Atec 8000, Operation And Maintenance Manual

Page 1: ...Model 8000 Automated Sampler Operations and Maintenance Manual Version 3 02 January 17 2019 2019 ATEC 9727 Cotharin Road Malibu CA 90265 2112 ...

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Page 3: ...nit by anyone other than ATEC physical abuse to or misuse of the unit operation in a manner contrary to the instructions which accompany the unit freight damage or any damage caused by acts of God such as lightning or fluctuation in electrical power This warranty also excludes all costs arising from installation adjustment of user controls initial technical adjustments set up and user required mai...

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Page 5: ...te and Time 10 3 4 Site Identification 10 3 5 Cartridge Sampling Information 10 3 6 Ozone Scrubber Temperature 11 3 7 Abort 11 3 8 Function Tabs 11 4 PROGRAMMING THE MODEL 8000 13 4 1 Time Date 13 4 2 Setup 13 4 3 Schedule 15 4 4 Leak Check 16 4 5 Data 17 4 6 Power Failures 19 4 7 SOP 19 4 8 Manual Mode 19 4 9 Advanced 20 5 LOCAL AREA NETWORK CONNECTION 21 5 1 Initial Network Setup 21 6 MAINTENANC...

Page 6: ...pheric Technology 6 2 Cartridge Filter 26 6 3 Ozone Scrubber 26 6 4 Mass Flow Controller Calibration Procedure 27 7 MODEL 8000 PARTS LIST 31 APPENDIX A SCHMATICS 33 APPENDIX B MANUAL FOR MASS FLOW CONTROLLER 49 ...

Page 7: ...orts on Channel 1 can be increased in multiples of 8 up to a total of 24 ports by adding the Model 80xx expansion modules The sampler has the following features Channel 1 ports and Channels 2 and 3 can be programmed to sample on a specified date e g 06 01 95 for a specified duration All channels are automatically leak checked prior to sampling If a leak is detected a leak check error is recorded f...

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Page 9: ... with independent operation are optional One blank position The number of channels can be increased up to 24 with the addition of the either the Model 8008 or Model 8016 expansion modules Size 17 width x 19 depth x 7 high Weight Approximately 50 pounds Power 115VAC 7 amps maximum Inlet tubing connector Cartridge Connections Polypropylene Luer fittings Construction Materials Teflon filter and PFA T...

Page 10: ...r Air enters the sampler to the inlet valve The inlet valve is normally closed and allows leak checking of the entire flow system Out of the inlet valve the air passes through the ozone scrubber and filter and then enters a solenoid manifold When a selected port is activated the air stream passes through the inlet solenoid through the cartridge and returns to the outlet solenoid valve Two solenoid...

Page 11: ... from the air stream prior to entering the flow lines The filter should be periodically changed the frequency will depend on conditions at the sampling site 3 1 2 3 Temperature Controlled Ozone Scrubber A temperature controlled copper tube coated with KI is used to remove ozone during carbonyl sampling with DNPH cartridges The microcomputer maintains a constant heater temperature inside the ozone ...

Page 12: ...l Operation and maintenance instructions are provided in Appendix A Using the Setup option on the display sets the flowrate 3 1 2 7 Vacuum Pump A diaphragm pump is used to draw air through the instrument The pump is mounted inside the sampler It is rated for continuous duty and can maintain a maximum vacuum level of 24 in Hg using two MFCs flowing at 1 lpm 3 1 2 8 Optional 8 Port or 16 Port Expans...

Page 13: ...Atmospheric Technology 7 expansion module and the Model 8000 is correctly made the additional ports will display once the Model 8000 is turned off and then turned back on ...

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Page 15: ...finger touch or stylus A pencil eraser also works well The touch level of the screen can be calibrated by using the TouchScreen button in the Setup function A USB connector is mounted below the touchscreen This can be used to connect a mouse keyboard label printer or jump drive for retrieving data and updating the sampler software All components tubing and fittings have been cleaned prior to assem...

