YZ Systems DynaPak DP-2010TP, System Support Manual

Page 1: ...DynaPak GasSampler S Y S T E M S U P P O R T M A N U A L DP 2010TP ...

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Page 3: ...DP 2010TP INSTRUCTION OPERATING MANUAL Version 10012004 ...

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Page 5: ...tem Connections 8 Optional DPS 2 Installation 9 Section 3 Sample Vessel Installation 11 Variable Pressure Constant Volume Cylinders 11 Link Plus 11 Section 4 System Control Electronics 13 Overview 13 Section 5 Programming for Proportional to Flow Operation 15 Setting Operator Input Parameters 15 Section 6 Programming For Proportional To Time Operation 19 Setting Operator Input Parameters 19 Sectio...

Page 6: ...41 For Additional Help 41 Step by Step Resolution 41 Battery Power 42 Battery Power Troubleshooting Steps 42 Z 65 Counter Mode 43 Z 65 Counter Mode Troubleshooting Steps 43 Z 65 Timer Mode 44 Z 65 Timer Mode Troubleshooting Steps 45 Appendix A Illustrations 49 DP 2000 Sample Pump Assembled 49 DP 2000 Sample Pump Exploded View 50 Filter Regulator Assembled 51 Filter Regulator Exploded View 52 Link ...

Page 7: ...ced item Measurement units are listed in italic parenthesis text following their US standard equivalent As an example for defining a distance 15 4 5 meters is how the text will appear throughout the manual Items that require action for example the pressing of a key for programming the controller will feature the action item in sentence case Bold Text followed in normal text by the item such as the...

Page 8: ... g Pump Displacement 2 4 cc Stroke Operating Temp Range 0 to 140 degrees F 17 C to 60 C Power Supply Internal Battery Pack Flow Signal Dry Contact or Voltage Pulse Electric Heater Voltage 120 VAC The External Power Option can be used in lieu of the internal battery pack The External Power Option model EPO 120 consists of an AC to DC convertor and intrinsically safe barrier to convert 120 VAC power...

Page 9: ...l pressure switch DPS 2 this mode of operation is similar to the time based sampling mode except that the DPS 2 converts a differential pressure signal to an electrical signal that the Z 65 timer uses to determine if flow is present in the pipeline In effect the DPS allows the Z 65 timer to shut off when flow stops in the pipeline and when flow starts again the ability to start up and resume opera...

Page 10: ...0 psi maximum working pressure sample vessels Available in 300 and 500 cc sizes KK 1 KK 2 KK 3 carrying cases that meet DOT requirements for transporting portable sample vessels 1 4 stainless steel tubing Dielectric Isolator Union These should be installed in every tubing line that attaches the sampler to the pipeline in any manner For example the supply gas product connection to the system and di...

Page 11: ...l requlator capable of reducing pressure from line pressure of up to 1500 psi down to system supply pressures in one step Low Power Solenoid figure 2 provides interface between the Z 65 Electronic Controller and the Pump Pneumatic actuation Z 65 Controller Enclosure figure 1 Provides a weathertight enclosure for the Z 65 controller Z 65 Controller figure 1 Provides control functions for the DynaPa...

Page 12: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 6 DP 2010 TP ver 10012004 SECTION 2 SYSTEM INSTALLATION System Flow Schematic figure 2 ...

Page 13: ...m of five pipe diameters from any device which could cause aerosols or significant pressure drops 2 The sample probe should not be located within the defined meter tube region AGA 3 manual A The number of unobstructed straight pipe diameters upstream see AGA 3 manual B The number of unobstructed straight pipe diameters downstream see AGA 3 manual 0HWHU 7XEH 2SWLPXP 6DPSOHU 3UREH RFDWLRQV LIIHUHQWL...

Page 14: ...er pipeline pressure has been applied to the sampler check the probe body pipeline connection using a liquid leak detector CAUTION Incorrect operation of valves over tightening can result in damage to the valve components isolation valve bonnet assembly which might result in the valve stem being screwed out of the probe body This of course results in product at pipeline pressure being vented conti...

