Universal Analyzers 1095E Manual de usuario
MAN.1095E. REVB.12232014
Instruction Manual
Model 1095E
Acid Aerosol "Freezer Chiller"
5200 Convair Drive Carson City, NV 89706 • Phone: 775-883-2500 • Fax: 775-883-6388 • www.universalanalyzers.com
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MAN.1095E.REVB.12232014
Contents
Receiving and Storage 3
Denition of Symbols 4
Specications 5
Description and Principle of Operation 6
Installation 10
Electrical Connections 11
Start-Up 12
Shutdown 12
Maintenance 13
Troubleshooting 15
Spare Parts 17
Drawings - Model 1095E 19
Limited Warranty 23
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Receiving and Storage
The Universal Analyzers Model 1095E Acid Aerosol "Freezer Chiller" is a complete assembly. No assembly is necessary
when received on-site.
Carefully inspect the product and any special accessories included with it immediately upon arrival by removing them from
the packing and checking for missing components against the packing list.
Check the items for any damage in transit and, if required, inform the shipping insurance company immediately of any
damage found.
Storage location should be protected from the elements. Although all components provided are designed to resist
corrosion, additional protection from heat (>140°F/60°C) and humidity is recommended.
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MAN.1095E.REVB.12232014
Denition of Symbols
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED
OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR
HAZARDOUS AREA INSTALLATION.
THE SUPPLY POWER CIRCUIT MUST INCLUDE AN OVERPROTECTION DEVICE WITH A MAXIMUM RATING OF 20
A. A DISCONNECT SWITCH MUST BE LOCATED IN CLOSE PROXIMITY TO THE PROBE.
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION
PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED PER CLAUSE 5.4.4(i) IN STANDARD EN 61010-1
CAUTION, RISK OF DANGER SYMBOL INDICATES INJURY MAY OCCUR IF MANUFACTURER’S INSTRUCTIONS
ARE NOT ADHERED TO. PLEASE READ MANUAL CAREFULLY WHEN SYMBOL IS DISPLAYED
CAUTION, HOT SURFACE SYMBOL INDICATES EXPOSED SURFACE TEMPERATURE CAN CAUSE BURNS OR
PERSONAL INJURY. CARE SHOULD BE TAKEN WHEN CONTACT IS REQUIRED.
CAUTION, RISK OF ELECTRICAL SHOCK SYMBOL INDICATES ELECTRICAL SHOCK MAY OCCUR. CAUTION
SHOULD BE TAKEN BEFORE DISCONNECTING OR CONTACTING ANY ELECTRICAL CONNECTIONS.
PROTECTIVE CONDUCTOR TERMINAL SYMBOL INDICATES THE TERMINAL LOCATION FOR THE
PROTECTIVE CONDUCTOR. FAILURE TO CONNECT TO THE PROTECTIVE CONDUCTOR TERMINAL MAY RESULT
IN A SHOCK HAZARD.
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Specications
OPERATING SPECIFICATIONS
Sample Flow Rate 0 to 5 l/m total (at STP)
Maximum Inlet Temperature
Stainless Steel Heat Exchanger 700°F (351°C)
Kynar/Glass Heat Exchanger 280°F (138°C)
Maximum Inlet Gas Dew Point 178°F (81°C)*
Maximum Inlet Water Concentration 50%*
Minimum Ambient Temperature 34°F (1°C)
Maximum Ambient Temperature 105°F (41°C)*
Maximum Cooling Power 540 BTUs per hour (160 watts/hr.)
Outlet Sample Dew Point -13°F (-25°C)
Gas Sample Inlet Fitting 3/8" tubing tting
Gas Sample Outlet Fitting 1/4" tubing tting
Bottom Water Drain Fitting 3/8" tubing tting
Maximum Input Power 900 watts
Voltage 115/230VAC, 50/60 Hz
Electrical Classication General Purpose, NEMA 1
Dimensions 27" H x 21" W x 14 1/4" D
Weight 75 lbs (34kg)
Soluble Gas Removal Rates NO 0% loss
NO2<10% loss
SO2< 2% loss
CO 0% loss
CO2< 2% loss
*AT REDUCED FLOW RATE ABOVE 77°F. (25°C.) AMBIENT.
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MAN.1095E.REVB.12232014
Description and Principle of Operation
APPLICATION
The Universal Analyzers Model 1095E Acid Aerosol "Freezer Chiller" is a system on a 21" x 27" plate designed to
achieve an exit dew point of -25°C. It is designed to remove moisture to a level of 650 PPM. This reduces the chances
of low levels of acid formation therefore protecting downstream components as well as minimizing losses of measured
components.
The use of a heated lter and a heated sample line are required to be installed between the sample extraction location
and the input of the 1095E sample cooler. The temperature of the sample must be kept above the boiling point of water
and above the dew point of any chemical reactions that would skew the desired analytical results.
