Ametek Universal Analyzers 1095E User manual

5200 Convair Drive • Carson City, NV 89706
[phone] • [e-mail] • www.universalanalyzers.com
Model 1095E
Acid Aerosol Freezer Chiller
Instruction Manual

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TABLE OF CONTENTS
1.0 RECEIVING AND STORAGE .......................................................................................................................... 3
2.0 DEFINITION OF SYMBOLS ...........................................................................................................................4
3.0 SPECIFICATIONS .........................................................................................................................................5
4.0 DESCRIPTION AND PRINCIPAL OF OPERATION ...........................................................................................6
4.1 TOUCH-SCREEN USER INTERFACE ..................................................................................................................8
4.1.1 MAIN DISPLAY/Operator interface ........................................................................................................8
4.1.2 SYSTEM STATUS AND ALARMS ..............................................................................................................9
4.1.3 MAIN MENU.........................................................................................................................................10
4.1.4 SYSTEM CONTROL SCREEN...................................................................................................................11
4.1.5 SEQUENCE TIMES SCREEN ...................................................................................................................12
5.0 INSTALLATION .......................................................................................................................................... 13
6.0 START-UP ................................................................................................................................................. 14
7.0 SHUTDOWN ............................................................................................................................................. 15
8.0 MAINTENANCE......................................................................................................................................... 16
8.1 MAINTENANCE SCHEDULE...........................................................................................................................16
8.2 MAINTENANCE PROCEDURES ......................................................................................................................16
8.2.1 REPLACEMENT OF PERISTALTIC TUBING (IF EQUIPPED) ......................................................................16
8.2.2 REPLACEMENT OF SAMPLE PUMP DIAPHRAGM .................................................................................16
8.2.3 INSTALLING OR REPLACING HEAT EXCHANGERS .................................................................................17
8.2.4 INSPECT/ CLEAN HEAT SINK FINS.........................................................................................................17
9.0 TROUBLESHOOTING .................................................................................................................................18
10.0 DRAWINGS AND SPARE PARTS................................................................................................................. 20
11.0 STANDARD TERMS & CONDITIONS OF SALE AND WARRANTY.................................................................. 21

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1.0 RECEIVING AND STORAGE
The Universal Analyzers Model 1095E Acid Aerosol Freezer Chiller is completely pre-assembled. No
assembly is necessary when received on-site.
Carefully inspect the product and any special accessories included with it immediately on arrival by removing
them from the packing and checking for missing articles against the packing list.
Check the items for any damage in transit and, if required, inform the shipping insurance company
immediately of any damage found.
Storage Location should be protected from the elements. Although all components provided are designed to
resist corrosion, additional protection from heat (>140°F/ 60°C) and humidity is recommended.

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2.0 DEFINITION OF SYMBOLS
CAUTION, RISK OF DANGER SYMBOL INDICATES INJURY MAY OCCUR IF MANUFACTURER’S
INSTRUCTIONS ARE NOT ADHERED TO.
PLEASE READ MANUAL CAREFULLY WHEN SYMBOL IS DISPLAYED
CAUTION, HOT SURFACE SYMBOL INDICATES EXPOSED SURFACE TEMPERATURE CAN
CAUSE BURNS OR PERSONAL INJURY. CARE SHOULD BE TAKEN WHEN CONTACT IS
REQUIRED.
CAUTION, RISK OF ELECTRICAL SHOCK SYMBOL INDICATES ELECTRICAL SHOCK MAY
OCCUR. CAUTION SHOULD BE TAKEN BEFORE DISCONNECTING OR CONTACTING ANY
ELECTRICAL CONNECTIONS.
PROTECTIVE CONDUCTOR TERMINAL SYMBOL INDICATES THE TERMINAL LOCATION FOR
THE PROTECTIVE CONDUCTOR. FAILURE TO CONNECT TO THE PROTECTIVE CONDUCTOR
TERMINAL MAY RESULT IN A SHOCK HAZARD.