Page 15: ...is open Failure to do so may damage the DPS 2 s internal components d Open the other supply valve e Close the equalization valve f Run the free end of the DPS 2 cable through the cable entry connector located on the upper left side on the DynaPak 2010 enclosure g Connect the DPS 2 cable as shown in the diagram h Tighten the cable entry connector allowing for enough cable length to open the enclosu...

Page 16: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 10 DP 2010 TP ver 10012004 SECTION 2 SYSTEM INSTALLATION Notes ...

Page 17: ...inless steel tubing and fittings from the sample discharge port of the sampler are pre installed to the product end of the sample cylin der when installed in this manner LinkPlus Install the optional LinkPlus directly into the sample discharge port of the sampler Use stainless steel tubing and fittings to connect the LinkPlus outlet to the product end of the sample cylinder LinkPlus Filter Regulat...

Page 18: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 12 DP 2010 TP ver 10012004 SECTION 3 SAMPLE VESSEL INSTALLATION Notes ...

Page 19: ...stems Always take necessary measures to assure that electrical classification in the area is considered before and during all repairs and that necessary steps are taken to maintain proper electrical procedures for the classification of the area The control package requires you to configure the Z 65 controller to operate in a Proportional To Flow mode refer Section 5 to page 16 a Proportional To Ti...

Page 20: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 14 DP 2010 TP ver 10012004 SECTION 4 SYSTEM CONTROL ELECTRONICS Notes ...

Page 21: ...t is either a dry contact or voltage pulse 2 If the input is a dry contact a Terminate the incoming connections to the Z 65 terminal strip see illustration b Turn mode switch 1 to on c Turn mode switch 2 to off d Turn mode switch 3 to on e Turn mode switch 4 to off OR 3 a Terminate the incoming connections to the Z 65 terminal strip see illustration b Turn mode switch 1 to on c Turn mode switch 2 ...

Page 22: ...ounter dials to the appropriate num ber of pulses you want to count before the sample pump strokes Example 20 pulses turn dials to 20 Press the test button once to load the value into the memory pump displacement a 2cc 2cc sample cylinder size b 300cc 300cc average flow rate c 10 MMCF per day 10MCM day sample period d 30 days 30 days pulses per volume metered e 100 pulses MMcf 100 pulses MCM Examp...

Page 23: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 17 DP 2010 TP ver 10012004 SECTION 5 PROGRAMMING FOR PROPORTIONAL TO FLOW OPERATION Notes ...

Page 24: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 18 DP 2010 TP ver 10012004 SECTION 5 PROGRAMMING FOR PROPORTIONAL TO FLOW OPERATION Notes ...

Page 25: ...12 400 18 36 60 9 13 27 45 3 6 4 9 18 9 15 30 300 200 100 Number of turns open on pump stroke knob sample pump displacement per stroke 1000 cc 500 cc 300 cc Sample cylinder volumes Sample rate minutes IMPORTANT NOTE To obtain maximum battery life choose the longest time interval and the largest pump displacement setting possible IMPORTANT NOTE The time 18 minutes above corresponds to the dial sett...

Page 26: ...itch 1 to on 5 Turn mode switch 2 to on 6 Turn mode switch 3 to on 7 Turn mode switch 4 to off 8 Press the test button once to initiate the timer sequence 3 Adjust the pump volume adjustment knob to the value used in the calculations in step 1 Number of turns open on the pump volume knob 3 6 12 Sample pump displacement per stroke 1cc 2cc 4cc 5 UVGO WVWCN RRTQXGF CEVQT figure 12 figure 13 ...

Page 27: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 21 DP 2010 TP ver 10012004 SECTION 6 PROGRAMMING FOR PROPORTIONAL TO TIME OPERATION Notes ...

Page 28: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 22 DP 2010 TP ver 10012004 SECTION 6 PROGRAMMING FOR PROPORTIONAL TO TIME OPERATION Notes ...

Page 29: ...00 200 100 Number of turns open on pump stroke knob sample pump displacement per stroke 1000 cc 500 cc 300 cc Sample cylinder volumes Sample rate minutes 18 minutes 3 2 0 9 6 8 7 1 3 2 5 4 0 9 1 6 7 8 5 4 IMPORTANT NOTE To obtain maximum battery life choose the longest time interval and the largest pump displacement setting possible IMPORTANT NOTE The time 18 minutes above corresponds to the dial ...

