Super Systems DP2000 User Manual
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
Model DP 2000
Portable Digital Dew Point Analyzer
For measurement of:
● Endothermic Atmosphere
● Endothermic Generators
● Nitrogen / Methanol Atmosphere
● Nitrogen / Hydrogen Atmosphere
● Plant Air Systems
SPECIFICATIONS –
Measurement Range: 0 to +80°F (-18 to +27°C)
Temperature Range: 0 to +120°F (-18 to +49°C)
Power Supply: Factory set to 115 or 240 VAC
Display Type: LED Digital
Display Resolution: +/- 1°F (+/- 0.1°C)
Retransmission Output: 4 –20 mA (range is –50 to +80°F)
Battery Specifications: 12 V Rechargeable
Battery Life: Approximately 8 hours
Size (Closed Case): 11” x 10” x 7”
Weight: 8.2 lbs (3.7 kg)
SSi Manual 4545 – DP2000 Super Systems, Inc. Page # 1 of 17
Revision Level “F” (800
) 666-4330
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
TABLE OF CONTENTS –
SPECIFICATIONS –..................................................................................................................................1
TABLE OF CONTENTS –.........................................................................................................................2
INTRODUCTION – ...................................................................................................................................2
WARNINGS –............................................................................................................................................2
STARTUP –................................................................................................................................................3
OPERATION - ...........................................................................................................................................3
I
NSTRUMENT DAMAGE –..............................................................................................................................4
WHAT IS DEW POINT? ...........................................................................................................................5
HOW IT WORKS –....................................................................................................................................5
MAINTENANCE / SAFETY ISSUES –....................................................................................................6
FACTORY CALIBRATION –...................................................................................................................6
FIELD CALIBRATION – ..........................................................................................................................6
RECHARGING THE MODEL DP2000 – ...............................................................................................12
RETURNING THE UNIT TO SS
SPARE PARTS –......................................................................................................................................14
APPENDIX “A” – ....................................................................................................................................15
APPENDIX “B” –.....................................................................................................................................16
I –.........................................................................................................13
INTRODUCTION –
Thank you for selecting Super Systems Inc. and the DP2000 as your source for accurate
dew point measurements.
We have taken every precaution to protect this unit during shipment. It has been packed
in a customized foam carrier to protect it against mishandling during shipment. Please
retain this packing material to use when returning the instrument to SSi for calibration or
service. Carefully unpack the Model DP2000 Dew Point Analyzer, and if there are any
signs of shipping damage, notify SSi and the shipper immediately.
Keep this instruction book in a secure place and refer to it when there is a question about
the analyzer. An electronic version of this manual can be downloaded for free from our
website: www.supersystems.com.
WARNINGS –
Although it is intended for use in an industrial environment, the DP2000 is a sensitive
piece of analysis equipment. Care should be taken not to drop the analyzer or to operate
it in a manner inconsistent with its intended use.
• Open all sample ports and remove all soot and/or moisture from the lines prior to
attaching the sample tubing.
• The analyzer must be stored at ambient temperature (65-80°F) for at least four hours
prior to operation.
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Revision Level “F” (800
) 666-4330
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
• When the unit is to be returned to SSi for service or any other reason, it should be
shipped in its original protective packaging. If this packaging is not available, protect
the instrument with at least four inches of foam or other impact-absorbing material.
• For maximum battery life, do not charge the unit until the “battery low” indicator on
the display is illuminated.
• This unit is not designed to measure the dew points in corrosive gasses, such as
Ammonia, S03, Chlorine, and HCL.
• Please read and understand this Product Manual before operating the unit.
Failure to comply with these conditions may cause damage to the unit that will not be
covered under the warranty. Super Systems, Inc. is not responsible for damage to this
unit caused by disregard of these warnings, neglect, or misuse.
STARTUP –
The DP2000 Dew Point Analyzer has been calibrated and fully charged before it was
shipped from Super Systems, Inc. You can begin typical operation as soon as the unit has
been allowed to stabilize in a temperature similar to the temperature in the heat-treating
department. This is particularly important for units that may have been sitting overnight
in a delivery van in sub-zero weather, since the rapid temperature change can cause
condensation on the sensor which will cause the unit to temporarily display inaccurate
readings.
