Halma PERMA PURE Baldwin 5210 User manual

PERMA PURE LLC
[phone] ▪[phone] ▪fax [phone] ▪www.permapure.com ▪[e-mail]
PERMA PURE LLC
8 Executive Drive ▪P.O. Box 2105 ▪
T
oms River
,
NJ 08754
Baldwin™-Series
Model 5210
Thermo-Electric Cooler
User’s Manual

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 2 of 21
Contents
Introduction...................................................................................................................... 3
General description ............................................................................................................ 4
Specifications.................................................................................................................... 6
Connections................................................................................................................... 6
Important Safety Warnings ................................................................................................. 7
Installation ....................................................................................................................... 8
Hardware required for installation..................................................................................... 8
Mounting....................................................................................................................... 8
Connections...................................................................................................................... 8
Sample and Drain........................................................................................................... 8
Electrical –Relay Board.................................................................................................... 9
LED Summary.............................................................................................................. 10
Start-up ......................................................................................................................... 10
Set Points....................................................................................................................... 11
Troubleshooting and Maintenance Guide.............................................................................. 12
Replacement Parts........................................................................................................... 14
Classic Model 5210 ....................................................................................................... 14
Sample Conditioning Systems w/ Classic Model 5210 Thermo-Electric Cooler ........................ 14
Appendix B: Cooler Drawings............................................................................................ 16
B1: Model 5210 dimensional drawing, 4C-5210-01-01 ...................................................... 16
B2: Interconnect wiring diagram.................................................................................... 16
B3: Contact states diagram........................................................................................... 16
Appendix C: Sample Conditioning System Drawings............................................................. 17
C1: Flow schematic...................................................................................................... 17
C2: 4S-9PA Piping and dimensional drawing.................................................................... 17
C3: Rack mounting plates dimensional drawing................................................................ 17
C4: Wall mounting plates dimensional drawing ................................................................ 17
Appendix E: Perma Pure Sample Pump Maintenance Instructions........................................... 18
Appendix G Warranty and Disclaimer................................................................................. 21

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 3 of 21
Unpacking
Perma Pure has made every effort to ship you a high quality product that has been thoroughly
inspected and tested. It has been carefully packed to ensure that it arrives at your facility in good
condition. Even though every effort has been made to prevent damage during the transportation
process, damage can occur by the carrier. This is out of control of Perma Pure and is the
responsibility of the carrier to ensure that your equipment arrives intact and undamaged.
Inspect outside packaging. If there is any visible damage, inform the carrier at the time of
deliver. This inspection is important! Once the package is signed for, responsibility for
any visible damage then transfers to the consignee.
Unpack your equipment. Visually inspect the outside of your equipment for any damage. If
there is any damage, contact the carrier immediately. Generally, a carrier must be notified
within 24 hours of the delivery to make a hidden damage claim.
Items in the carton include:
(1) Model 5210 thermo-electric cooler
(1) User’s Manual
Optional glass impingers will ship separately.
If any of the above parts are missing or damaged, call the helpline at [phone] ext-145.
Introduction
Thank you for purchasing this product from Perma Pure LLC. This manual has been assembled so
that it can answer all questions regarding operation. Please keep the operators manual near the
equipment for future reference. There may also be optional equipment available that was not
ordered at the time of original purchase, which may be described and/or illustrated in this manual.
If you still have any questions regarding your equipment’s operation, available options or technical
support, please contact your purchasing dealer or contact Perma Pure directly.
Perma Pure LLC Tel: [phone]
P.O. Box 2105 Tel: [phone] (toll free US)
8 Executive Drive Fax: [phone]
Toms River, NJ 08754 e-mail: [email protected]
website: www.permapure.com
This equipment is to be installed and operated by trained personnel, with sufficient command of
the English language to clearly understand the instructions and safety warnings.