DESCRIPTION
The Universal Analyzers Model 1095E Acid Aerosol "Freezer Chiller" contains a combination of Kynar and Glass/Kynar
impinger type heat exchangers. These are mounted within heat transfer blocks, which are cooled by thermoelectric
elements utilizing the "Peltier Effect". The condensate is removed in multiple stages, one at the temperature of the
ambient air surrounding the Freezer Chiller by owing through the impinger referred to as the Passive Channel, then
by passing the sample into a heat exchanger cooled to 4°C by the thermoelectric elements referred to as the Active
Channel. The sample gas is then further cooled by special cascaded Peltier elements to negative 25°C freezer alternating
Impingers controlled by a PLC. The 4°C Active Channel is also referred to as Channel 1 and the two freezer Channels are
referred to as Channel 2 and Channel 3.
In standard operation Channel 1 will always hold at 4°C within a band 1°C. Channel 2 and Channel 3 cycle their operation.
The normal cycle operations (no alarms) are as follows:
Channel 2 Pre-Chill and Channel 3 Off - This cycle is the initial status upon startup. The switching valve selects Channel 2
and Channel 2 has power applied to the cooling elements until it has reached -10°C or the Pre-Chill time has elapsed.
Channel 2 Dwell and Channel 3 Off - This Cycle is the main cycle for the cooling elements on Channel 2 to chill and
for sample to run through Channel 2. It will need to be adjusted to be long enough for Channel 3 to properly defrost but
shorter than the time for ice to build up in the outlet of Channel 2, causing the owswitch to trigger a 'Frozen Column'
alarm.
Channel 2 Dwell and Channel 3 Pre-Chill - During this cycle Channel 2 Dwell Time completes, Channel 2 continues to
cool, and sample continues to run through Channel 2. Channel 3 is triggered to cool for up to 30 minutes. If Channel 3
reaches negative 10°C before 30 minutes has elapsed this cycle will complete and move to the following cycle.
Channel 2 Off and Channel 3 Dwell - This Cycle is the main cycle for the cooling elements on Channel 3 to chill and
for sample to run through Channel 3. It will need to be adjusted to be long enough for Channel 2 to properly defrost but
shorter than the time for ice to build up in the outlet of Channel 3, causing the owswitch to trigger a 'Frozen Column'
alarm.
Channel 2 Pre-Chill and Channel 3 Dwell - During this cycle Channel 3 Dwell Time completes, Channel 3 continues to
cool, and sample continues to run through Channel 3. Channel 2 is triggered to cool for up to 30 minutes. If Channel 2
reaches negative 10°C before 30 minutes has elapsed this cycle will complete and move to the following cycle.
A Moisture sensor is provided to sense the presence of condensate, should any exist in the tubing following the chiller.
This WCSF (Water Carry-Over Sensor with Filter) includes a visible steel ber lter. This WCSF allows the operator
to inspect the condition of the heated stack lter. The integral moisture sensor with the sensing elements is located in
the bottom of the lter bowl to provide an early warning if liquid carries over past the freezer chiller. If water carry-over
is sensed, the Alarm Message “Water Carry-Over” is displayed. With Channel 1 Chiller high temperature (>10°C) the
Operator Interface displays “Ch1 High Temp”. Either of these stops the Sample Pump.
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A Vacuum switch is provided to monitor and alarm high inlet vacuum. The message “System Vacuum” will appear on the
top system status line of the operator interface, if there is high inlet vacuum.
A Flow switch alarms on low ow. The message “Low Sys Flow” will appear on the top system status line of the operator
interface, if there is low ow.
The heated head sample pump (oil-less diaphragm pump) is placed in the sample line between the 4°C and minus 30°C
heat exchangers. The rst chilled heat exchanger takes enough of the water vapor from the sample to protect the pump.
The freezer heat exchangers are under a slight pressure because they are on the discharge side of the pump. This will
cause the dew point of the sample to be at its minimum. The pump has a sample pressure controller that is set at 10 PSI.
A Teon Solenoid is used to alternate the online negative 25°C column and the ofine channel that is in defrost mode.
The active freezer column ow impedance is monitored by a Flow switch to sense column freeze-up. If a ow restriction
is sensed before Online Dwell time out, the Alarm Message “Column Frozen” is displayed and after a time delay of 60
seconds the PLC will sequence to the other Freezer Column.
The ofine column is pre-chilled to approximately negative 10°C before the column is brought online. Once the pre-chill
column is below negative 10°C, the program automatically advances to that column or after 30 minutes of pre-chill time
the pre-chill channel goes online. If the column fails to cool for 15 minutes once it is online, the message “Ch2 or Ch3
Malfunction” will be displayed.
The standard drain is a peristaltic pump is a positive displacement pump that allows for use in either a pressure or
vacuum sample. It provides for easy leak detection but does require periodic maintenance in replacement of the tubing.
A preventative maintenance program replacing the tubing every 6 months is a good practice.