OPERATION -
The use of the DP2000 is somewhat dependent upon the application. Although they are
fundamentally alike, the operation procedures are different for sampling heat treating
furnaces and endothermic generators. Regardless of the application, allow the DP2000 to
operate for two to three minutes before recording any data. This assures that the sensor
has achieved equilibrium in the sample gas. Also, make sure that the in-line filter (P/N
31033 or equivalent) is clean and functional. Not only will this ensure that the sample
reading is not abnormally high (since soot tends to trap moisture), but it will also prevent
soot and other contaminants from entering the unit and damaging the sensor. The
optimum flow rate of the sample gas should be between 1.5 and 2.0 Standard Cubic Feet
per Hour (SCFH), although a flow rate as low as 1.0 SCFH is acceptable. If the unit is
reading less than 1.0 SCFH, verify that there are no obstructions to the flow such as a
clogged sample line or a poorly adjusted knob on the DP2000’s flow meter. If these
conditions do not exist, the unit may need to be returned to SSi for replacement of the
pump. The pump’s life is dependent upon how frequently it is used as well as the
cleanliness of the sample gas. Insufficient filtration will significantly reduce the
operating life of the pump.
SSi Manual 4545 – DP2000 Super Systems, Inc. Page # 3 of 17
Revision Level “F” (800
) 666-4330
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
Heat Treat Furnace Sampling: A gas sample may be extracted from a process using the
built-in pump. The sample tube from which the sample is taken out of the furnace should
extend into the furnace past the HOT face of the refractory. For accurate results, a
designated sample port should be used to extract the sample. SSi offers a sample port
assembly (part number 20263) which is ideal for this purpose. If a designated sample
port is not available, then a clean “burn-off” port on a Gold Probe™, an industry leading
oxygen sensor for atmosphere control, can be used. Readings taken from the burnoff port
on a probe may be artificially high due to the presence of soot in the probe sheath.
Endothermic Generator Sampling: For applications under pressure, the pump should be
switched off and the flow controlled by the small restriction valve on the flow meter. A
flow rate between 1.5 and 2.0 SCFH is ideal. The sample should be taken from the
endothermic gas manifold after the gas has been cooled. NOTE: Allow the sample port
to blow out any soot and / or water before connecting the sample tube. Failure to do
so will result in inaccurate readings and expose the sensor to potential damage.
Instrument Damage –
The two main causes of damage to the DP2000 are the ingestion of soot and water. Both
of these contaminants will cause erroneous readings in the short term, and cause longterm damage to the sensor and internal components.
Soot / Particulate Contaminants
When taking a sample from a furnace or a generator, care should be taken to reduce the
amount of soot that enters the instrument. The in-line filter will trap these particles, but
cleaning the sample line before attaching the DP2000 will increase the life of the filter.
Furnace ports can be burned off by pumping air through them while hot, or by removing
them from the heat and mechanically cleaning them. Generator ports should be opened
before the instrument is attached to allow any particulate buildup to be blown out. It is
also helpful to tap on the port while it is being blown out to eject any loose particles
before the instrument is attached.
If soot is allowed to collect on the dew point sensor in the instrument, it could result in
higher readings. This soot will also retain moisture than can corrode the sensor over
time. The sensor tip can be cleaned by carefully removing it from the sample block (see
Section 2.3 of the Field Calibration instructions) and rinsing it in isopropyl alcohol. The
power should be off while this is done, and the power should remain off for at least 30
minutes after this procedure to allow all of the alcohol to completely evaporate.
Water / Moisture Contamination
When a furnace or generator is being started up or cooled down, the resulting gases will
contain unusually high amounts of CO2. When these gases cool, moisture will
precipitate out and become condensation inside the sample tubing assembly. Even if the
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Revision Level “F” (800
) 666-4330
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
furnace or generator is operating normally, residual moisture may still be present in the
sample tube or plumbing system. In the same way that the ports are checked for soot (see
above) they should be checked for moisture before attaching the instrument. This is
especially important when taking a sample from a generator, since the sample port is
usually preceded by a significant amount of plumbing. All traces of moisture should be
eliminated before attaching the instrument. Failure to do so will result in erroneous
measurements and could result in damage to the analyzer.
The first signs of moisture in the instrument will be visible condensation in the sample
tubing and an unusually high dew point. The upper range of the sensor is +80°F, so if
that value is displayed on the instrument it is probably due to the presence of moisture. If
this moisture is not removed, it will cause the sensor tip to corrode and will eventually
require the sensor to be replaced.