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 4 of 21
General description
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 compounds of interest.
The Baldwin-Series Classic TE Cooler is an ideal way to decrease the dew point of combustion
gases to a repeatable, stable, constant low dew point. The Classic cooler prevents water
condensation in sample pre-filters, pumps, and analyzers. For gas analyzers where water vapor is
an interferent, a stable, repeatable dew point becomes a part of the gas analyzer performance
specification. Classic coolers provide this constant low water concentration, resulting in an accurate
gas measurement.
All Classic coolers use thermo-electric
elements (Peltiers) to cool the sample gas
to the desired dew point temperature. A
Classic Thermo-Electric (TE) Cooler is best
illustrated as a small heat pump with no
moving parts. The Peltier operates 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 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 Classic Cooler removes the moisture from the sample gas by cooling it 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 an analog 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 1: Thermo-electric element (Peltier)

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 5 of 21
Figure 2: Heat Exchanger, Impinger and Heat Sink
The sample gas is passed to the cooler via the heated filter sample probe and heated sample line.
The cooler lowers the sample dew point to 5°C (41°F). As the gas cools and the moisture vapor
condenses, the condensate exits the heat exchanger through the bottom drain connection.
Particulate matter passing through the sample cooler can be removed by an optional Baldwin-
Series 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.

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 6 of 21
Physical Description
•Single channel system
•2 x 10” heat exchangers connected in series only
•1 Passive (cooled to ambient), 1 Active (cooled to 4°C) heat exchangers
•LCD temperature display
•Dimensions: 14.5” x 11” x 10.5” HWD (37 x 28 x 26.5 cm)
•Weight: 27 lbs (12 kg)
Specifications
Sample gas flow range Up to 8 LPM (Up to 17 SCFH)
Avg. inlet dew point at rated flow 20% H2O (60°C DP) @ 5 LPM
Maximum cooling rate 440 BTU/ht (464 kJ/hr)
Maximum inlet sample temp. 400°F (205°C) for SS or glass impingers
280°F (138°C) for Kynar™ impingers
Maximum inlet pressure 15 psig (1 bar;760 mmHg)
Maximum pressure drop <+1 in H2O
Ambient temperature range 33-110°F (0.6-43°C)
Outlet sample gas dew point 41°F (5°C)
Voltage 115/230 VAC
50/60 Hz
Power supply 250W
Cooling down time Less than 6 minutes
Connections
•Sample gas inlet: Kynar, 3/8” tube compression fitting
•Sample gas outlet: Kynar, 1/4” tube compression fitting
•Drain tubing connection: Kynar, 3/8” tube compression x ¼” barbed tube fitting
An automatic condensate drain, dual-head peristaltic drain pump is recommended for
water removal, Perma Pure part number 3KPB-003; size 17 tubing.
Always use factory supplied fittings; Perma Pure cannot warrantee against damage to the Peltier
elements or heat exchangers if our fittings are not used.

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 7 of 21
Important Safety Warnings
Please be sure to review the following basic safety procedures. These procedures
represent the MINIMUM requirements to operate the equipment safely. It is the ultimate
responsibility of the operator to ensure proper safety practices are utilized at the point
of operation.
•NEVER attempt to operate this equipment in an explosive or otherwise hazardous area.
•NEVER exceed any specified rating for the equipment. Voltage, temperature and pressure
ratings must be closely observed and not exceeded. Voltage rating of the equipment MUST
match the rating on the data label. Please make sure that it matches before powering up the
equipment.
•This equipment is NOT designed to be used in an explosive environment.
•This equipment is NOT designed to operate in a wet environment.
•Condensate is potentially dangerous. NEVER handle drain lines, impingers or any other
item that may have come in contact with the gas stream or any hazardous material, without
adequate personal protective equipment. ALWAYS assume that any liquid present is
hazardous.
•Sample gas is potentially dangerous. A leak test is recommended at initial startup and as
often as necessary to maintain a safe working environment around the equipment. The gas
stream exhaust must exit away from all personnel to prevent dangerous exposure.
•NEVER operate the equipment with any part of the enclosure unsecured. All operated
doors and covers must be in place and secured prior to operation. Electrical current may be
present behind covers or doors, even if tools are not necessary to access these components.
•NEVER attempt service on this equipment without first disconnecting all energy sources.
Repair of this equipment should only be done by properly trained personnel that are familiar
with the potential risks involved with servicing of the equipment.
•NEVER replace fuses with types other then the sample specification of type and current. Do
not bypass this or any other safety device.
•NEVER operate this equipment if it is visibly damaged or the possibility exists that it may have
been damaged.
•The use of components that have not been purchased through an authorized Perma Pure
dealer or directly from Perma Pure may compromise the safety of the operator. Additionally,
use of non-authorized components may change the operating characteristics of this equipment.
Any changes to the equipment, that modify its operation in any way, are dangerous, and are
strictly prohibited.
•Read the entire operating manual before attempting to set up or operate the equipment.
•Please heed all warning labels that are on the equipment. They are there to remind you of
possible hazardous conditions.
•Verify the integrity of any mechanical and/or electrical connections that are made to the unit.
Verify that the unit is connected to the proper rated power for the system
Verify that the unit is plumbed properly to operate effectively

