Digital control board
Dual channel system
2 x 5 inch heat exchangers connected in series (single stream) or parallel (dual stream)
Jumbo 2-line LCD temperature and alarm display
Single head mini sample pump
Dual head mini peristaltic drain pump
Model Specifications
Model Standard
MP5400 3-4 LPM
Capacity
6-8 SCFH
General Specifications
Digital Boards Main control board
Alarms Cooler over temperature
Display Jumbo dual-line LCD
Heat Exchanger
Type
Heat Exchanger
Material
Heat Exchanger
Connections
Heat Sink High heat transfer aluminum
Voltage
Water slip alarm relay board
Cooler thermocouple failure
Water slip (optional)
LED red, amber, green heat exchanger status
indicators
EZ-Clean™ twist apart
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
)
C: PRINCIPLE OF OPERATION
Thank you for purchasing a Baldwin eCOOL™ Mini Digital Portable Gas Sample
Conditioning System.
All Baldwin coolers use thermo-electric elements (Peltiers) to cool the sample gas to
the desired dew point temperature. A thermo-electric cooler is best illustrated as a
small heat pump with no
moving parts. The Peltiers
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 ntype 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
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.
Baldwin 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
inert coating over 316L stainless steel), PVDF (Kynar
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
Figure 1: Thermo-electric element (Peltier
®
®
), or glass, is mounted within
(a corrosion-resistant
Section C: Principle of Operation 5
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 proportional controller. The
controller uses a type K thermocouple in the heat transfer block located very close to
the cold side of the peltier element as the input sensor.
Figure 2: Heat Exchanger, Impinger and Heat Sink Assembly
The sample gas is passed to the thermo-electric cooler via the heated filter sample
probe and heated sample line. The thermo-electric cooler lowers the sample dew
point to 5
condensate exits the heat exchanger through the bottom drain connection.
Particulate matter which passes through the sample cooler is removed by an
optional Baldwin 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.
°
C (41°F). As the gas cools and the moisture vapor condenses, the
Section C: Principle of Operation 6
D: INSTALLATION
The eCOOL™ Mini should be located away from heat sources in a well ventilated
area of an instrument rack or enclosure.
Sample tubing connections to the eCOOL™ Mini depend on the heat exchanger
material of construction. A cooler with stainless steel heat exchangers uses a
stainless steel inlet fitting on the first heat exchanger. All other inlets and outlets are
Kynar® standard compression type tube fittings with Teflon® ferrules. PVDF
(Kynar®) heat exchangers use all Kynar® standard compression type tube fittings
with Teflon® ferrules. Baldwin cannot warrantee against damage to the Peltier
elements or heat exchangers if our supplied Kynar® tube fittings are not used.
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.
The inlet and outlet tubing of all metal or Kynar® heat exchangers is 1/4" NPT. The
operator should use the compression type fittings. The inlet of the first heat
exchanger uses a 1/4” tube x ¼” MNPT, tube connector fitting to mate with most
standard 1/4” sample lines. The condensate drain connections are Kynar® elbows,
3/8” MNPT x 1/4” barbed tube fittings.
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.
Section D: Installation 7
E: START-UP PROCEDURE
Plug in the power cord to a properly grounded main circuit. The LCD will display the
actual temperature. The temperature of each heat exchanger will fall until it reaches
approximately 5°C.
If there are no alarms (an alarm condition consists of water slip detection after the
cooler, thermocouple failure, or actual temperature > 10°C), then the LED(s) should
turn to an amber color. This indicates that the alarms are cleared and the user can
PRESS THE RESET BUTTON, located on the back of the unit, to begin operation.
Once the reset button is pressed, the LED(s) should turn green indicating that there
are no alarms and sample flow can begin. If the sample pump is wired through the
relay board alarm contacts and all alarms are cleared, the sample pump will start.
The sample pump will stop if any alarms are detected.
Note: Current alarm conditions are displayed on the second line of the LCD.
The eCOOL™ Mini Digital Portable Gas Sample Conditioning System is virtually
maintenance free. However, in the event of electrical problems, refer to the
Troubleshooting section in this manual.
Section E: Start-up Procedure 8
F: LEDS & LCD
The eCOOL™ Mini has a jumbo 2-line LCD display and 2 LED indicators.
Each of the two LED indicators corresponds to an active heat exchanger and will be
colored Green, Amber, or Red:
LED Summary GREEN: Status OK, Sampling can begin. Sample pump will run.