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3.0 SPECIFICATIONS
OPERATINGSPECIFICATIONS
Sample Flow Rate
0 to 5 l/m total (at STP)
Maximum Inlet Temperature
Stainless Steel Heat Exchanger
700°F (351°C)
Kynar/Glass Heat Exchanger
280°F (138°C)
Maximum Inlet Gas Dew Point
178°F (81°C)*
Maximum Inlet Water Concentration
50%*
Minimum Ambient Temperature
34°F (1°C)
Maximum Ambient Temperature
105°F (41°C)*
Maximum Cooling Power
540 BTUs per hour (160 watts/hr.)
Outlet Sample Dew Point
-13°F (-25°C)
Gas Sample Inlet Fitting
3/8" tubing fitting
Gas Sample Outlet Fitting
1/4" tubing fitting
Bottom Condensate Drain Fitting
3/8" tubing fitting
Maximum Input Power
900 watts
Voltage (Factory Configured)
115/230VAC, 50/60 Hz
Electrical Classification
General Purpose, NEMA 1
Dimensions
27" H x 21" W x 14 1/4" D
Weight
75 lbs (34kg)
Soluble Gas Removal Rates
NO 0% loss
NO <10% loss
2
SO < 2% loss
2
CO 0% loss
CO < 2% loss
2
*At reduced flow rate.

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4.0 DESCRIPTION AND PRINCIPAL OF OPERATION
Application
The Universal Analyzers Model 1095E Acid Aerosol "Freezer Chiller" is a system on a 21" x 27" plate
designed to achieve an exit dew point of negative 13°F(-25°C). It is designed to remove moisture to a level of
650 PPM. This reduces the chances of low levels of acid formation therefore protecting downstream
components as well as minimizing losses of measured components.
The use of a heated filter and a heated sample line are required to be installed between the sample extraction
location and the input of the 1095E sample cooler. The temperature of the sample must be kept above the
boiling point of water and above the dew point of any chemical reactions that would skew the desired
analytical results.
Description
The Universal Analyzers Model 1095E Acid Aerosol "Freezer Chiller" contains a combination of Kynar and
Glass/Kynar heat exchanger type heat exchangers. These are mounted within heat transfer blocks, which are
cooled by thermoelectric elements utilizing the "Peltier Effect". The condensate is removed in multiple stages,
one at the temperature of the ambient air surrounding the Freezer Chiller by flowing through the heat
exchanger referred to as the Passive Channel, then by passing the sample into a heat exchanger cooled to
39°F(4°C) by the thermoelectric elements referred to as the Active Channel (or Channel 1). The sample gas is
then further cooled by special cascaded Peltier elements to negative 13°F(-25°C) in the freezer channels
(Channels 2 & 3) which alternate based on the user defined PLC settings.
In standard operation Channel 1 will always hold at 39°F(4°C) within a band of 1 to 2 degrees. Channel 2 and
Channel 3 cycle their operation. The normal cycle operations (no alarms) are as follows:
Channel 2 Pre-Chill and Channel 3 Off: This cycle is the initial status upon startup. The switching valve
selects Channel 2 and Channel 2 has power applied to the cooling elements until it has reached 14°F(-10°C)
or the Pre-Chill time has elapsed.
Channel 2 Dwell and Channel 3 Off: This Cycle is the main cycle for the cooling elements on Channel 2 to
chill and for sample to run through Channel 2. Note: It may need to be adjusted to be long enough for
Channel 3 to properly defrost but shorter than the time for ice to build up in the outlet of Channel 2, causing
the flow switch to trigger a 'Frozen Column' alarm.
Channel 2 Dwell and Channel 3 Pre-Chill: During this cycle Channel 2 Dwell Time completes, Channel 2
continues to cool, and sample continues to run through Channel 2. Channel 3 is triggered to cool for up to 30
minutes. If Channel 3 reaches 14°F(-10°C) before 30 minutes has elapsed this cycle will complete and move
to the next cycle.
Channel 2 Off and Channel 3 Dwell: This Cycle is the main cycle for the cooling elements on Channel 3 to
chill and for sample to run through Channel 3. Note: It may need to be adjusted to be long enough for
Channel 2 to properly defrost but shorter than the time for ice to build up in the outlet of Channel 3, causing
the flow switch to trigger a 'Frozen Column' alarm.
Channel 2 Pre-Chill and Channel 3 Dwell: During this cycle Channel 3 Dwell Time completes, Channel 3
continues to cool, and sample continues to run through Channel 3. Channel 2 is triggered to cool for up to 30
minutes. If Channel 2 reaches 14°F(-10°C) before 30 minutes has elapsed this cycle will complete and move
to the next cycle.