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 8 of 21
Installation
Hardware required for installation
•(4) ¼-20 mounting screws
•For stainless steel sample lines, 2 inches of 3/8” Teflon tube
•Peristaltic drain pump, dual head
Mounting
The Classic Model 5210 Thermo-Electric Cooler should be installed away from heat sources in a
well vented area.
NOTE: The operational stability of the cooler dew point is influenced by the
stability of the ambient temperature.
For proper operation, the ambient temperature cannot exceed 43°C (110°F). At, or close to
the maximum ambient temperature, the cooler will not be able to control the temperature
to reduce the dew point of the sample gas to the 5°C set point. This will result in
compromised operation and water slip or carryover, possibly into the analyzer. Also, at or
near this temperature, the cooler will be running “full on” and Peltier life will be greatly
reduced.
Connections
Sample and Drain
1. Connect the sample inlet to the 3/8” tube fitting shown in figure 1.
NOTE: If using 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.
2. Connect the sample outlet to the 1/4” tube fitting
shown in figure 1.
3. Connect the peristaltic pumps to the ¼” barbed
tube fittings shown in figure 1.
NOTE: Do not reduce the size of the condensate
tubing since doing so restricts water flow resulting
in water carryover into the sample.
For instructions on installing a Perma Pure
peristaltic pump, see appendix 1. Note that the
rating on this pump tubing is 20 psi (1.7 bar).
Figure 1 - Model 5210 Cooler
Sample Inlet Sample
Outlet
Drain
Port

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 9 of 21
Electrical –Relay Board
Make the following connections while referring to Appendix B3: Interconnect wiring
diagram.
•Computer status alarms wire to TB2
a. Terminals 1 and 3 for water slip alarms
b. Terminals 4 and 6 for ready/slip alarm status
•Sample pump control-water slip only
a. Jumper line, neutral, and ground from the power supply line terminals to TB8
(GNL) on the relay board.
b. Wire the sample pump power leads to TB2, terminals 6 (hot), 7 (neutral), and 8
(ground).
•Sample pump control-water slip plus read/slip/power fail safe start
a. Jumper hot, neutral, and ground from the power supply line terminals to TB8
(GNL) on the relay board.
b. Wire the sample pump power leads to TB2, 7 (neutral), and 8 (ground).
c. Wire a jumper on TB1 from terminal 3 to terminal 4, and wire another jumper on
TB9 from terminal 1 to terminal 2.
d. Wire sample pump hot wire to TB9 terminal 5.
e. Wire water slip sensor to TB1 terminals 1 and 2.
Sample pump is now in series with water slip sensor and the ready/slip/power failure relay,
which will only allow the sample pump to start if both conditions are true; ie. No water slip and
safe operating temperature of the sampling system.

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 10 of 21
LED Summary
The Classic Model 5210 has a single-channel, digital operating temperature front panel indicator
and 3 LED status displays, 2 green and 1 red. These indicators are arranged vertically on the
front of the cooler.
●“Ready” Green LED comes on when output
stream dew point is below 10°C.
●“Slip” Green LED comes on when water is not
present on water slip sensor.
●“Failure” Red LED comes on if the
thermocouple failed.
NOTE: “Slip” LED is connected to the water slip sensor, which is normally dry on start up. If the
“Slip” Green LED goes out, this indicates water is “slipping” past the heat exchanger. The relay
then shuts off the sample pump so that water is not allowed to reach the analyzers, preventing
damage to the analytical instruments. Steps need to be taken at this time to determine the
cause of the moisture and correct the situation.
Classic Model 5210 is operating properly when both Green LED’s are lit.
Start-up
1. Plug power cord into a properly grounded main circuit. Green “Slip” LED will come on.
2. Wait for the green “Ready” LED light to come on, approx. 6 minutes. This will indicate the
impinger temperature is below 10°C and the sample gas flow can begin.
3. After approx. 3 more minutes, the factory set-point of +5°C (41°F) will be reached.
The SLIP Green LED is always on unless;
•Moisture is detected by the water slip sensor
•There is a malfunction (eg. Shorted water slip sensor leads or a bad relay board)
NOTE: All voltages can be read at the PCB terminal strip.