Page 16: ...he following status indicators will also be shown in each status box depending upon the sampling conditions Sampling Indicates a channel is sampling Waiting Indicates a channel has been programmed to sample Purging Indicates a channel is purging prior to sampling Idle Indicates a channel has not been programmed to sample Monday November 26 2005 18 58 Flow Volume Status Cartridge Time Date Setup Sc...

Page 17: ...emperature of the ozone scrubber is displayed in the lower right hand corner of the screen 4 7 Abort The Abort button is used to terminate sampling after purging has started Pressing the Abort button will require the operator to enter a new sampling sequence to resume sampling 4 8 Function Tabs Several function tabs are located along the top of the screen to enable the operator to interact with th...

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Page 19: ... be uniquely activated to allow checkout and troubleshooting The system configuration and advance parameters are entered using the Advanced tab 5 1 Time Date The time and date that is stored in the Model 8000 can be changed using the Time Date tab When this tab is touched the operating system data and time selection screen will appear Once the changes have been made pressing the OK button in the u...

Page 20: ...error status for flow tolerance will be generated This value has the same units as the flow rate Cycled Schedule The Cycled Schedule value specifies the time interval in days between schedules This allows the operator to schedule repeated samples at a set interval automatically i e sampling repeated every 6 days if set to 6 The value must be greater than 1 to be applied Purge Time Purge time speci...

Page 21: ...ating files the sampler software will be updated If the update is successful a message will appear on the screen instructing that file transfer was successful and that the system will reboot If the jump drive cannot be recognized or it does not have the proper update files a message will be display warning of an incomplete update and no software changes will be made 5 3 Schedule The Schedule tab i...

Page 22: ... Check and is used to leak check the Port 1 cartridge Cartridges are leak checked by turning on the vacuum pump and closing the upstream isolation solenoid valve The downstream solenoid valve remains open to evacuate the cartridge mass flow controller and tubing to the pump If a leak is present the flow controller will show a small flow A leak is identified if the flow rate exceeds the flow leak l...

Page 23: ...The stored data includes start time stop time average minimum and maximum flow rate collected volume error status and elapsed time NOTE The start time is when the sampling cycle starts This includes 20 seconds of leak check prior to allowing flow through the cartridge The end time is when the sampling cycle is completed after a thirty second leak check Therefore the total time for flow through the...

Page 24: ...be deleted from the jump drive before the drive can be used again to store data Once all the files have been received a message will appear confirming completion of the transfer An example of transmitted data is shown below Southern County Site Cartridge A312 Ch 1 Cartridge Started at 11 25 01 8 15 06 PM Flow Rate Set Point 1 000 lpm Stopped at 11 26 01 8 15 36 PM Total Volume 1428 05 liters Total...

Page 25: ...ng the Model 8000 The SOP software guides the user through the required procedures and enables inexperienced operators to successfully program the sampler Pressing the SOP tab initializes the program The Back Next and Exit buttons are used to advance through the procedure or return to the main screen Initially the program brings up a screen that requires the user to check the number of cartridges ...

Page 26: ...ould only be used by individuals familiar with the operation and calibration of components used in the Model 8000 Changing the values in the Advanced Setup will alter the accuracy of the instrument Several of the parameters are hardware dependent These are set at the factory and require a password to be entered to be changed Mass Flow Controller Calibration The calibration of the mass flow control...

Page 27: ...mmunicate and other devices will be locked out The remote PC tablet must also have a copy of VNC Viewer for communicating enclosed on jump drive This software is available on the internet The following steps need to be done only once unless noted 1 Connect the PC tablet and the sampler to the LAN 2 On the PC tablet bring up the command prompt window Type ipconfig Record the IP Address that appears...

Page 28: ...s 169 254 1 1 d Exit the screen by OK in the upper right corner of the small center screen e Exit the Network Connections screen by selecting the X in the upper right hand corner 5 Select the Remote IP Address text box A keypad will appear in the upper left corner Enter the IP Address of the PC Tablet that is to be connected to the sampler 6 On the Sampler press the Enable Network button to start ...

Page 29: ...nt PC Tablet is to be used the Remote IP Address will have to updated in the sampler If communication is no longer needed clicking the Disable Network button the Setup screen will terminate communication It can be reactivated at any time by clicking on the Enable Network button The values for the IP Addresses and the network status enabled or disabled are retained in memory and communication will ...