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A Moisture sensor is provided to sense the presence of condensate, should any exist in the tubing following
the chiller. This CCSF (Condensate Carry-Over Sensor with Filter) includes a visible steel fiber filter. This
allows the operator to inspect the condition of the filter. The integral moisture sensor with the sensing
elements is located in the bottom of the filter bowl to provide an early warning if liquid carries over past the
freezer chiller. If condensate is sensed, the Alarm Message “Condensate Carry-Over” is displayed. A
condensate carry-over alarm will stop the Sample Pump.
A Vacuum switch is provided to monitor and alarm high inlet vacuum. The message “System Vacuum” will
appear on the top system status line of the operator interface, if there is high inlet vacuum. This logic is often
used to trigger an automatic blowback of the probe filter.
A Flow switch alarms on low flow. The message “Low Sys Flow” will appear on the top system status line of
the operator interface, if there is low flow.
The heated head sample pump (oil-less diaphragm pump) is placed in the sample line between the 39°F(4°C)
and negative 22°F(-30°C) heat exchangers. The first chilled heat exchanger takes enough of the water vapor
from the sample to protect the pump. The freezer heat exchangers are under a slight pressure because they
are on the discharge side of the pump. This will cause the dew point of the sample to be at its minimum. The
pump has a sample pressure controller that is set at 10 PSI. A Teflon Solenoid valve is used to alternate which
channel is online and which is in defrost mode. The active freezer column flow impedance is monitored by a
Flow switch to sense column freeze-up. If a flow restriction is sensed before Online Dwell time out, the Alarm
Message “Column Frozen” is displayed and after a time delay of 60
seconds the PLC will sequence to the other Freezer Column.
The offline column is pre-chilled to approximately 14°F(-10°C) before the column is brought online. Once the
pre-chill column is below 14°F(-10°C), the program automatically advances to that column or after 30 minutes
of pre-chill time the pre-chill channel goes online. If the column fails to cool for 15 minutes once it is online,
the message “Ch2 or Ch3 Malfunction” will be displayed.
The standard drain, a peristaltic pump is a positive displacement pump that allows for use in either a pressure
or vacuum sample. It provides for easy leak detection but does require periodic maintenance in replacement
of the tubing. A preventative maintenance program replacing the tubing every 6 months is a good practice.
To assist with the flow control a 5 Liter per minute flowmeter with needle valve is provided. Many analyzers
require between 1/2 Liter and 1 Liter per minute. Any extra flow can be sent into a bypass to increase the total
flow which in turn decreases the response time of the system.

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4.1 TOUCH-SCREEN USER INTERFACE
4.1.1 MAIN DISPLAY/OPERATOR INTERFACE
The Model 1095E "Freezer Chiller" is manually controlled through the Operator Interface located on the front
of the unit, or remotely by the I/O inputs to the PLC. The 128x64 pixel operator interface (HMI) is used to
display and manually operate the 1095E Chiller.
This is the main display screen of the touch Screen style user interface:
The top of the display contains the System Status or the current Alarm State.