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 11 of 21
Set Points
Both the operating control temperature and ready relay set points are adjusted by 20 turn
potentiometers located on the control board.
Using a digital voltmeter (DVM), attach the black lead to P1 for ground reference point and attach
the red lead to test points 1, 2, or 3 located just above terminal TB1 where the control
thermocouple terminates.
TP1 is the thermocouple zero/span adjustment test points, and should not be adjusted by
the user.
TP2 is the control set point temperature (set point #2)
TP3 is the ready relay set point temperature (set point#3)
To adjust either set point, open the cooler front door, attach the DVM, and adjust the labeled
potentiometer on the control card.
NOTE: These set point potentiometers are factory set and sealed for proper cooler
operation. Please consult the factory before making any changes to these set point
adjustments.
SET POINT #2 is factory adjusted to 5°C (.500 VDC)
SET POINT #3 is factory adjusted to 10°C (1.00 VDC)

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 12 of 21
Troubleshooting and Maintenance Guide
Symptom
Diagnostic Fix
No LED(s) and no fan. AC power input. Ensure that AC power is
connected.
No LED(s) and no fan. DC 3A fuse (F1) on control Bd.
AC 15A fuse on power supply.
Check for +15VDC at P1 & P11
of control bd.
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.
LED(s) on and no fan. Wire harness at P10 on control
board over to P1 on relay
boards.
Relay Board for +12VDC at TB7
pins 1&2 and 3&4.
If loose then reseat connectors.
If no voltage or low reading,
replace relay board.
F1 on control board
keeps blowing.
Replace fuse (3A) and
disconnect P10 cable going to
relay board.
If fuse does not blow, replace
relay board.
Impinger remains at
ambient temperature.
Peltier current draw. Should
be between 6 and 8 amps.
Replace Peltier element.
Thermocouple failure
LED is on.
Thermocouple connection TB1. Ensure proper connection.
Try a good thermocouple in
place of old one
Replace thermocouple.
Impinger frozen and
cooler indicates ambient
temperature.
Thermocouple placement in
heat exchanger block.
Peltier current draw (>6A) for
both elements on that channel.
Ensure proper placement.
Replace bad peltier
Impinger does not reach
set temperature, but is
below ready
temperature.
System loading.
Calibration and set
temperature adjustment.
Ensure system loading is not
exceeding cooler capacity.
Adjust as necessary.
Impinger temperature
cycles up and down.
Peltier connections on control
board.
Ferrite bead on thermocouple
going into terminal TB1.
Ensure a firm connection on
flag connectors on control
board. Ensure system loading
is not exceeding cooler
capacity.
Wrap thermocouple wires
around a Ferrite bead

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 13 of 21
Water carryover in
system.
Impinger temperature. Should
be below 6°C.
Ensure system loading is not
exceeding cooler capacity.
Slip LED does not come
on
Water carryover in system.
Water slip sensor connections.
Ensure system loading is not
exceeding cooler capacity.
Ensure that all water slip
sensor connections are made.
Disconnect sensor at base of
unit, Clean tip of sensor.
Replace alarm relay/water slip
board.
Pump does not start.
Ready and slip LED(s)
are on
Pump electrical connections. Ensure proper connections.
Replace board.