To remove moisture from the instrument, the sample tubing and filter should be removed
from the instrument since they will probably be wet. An inert gas such as Nitrogen or
Argon should then be flowed through the instrument (with the pump off) for as much
time as it takes to dry out. This dry-out time will depend on the amount of moisture
present in the instrument. The condition of the sensor can be monitored by periodically
reading the dew point from the display and watching the value decrease over time. To
test if it is operating properly, verify the ambient dew point against a web-based weather
station that will report the ambient dew point for your area. If the displayed reading is
within three degrees of the reported dew point when the instrument is taken outside, then
all of the moisture has probably been successfully removed. The wet filter and sample
tubing can be re-attached after they have been completely dried out.
To prevent the possibility of moisture damaging the instrument, be sure that the measured
dew point is below ambient levels before it is stored. If necessary, Nitrogen or Argon can
be used to dry out the instrument after use.
WHAT IS DEW POINT?
Dew point can be defined as the temperature at which the water vapor pressure of the gas
equals the saturated water vapor pressure. In other words, it is the temperature at which
condensation will just begin to occur as the gas is cooled. Dew point and relative
humidity are not the same measurement. Relative humidity is the amount of water vapor
in the air compared to the amount the air could hold if it was totally saturated, and it is
expressed as a percentage, not a temperature. To determine dew point, two main
variables are required: Relative Humidity and Temperature. The DP2000 measures both
variables to compute the displayed dew point.
HOW IT WORKS –
The dew point sensor is a “dielectric ceramic” that varies its electrical capacitance with
changes in relative humidity. The sensor is mounted in a short probe, which is installed
in a T-fitting that allows the sample gas to flow past the sensor. The tip of this probe
SSi Manual 4545 – DP2000 Super Systems, Inc. Page # 5 of 17
Revision Level “F” (800
) 666-4330
SSi Super Systems Inc.
Product Manual - Model DP2000 Portable Dew Point Analyzer
contains the dielectric ceramic relative humidity (RH) sensor, as well as a built in
temperature sensor to determine its dry bulb temperature. Information from both of these
sensors is used to compute the resultant dew point, which is displayed on the digital LED
display.
MAINTENANCE / SAFETY ISSUES –
One of the added features of the DP2000 is the ability to monitor the sensor’s operating
temperature through the built-in thermister in the probe tip. The temperature of the
sample gas can be determined by pressing the switch labeled “Sensor Temp”. It is spring
loaded, so it will automatically return to displaying dew point.
Maintaining proper sensor temperature will prevent the premature failure of the sensor.
The operating temperature of the sensor should remain below 140° F (60°C) at all times.
Periodic checks of the sensor temperature will verify that the sensor is not being exposed
to excessive heat. If these periodic checks show a high sensor temperature, then the
length of sample tubing should be increased to allow for adequate cooling of the sample
before it passes the sensor tip.
Continuous operation of the DP2000 Dew Point Analyzer will lead to premature failure,
since many the internal components are not designed for uninterrupted use. If continuous
monitoring of Dew Points is required, please contact Super Systems, Inc. at (800) 6664330 to inquire about products intended specifically for this application.
FACTORY CALIBRATION –
Factory calibration is recommended every six months if the unit is used regularly. SSi’s
calibration is NIST traceable and includes a numbered “Certificate of Calibration”. This
certificate also indicates the accuracy of the analyzer before and after calibration. Please
contact Super Systems, Inc. at (800) 666-4330 for more information regarding this
service.
FIELD CALIBRATION –
It is also possible to calibrate the DP2000 in the field, which will require the optional
calibration kit (Part Number 31030). The instructions for a field calibration are shown
here, however please feel free to contact Super Systems at 800-666-4330 if you would
like to review the process with us before you begin.
The calibration kit consists of two bottles of saturated salt solution in which each bottle
generates a precise relative humidity percentage (R.H.%) value. One bottle is 11.3%
R.H., and the other is 75.3% R.H. These two specific calibration points are already preprogrammed into the microprocessor board.
1.0 Open the unit
SSi Manual 4545 – DP2000 Super Systems, Inc. Page # 6 of 17
Revision Level “F” (800
) 666-4330
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