Michell Instruments Condumax II Owner's manual

Condumax II
(Class 1 Division 1)
Hydrocarbon Dew-Point Analyzer
Sampling System
Installation, Operation & Maintenance Manual
97525, Issue 1
November 2016

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© 2016 Michell Instruments
This document is the property of Michell Instruments Ltd. and may not be copied or
otherwise reproduced, communicated in any way to third parties, nor stored in any Data
Processing System without the express written authorization of Michell Instruments Ltd.
Condumax II
For Michell Instruments' contact information please go to
www.michell.com

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Contents
Safety ................................................................................................................................vi
Electrical Safety ...........................................................................................................vi
Pressure Safety ............................................................................................................vi
Toxic Materials .............................................................................................................vi
Repair and Maintenance ...............................................................................................vi
Safety Conformity ........................................................................................................vi
Abbreviations .....................................................................................................................vii
Warnings ...........................................................................................................................vii
1 INTRODUCTION ................................................................................................1
1.1 General ............................................................................................................ 1
2 INSTALLATION ..................................................................................................4
2.1 Gas Connections ............................................................................................... 6
2.2 Power Supply Connection .................................................................................. 6
2.3 Output Wiring Connections ................................................................................ 7
3 OPERATION ......................................................................................................9
3.1 System Start-Up Procedure .............................................................................. 10
3.2 System Shut-Down Procedure .......................................................................... 11
3.3 Pressure Regulator Temperature Control ........................................................... 12
4 OPTIONS ........................................................................................................13
4.1 Enclosure Heater Temperature Control .............................................................. 13
4.2 Enclosure Cooling ........................................................................................... 13
5 MEMBRANE AND PARTICULATE FILTER ELEMENT REPLACEMENT .......................14
5.1 Service Intervals ............................................................................................. 14
5.2 Installing the Filter Element and Membrane ...................................................... 14

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Michell Instruments v
Figures
Figure 1 Condumax II Sampling System - Indoor Version ...........................................4
Figure 2 Condumax II Sampling System - Outdoor Version .........................................5
Appendices
Appendix A Technical Specications ..............................................................................18
Appendix B Quality, Recycling & Warranty Information ...................................................20
B.1 Pressure Equipment Directive (PED) 97/23/EC ..............................20
B.2 Recycling Policy .......................................................................... 20
B.3 WEEE Compliance .......................................................................20
B.4 RoHS2 Compliance ......................................................................21
B.5 Warranty .................................................................................... 21
B.6 Reach Compliance ....................................................................... 22
B.7 Calibration Facilities .....................................................................22
B.8 Return Policy ..............................................................................23
B.9 Manufacturing Quality ................................................................. 23
Appendix C Analyzer Return Document & Decontamination Declaration ..........................25
Tables
Table 1 Wire colors .................................................................................................6
Table 2 Terminal marks ...........................................................................................7
Table 3 Minimum cable requirements, power connectors ............................................7
Table 4 Wire Numbers, HC Dew-Point Version ...........................................................7
Table 5 Wire Numbers, HC and Water Dew-Point Version ...........................................8
Table 6 Minimum cable requirements, wire connectors ...............................................8
Table 7 Potentionmeter markings - CSA Version ......................................................12

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Safety
The manufacturer has designed this equipment to be safe when operated using the procedures
detailed in this manual. The user must not use this equipment for any other purpose than that
stated. Do not apply values greater than the maximum value stated.
This manual contains operating and safety instructions, which must be followed to ensure the safe
operation and to maintain the equipment in a safe condition. The safety instructions are either
warnings or cautions issued to protect the user and the equipment from injury or damage. Use
competent personnel using good engineering practice for all procedures in this manual.
Electrical Safety
The instrument is designed to be completely safe when used with options and accessories supplied
by the manufacturer for use with the instrument. The input power supply voltage limits are 110 to
120 V AC, 60 Hz or 220 to 240 V AC, 50 Hz.
Pressure Safety
DO NOT permit pressures greater than the safe working pressure to be applied to the instrument.
The specied safe working pressure is 100 barg (1450 psig). Refer to Appendix A, Technical
Specications.
Toxic Materials
The use of hazardous materials in the construction of this instrument has been minimized. During
normal operation it is not possible for the user to come into contact with any hazardous substance
which might be employed in the construction of the instrument. Care should, however, be exercised
during maintenance and the disposal of certain parts.
Repair and Maintenance
The instrument must be maintained either by the manufacturer or an accredited service agent. Refer
to www.michell.com for details of Michell Instruments’ worldwide ofces contact information.
Safety Conformity
This product meets the essential protection requirements of the relevant EU directives.