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 14 of 21
Replacement Parts
Classic Model 5210
Part No. Description
3CCB-010* Control Board: Single Channel
2FAN-005 Fan: Muffin, 4” x 1”, 12 VDC
2FAN-004 Fan: Muffin, 4” x 1½”, 12 VDC
3CXD-022 Impinger: 10" EZ-clean twist-apart Durinert®
3CXD-024 Impinger: 10” NJ, EZ-clean twist-apart Durinert coated
3CXG-002 Impinger: 10” Glass, threaded w/ fittings
3CXK-003 Impinger: 10” Kynar
3CXS-022 Impinger: 10” Stainless Steel, EZ-clean twist-apart
3CXS-024 Impinger: 10” NJ, Stainless Steel, EZ-clean twist-apart
3KPE-004* Peltier Element Kit, 40 mm
1PSD-008* Power Supply: 250 W, 15 VDC
3CCB-004* Relay Board: Single Channel
1TTC-001 Thermocouple: Temperature, Control, Type K, 24”
* Recommended Spares
Sample Conditioning Systems w/ Classic Model 5210 Thermo-Electric Cooler
Part No. Description
3KFA-001 Filter Assembly, Sample in-line, 2-micron
3FHG-001 Filter Bowl, Glass
3FEC-002** Filter Element: Ceramic, 2-micron
3KPB-003 Peristaltic Pump: Dual, Kit, 115V Complete w/ Enclosure
2PBM-003 Peristaltic Pump: Head Only, Standard
2PBM-001 Peristaltic Pump: Motor Only, 115V AC 60 Hz
2PBT-002PK* Peristaltic Pump: Tubing, Norprene, Size 17 (10 feet)
3KPA-001* Sample Pump: Assembly, Single Head w/ Check Valve, 115V
2PAS-008 Sample Pump: Single Head, Mini-Dia-Vac, 115V (bare)
2PAM-001* Sample Pump: Repair Kit, Single
3CWS-001 Water Slip Sensor (Hastelloy/SS Pins)
3KCW-002 Water Slip Sensor (SS Pins) w/ Holder Assembly
* Recommended Spares **Consumables

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 15 of 21
Appendix A: Installation of Peristaltic Pump
NOTE: Perma Pure peristaltic pumps are rated for a maximum pressure of 20 psi.
If supplied loading key is not available, use a flat head screwdriver.
Single pump head loading
a) Separate the end bells (the pump head halves). Hold the end bell containing the
rotor as shown with the tubing retainer grooves facing down.
b) Place tubing in the right groove and against the first two rollers. Hold tubing
with thumb. Near groove, insert smaller prong of loading key between the top of
the rotor and tubing. Push key in as far as possible.
c) Push down and turn key counterclockwise completely around the rotor. The key
will push the tubing uniformly into the end bell assembly. Hold the second end of
the tubing. Remove key.
d) Position the other end bell on top and press the end bells together. Be careful
not to pinch the tubing. If end bells do not snap tightly together, reload tubing.
If necessary, turn key in slot on rotor shaft to adjust tubing (as in step e).
e) With key in slot on rotor shaft, turn key to align tang on rotor shaft with slot in
motor drive shaft. Point tubing retainer grooves up. Shift the pump head slightly
till it snaps on the alignment pins (if present). Secure with four provided screws.
Tighten with fingers only.
Multi-channel mounting
a) Load the pump heads with tubing.
b) Install the four correct length mounting screws in drive.
c) Slide the first pump head into the mounting screws.
d) Place key in slot on mounting shaft. Twist to align tang on rotor shaft with slot in motor drive shaft. Shift the pump
housing around till it drops over the alignment pins (if present).
e) Repeat for each additional pump head, aligning pump head tang with slot on previously mounted pump head.
f) Slide the flow flat washers onto screws and secure with the four wingnuts. Tighten with fingers only.
Replacement parts
2PBM-001 Peristaltic pump, motor only, 115 VAC 60 Hz
2PBM-002 Peristaltic pump, motor only, 230 VAC 50 Hz
2PBM-003 Peristaltic pump, head only, standard
2PTB-002PK Peristaltic pump, tubing, Norprene, size 17 (10 feet)
2PBM-015 Single head hardware kit
2PBM-006 Dual head hardware kit

PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 16 of 21
Appendix B: Cooler Drawings
B1: Model 5210 dimensional drawing, 4C-5210-01-01
B2: Interconnect wiring diagram
B3: Contact states diagram

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COPYRIGHT 2008, ALL RIGHTS RESERVED, Original Instructions
PERMA PURE LLC
Model 5210 User’s Manual
Doc. #561: Revision: 000
Page 17 of 21
Appendix C: Sample Conditioning System Drawings
C1: Flow schematic
C2: 4S-9PA Piping and dimensional drawing
C3: Rack mounting plates dimensional drawing
C4: Wall mounting plates dimensional drawing