Page 30: ...tch 1 to on 5 Turn mode switch 2 to on 6 Turn mode switch 3 to off 7 Turn mode switch 4 to off 8 Press the test button once to initiate the timer sequence Number of turns open on the pump volume knob 3 6 12 Sample pump displacement per stroke 1cc 2cc 4cc 5 UVGO WVWCN RRTQXGF CEVQT IMPORTANT NOTE For the Z 65 to operate the DP 2010 System a minimum pressure differential of 3 of water must exist bet...

Page 31: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 25 DP 2010 TP ver 10012004 SECTION 7 PROGRAMMING FOR PROPORTIONAL TO TIME W DPS 2 Notes ...

Page 32: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 26 DP 2010 TP ver 10012004 SECTION 7 PROGRAMMING FOR PROPORTIONAL TO TIME W DPS 2 Notes ...

Page 33: ...10 TP ver 10012004 SECTION 8 MECHANICAL SYSTEM Overview The DynaPak mechanical system figure 18 are composed of the sample pump and filter regulator These components of the system are shown here and described in the following pages figure 18 FilterRegulator SamplePump SVL CustomerSupplied SampleProbe ...

Page 34: ...Turn the volume adjustment knob clockwise to increase the pump volume displacement per stroke or turn the volume adjustment knob counter clock wise to decrease the pump volume displacement per stroke Final control of the volume of sample to be gathered during the sample cycle period is achieved by the Z 65 controller This pump has internal pressure balancing capabilities that allows the pump to fu...

Page 35: ...ered regulator to supply the supply gas required to actuate the sample pump It is capable of providing actua tion pressure from pipeline pressures to required actuation pressures in a single dependable step Maintenance is minimal but is certainly depen dant on gas quality Should the gas supplied to the filter regulator require significant filtration replacement of the filter may be more frequent t...

Page 36: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 30 DP 2010 TP ver 10012004 SECTION 8 MECHANICAL SYSTEM Notes ...

Page 37: ...e top of the pump counterclockwise to set the pump displacement at 4 cc stroke refer to Section 8 page 28 4 Move all of the mode switches on the Z 65 to their off positions figure 20 5 Move both timer counter dials to the 0 posi tion 00 minutes figure 21 6 Move mode switches 1 2 and 3 to the on position The pump will begin stroking once every 2 seconds in a diagnostic test mode figure 22 7 Allow t...

Page 38: ...on of that area 12 Connect the conduit pack off etc to the right side of the thermostat enclosure 13 Connect the white lead of the incoming 120 VAC power supply wiring to the loose white lead inside the thermostat enclosure 14 Connect the black lead of the incoming 120 VAC power supply wiring to the right terminal on the thermostat It should have no other wires connected to it 15 Connect the green...

Page 39: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 33 DP 2010 TP ver 10012004 SECTION 9 SYSTEM OPERATION Notes ...

Page 40: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 34 DP 2010 TP ver 10012004 SECTION 9 SYSTEM OPERATION Notes ...

Page 41: ...ication of the sampler Many of these considerations include the weather environment the condition of the actuation gas the product condition and quality and the pump stroke frequency All of these issues must be considered when establishing a preven tative maintenance schedule Recommended Maintenance Schedule Monthly Inspection 1 Verify system pressures 2 Check for leaks 3 Test the battery 4 Test t...

Page 42: ...check valve assembly Separation at this point is recommended to maintain proper tubing location and alignment between the pump body and the probe body Do not remove the inlet check valve body from the manifold unless cleaning is necessary To replace the inlet check valve o ring carefully cut the o ring off the head of the dart and stretch the new o ring over the head of the dart using a light coat...

Page 43: ...m of the pump body figure 26 11 Insert all other bushings springs and o rings in their respective sequence on the plunger shaft figure 26 12 Carefully install assembly into the top of the pump body and screw the actuator assem bly onto the pump body Tighten firmly by Hand ONLY 13 Install the pump assembly on the inlet valve assembly Tighten firmly by Hand ONLY 14 Connect the 1 8 stainless steel tu...