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Michell Instruments vii
Abbreviations
The following abbreviations are used in this manual:
AC alternating current
barg pressure unit (=100 kP or 0.987 atm)
°C degrees Celsius
°F degrees Fahrenheit
lbs pound(s)
kg kilogram(s)
HCdp hydrocarbon dew-point
Nl/min normal liters per minute
m meter(s)
mA milliampere
max maximum
m3/hour cubic meters per hour
mm millimeters
% percentage
psig pounds per square inch
temp temperature
V Volts
W Watts
Warnings
The following general warnings listed below are applicable to this instrument. They are
repeated in the text in the appropriate locations.
Where this hazard warning symbol appears in the following
sections it is used to indicate areas where potentially hazardous
operations need to be carried out.
Where this symbol appears in the following sections it is used to
indicate areas of potential risk of electric shock.

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Condumax II Sampling System -
NEC Compatible IOM Manual
Michell Instruments 1
INTRODUCTION
1 INTRODUCTION
1.1 General
The Condumax II Hydrocarbon Dew-Point Analyzer Sampling System is specifically
designed for the measurement of hydrocarbon and water dew-point in natural gas.
The addition of water dew-point is optional to factory order. The system is configured
with the necessary pressure letdown and flow control required for measurement at
pressure before finally venting to an atmospheric or a low pressure flare line system.
A fast-loop bypass flow arrangement is included to reduce sample flow response time
lag and to enable the filter to be drained automatically of any potential hydrocarbon
liquids and hydrates formed. Tube and process connections are 1/4” OD.
HC dew-point analysis pressure is adjusted by a heated pressure regulator in the
range up to 35 barg (500 psig). However, it is typical for measurements to be made at
the cricondentherm condition of 27 barg (400 psig), where the highest HC dew-point
temperature will be detected on the retrograde phase envelope.
The water dew-point (where fitted) is measured at full pipeline pressure, to determine
the highest water dew-point for the gas sample being analyzed.
The complete Condumax II Hydrocarbon Dew-Point Analyzer Sampling System can be
located close to the gas sample take-off point in a potentially explosive environment
- designated Class 1 Division 1 hazardous area.
The indoor version Sampling System gas handling components are assembled on
a stainless steel plate suitable for wall mounting within a temperature controlled
analyzer house.
The outdoor version Sampling System is housed within a stainless steel enclosure (304
or 316) for direct field installation next to the process line (with overall environmental
protection to IP66).
The Sampling System must be located in a constant temperature controlled environment
of at least +10°C (+18°F) above the highest envisaged dew-point temperature.
All sample gas wetted metallic parts are in AISI 316L stainless steel with Viton® soft
parts that comply with the NACE standard MR-01-75 (latest edition). Tube fittings are
twin ferrule compression type. All gas and cable entries are located in the base of the
enclosure.
The sample flow gas handling components are as follows:
• Gas Inlet Isolation Valve (BV1):
Allows user to manually isolate the system from the process sample gas
supply line for maintenance or servicing.
• Coalescing & Membrane Filter (F1):
Provides system protection from contamination of liquid carry-over of
hydrocarbon / glycol mist particles using membrane ltration.

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INTRODUCTION
• Line Pressure Gauge (PG1):
Indicates the sample gas line pressure.
• HCdp Pressure Regulator (PR1):
Allows the user to manually set the sample gas analysis pressure for
hydrocarbon dew-point measurement.
• HC and H2O Dew-Point Analyzer (Condumax II):
Provides measurement and output of hydrocarbon & water dew point of the
sample gas.
• Non Return Valve (NRV1):
Provides system protection from back pressure of vent gas when sample gas
is not owing.
• HCdp Flow Metering Valve (FV1):
Allows the user to manually set the sample gas ow rate across the
hydrocarbon dew-point sensor.
• HCdp Flowmeter (FM1):
Provides indication of the sample gas ow rate across the hydrocarbon dew-
point sensor.
• H2Odp Letdown Pressure Regulator (PR3) {if tted}:
Provides pressure letdown from line pressure to a lower vent pressure.
• Non Return Valve (NRV3) {if tted}:
Provides system protection from back pressure of vent gas when sample gas
is not owing.
• H2Odp Flowmeter/Metering Valve (FM3) {if tted}:
Allows the user to manually set and provide indication of the sample gas
owrate across the water dew-point sensor.
• Gas Outlet Isolation Valve (BV2):
Allows the user to manually isolate the system from the gas outlet line for
maintenance or servicing.

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NEC Compatible IOM Manual
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INTRODUCTION
The bypass ow gas handling components are as follows:
• Bypass Flow Letdown Pressure Regulator (PR2):
Provides pressure letdown from sample line pressure to a lower vent pressure.
• Non Return Valve (NRV2):
Provides system protection from back pressure of vent gas when sample gas
is not owing.
• Bypass Flowmeter & Valve (FM2):
Allows the user to manually set and provide indication of the bypass gas ow
rate across the membrane lter.
• Letdown Gas Vent Isolation Valve (BV3):
Allows the user to manually letdown the sample gas pressure trapped in the
system for maintenance or servicing.