AMBER: Alarm is no longer present. User must press the reset button to
acknowledge the alarm and return to normal operation.
Sample pump off.
RED: Alarm - see message on LCD screen. Sample pump off.
The top line of the LCD screen displays the temperature of each active heat
exchanger in degrees Celsius (e.g., 4.5°C). The scrolling bottom line of the LCD
screen displays cooler status, such as alarm messages.
Alarm Summary
Thermocouple failure
Channel over-temperature alarm
Water slip (water detect) alarm
Please refer to the Troubleshooting section of this manual if your cooler displays any
of the alarms above. Press the reset button, located on the back of the unit, to clear the
alarms.
.
Section F: LEDs & LCD 9
G: BOARDS
Control Board
The control board is the motherboard for the eCOOL™ system. The control board
handles the majority of the functions for the cooler module. It contains the
microprocessor that controls all of the functional areas of the design, as well as the
temperature measurement of the controlled vapor flow as well as the Pulse Width
Modulation (PWM) control of the peltier modules to cool the vapor.
Inputs:
4 Thermocouple Inputs (Channel 1, Channel 2, and two Spare)
12-24VDC Power Inputs
12-24VDC Control Board Power Inputs
1 Analog Input
Outputs:
4 Analog Outputs (scaled 0 to 4.5VDC matching the Thermocouple Inputs)
Peltier Power Outputs (spade terminals)
DC Fan Power Output 1
DC Fan Power Output 2
Power Connections
The board is powered in two locations by a DC power supply rated to handle the
current required by the peltiers present in the system. The thermo-electric element
(Peltier) power is supplied via the E1 and E2 lugs, where E2 is connected to the
positive terminal and E1 is connected to ground. The rest of the board is powered
by the JP1 power connector. This connector has two terminals on it with number 1
connected to the positive DC voltage coming from the power supply and number 2
connected to ground. The wires that are used to connect to the power supply should
be individually routed back to the power supply to minimize the noise created by the
peltiers.
Fuses
The fuses are labeled as F1, F2, F3. They are self-resetting fuses. If one of the
fuses trips, disconnect all power, identify and correct the problem that caused the
high current draw, and reconnect power. It could take up to 5 minutes for a fuse to
self-reset in a power off state.
Section G: Boards 11
Main Control Board Overview
Configuration Switches
The configuration switches identify which components are connected to the system.
They are used by the control firmware to determine how the board is going to
operate in the system. The switches are read at power up, or when the external
reset switch is activated. The table below identifies the switch positions and their
functions.
SW3 Function OFF ON
1 Heated Line Control OFF ON
2 Probe Control OFF ON
3 Peltiers 1 per channel 2 per channel
4 Channels 1 2
5 Peltier Power Share Full Power Power Sharing
6 ISO Channels Inactive Displayed
Section G: Boards 11
SW2 Function ON OFF
1 ICE VCC Enabled Disabled
2 JTAG ICE ResetN Enabled Disabled
3 Calibration Enabled Normal Operation
4 Dflash Res Enabled Normal Operation
5 Init Clr Enabled Normal Operation
Button Control
The buttons are used to control the calibration settings. Follow the bottom line on
the display to determine the functions in the different modes. The three
combinations that are available are left only, right only, or both. To select the center
option on the bottom line of the display, press both buttons together.
Calibration Menus
The calibration mode allows the board to be setup with min and span points as well
as all of the other configuration information applicable depending on the
configuration switch settings.
Ch1, Ch2, TC1, TC2
Min = 0
Span = 5°C
Max = 8*Span Temp (360°C limit)
The calibration is performed by first calculating the expected settings for the
calibration resistors before entering the calibration operation to get a good starting
point. Then the 0 point is adjusted to the minimum point in the ADCC (memory
chip). The span temperature is then set and the span gain is adjusted to make the
span point 1/8 of the entire range for the temperature measurements.
Probe, Heated Line
Min = 0°C
Span =
Max = 360°C
Calibration is performed by setting the gain of the span circuit to minimal gain then
adjusting the 0 point to the minimum reading from the ADCC. The span temperature
is used to measure the ADCC value and calculate the step size of the ADCC.
Isolation Channels
Min = 0°C
Max = 25°C
The temperature range for the isolation circuit is 0 to 25°C. The calibration is
performed by first calculating a good starting point for the offset and span resistors.