Page 44: ...ver plate and orange terminal connector 2 The battery is located in the lower left hand corner of the Z 65 controller assembly 3 Unclip the battery plug from the battery receptacle 4 Replace the depleted battery with a fresh battery pack part No E3 2001 Refer to figure 27 to assure proper battery wire place ment in the Z 65 enclosure 5 Return the mode switches to their original positions DWWHU 3DF...

Page 45: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 39 DP 2010 TP ver 10012004 SECTION 10 SYSTEM MAINTENANCE Notes ...

Page 46: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 40 DP 2010 TP ver 10012004 SECTION 10 SYSTEM MAINTENANCE Notes ...

Page 47: ... F 1 936 788 5720 Em Service yzhq com SAFETY NOTES Always use extreme care when performing mainte nance on Sampling Systems Always take necessary measures to assure that electrical classification in the area is considered before and during all repairs and that necessary steps are taken to maintain proper electrical procedures for the classification of the area Take special care when disconnecting ...

Page 48: ...Troubleshooting Steps 1 Set the mode switches as follows figure 28 Position 1 2 and 3 on 2 Set the time switches to the 01 position figure 29 This will set the solenoid output rate to one actuation every one minute based on the factory set time range for the Z 65 model refer to figure 45 page46 3 Depress the test switch to test the battery A green LED will illuminate if the battery is good and a r...

Page 49: ...Set the count switches to 00 to enter the diagnostic mode refer to figure 32 This mode enables the user to determine if the proper input pulses are being received at the count input ter 3 A Dry Contact Input mode switch 4 should be in the off position refer to figure 34 Depress the test switch and hold A red LED should illuminate When the dry contact input is received at the counter input ter 3 th...

Page 50: ... pulse input is received at the count input ter 3 the red LED will turn on and off and the green LED will illuminate again This will normally occur very quickly and give the appearance that the red LED blinks on when the pulse input is received and removed figure 36 CEVQT 5 UVGO RRTQXGF WVWCN figure 36 Z 65 Timer Mode If the Z 65 controller is to be operated in the timer mode it acts a a simple re...

Page 51: ... Set the time dials to 00 to enter the diagnostic mode figure 40 3 This mode enables the operator to determine if the DPS is operating properly This is accomplished by depressing and holding the test switch If the DPS is sensing flow in the pipeline the green LED should illumi nate If flow is not present the red LED should illuminate figure 41 LCD Stroke Indicator Test Mode 1 To test the stroke co...

Page 52: ...each time the solenoid fires When the counter display reads 999999 the test is complete Timer Range Setting There are two Z 65 models the Z 65 6 1 and Z 65 6 03 Each Z 65 timer has two ranges for the timer setting dials 1 Z 65 6 1 Range Setting xx minutes set the configura tion jumper to the far left posi tion factory setting figure 45 x x minutes set the configura tion jumper to the center posi t...

Page 53: ... configuration jumper to the far left position factory setting figure 47 xx minutes set the configuration jumper to the center position figure 48 WVWCN 5 UVGO RRTQXGF CEVQT IDFWRU SRVLWLRQHG IRU FRXQWV XPSHU VZLWFK ORFDWLRQ XPSHU VZLWFK ORFDWLRQ IRU FRXQWV WVWCN 5 UVGO RRTQXGF CEVQT IMPORTANT NOTE To obtain maximum battery life choose the longest solenoid stroke rate possible figure 47 figure 48 ...

Page 54: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 48 DP 2010 TP ver 10012004 SECTION 11 SYSTEM TROUBLESHOOTING Notes ...

Page 55: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 49 DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS DynaPak 2000 Pump Assembled Figure 49 ...

Page 56: ...O Ring 010 P N A5 1010 Volume Adjustment Knob matic Fitting P N A1 0113 lume Adjustment Spring ume Adjustment Detent per Diaphragm Housing Diaphragm P N B1 0003 P N C3 0005 P N B1 0030 Set Screw P N C0 0096 P N C0 0014 Cap Screw 6 Each P NB1 0020 P N C0 0026 Inlet Screen P N C4 0006 P N C3 0008 Inlet Check Valve Spring Inlet Check Valve Spring Guide Nut Body Bushing P NB1 0016 P NB1 0018 Inlet Che...