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Page 31: ...al injury and or property damage would result To clean or replace the filters and or rubber gasket remove the five screws in the top of the unit The filters and gasket are located beneath this top plate Remove the filters and wash them in a solvent and or blow off with air and replace The gasket may be cleaned with water Replace the filters in proper position and replace the gasket Note that the g...

Page 32: ...ould periodically replace the Teflon filter located in the cartridge sample path The replacement frequency will depend on site conditions The filters must be replaced when the flow rate through the cartridges cannot be maintained However it is recommended that the filter be replaced before this condition exists The operator should periodically check the filter and determine when it needs to be rep...

Page 33: ... all channels should be very close to zero after several minutes of sampling If a flow is indicated usually 0 03 slp or larger the interior lines should be checked for the presence of a leak 7 4 Mass Flow Controller Calibration Procedure Each mass flow controller should be calibrated on an annual schedule The mass flow controllers can be calibrated either electronically or manually Manual calibrat...

Page 34: ... followed 1 Go to the Advanced screen and change the slope for the MFC to be calibrated to 1 00 and change the intercept value to the negative value of 1 5 of the full MFC range the MFC range is displayed in the Advanced Screen For example if the MFC has a full range of 2 0 lpm the intercept value should be set to 0 030 2 Go to the Manual screen and check the box next to Calibrated Values With no ...

Page 35: ...tion data and desired sampler reference conditions where PC calibrator pressure mm Hg TC calibrator temperature K T Sampler MFC reference temperature K normally 298 K PF MFC factory reference pressure 760 mm Hg TF MFC factory reference temperature 273 K W calibrator flow rate F sampler flow rate set Slope TF x PC x W x T PF x TC x F x TF To simplify this equation reduces to Slope 0 392 X PC X W TC...

Page 36: ...e should be very close to that shown in the Flow Set box It can be trimmed in by adjusting the slope using the following New Slope Old Slope x calculated flow desired flow Final Note The MFC zero will drift over time To compensate for this the sampler software auto zeros the MFC prior to sampling However a zero tolerance error flag will be displayed whenever the computer needs to zero compensate 1...

Page 37: ...r 47mm Teflon 8000 200 6 Ozone Scrubber Heater Complete 8000 200 10 Ozone scrubber KI copper coil 8000 200 11 Heater Relay 8000 300 1 Vacuum Pump 8000 200 12 Vacuum Pump Relay 8000 300 2 2 Way Solenoid Valve 8000 200 13 Single Board Computer 8000 400 1 GPIO Board 8000 400 2 Interface Board 8000 400 3 Temperature Probe 8000 400 4 Power Supply 8000 300 3 Cooling Fan 8000 300 4 Power Switch 8000 300 ...

Page 38: ...32 Atmospheric Technology GPIO Cable Set 8000 700 5 Rear Panel Output Cable Set 8000 700 7 Interface Board Ribbon Cable Set 8000 700 8 Vacuum Pump Relay Cable 8000 700 10 ...

Page 39: ...Atmospheric Technology 33 Appendix A Schmatics ...

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Page 41: ...1 Model 2200V11 Interface Board Schematic 1 sch 7 ...

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Page 55: ...Atmospheric Technology 49 Appendix B Manual for Mass Flow Controller ...

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Page 57: ...INSTRUCTION MANUAL 200 202 SERIES FLOWMETERS CONTROLLERS TELEDYNE HASTINGS INSTRUMENTS I S O 9 0 0 1 C E R T I F I E D ...

Page 58: ...Revision D Document Number 140 082005 August 2005 Revision E Document Number 140 112007 November 2007 Revision F Document Number 140 062008 June 2008 Revision G Document Number 140 082008 August 2008 Revision H Document Number 140 022009 February 2009 Revision J Document Number 140 102009 October 2009 Revision K Document Number 140 102009A October 2009 Revision L Document Number 140 082010 August ...

