Super Systems DPC2530 User Manual

SSi Super Systems Inc.

Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

Model DPC2530

Continuous Digital Dew Point Analyzer

For measurement of:

● Endothermic Atmosphere

● Exothermic Atmosphere

● Nitrogen / Hydrogen Atmosphere

● Plant Air Systems

SPECIFICATIONS –

Measurement Range: -50 to +80°F (-47 to +27°C)
Temperature Range: 0 to 120°F (-18 to +49°C)
Power Supply: 115 VAC 60Hz
Display Type: LED Digital
Display Resolution: +/- 1°F (+/- 0.1°C)
Digital Communications: RS485 Modbus
Control / Retransmission Output: 4 –20 mA
Alarms: Two Alarm Relays
Size: 11”H x 10”W x 7”D
Weight: Approximately 8 lb.

SSi Manual 4553 – DPC2530 Super Systems, Inc. Page # 1 of 17
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Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

TABLE OF CONTENTS –

SPECIFICATIONS – .................................................................................................................................. 1

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

INTRODUCTION –.................................................................................................................................... 2

WARNINGS – ............................................................................................................................................ 2

TERMINAL BLOCK WIRING – ............................................................................................................... 3

INSTRUMENT SETUP – ........................................................................................................................... 3

STARTUP – ................................................................................................................................................ 4

OPERATION - ............................................................................................................................................ 4

HOW IT WORKS – .................................................................................................................................... 5

FACTORY CALIBRATION – ................................................................................................................... 5

FIELD CALIBRATION – ........................................................................................................................... 5

RETURNING THE UNIT TO SSI – ......................................................................................................... 12

SPARE PARTS – ...................................................................................................................................... 12

APPENDIX “A” (DETERMINING THE DEW POINT IN °F)– ......................................................................... 13

APPENDIX “B” (DETERMINING THE DEW POINT IN °C) – ........................................................................ 14

APPENDIX “C” – (DETERMINING THE SENSOR TEMPERATURE IN °F) ...................................................... 15

APPENDIX “D” – (DETERMINING THE SENSOR TEMPERATURE IN °C) ...................................................... 16

REVISION HISTORY – ........................................................................................................................... 17

INTRODUCTION –

Thank you for selecting Super Systems Inc. and the DPC2530 as your source for accurate
dew point measurements.

We have taken every precaution to protect this unit during shipment. Carefully unpack
the instrument, 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.

WARNINGS –

Although it is intended for use in an industrial environment, the DPC2530 is a sensitive
piece of analysis equipment. Care should be taken not to operate it in a manner
inconsistent with its intended use.

 Moisture (water) cannot be allowed to enter the analyzer. If water is present in the

sample gas, use an in-line dryer for sample conditioning. In the event that the sensor
becomes wet, use an inert gas (Nitrogen or Argon) to dry the inside of the instrument.
Under no circumstances should Methane (Natural Gas) be used to dry the DPC2530.

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FU100 - 2.0 AMP

FU103 - 1.0 AMP

1000 Positive
1002 Negative
GND Ground
1101 Shield
1111 Positive
1121 Negative
1151 Positive
1161 Negative

120V 1 PHASE 60 HZ

SUPPLY POWER

4-20 mA

OUTPUT

RS 485 (MODBUS)

COMMUNICATIONS

Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

 The analyzer must be stored at ambient temperature (65-80°F) for at least four hours

prior to operation.

 An in-line dryer for sample conditioning should be used for exothermic and

combustion applications.

 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.

TERMINAL BLOCK WIRING –

Power and communications wiring for the DPC2530 should be performed according to
the following diagram:

INSTRUMENT SETUP –

The instrument should be fully configured at the factory for immediate use. In the event
that the settings are ever lost, the following chart shows the appropriate input parameters
for the 7EK controller. When the instrument is set up in Fahrenheit using these
parameters, the input is scaled from –50 to +80°F and the 4-20mA output is scaled from –

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7EK Input Parameters

Parameter

Fahrenheit

Celsius

P1

16

16

P2

No Decimal Place

One Decimal Place

P3

-50

-45.6

P4

600

315.5

P5

PU.rt

PU.rt

P6

4 – 20

4 – 20

P7

- 50

- 45.0

P8

80

25

Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

50 to +80°F. When the instrument is set up in Celsius using these parameters, the input is
scaled from –45.6 to +26.7°C and the 4-20mA output is scaled from –45 to +25°C.

In addition to these parameters, the jumpers located at position J1 inside the instrument
should be set with one jumper connecting pins 1 and 2, and the other jumper connecting
pins 5 and 6. Once again, these jumper settings will be set at the factory prior to
shipment.

STARTUP –

The DPC2530 Dew Point Analyzer has been calibrated 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 -

To obtain consistent accurate readings from the DPC2530, be sure that the element in the
bowl filter on the side of the instrument 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 DPC2530’s flow meter.

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

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Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

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.

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” before connecting the sample tube. Failure to do so will
unnecessarily coat the sample tubing assembly and possibly some internal components
with soot, resulting in inaccurate readings and exposing the sensor to potential damage.

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
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.

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 at [phone] for more information regarding this service.

FIELD CALIBRATION –

It is also possible to calibrate the DPC2530 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%

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SPAN

BUTTON

(75.3)

ZERO
BUTTON
(11.3)

CAL

BUTTON

Dew Point Microprocessor Board

Product Manual #4553 - Model DPC2530 Continuous Dew Point Analyzer

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.

1.1 Undo the latches on the side of the enclosure.

2.0 Locate the key components within the unit.

2.1 The microprocessor board is located in the front right side of the unit.

This board contains three very small buttons that are used for calibration.

Two are next to one another, and they are marked “75.3%” and “11.3%”,
while the other has no label. The unmarked button is the “Calibrate” button.

The approximate locations of each button are shown on this diagram:

2.2 The sensor-sampling chamber is located in the bottom left of the unit. It

is the gray rectangular box with brass barb fittings on either side and a black
plastic gland protruding from the center.

2.3 The sensor probe is positioned in the sensor sampling chamber. It is held

3.0 Remove the sensor probe from the sensor-sampling chamber.

in place by the nut on the black plastic gland.

3.1 Loosen the black plastic gland nut and slowly slide the sensor probe out

through the airtight seal. Care must be taken when removing this sensor probe,
since the tip is very delicate and can be easily damaged if it is mishandled.

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