Perma Pure 3300 User Manual

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INSTRUCTION MANUAL

FLOW CONTROL DRAWERS
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ANUAL / PLC CONTROL SERIES

Model 3300

Version 4.06

Perma Pure LLC Tel: [phone]
P.O. Box 2105, 8 Executive Drive Tel: [phone] (toll free US)
Toms River, NJ 08754 Fax: [phone]

www.permapure.com

Email: [email protected]

TABLE OF CONTENTS

TABLE OF CONTENTS .......................................................................................2

A: LIMITED WARRANTY.....................................................................................3

B: DESCRIPTION.................................................................................................4

C: SPECIFICATIONS...........................................................................................6

D: OPERATION ....................................................................................................7

E. BACK PANEL CONNECTIONS.....................................................................11

F. PRESSURE SENSOR BOARD......................................................................12

G: TROUBLESHOOTING ..................................................................................13

APPENDIX .........................................................................................................14

Section A: Limited Warranty 2

A: LIMITED WARRANTY

Perma Pure LLC

WARRANTY and DISCLAIMERS

Perma Pure (Seller) warrants that product supplied hereunder shall, at the time of delivery to
Buyer, conform to the published specifications of Seller and be free from defects in material and
workmanship under normal use and service. Seller’s sole obligation and liability unde r this
warranty is limited to the repair or replacement at its factory, at Seller’s option, of any such
product which proves defective within one year after the date of original shipment from seller’s
factory (or for a normal usable lifetime if the product is a disposable or expendable item) and is
found to be defective in material or workmanship by Seller’s inspection.

Buyer agrees that (1) any technical advice, information, suggestions, or recommendations given
to Buyer by Seller or any representative of Seller with respect to the product or the suitability or
desirability of the product for an particular use or application are based solely on the general
knowledge of Seller, are intended for information guidance only, and do not constitute any
representation or warranty by Seller that the product shall in fact be suitable or desirable for any
particular use or application; (2) Buyer takes sole responsibility for the use and applications to
which the product is put and Buyer shall conduct all testing and analysis necessary to validate the
use and application to which Buyer puts the product for which Buyer may recommend the use or
application of the product by others; and (3) the characteristics, specifications, and/or properties
of the product may be affected by the processing, treatment, handling, and/or manufacturing of
the product by Buyer or others and Seller takes no responsibility for he nature or consequence of
such operations or as to the suitability of the product for the purposes intended to be used by
Buyer or others after being subjected to such operations.

SELLER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, OF THE PRODUCT
SUPPLIED HEREUNDER, INCLUDING, WITHOUT LIMITATION, IMPLIED WA RRANTIES OF
MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE, AND ALL SUCH
WARRANTIES ARE HEREBY EXPRESSLY EXCLUDED. SELLER SHALL HAVE NO LIABILITY
FOR LOSS OF PROFITS, OR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES
UNDER ANY CIRCUMSTANCES OR LEGAL THEORY, WHETHER BASED ON NEGLIGENCE,
BREACH OF WARRANTY, STRICT LIABILITY, TORT, CONTRACT, OR OTHERWISE. SELLER
SHALL IN NO EVENT BE LIABLE IN RESPECT OF THIS ORDER AND OR PRODUCT
DELIVERED ON ACCOUNT OF THIS ORDER FOR ANY AMOUNT GREATER THAN THAT
PAID TO SELLER ON ACCOUNT OF THIS ORDER.

Section A: Limited Warranty 3

B: DESCRIPTION

The Baldwin™-Series Model 3300 Flow Control Drawer allows easy control of sample
and calibration gases. With the Model 3300, you may choose whether to control sample
gases, cal gases, and stack probe blowback, manually or by PLC.

The standard Model 3300 is configured for two gas channels, and two calibration gases
(zero and span). Manual control switches are provided for selection of system or direct
calibration. Four flow meters are included for visual indication & control of stack
calibration gas flow, individual analyzer flow, and bypass.

Model 3300 has a provision for system bias checks. System integrity is verified by
comparing the calibration gas flow to the stack filter head and through the entire sample
system to the calibration gas introduced directly to the continuous gas analyzer common
sample manifold. This check indicates problems such as system leakage and gas
component loss.