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4.1.2 SYSTEM STATUS AND ALARMS
Status and alarm messages displayed on top of screen:
MESSAGE
COMMENTS/NOTES
System Normal
Condensate Carry-over
Channel 1 Hi Temperature
39°F(4°C) Channel
Channel 2 Hi Temperature
-13°F(-25°C) Channel
Channel 3 Hi Temperature
-13°F(-25°C) Channel
Column 2 Frozen
Flow alarm before dwell timeout
Column 3 Frozen
Flow alarm before dwell timeout
Column 2 Malfunction
Freezer channel fails to cool in 15 minutes
Column 3 Malfunction
Freezer channel fails to cool in 15 minutes
Hi System Vacuum
Low Sample Flow
System Offline
Column Held
From user input during calibration
RTD Failure
High Ambient Temperature
“Amb”measures the ambient temperature inside of the electronics enclosure.
The DwellTime displays the time remaining in whichever channel's status is dwell.
The CoolTime will display as zero during the defrost cycle and during the Pre-Chill cycle of a channel will
display the time remaining on that Pre-Chill cycle. If the column reaches 14°F(-10°C), the cycle will
automatically switch from Pre-Chill to Dwell. Below are the possible available status messages for each
channel.
Note: “*”Indicates the active column (4 minutes remaining on Active Step)
Channel 1 Status Messages:
•OK
•Fault
•Warm
Channel 2 / Channel 3 Status Messages
•Offline
•Dwell (Channel on, normal cycle)
•Warm (not at temperature after chill cycle)
•Chill (pre-cooling before going online)
•Fault (not cooling or RTD failure)
Ambient Status Messages:
•OK
•Fault
•Warm

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4.1.3 MAIN MENU
This menu provides access to the System Control Menu (System) and the Sequence Times Menu
(Sequence). The Main button returns the user to the main display screen.

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4.1.4 SYSTEM CONTROL SCREEN
The Acknowledge Alarms button is used to clear alarms displayed on the Main Display screen once
the alarming condition has been corrected.
The System Online Set Logic button is used to change the logic of the System Online/Offline digital
input between Normally Open and Normally Closed
The Advance Sequence button is used to advance the Freezer Channel cycle for troubleshooting.
The Turn System Online/Offline button is used to turn the Sample Pump on or off.
The Main button returns to the Main Display screen.
The Menu button returns to the Main Menu screen.

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4.1.5 SEQUENCE TIMES SCREEN
The Dwell Time Minutes button allows the user to adjust Freezer Channel sequence time
between 50 and 180 minutes.
The Pre-Chill Time Minutes button allows the user to adjust the Next Up Channel pre-chill
time between 20 and 40 minutes.
System Defaults:
The PLC will have following default values:
•Dwell: 180 Minutes - Length of time freezer Column is online
•Pre-Chill: 30 Minutes - Pre-Chill on the Offline Column, prepares the Column to become active.

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5.0 INSTALLATION
The sample inlet is a 3/8” compression fitting supplied on the top of the first heat exchanger. The heat
insulation on the heated tube bundle should be stripped no more than 3” to avoid plugging the exposed line.
The sample outlets are 1/4" compressions fittings on the flowmeter.
A 3/8" tube is provided as the condensate drain connection. Two dual-head peristaltic pumps are used to
withdraw the condensate from each heat exchanger. Care must be taken to drain the condensate into an
appropriate drain because of the presence of condensed sulfuric acid.
The electrical power, maximum 8A at 115VAC or 4A at 230VAC should be supplied. Installation shall be in
accord with the manufacturer's instructions and the national electric code (ANSI/NFPA70). Tampering and
replacement with non-factory components may adversely affect the safe use of the system. Customer input
power connections are on TB6. Customer 24VDC input signals to manually hold a column are on TB5-1 and
TB5-2. Customer 24VDC input signals to manually activate the system offline function are on TB5-3 and TB5-
4. The 24VDC output signal that signifies there is a system error, may be wired on TB5-5 and TB5-6.

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6.0 START-UP
NOTE: IT IS IMPORTANT THAT THE HEATED PROBE AND HEATED SAMPLE LINE
SHOULD BE AT OPERATING TEMPERATURE BEFORE STARTING THE CHILLER
AND SAMPLE PUMP.
Apply power to the sample cooler. Channel 1 temperature should start to drop immediately. It will be below
the overtemperature set points, 50°F(10°C), after several minutes, once Channel 2 reaches 14°F(-10°C) the
sample pump will turn on as the system leaves startup mode and enters run mode. Channel 1 will operate at
approximately 39°F(4°C).
For Touch-Screen User Interface See Page 8.