Then adjust the 0 point to the minimum point in the ADCC. The last step is to set
the input to 25°C and adjust the span gain to achieve the max value in the ADCC.
ChX: MIN = xx°C
ChX: MAX = xx°C
ChX:MIN TMP= xx°C
ChX:MAX TMP= xx°C
ChX:SET TMP= xx°C
ChX: GAIN=%3u
Water Slip (Moisture Carryover) Relay Board (OPTIONAL)
Note: For the following instructions, typical applications run each of the relays in
series through the Common and Normally Open (NO) contacts.
A: Computer Status Alarms (External PLC monitoring).
Wire computer status alarms to JP4 & JP2. Wire the Common and Normally
Open Contacts in series to a PLC. If an alarm occurs, one or both of these
contacts will open.
B: Sample Pump Control – Water slip, over-temperature, thermocouple failure
alarms.
Wire the Line (hot) power for the sample pump through terminals through JP3
and JP1. Wire the Common and Normally Open (NO) contacts in series. If
an alarm occurs, one or both of these contacts will open.
The sample pump is now in series with the Water Slip (Moisture Carryover) Sensor
and the Ready/Slip/power failure relay, which will only allow the sample pump to
start if conditions are satisfactory (i.e., no water slip, and safe operating temperature
of the sampling system, and no thermocouple failure).
Section G: Boards 13
H: DEFAULT SETPOINTS
eCOOL Mini Heat Exchangers:
Setpoint Temperature = 5°C
Ready (Run) Temperature = 10°C
Cooler must operate below the Ready Temperature to avoid the over temperature
alarm condition.
Relay Board:
Relay contacts are in their Normal state (de-energized state) during an alarm
condition.
Analog output 0-4.5 VDC equates to 0-10°C corresponding to each thermocouple.
Section H: Default Setpoints 14
I: MAINTENANCE
Note: Please refer to the Spare Parts section of this manual for part numbers and
descriptions.
Daily
Verify each channel is running at 5°C (+/- 1.5°C).
LED’s should be Green.
Verify cooling fans are running.
Verify that the peristaltic pump is running and water is draining out.
Verify that the sample pump is drawing full flow.
Quarterly
Verify power supply voltage is above 14.5 VDC.
Inspect and clean the EZ-Clean Twist-Apart heat exchangers with de-ionized water.
Depending on the composition of the sample stream, heat exchangers may need to
be cleaned more often.
Inspect and replace the sample pump diaphragm when needed.
Inspect and replace the peristaltic pump tubing.
Inspect the water slip sensor and verify that there is no corrosion or restrictions to
the sensing pins.
Annually
Check and replace the Peltier cooling elements. At room temperature, a Peltier
should have a resistance of 5-10 Ohms. Higher resistance signifies the Peltier is
stressed and could fail soon.
Using a K-type thermocouple simulator, disconnect each thermocouple and simulate
a temperature between 0°C and 10°C. Verify that the readout on the display
matches the temperature to within 0.5°C. If it does not, the cooler needs to be
recalibrated. Contact Baldwin for the calibration procedure and assistance.
Section I: Maintenance 15
J: TROUBLESHOOTING
Alarm Message Symptom Action(s)
Thermocouple
Failure Channel #
Water Slip Alarm Water has slipped passed the
Heat Exchanger
(Channel) Over
Temp Alarm
Problem Check Action(s)
No LCD or LED(s)
and no fan.
Heat exchanger
remains at
ambient
temperature.
Heat exchanger
frozen and cooler
indicates ambient
temperature.
Heat exchanger
does not reach set
temperature, but is
below ready
temperature.
Heat exchanger
temperature cycles
up and down.
Water carryover in
system.
Pump does not
start. LCD(s) are
green.
Thermocouple is failing or
disconnected
thermo-electric cooler and tripped
the water slip sensor.
Cooler channel does not maintain a
temperature below 10°C.
AC power input.
DC 3A fuse (F1) on control board.
AC 15A fuse on power supply.
Check for +15VDC at P1 & P11 of
control board.
Peltier element current draw.
(Should be above 6 amps.)
Thermocouple placement in heat
exchanger block.
Peltier current draw (>6A) for both
elements on that channel.
System loading.
Calibration and set temperature
adjustment.
Peltier element connections on
control board.
Ferrite beads on thermocouples
going into terminal TB1 & TB2
Heat exchanger temperature.