Model 3300

Features:

• Manual or PLC control of sample and calibration gases

• Up to 6 gas analyzer channels

• Up to 8 cal gas channels (including zero and span)

• Multiple flow meters: cal gas to probe, total flow to analyzers, individual analyzer

channels

• Pump vacuum gauge

• Sample / cal gas pressure gauge

• Cal gas regulator

• Optional pressure transmitters (sample, cal gas and vacuum), Model 3300P

The Model 3300 Flow Control Drawer is a 19" Rack Mountable integrated gas flow
control system for monitoring and controlling of:

Section B: Description 4

1. Total Extracted Sample Flow

2. Individual Analyzer Sample Flow

3. Bypass Flow Control

4. Calibration Gas Pressure Regulation & Flow

5. Bias Check (Sample Loss Due to Leaks or Gas Absorption)

6. Calibration Gas Leak Detection

7. Stack Probe Blowback
Upgrades to the Model 3300:

• Additional analyzer gas channels (6 Gas Channels Maximum).

• Additional calibration gas valves (8 Cal-Gas Channels Maximum).

• 3 Pressure transmitters (sample, cal gas, vacuum) Model 3300P

Section B: Description 5

C: SPECIFICATIONS

Input Cal-Gas Channels:

Flowmeters: Sample 5-15 Psig
Vacuum 0-30" Hg
Calibration 5-35 Psig

Output Gas Channels:
Flowmeters: 0 – 2.5 LPM

Blowback: Specify 12VDC, line voltage or dry

contacts

Voltage: 90 - 240VAC, 50/60 Hz
Power: 100 Watts

Mounting Dimensions: 5U (8.75"), 19" Rack Mount
18" Depth
Weight: Approx. 24 lbs

Section C: Specifications 6

D: OPERATION

General Overview

Sample gas is extracted from the process through a filter probe, such as a Baldwin™­Series Heated Filter Probe, to remove particulate. The filtered gas is then transported to
a Baldwin Sample Conditioning System where the moisture is removed. The Sample
Conditioning System supplies a clean, dry sample when it enters the back panel of the
Model 3300 Flow Control Drawer. The stack probe filter and sample pump performance
are indicated by the Flow Control Drawer Vacuum/Pressure Gauges.

Note: Please refer to the attached Model 3300 Flow Diagram for an example of an
integrated continuous emissions monitoring system flow schematic using the Model
3300 Flow Control Drawer.

Flow from the Sample Conditioning System enters the Model 3300 Flow Drawer
sample/calibration manifold. Here, either sample or calibration gas (for direct calibration)
can be directed to the atmospheric pressure sample manifold and then on to the
individual analyzer gas channels. Individual sample flowmeters indicate the flow rate of
each gas channel. A bypass flowmeter vents excess sample gas not used by the
continuous gas channels and also acts as an atmospheric vent.

The Model 3300 Flow Control Drawer has the ability to switch the sample and as many
as eight (8) calibration gases to the analyzer rack directly or via the total sampling
system. This is done through two (2) sets of solenoid valves: (1) the calibration gas
solenoid valves which are mounted on a common manifold at the rear of the drawer, and
(2) the system/direct solenoid valves located in the front of the drawer. A block & bleed
solenoid valve, which prevents the manifolds from being pressurized during sampling, is
also part of the system/direct solenoid valve set.

The calibration function will only take place when both a calibration gas solenoid valve
and either the system solenoid valve or direct solenoid valve have been selected. In
Local mode, the calibration gas solenoid valves are cascaded, that is if there are more
than one (1) calibration gas solenoid valve switches in the on position, only the highest
numerical calibration gas solenoid valve will be active. This is not the case with
computer control. The programmer can select any or all of the calibration gas solenoids.
Also, computer control is not allowed in the Local mode. While in the Local/Direct
Calibration mode, manual blowback is allowed, but not while in the Local/System
Calibration mode. While under computer control, blowback is allowed when nothing else
is activated, but not in any Calibration mode.

The Model 3300 has a provision for system bias checks. System integrity is verified by
comparison of calibration gas flow through the stack filter assembly to calibration gas
flow directly to the gas analyzers. This check indicates problems such as system
leakage and gas component loss.

A probe filter blowback relay contact is provided on the Flow Control Drawer to facilitate
Manual or computer initiated blowback. For Blowback there is a 250V, 6Amp dry

Section D: Operation 7

contact form C relay output provided on the back panel for blowback implementation.
There are two (2) vertical terminal block assemblies on the back panel provided for
computer interface. The 16-point terminal block is used for computer control and the 40­point terminal block is used for computer verification of flow control drawer operation.

Pressure Sensor Board Option

Upstream, (stack filter/and sample line) the pressure drop is actively monitored by a
vacuum transmitter, the sample gas flow is verified by a sample manifold pressure
transmitter and presence of adequate calibration gas is verified by a pressure transmitter
on the calibration gas manifold.

