5-1
7. Push rubbing into Inlet port, anchoring tubing in grippers (Figure 5-2) which rotating roller bracket assembly
8. Continue to rotate roller bracket assembly, pushing tubing into roller race, as shown in Figure 5-3
9. Finally, insert tubing intooutlet port (Figure 5-4) and replace cover

Caution: Do not run motor while changing tubing. Severe pinching of fingers can occur.

Troubleshooting

Warning: Attempting the repair of this unit by persons not familiar with the basic of electricity, electronics, and pneumatics may be dangerous to both the person attempting the repair, and/or the instrument system. Test will be conducted with power removed. Electrical and Pneumatic systems operating with 120 VAC power applied and pressures up to 30 PSIG may be present. Physical contact with these voltages or pressures may result in damage to persons or equipment. Clean Air Engineering Express recommends that only qualified technicians attempt to repair this unit. The procedures, to the best of its knowledge, will not result in damage to the unit or to the persons repairing the unit. However, Clean Air Engineering Express does not represent this information as being absolute or accurate under all possible conditions. Do not assume that following the procedures presented in this section are safe under all conditions. The technician must exercise good judgment and safety practice when attempting any repair. For repair of the unit, contact Clean Air Engineering Express for free consultation regarding any problem or for shipping instructions in the event that the unit is under warranty.

Troubleshooting Flow Charts

The following flow charts are provided for troubleshooting and attempt to present a “common sense” approach to solving potential causes for malfunction. It is assumed that only qualified service personnel familiar with instrumentation, electronic, and pneumatic systems will attempt to repair this unit.

Figure 6-1 Electrical Troubleshooting Flow Chart

Figure 6-2 Temperature Troubleshooting Flow Chart

Figure 6-3 Sump Drain Troubleshooting Flow Chart

Figure 6-4 Sample Gas Outlet Troubleshooting Flow Chart

Figure 6-5 Pressure Pump Troubleshooting Flow Chart

Figure 6-6 Water Intrusion Troubleshooting Flow Chart

CLEAN AIR ENGINEERING

Parts List

• SGC 4000- Sample Gas Conditioner
• December 14, 2009
• Parent Part #: 0700 Type: F

Figure A-1 Sample Gas Conditioner Schematic Diagram

Figure A-2 Water Intrusion Monitor Schematic Diagram

Figure A-3 Power Supply Schematic Diagram

Our Guarantee

Clean Air Engineering warrants products to be free from defects and workmanship for a period of one year after delivery date. The remedy for defective goods shall be repair or replacement of defective parts or payment price of the goods for which damages are claimed, at Clean Air Engineering’s option. © Clean Air Engineering – December 2009

Questions? Contact us at 800-223-3977 or online at  http://www.cleanair.com/equipment/Express/main.html

References

• CleanAir - Express Equipment Sales

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