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7.0 SHUTDOWN
Before removing power from the unit, ensure the system has been purged of any potentially hazardous
components. To purge the system, perform the following:
1. Perform a manual blowback operation.
2. If feasible, provide instrument air to the probe via a cal gas line. If not, disconnect the sample line.
3. Allow the system to run for at least 10 minutes.
4. Once purging is complete disconnect and cap the sample outlet tube connections and disconnect
power from the unit.
Note: If electrical wires are to be disconnected, follow applicable ‘Lock Out/Tag Out’ requirements.

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8.0 MAINTENANCE
8.1 MAINTENANCE SCHEDULE
DAILY
1. Check alarm status for normal operation
2. Check chiller temperature indication
a. CH1 4°C ± 1°C
b. Online Freezer - Cold
c. Offline Freezer - Warm
3. Check sample flow rate through chiller to be normal < 5 l/min
WEEKLY
1. Check Sample Pump for Normal Operation –5-8 l/min @ <2” HG @ 10 PSIG
a. Pump Diaphragm replacement dependent on Load, Ambient Temperature and Sample
Composition
2. Check Sample Filter by observing color and noting any flow restriction
a. Change as required
BIANNUALLY
1. Replace Tubing on Peristaltic Liquid Pump
2. Replace Diaphragm and Gaskets on Sample Pump
3. Check Pressure setting of Back Pressure Regulator on Sample Pump
4. Leak Check Sample System (@15 psig for fifteen minutes)
8.2 MAINTENANCE PROCEDURES
Before performing any maintenance on the cooler, ensure that all plant safety procedures are followed. As
with any electrical device, ensure power is removed before performing any procedures.
The cooler is designed for maintenance free operation but if any is required, ensure power has been removed
before maintenance or repair is performed.
8.2.1 REPLACEMENT OF PERISTALTIC TUBING (IF EQUIPPED)
1. Please refer to manufactures website for instructions:
http://www.masterflex.com/catalog/product_view.asp?-sku=0701520
2. YouTube: http://www.youtube.com/watch?v=zC1INbSnf8o&feature=player_embedded#at=242
8.2.2 REPLACEMENT OF SAMPLE PUMP DIAPHRAGM
1. Please refer to manufactures website for instructions: http://www.airdimensions.com

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8.2.3 INSTALLING OR REPLACING HEAT EXCHANGERS
REMOVING THE HEAT EXCHANGER
1. Remove the inlet and outlet tubes by loosening the compression fittings. Always use a backup
wrench on the fitting body to ensure no damage to the heat exchanger occurs.
2. Remove the drain fitting using the same procedure as the inlet/outlet. Remove the drain fittings
from the exchanger. Use a backup wrench on the lower heat exchanger hex to prevent damage
to the exchanger.
REPLACING THE HEAT EXCHANGER
1. Dry and clean the heat exchanger opening in the heat transfer block using a dry, lint-free cloth (If
reusing the heat exchanger, clean the outside as well.) Dried heat transfer paste can be removed
by using a very fine abrasive pad wrapped around a drill bit
2. Apply a thin layer of heat transfer paste onto the outer diameter of the heat exchanger.
3. Gently push the heat exchanger into the heat transfer block until the head is fully seated against
the insulation on top.
4. Reinstall the drain fitting. Ensure pipe tape is used on the pipe threads before installation. Use a
backup wrench on the heat exchanger lower hex to prevent damage to the exchanger.
5. Reconnected the drain, inlet and outlet tubes.
8.2.4 INSPECT/ CLEAN HEAT SINK FINS
INSPECT HEAT SINK FINS
Using a flashlight (or other light source), shine a light through the heat sink fins. If the fins are
unobstructed, you should be able to see the exhaust fan. If the fan is not visible or partial obstruction
exists, clean the heat sink fins.
CLEAN HEAT SINK FINS
Using a soft bristled brush, gently remove to debris from the heat sink. Alternatively, a computer safe
aerosol cleaner can be used to remove the debris. Clean any loose debris from the enclosure and
blower motor using a vacuum or compressed air.
REPLACING PELTIER ELEMENT
Contact Factory for Peltier replacement options. It is recommended on the 1095E Freezer Chiller
elements be replaced at the factory. In rare occurrences a procedure to replace the elements may be
obtained.