Page 59: ...of Gases 12 2 7 OPERATION WITH EXTERNAL DEVICES 12 2 7 1 Operation with a Hastings power supply 12 2 7 2 Operation with a Power Supply other than a Hastings 13 2 7 3 Operation with an external sensor Fig 2 2 14 2 7 4 Response to Command Changes 14 2 8 RANGE CHANGING 15 2 9 VALVE OVERRIDE CONTROL 15 3 THEORY OF OPERATION 16 3 1 OVERALL FUNCTIONAL DESCRIPTION 16 3 2 SENSOR 16 3 3 ELECTRONICS 17 3 4 ...

Page 60: ... is inherently linear no linearization circuitry is employed Should recalibration in the field be desired a calibration standard is required the customer needs to simply set the zero and span points There will be no appreciable linearity change of the instrument when the flowing gas is changed MODULAR SENSOR The HFM 200 HFC 202 series incorporates a removable replaceable sensor module Field repair...

Page 61: ...arity 1 F S Repeatability 0 05 F S Std Pressure Rating 500 psig High Pressure Option Proof tested to 1500 psig Pressure Coefficient 0 0067 psi 0 1000 psig N2 typical Control Valve DP per customer order Leak Integrity 1x10 9 sccs Temperature Coefficient 3 Zero 0 035 FS C 0 60 C Span 0 05 RDG C 0 60 C STP 0 C and 760 Torr Power 15 Volt controller 14 16 VDC 60 mA 185 mA 3 Watts Power 24 Volt controll...

Page 62: ...op since the signal common is galvanically isolated internally from the supply common This line must be current limited 50 mA to prevent short circuit currents from damaging the receiving circuit in the flow controller 1 5 Other Accessories 1 5 1 Hastings Power supplies Hastings Power Pod power supply display units are available in one and four channel versions They convert 100 115 or 230 VAC to t...

Page 63: ...ths to connect from the 15 pin D connector on the back of the Power Pod directly to any of the 200 series and 300 series flow instruments including digital versions More information about the available cables can be found in the Power Pod 400 bulletin on the Hastings web site http www teledyne hi com pdfs bulletins htm ...

Page 64: ... to prevent power spikes reaching the instrument The Hastings power supplies described in Section 1 4 1 satisfy these power requirements The HFM 200 HFC 202 series 24 Volt version require 14 32 VDC 1 9 Watts HFM 200 and 4 2 Watts HFC 202 for proper operation The supply voltage should be reasonably regulated as power supply ripple may propagate to the output The supply common is galvanically isolat...

Page 65: ...nding upon the size of the installed orifice There are two 8 32 threaded holes located on the bottom of the base that can be used to secure it to a mounting bracket if desired screws provided Other holes for special mounting can be added to the end cap as desired The standard inlet and outlet fittings for the 200 202 are 0 25 and 0 125 Swagelok optional VCR or VCO fittings The O rings for the end ...

Page 66: ...version of the HFM 200 HFC 202 installation consists of connecting the HFM 200 HFC 202 series cable AF 8AM from the D connector on the rear of the power supply to the D connector on the top of the flow meter If a different power supply is used follow the instructions below when connecting the flow meter Bipolar 15 Volt Power Supply to Bipolar Connections Connecting the HFM 200 HFC 202 series flow ...

Page 67: ...or use at this time If the override switch is desired connect the center pin of a single pole three position switch with the center off position to pin 8 of the DA 15 15 Volt Pin 6 of the DE 9 24 Volt Connect a voltage source 10 VDC to one end of the switch and negative voltage to the other end This will result in the valve being full open when the positive is supplied to the override pin off when...

Page 68: ...irst gas EXAMPLE Flow controller A has 0 100 slpm range with a 5 00 Volt output at full scale Flow controller B has 0 10 slpm range with a 5 00 Volt output at full scale If flow controller A is set at 80 slpm its output voltage would be 4 00 Volts 80 slpm 100 slpm x 5 00 Volts 4 00 Volts If the output signal from flow controller A is connected to the command potentiometer of flow controller B it t...