Local Mode Operation

To enter the Local mode, toggle the Remote/Local switch to the right. While in the Local
mode, the operator can perform manual calibrations and blowback.

The flow control drawer is in Local Control when the Local Switch is selected, the red
LED is on and the green Sample LED is on as well. In this mode, all switches on the
front panel are enabled for local operator control and Computer Control is disabled. All
Calibration Gas (CG) functions, Direct/System, and blowback are available for the local
operator. When the Local LED is OFF, the PC or PLC has control and can remotely
duplicate local control functions. The Local Switch provides an output to the PLC/PC to
indicate that the Flow Control Drawer is offline, (i.e., the analyzers’ outputs are not
reliable).

CONTROL FUNCTIONS:

Sample Blowback Direct

SWITCHES

Local X X X
Direct X
System X
Blowback X
Cal Gas 1-8 X X

Manual System Calibration: To perform manual system calibration, toggle the
Direct/System switch to the right. Then toggle any of the Calibration Gas switches to the
right. This will allow the selected calibration gas to flow to the analyzer suite via the total
sampling system. In this mode, manual blowback is not allowed.

Manual Direct Calibration: To perform manual direct calibration, toggle the Direct/System
switch to the left. Then toggle any of the Calibration Gas switches to the right. This will
allow the selected calibration gas to flow to the analyzer suite directly, bypassing the
total sampling system. In this mode, manual blowback is allowed.

Manual Blowback: To perform manual blowback, depress the Blowback switch to the
right. This switch is a momentary switch, that is, it will return when released. When the
operator toggles the Blowback switch, two things happen; first, the blowback relay will be
activated, and second, the direct solenoid valve will be activated. With the direct

Calibration

System

Calibration

Section D: Operation 8

solenoid valve activated, the analyzer suite will be protected from blowback
pressurization.

Computer Control Mode Operation

Computer Control (CC): To enter Computer Control mode operation the Remote/Local
switch must be toggled to the left. Computer control is initiated through the 16 Position
vertical terminal block on the back panel. To activate a particular function, 5VDC is
applied to the appropriate terminal. The Remote and Local functions are identical. This
can be done in one of two ways. The first way is to take the +5 VDC from terminal 10 or
12, pass it through a set of dry contacts on a computer controlled relay, and back to the
appropriate terminal. The second way is to take +5VDC directly from the computer
control to the appropriate terminal. For this method, please note that the flow control
drawer GND on Terminal 14 and 16 must be connected to the GND on the computer
control unit, to electrically reference both systems together.

Computer Control Terminals Summary

Terminal 2 = System Calibration Terminal 1 = Cal Gas 1
Terminal 4 = Direct Calibration Terminal 3 = Cal Gas 2
Terminal 6 = Blowback Terminal 5 = Cal Gas 3
Terminal 8 = NA Terminal 7 = Cal Gas 4
Terminal 10 = +5 VDC Terminal 9 = Cal Gas 5
Terminal 12 = +5 VDC Terminal 11 = Cal Gas 6
Terminal 14 = GND Terminal 13 = Cal Gas 7
Terminal 16 = GND Terminal 15 = Cal Gas 8

Computer Sense CS: Along with the computer control mode of operation, a computer
verification method is also incorporated into the system. A 40 pin vertical terminal block
on the back panel allows the computer to verify the actions initiated by the computer.
This is done through a set of normally open dry contacts that are associated with each
particular function.

Computer Sense Terminals Summary

FUNCTION TERMINALS
Cal Gas Valve 1 1 & 2
Cal Gas Valve 2 3 & 4
Cal Gas Valve 3 5 & 6
Cal Gas Valve 4 7 & 8
Cal Gas Valve 5 9 & 10
Cal Gas Valve 6 11 & 12
Cal Gas Valve 7 13 & 14
Cal Gas Valve 8 15 & 16
System Calibration 17 & 18
Direct Calibration 19 & 20
Blowback* 31 & 32
Local Mode* 39 & 40

*Note: The sense contacts are normally closed when activated except for blowback

Section D: Operation 9

COMPUTER CONTROL TRUTH TABLE
Terminal # | 2 | 4 | 1 | 3 | 5 | 7 | 9 | 11 | 13 | 15 | 6 |
FUNCTION | | | | | | | | | | | D |
System/Calibration 1 | * | | * | | | | | | | | D |

System/Calibration 2 | * | | | * | | | | | | | D |
System/Calibration 3 | * | | | | * | | | | | | D |
System/Calibration 4 | * | | | | | * | | | | | D |
System/Calibration 5 | * | | | | | | * | | | | D |
System/Calibration 6 | * | | | | | | | * | | | D |
System/Calibration 7 | * | | | | | | | | * | | D |
System/Calibration 8 | * | | | | | | | | | * | D |

