TABLE OF CONTENTS
INSTRUCTION MANUAL
Perma Pure LLC Integrator Series
Model iCOOL
Table of Contents 1
TABLE OF CONTENTS
A: Specifications ................................................................................................................. 3
B: Limited Warranty ............................................................................................................ 4
C: Principle of Operation ..................................................................................................... 5
D: Installation ...................................................................................................................... 8
E: Start-up Procedure ......................................................................................................... 9
F: LED Indicators .............................................................................................................. 10
G: I/O Terminal Block Description .................................................................................... 11
H: Test & Adjustment Procedures .................................................................................... 12
Table of Contents 2
Sample Gas Flow Range
1-3 LPM
2.1-6.4 SCFH
Inlet Dew Point at Rated Flow
300F @ 12% H2O, 2.5 LPM
Maximum Cooling Rate
58 BTU/Hr
Dimensions
7.25 x 8.25 x 10.5 in. HWD
18.5 x 21 x 26.7 cm
Weight
11 lbs
5 kg
Maximum Inlet Sample
Temperature
392F (200
°
C) SS, Durinert
®
, Glass
Impingers
280F (138
°
C) Kynar Impinger
Maximum Inlet Pressure
45 psig
3 bar / 2250 mmHg
Maximum Heat Exchanger
Pressure Drop
<+1 in. H2O
Ambient Temperature Range
33-104F
0.6-40°C
Outlet Sample Gas Dew Point
39.2F
4°C
Inlet Tubing Connection
3/8 in. FPT
Outlet Tubing Connection
¼ in. FPT
Drain Tubing Connection
3/8 in. FPT
Voltage
90-240 VAC
50/60 Hz
Thermoelectric Elements
40 mm
Power Supply
100W
Cooling Down Time
Less than 3 minutes
A: SPECIFICATIONS
Physical Description
Single Channel System
1 x 5” Heat Exchanger
1 Active (cooled to 3.5C) Heat Exchanger
LCD temperature display
Operating Specifications
Section A: Specifications 3
B: 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 under 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 WARRANTIES 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 B: Limited Warranty 4
Figure 1: Thermo-electric element (Peltier)
C: PRINCIPLE OF OPERATION
Thank you for purchasing the Perma Pure Integrator Series Thermo-Electric Cooler.
Our ICOOL features a unique slim design leaving additional space to install or
access other sample conditioning system components. A unique shell design on
this model provides easy access to electronic board, fan and the power supply. All
electronic boards (control, relay, and display) are mounted on the front panel for
easy access.
The process of sampling combustion product stack gas or exhaust from internal
combustion engines requires a method to remove the moisture from the sample,
without removing the gas components of interest. The Integrator Series ThermoElectric Cooler is an ideal way to decrease the dew point of combustion gases to a
repeatable, stable, constant low dew point. The Integrator Series cooler prevents
water condensation in sample pre-filters, sample pumps, and gas analyzers. For
gas analyzers where water vapor is an interferent, a stable, repeatable dew point
becomes a part of the gas analyzer performance specification. Perma Pure’s
Integrator Series coolers provide this constant low water concentration, resulting in
an accurate component gas measurement.
All Perma Pure coolers use thermo-electric elements (Peltier elements) to cool the
sample gas to the desired dew point temperature. A Perma Pure Thermo-Electric
Cooler is best illustrated as a
small heat pump with no
moving parts. The Peltier
elements operate on direct
current and may be used for
heating or cooling by reversing
the direction of current flow.
This is achieved by moving
heat from one side of the
module to the other with current
flow and the laws of
thermodynamics. A typical
single stage Peltier (Figure 1)
consists of two ceramic plates
with p- and n-type
semiconductor material
(bismuth telluride) between the
plates. The elements of
semiconductor material are connected electrically in series and thermally in parallel.
When a positive DC voltage is applied to the n-type thermo-electric element,
electrons pass from the p- to the n-type thermo-electric element and the cold side
temperature will decrease as heat is absorbed. The heat absorption (cooling) is
Section C: Principle of Operation 5
Figure 2: Heat Exchanger, Impinger and Heat Sink Assembly
proportional to the current and the number of thermo-electric couples. This heat is
transferred to the hot side of the Peltier element where it is dissipated into the heat
sink and surrounding environment.