Page 57: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 51 DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS YZ Filter Regulator Assembly Figure 51 ...

Page 58: ...w Figure 52 LOWHU 5HJXODWRU 5HSDLU LW 3 1 3UHVVXUH DXJH 3 1 3 1 RZHU 6SULQJ RZHU DUW 2 5LQJ 5HWDLQLQJ 1XW 3 1 6HDW 3 1 8SSHU DUW 3 1 8SSHU 6SULQJ 3 1 3 1 3LVWRQ 3 1 3LVWRQ 6SULQJ 6SULQJ DS 3 1 3 1 RQQHW 3QHXPDWLF LWWLQJ 3 1 3 1 GMXVWPHQW 6FUHZ 3 1 2 5LQJ LOWHU RXVLQJ 3 1 LOWHU OHPHQW 3 1 LOWHU 7XEH 3 1 3 1 3 1 RG 7XELQJ LWWLQJ 3 1 3QHXPDWLF 3 1 LWWLQJ 2 5LQJ 3 1 P N A8 0061 ...

Page 59: ...Valve Seat P N A3 0063 P N A3 0062 P N A3 0095 Valve Handle P N A3 0217 P N C0 0099 P N Varies See Above Pressure Gauge Stainless Steel Set Screw Inlet Rupture Disc 1800 psi P N A3 0083 Rupture Disc Retainer P N A3 0084 YZ Valve Body P N A3 0137 0 1000 PSI LinkPlus Model No C1 0005 0 2000 PSI LinkPlus Model No C1 0006 0 600 PSI LinkPlus Model No C1 0004 Outlet P N A8 0007 P N A8 0012 P N A8 0011 P...

Page 60: ...DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS OptionalDPS 2 Figure 54 3 1 6HW 6FUHZ 3 1 0DJQHW LDSKUDJP 66 H 1XW 3 1 4W 3 1 3 1 DEOH VVHPEO W 6KULQN UDS 66 ROW 3 1 4W 3 1 4W 0DJQHW 6XSSRUW RG LDSKUDJP RG LDSKUDJP RG 3 1 LJK 3UHVVXUH 3 1 3 1 RZ 3UHVVXUH 3 1 5HHG 6ZLWFK DS 3 1 3 1 6WUDLQ 5HOLHI ...

Page 61: ...TP ver 10012004 APPENDIX A ILLUSTRATIONS Z 65 and Solenoid Figure 55 5HSDLU LW XVH 5HSODFHPHQW LW XVHV 3HU LW 5HI 1R HVFULSWLRQ 3DUW 1R 4W RQWUROOHU VVHPEO 0RGHO 0RGHO DWWHU 3DFN 6WURNH RXQWHU VVHPEO 7HUPLQDO 6WULS 3RVLWLRQ 6ZLWFK 0RGH 6ZLWFK DFH 3ODWH 0RGHO 0RGHO 7KXPE 6FUHZ DEOH VVHPEO 6ROHQRLG 9DOYH ...

Page 62: ...nc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 56 DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS Z 65 Wiring Control Document Figure 56 6 VWHP QVWDOODWLRQ 1RWHV DQG 5HFRPPHQGDWLRQV ...

Page 63: ...88 5720 Page 57 DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS ElectricHeater The120VACElectricHeaterinconjunctionwithathermostatic controlprovidestherequiredheattomaintaintheinsideofthe enclosureatatemperaturesetbytheoperator Figure 57 Heater Thermostat Temperature Guage SV L ...

Page 64: ...YZ Systems Inc 3101 Pollok Drive Conroe Texas USA 77303 P 936 788 5593 F 936 788 5720 Page 58 DP 2010 TP ver 10012004 APPENDIX A ILLUSTRATIONS Notes ...

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Page 66: ...es terms and conditions which are subject to change without notice All prices and specifications if published are subject to change without notice YZ Systems Inc represents and warrants that for a period of 3 years from receipt of the product 1 the product will be free from defects in materials and workmanship and 2 the product will perform substantially in accordance with product manuals literatu...