Direct/Calibration 1 | | * | * | | | | | | | | |
Direct/Calibration 2 | | * | | * | | | | | | | |
Direct/Calibration 3 | | * | | | * | | | | | | |
Direct/Calibration 4 | | * | | | | * | | | | | |
Direct/Calibration 5 | | * | | | | | * | | | | |
Direct/Calibration 6 | | * | | | | | | * | | | |
Direct/Calibration 7 | | * | | | | | | | * | | |
Direct/Calibration 8 | | * | | | | | | | | * | |

Blowback | | | | | | | | | | | * |
D = Disabled

Section D: Operation 10

E. BACK PANEL CONNECTIONS

See drawing Flow Control Drawer Back Panel

Mechanical Connections Inlet/outlet Gas Bulkhead Fittings

1. All Sample Gas Connections are via 1/4" stainless steel bulkhead fittings.

2. All Calibration Gases are 1/4" SS Tube Quick Connects.

3. All Bulkhead Connections are labeled and follow the following functions:
Sample In ---------------------------------------------------- (SAMPLE)

Sample Vacuum Sense In -------------------------------- (VACUUM)
Calibration Gas Out to Stack Filter Assembly -------- (STACK)
Analyzer #1 ----------------------------------------------- (CH1)
Analyzer #2 ----------------------------------------------- (CH2)
Analyzer #3 ----------------------------------------------- (CH3)
Analyzer #4 ----------------------------------------------- (CH4)
Analyzer #5 ----------------------------------------------- (CH5)
Analyzer #6 ----------------------------------------------- (CH6)
Calibration Gas #1-8 --------------------------------------- (CG1-8)

Section E: Back Panel Connections 11

F. PRESSURE SENSOR BOARD

The pressure sensor option provides:

• Vacuum pressure sensor 0- (-15) psig

• Sample pressure sensor 0-30 psig

• Calibration gas pressure sensor 0-30 psig

Outputs

1. The standard output from all sensors is 4-20 mADC, isolated, loop powered1

2. Outputs are terminated on the Flow Control Drawer back panel on the analog
output Pressure Transducer Terminal Strip.

Connections
24 VDC Supply
Vacuum
Sample
Calibration gas

Sensor Calibration

1. All sensors are calibrated at the factory, and should not be adjusted in the
field without proper calibration pressure sources.

4 to 20mA Output

Pin 1 Pin 2

Pin 7 Pin 8

Pin 9 Pin 10

Section F: Pressure Sensor Board 12

G: TROUBLESHOOTING

Symptom Check Action

No LED display Not plugged in

Power switch is off
Fuse blown
Power supply defect
12 VDC red-black
Check jumper JP1

Ribbon cable loose
Defective control board

Manual Control (Local)

Switches have no effect
Inadequate sample flow
No system cal gas flow

No direct cal gas flow

Computer Control (Remote)

Computer control has no effect

No computer sense

Remote/Local switch in remote
Low sample pressure

No cal gas from bottle
Cal gas solenoid not operating

Flow drawer regulator set <10psig
Cal gas Flowmeter closed
Block/bleed solenoid constantly
vents
System cal gas solenoid valve
defective

Direct cal gas solenoid valve
defective

Remote/Local switch in local
Computer control wiring to
terminal block is wrong

Ribbon cable is loose
Defective control board
Computer sense wiring to terminal
block is wrong
Ribbon cable is loose

For further service assistance, contact:

Perma Pure LLC
P.O. Box 2105
8 Executive Drive (08755)
Toms River, NJ 08754
Tel: [phone] (toll free U.S.)
Tel: [phone]
Fax: [phone]
Email: [email protected]

Plug in instrument
Turn on power
Replace fuse

Replace power supply
Jumper 1-2
Jumper 3-4
Jumper 5-6
Tighten ribbon cables
Replace control board
Select local
Adjust sample pressure
Cylinder to 15 psig
Check cabling
Replace cal gas solenoid
Replace control board
Set regulator to 10 psig
Adjust Flowmeter
Replace solenoid SV9

Replace solenoid SV10

Replace solenoid SV11
Check cables and connector
boards for good connections
Select remote
See the computer control wiring
section in manual, also if using
a PLC for control make sure to
match your DC GND with the
Unit DC GND reference points
on pins 14 or 16.
Check cables.
Replace control board
See computer control wiring
section in manual
Check cables

APPENDIX