The Integrator Series Thermo-Electric Coolers remove the moisture from the sample
gas by cooling the gas as it passes through a laminar impinger (heat exchanger).
A diagram showing the gas flow path through an impinger is shown in the Appendix.
The heat exchanger, made of 316L stainless steel, Durinert® (a corrosion-resistant
inert coating over 316L stainless steel), PVDF (Kynar), or glass, is mounted within a
thermally insulated heat transfer block bored to receive the heat exchanger without a
mechanical lock. This assembly allows the easy removal of any heat exchanger
simply by slipping it out of the cooling block by hand. The heat transfer block cools
the heat exchanger through the heat pumping action of the peltier element. The
heat transfer block is on the cold side of the thermo-electric element and the heat
sink is on the hot side of the thermo-electric element. The heat from the heat
transfer block is pumped to the heat sink where it is then dissipated into the air by
the heat sink fan. See Figure 2. The desired temperature is maintained by a closed
loop control system, which is implemented through a digital controller. The controller
uses an interchangeable thermistor in the heat transfer block located very close to
the cold side of the peltier element as the input sensor.
The sample gas is passed to the Classic Thermo-Electric Cooler via the heated filter
sample probe and heated sample line. The Integrator Series Thermo-Electric Cooler
Section C: Principle of Operation 6
lowers the sample dew point below 4o C (39.2°F). As the gas cools and the moisture
vapor condenses, the condensate exits the heat exchanger through the bottom drain
connection. Particulate matter which passes through the sample cooler is removed
by an optional pre-filter, located downstream from the cooler along with an optional
water slip sensor. The conditioned sample gas can then be directed to the gas
analyzers.
Section C: Principle of Operation 7
D: INSTALLATION
The Model ICOOL should be installed away from heat sources in a well ventilated
area of an instrument rack or enclosure. REMEMBER, the Model ICOOL can only
control to 61°F DIFFERENTIAL from ambient temperature. Thus, at an output
temperature control of 39°F, the maximum ambient temperature is 100°F, above
which cooling control is lost. When this differential is exceeded, the controller will go
full-on, with the cooling capacity floating in relation to the ambient temperature
above 104°F. No damage will occur to the cooler; however, the output dew point will
also float in relation to the ambient temperature. The more stable the ambient
temperature environment around the ICOOL, the better the output dew point
stability.
The outlet tubing of all metal or Kynar heat exchangers is 1/4" compression tube
fittings; the user should always use the compression type fittings provided for that
purpose by the factory. The inlet tubing of all metal or Kynar heat exchangers is 3/8”
tube fitting to mate with most standard 3/8” sample lines.
The condensate drain connection is a Kynar® straight 3/8” MNPT x 1/4” barbed tube
fitting. An automatic condensate drain, Model 3KPB-001 Peristaltic Pump, dual
head, is recommended for water removal. This pump uses size 17 tubing.
CAUTION: Do not reduce the size of the condensate tubing since doing so restricts
water flow resulting in water slip (moisture carryover) in the sample.
CAUTION: If using a stainless steel sample line, place 2 inches of TEFLON tubing
in between the exchanger inlet fitting and the heated line. This prevents the sample
cooler from heat sinking the incoming heated line, which adds undue load to the
cooler.
.
Section D: Installation 8
E: START-UP PROCEDURE
Plug in the power cord to a properly grounded main circuit. The Ready Green LED
will come on within 3 minutes, indicating the relay temperature (10°C) has been
achieved. After approximately 3 minutes, the set point of +3.5°C. (38.3°F) is
achieved. The sample gas flow may be started immediately after the Green LED
comes on.
The ICOOL is virtually maintenance free. However, in the event of electrical
problems, contact the Perma Pure LLC service department for troubleshooting
assistance.