Page 69: ...ns RS232 RS232 RS485 2 7 2 Operation with a Power Supply other than a Hastings The flow controller must be connected to the power source as specified in section 2 6 In general a 0 5 VDC command signal proportional to the intended flow 0 Volts zero flow 5 Volts 100 of rated flow must be applied to pin 14 of the DA 15 15 Volt Pin 3 of the DE 9 24 Volt connector A 0 5 VDC signal proportional to the f...

Page 70: ...umpers installed horizontally The bottom jumper ties the flow output to the valve control circuit and the middle jumper ties Pin 1 of the DE 9 connector to reference voltage circuit Remove both of the lower two jumpers and reinstall one jumper vertically between the outside two pins pins 1 3 This will tie Pin 1 of the DE 9 connector to the valve control circuit and allow the controller to maintain...

Page 71: ...ed jumper place it over one pin only on JP4 JP6 2 8 Range Changing The range of the flow controller can be changed in the field if recalibration facilities are available The flow controller may require a different orifice which can be purchased separately from the factory A listing of the orifices available and their flow rates can be found in Section 5 0 The instructions to change the flow range ...

Page 72: ...is output to control the valve position The valve is an automatic metering solenoid type its height off the seat is controlled by the voltage in its coil All of these components working together result in a fast stable flow controller 3 2 Sensor The Hastings HFM 200 HFC 202 series operates on a unique thermal electric principle whereby a metallic capillary tube is heated uniformly by a resistance ...

Page 73: ...digit output The controller circuitry utilizes the command and the flow voltages as input signals The 0 5VDC command signal is subtracted from the 0 5VDC flow signal creating an error signal This signal is amplified and causes the solenoid valve to move The amount and direction of the movement is dependent upon the value and the sign of the error signal and tends to minimize the error signal 3 4 S...

Page 74: ... plunger tightly against an orifice to shut off flow The magnetic plunger is surrounded by an electrical coil which when energized with electrical current lifts the plunger off the orifice and allows flow to pass between the orifice and the plunger seat Controlling the current through the coil controls the distance between the orifice and the plunger seat effectively controlling the flow through t...

Page 75: ...t being heated ACTION Unplug connector J1 Check the following resistance The resistance between pins 2 3 of the sensor should be approximately 2500 Ohms see Figure 3 1 on page 8 The resistance between pins 1 4 should be approximately 2 3 Ohms The resistance between pins 2 3 and the base of the sensor should be essentially infinite If not replace the sensor unit If sensor reads O K check the voltag...

Page 76: ...d 6 adjusting the SPAN pot and performing a calibration run will require the use of a calibration reference 1 Connect power cable to D connector as specified in Section 2 7 Allow instrument to warm up for 30 minutes with 10 flow and instrument in AUTO position 2 After the warm up period set the flow to zero and insure that indeed there is zero flow Wait for 2 minutes 3 Set ZERO R13 on 15 Volt R20 ...

Page 77: ... four wire sensor plug and the two wire valve plug noting their orientation prior to removal Remove the screw that holds the PC board to the sensor Troubleshoot or replace as applicable Installation is the reverse of the above procedure Recalibrate if any components were changed or if any potentiometers were adjusted 4 6 Sensor Replacement If the sensor fails or becomes plugged it can be removed R...

Page 78: ...c gases 1 4 otherwise ρ0 Density of gas standard pressure and temperature of flow unit π Pi 3 1415 σ Specific gravity of gas ratio of gas density to density of air Choose the available orifice with the closest diameter that is larger than the calculated diameter Orifice diameters inches available are 0 001 0 002 0 003 0 007 0 014 0 032 0 042 0 052 0 070 Contact factory to order new orifice As an e...

Page 79: ...ound Push the orifice into its hole and screw it in until it is flush with the instrument base Apply pressure to the inlet side of the instrument Enable the Valve Override CLOSE function or unplug the instrument Screw the orifice in a few more turns until the flow through the instrument stops then turn it an additional 1 4 turn clockwise ...

Page 80: ... or workmanship during the warranty period Defective instruments should be returned to Hastings Instruments shipment prepaid together with a written statement of the problem and a Return Material Authorization RMA number Please consult the factory for your RMA number before returning any product for repair Collect freight will not be accepted 5 2 Non Warranty Repair Policy Any product returned for...