To assist with the ow control a 5 Liter per minute owmeter with needle valve is provided. Many analyzers require
between 1/2 Liter and 1 Liter per minute. Any extra ow can be sent into a bypass to increase the total ow which in turn
increases the response time of the system.
OPERATOR INTERFACE
The Model 1095E SO3 is manually controlled through the Operator Interface located on the front of the unit, or remotely by
the I/O inputs to the PLC. The Interface is used to display and manually operate the 1095E Chiller.
MAIN DISPLAY
Line 1 Alarms Displayed and Channel 1 temperature
2 Channel 2, Status “DWELL” “OFF” “CHILL” and temperature
3 Channel 3, Status “DWELL” “OFF” “CHILL” and temperature
Note“*” Indicates the active column
4 Minutes remaining on Active Step
SYSTEM DEFAULTS:
The PLC will have following default values:
Dwell 180 Minutes - Length of time freezer Column is online
Pre-Chill 30 Minutes - Pre-Chill on the Ofine Column, prepares the Column to become active.
Description and Principle of Operation
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MAN.1095E.REVB.12232014
Description and Principle of Operation
TOUCH-SCREEN USER INTERFACE
MAIN DISPLAY
The Model 1095E "Freezer Chiller" is manually controlled through the Operator Interface located on the front of the unit, or
remotely by the I/O inputs to the PLC. The 128x64 pixel operator interface (HMI) is used to display and manually operate
the 1095E Chiller.
This is the main display screen of the touch Screen style user interface:
The top of the display contains the System Status or the current Alarm State.
SYSTEM STATUS AND ALARMS DISPLAYED
System Normal
Water Carry-over
Channel 1 (chiller) Hi Temperature
Channel 2 (freezer) Hi Temperature
Channel 3 (freezer) Hi Temperature
Column 2 Frozen
Column 3 Frozen
Column 2 Malfunction (not cooling)
Column 3 Malfunction (not cooling)
Hi System Vacuum
Low Sample Flow
System Ofine
Column Held (from user input during Calibration)
RTD Failure
High Ambient Temperature
Amb measures the ambient temperature inside of the electronics enclosure.
The DwellTime displays the time remaining in whichever channel's status is dwell.
The CoolTime will display as zero during the defrost cycle and during the Pre-Chill cycle of a channel will display the time
remaining on that Pre-Chill cycle. If the column reaches negative 10°C the cycle will automatically switch from Pre-Chill to
Dwell. Below are the possible available status for each channel.
CHANNEL 1 STATUS DISPLAYED
OK
Fault
Warm
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CHANNEL 2, CHANNEL 3 STATUS DISPLAYED
Ofine
Dwell (Channel on, normal cycle)
Warm (not at temperature after chill cycle)
Chill (pre-cooling before going online)
Fault (not cooling or RTD failure)
AMBIENT STATUS DISPLAYED
OK
Fault
Warm
MAIN MENU
This menu provides access to the System Control Menu and the Sequence Times Menu.
The System Status button returns the user to the main display screen.
SYSTEM CONTROL SCREEN
The Acknowledge Alarms button is used to clear alarms displayed on the Main Display screen once
the alarming condition has been corrected.
The System Online Set Logic button is used to change the logic of the System Online/Ofine digital
input between Normally Open and Normally Closed
The Advance Sequence button is used to advance the Freezer Channel cycle for troubleshooting.
The Turn System Online/Ofine button is used to turn the Sample Pump on or off.
The Main button returns to the Main Display screen.
The Menu button returns to the Main Menu screen.
Description and Principle of Operation
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MAN.1095E.REVB.12232014
Description and Principle of Operation
Installation
The sample inlet is a 3/8” compression tting supplied on the top of the rst Impinger. The heat insulation on the
heated tube bundle should be stripped no more than 3” to avoid plugging the exposed line. The sample outlets are 1/4"
compressions ttings on the owmeter.
A 3/8" tubing tting is provided as the condensate drain connection at the bottom of each heat exchanger. This can be
removed to expose 3/8" NPT female connections. Two dual-head peristaltic pumps are used to withdraw the condensate
from each Impinger. Care must be taken to drain the condensate into a safe drain because of the presence of condensed
sulfuric acid.
The electrical power, maximum 7.83A at 115VAC or 3.92A at 230VAC should be supplied. Installation shall be in accord
with the manufacturer's instructions and the national electric code (ANSI/NFPA70). Tampering and replacement with
non-factory components may adversely affect the safe use of the system. Customer input power connections are on TB6.
Customer 24VDC input signals to manually hold a column indenitely are on TB5-1 and TB5-2. Customer 234VDC input
signals to manually activate the system ofine function are on TB5-3 and TB5-4. A 24VDC output signal to signify there is
a system error may be wired on TB5-5 and TB5-6.
SEQUENCE TIMES SCREEN
The Dwell Time Minutes button allows the user to adjust Freezer Channel sequence time
between 50 and 180 minutes.
The Pre-Chill Time Minutes button allows the user to adjust the Next Up Channel pre-chill
time between 20 and 40 minutes.
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