Section E: Start-up Procedure 9
F: LED INDICATORS
The ICOOL has one green and one red LED operating indicators. These indicators
are arranged horizontally on the front of the cooler. The green LED indicates the
READY operating temperature status, normally set for 3.5°C (38°F). After the setpoint temperature is reached, the sample pump may be turned on by the internal
relay. When the impinger temperature is below 10°C (50°F) the ready LED will be
on. At one degree above the set temperature, the ready LED will be off. The red
LED is the thermistor failure indicator. When this occurs, the red LED stays
illuminated.
The ICOOL cooler has an analog voltage output, the connector is found on the
bottom left side of the cooler marked TEMP OUT. This output is factory standard at
0-5 VDC = 0-20°C (0.25 V / °C).
The ICOOL cooler has a relay output, the connector is found on the bottom of the
cooler marked RELAY OUT. This output is Form C, rated for 10 AMP @ 250 VAC.
Section F: LED Indicators 10
G: I/O TERMINAL BLOCK DESCRIPTION
The I/O terminal blocks are found on the bottom back of the cooler:
TEMP OUT TEMP OUT is located between the power connector and the relay out
connector. TEMP OUT is the standard analog output (low voltage DC output) for
Integrator Series Thermo-Electric Coolers. ICOOL has one active 5” heat
exchanger. The output is 0vdc to 5vdc for a temperature range of 0°C to 20°C.
From left to right
Terminal 1 is the signal return.
Terminal 2 is earth ground. This terminal should be used to ground the shield of the
shielded twisted pair cable that is used to connect the analog output to a receiving
instrument.
Terminal 3 is the temperature output.
RELAY OUT RELAY OUT is located on the bottom of the unit on the right side.
RELAY OUT is the I/O terminal block used for the internal relay.
From left to right
X Terminal 1 is the normally open relay contact. This terminal can be used in
combination with the common connection as a ready alarm to control the sample
pump. This contact will be connected to the common connection when the
temperature of the impinger is below the ready temperature.
Terminal 2 is the common relay contact.
X Terminal 3 is the normally closed relay contact. This terminal can be used in
combination with the common connection as a high temperature alarm. This contact
will be connected to the common connection when the temperature of the impinger is
above the ready temperature.
Section H: Test & Adjustment Procedures 11
TEMP OUT
Connector
RELAY OUT
Connector
H: TEST & ADJUSTMENT PROCEDURES
NOTE: All test and adjustment procedures have been performed at the factory.
Therefore, no adjustment should be necessary.
Remove top cover panel to access the 4 push buttons, located on the control board.
The button located farthest to the right is considered Button #1 in this manual. The
buttons are then numbered from right to left which the left most button being Button
#4.
Temperature Set Point
The temperature set point is the temperature the unit will maintain the cooling block
surrounding the impinger, approximately equal to the output dew point.
Press and hold Button #1 to display the temperature set point.
Press and hold Button #3 to increase the set point.
Press and hold Button #4 to decrease the set point.
The value is automatically stored when Button #1 is released.
Section H: Test & Adjustment Procedures 12
Ready Set Point
The ready set point is the temperature the unit will turn on the output relay. The relay
will be reset, turn off, at one degree above the ready set point.
Press and hold Button #2 to display the ready set point.
Press and hold Button #3 to increase the set point.
Press and hold Button #4 to decrease the set point.
The value is automatically stored when Button #2 is released.
Voltage Output
The voltage output can be calibrated through the push buttons. A voltmeter is
required to adjust this output.
Connect the voltmeter to the TEMP OUT connector. Select an input range on the
voltmeter to accommodate the 0 to 5 VDC.
Press and hold Button #1 and Button #2 together. The value 10.0 will be displayed.
The voltmeter should read 2.5 VDC. Use Button #3 and Button #4 to correct the
voltage output if necessary.
Press and hold Button #3 to increase the output voltage.
Press and hold Button #4 to decrease the output voltage.
The value is automatically stored when Button #1 and Button #2 are released.
Section H: Test & Adjustment Procedures 13
For further service assistance, contact:
Perma Pure LLC
8 Executive Drive
Toms River, NJ 08755
Tel: 800-337-3762 (toll free U.S.)
Tel: 732-244-0010
Fax: 732-244-8140
Email: info@permapure.com
or your local representative
14
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