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9.0 TROUBLESHOOTING
The following table should give an overview of possible errors and an instruction to check and to repair them
(is not valid for the starting-up period of cooler).
TROUBLESHOOTING SHOULD ONLY BE DONE BY AN TRAINED TECHNICIAN.
Error
Possible reason
Check/Repair
No display, no fans
No display, no cooling
Loss of AC power
Reestablish AC power
Power supply
24VDC supply
Fuse blown
Replace power supply
Replace fuse
PLC
Loose connector cable
PLC failure
Check cable connections
Contact factory for replacement
No electronics fan
Fan failure
Replace fan
Sample pump not working
System offline
Water carry-over alarm
Ch 1 high temperature alarm
Sample pump malfunction
Place system online
See 'Water carry-over' error
See 'Ch1 temperature 10°C' error
Repair/replace pump
'Condensate carry-over'
Liquid in CCSF
Chiller BTU load high
Peristaltic pump failure
High ambient temperature
Clean CCSF sensor
Reduce sample flow rate
Replace peristaltic tubing
Replace peristaltic pump
Cool enclosure <40°C
“Ch ‘X’ high temp”
Chiller just energized
Allow chiller to cool
Ch 1 temperature >10°C
Chiller BTU load high
Reduce sample flow rate
Ch 2 & Ch 3 >-10°C
High ambient temperature
Cool enclosure <40°C
Heat sink fan failure
Replace heat sink fins
Heat sink fins obstructed
Clean heat sink fins
Peltier elements failure
Verify wire connections
Replace elements
Replace heat sink assembly
Column frozen
Online column frozen
Reduce dwell time
Check peristaltic tubing

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Column malfunction (not
cooling)
Peltier devices not functioning
Check cable & wiring connections Replace
peltier devices
Replace heat sink assembly
High system vacuum
System inlet vacuum >5" HG
Blowback heated filter
Replace heated filter for restriction
Low sample flow
Pump failure
Replace sample pump
Replace pump diaphragm
RTD failure
Faulty RTD or connection
Check cable and wiring connections. Replace
RTD
Replace or exchange heat sink assembly
High ambient temperature
Temperature in electronics enclosure
exceeds 50°C
Reduce ambient temperature in shelter Replace
electronics enclosure fan
No temperatures being
displayed, or system only
runs through one cycle
PLC in wrong mode
Rear switch must be in the center “Term”
position, not “Run”. To fix, push switch all the
way to the left, then all the way right, and finally
place switch into center position.
THE PRESENCE OF WATER IN LIQUID FORM AFTER THE SAMPLE COOLER IS AN
INDICATION OF A FAULT IN THE SYSTEM. REASONS FOR THE PRESENCE OF
CONDENSATE IN THE SYSTEM AFTER THE SAMPLE COOLER COULD BE ONE OR
MORE OF THE FOLLOWING:
1. Overloading of the cooling capacity of the cooler due to too much water vapor in the sample OR too
great a sample flow rate.
2. The condensate removal equipment (peristaltic pump, eductor, or drain pot) may be faulty. The heat
exchanger(s) may be full of condensate.
3. An air leak may be in the condensate removal system allowing air to enter and blow the condensate
back into the heat exchanger. (This assumes the heat exchanger is under a slight vacuum.)
4. The temperature of the air passing through the cooler to cool the heat sink is too high. This could be
due to placement of the cooler in a tightly sealed box.

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10.0 DRAWINGS AND SPARE PARTS
For the current revision of all Model 1095E drawings and spare parts, visit the Universal Analyzers website.
https://www.universalanalyzers.com/
Navigate to: Products -> Sample Conditioning Systems -> Model 1095E Chiller System
Links to all current drawings and spare parts for standard chiller systems are provided at the bottom of
the page.