(Should be below 6°C.)
Pump electrical connections. Ensure proper connections.
Ensure proper connection to TB6 for Channel 1, TB7 for
Channel 2.
Replace K-type thermocouple.
Ensure system loading (gas flow and water %) does not
exceed cooler capacity.
Verify that the cooler last impinger is holding a constant
temperature near 5°C.
If a dry sensor still trips the alarm, clean the sensor or
replace if necessary.
Verify that the system loading (gas flow and water %) does
not exceed the cooler capacity.
Verify that each Peltier element is drawing approximately 6
Amps. Replace the Peltier element if the current draw is
low.
Calibrate the temperature inputs using a thermocouple
simulator.
Ensure that AC power is connected.
Replace fuse as necessary.
Replace fuse as necessary.
If low reading, remove wires from P1 & P11, measure at
power supply and replace supply if voltage still is low.
Replace Peltier element.
Ensure proper placement.
Replace Peltier element.
Ensure system loading is not exceeding cooler capacity.
Adjust as necessary.
Ensure a firm connection on flag connectors on control
board. Ensure system loading is not exceeding cooler
capacity.
Wrap a Ferrite bead around thermocouple wires.
Ensure system loading is not exceeding cooler capacity.
3CCB-023 Circuit Board, eCool™, Relay Board
2FAN-004 Fan: Muffin, 4” x 1 ½”, 12 VDC
3CXD-023 Heat Exchanger, SS, EZ-Clean™ Twist-Apart, 5", Durinert® Coated
3CXK-001 Heat Exchanger: 5" Kynar
3CXS-023 Heat Exchanger, SS, Twist-Apart, 5"
3KPE-004 Peltier Element Kit, 40 mm
3KPB-014 Peristaltic Drain Pump: Mini Dual Head w/ 115 VAC Motor & Tubing
2PBM-012 Peristaltic Drain Pump: Mini Dual Head w/ 115 VAC Motor
2PBT-002PK Peristaltic Drain Pump Tubing, Norprene, Size 17 (10 feet)
1PSD-027 Power Supply: 240 W, 15 VDC
2PAS-018 Sample Pump: Mini Single Head, 115V
2PAM-017 Sample Pump: Repair Kit, Mini Single Head
1TTC-003 Thermocouple, Temperature, Control, Type K 36”
Section K: Spare Parts 18
APPENDIX: eCOOL™ MINI
19
Anko Peristaltic Drain Pump
Series 810 Standard Features
Electrical: 115 VAC, 60HZ with 6" leads.
In a peristaltic pump (dispensing pump), the material to be pumped only comes in
contact with the tubing. This is ideal for applications where the product to be moved or
pumped should not touch any foreign materials. For example; dispensing slurries,
dispensing food products, chemical or other difficult to handle fluids.
The peristaltic pump is self priming and can handle a wide variety of viscosities, from air
to gases to heavy slurries, with a consistent positive displacement. Each revolution of
the roller assembly delivers a precise amount of product. The feature of small positive
displacement pumps is particularly important for electronic metering applications . The
amount of product moved depends on the motor speed, internal diameter of the tube,
pump size and configuration.
MityFlex® 810 Series pumps are capable of pumping from 0.3mL/min to over
987mL/min.
Note: Gearmotors are UL & CSA recognized.
Series 810 General Specifications:
Flow Rate: 50 fixed flow rates available - .4 to 987mL/min
Motor: Shaded pole gearmotor
Stainless steel output shaft
Plastic cooling fan designed for operation at 25°C ambient temp.
Pressures: Up to 20 psi (2.7 bar)
Fluid Contacts:
Fluid being dispensed contacts tubing only
Pump:
Polypropylene with stainless steel fasteners self priming up to 29 ft. (8.8m)
Can be run dry continuously and is non-siphoning.
Rollers:
Nylon with bronze bearing, or for corrosive applications, UHMW polyethylene rollers with
bronze bearing
Roller bracket:
Powdered iron with hardened steel roller pins and spring tension fastener. Roller bracket
assembly attaches directly to motor output shaft.
Tubing:
Standard pumps designed to squeeze tubing with a maximum 60 Shore A durometer.
OPTIONS
Electrical:
24 to 240 VAC
50 Hz, 60 Hz or 50/60 Hz
Flow Rates:
Dual heads allow you to choose any flow rate up to 900 mL/min.