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INSTALLATION
2 INSTALLATION
The Condumax II Hydrocarbon Dew-point Analyzer Sampling System gas handling
components are assembled onto a stainless steel mounting plate suitable for wall
mounting.
The indoor version Sampling System should be located in a constant temperature
controlled environment of at least +10°C (+18°F) above the highest envisaged dewpoint
temperature at a point as close to the sample gas take-off point as possible. This
will minimize sample line response time lag in a designated IEC Zone 1 and Zone 2
hazardous area and NEC Class 1, Group B (for CSA Version Sampling System).
The outdoor version Sampling System provides environmental ingress protection to IP66
and should be mounted vertically, free of any appreciable vibration, in a permanently
shaded position to prevent heating effects through sun radiation. The Sampling System
enclosure has thermostatically controlled heating (xed set point, optional adjustable).
Enclosure cooling, using a compressed-air-driven vortex tube and adjustable thermostat,
is recommended for installation in hot climates.
GAS INTLET CONNECTION
6mm/1/4" OD TUBE FITTING
LET DOWN GAS VENT
6mm/1/4" OD TUBE FITTING
700mm 28"
750mm 30"
938mm 37"
970mm 38"
250mm 10" 13mm 1"
GAS OUTLET CONNECTION
6mm/1/4" OD TUBE FITTING
MOUNTING HOLES
O 8MM (5/16")
316SS MOUNTING
PLATE
CONDUIT ENTRY (1/2" NPT)
FOR OUTPUT CABLE
EARTH BONDING
CONNECTION
CONDUIT ENTRY (1/2" NPT)
FOR SUPPLY CABLE
Figure 1 Condumax II Sampling System - Indoor Version

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NEC Compatible IOM Manual
Michell Instruments 5
INSTALLATION
www.michell.com
MODEL: CONDUMAX II
TYPE: HC DEW POINT ANALYZER
SERI AL NUMBER : nnnnnn /201 6
TAG NUMBER :
SAMPLE GAS OUTLET
(1/4" OD TUBE)
316SS ENGRAVED
NAME/TAG PLATE
316SS MOUNTING
BRACKETS
(
O 10mm HOLES)
316SS, IP66,
INSULATED
ENCLOSURE
DOUBLE BIT
LOCKS (3mm)
LETDOWN GAS VENT/DRAIN
(1/4" OD TUBE)
SAMPLE GAS INLET
(1/4" OD TUBE)
ANALYZER
POWER INLET
(1/2" HUB)
EARTHING
POST (M8)
ANALYZER
SIGNAL OUTPUTS
(1/2" HUB)
800
758
300
1000 1050
BREATHER/DRAIN
WARM AIR VENT
VIA SILENCER
GALVANISED STEEL
LIFTING EYE BOLTS
INSTRUMENT AIR INLET
(1/4" NPTF)
HEATING
POWER INLET
(1/2" HUB)
Figure 2 Condumax II Sampling System - Outdoor Version

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INSTALLATION
2.1 Gas Connections
Ensure that the process sample gas supply line is well ushed
through to clear any liquids and debris present, prior to
connection to the Sampling System.
Connections are as follows:
1. Sample Gas Inlet
¼” OD Swagelok® tube tting
(100 narg (1450 psig) maximum supply pressure)
2. Sample Gas Outlet
¼” OD Swagelok® tube tting
(Vent to atmosphere/low pressure are. 7 barg (101 psig) maximum back
pressure)
3. Letdown Gas Vent
¼” OD Swagelok® tube tting (NEC version)
(Vent to atmosphere)
NOTE: All tube tting connections are made directly onto the isolation ball
valves.
2.2 Power Supply Connection
A single-phase AC mains power supply is required to operate the Sampling System.
The factory-set power supply voltage is indicated on a yellow label located on the rear
panel. NOTE: The user cannot change the specied power supply voltage.
The Condumax II analyzer is powered via the mains from the analyzer conduit.
Wire Color Power Connection
Brown Line Voltage
Blue Neutral
Green/Yellow Earth
Table 1 Wire colors

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Michell Instruments 7
INSTALLATION
Wiring connections, for power to heater circuit and heated regulator are made onto
terminals within the Power Circuits conduit box.
Terminals are marked:
Terminal No. Power Connection
1 Line Voltage
4Neutral
Ground / Earth
Table 2 Terminal marks
NOTE: A ground/earth stud is provided in the base of the enclosure. This
must be used to earth bond the Sampling System.
A local power isolator switch MUST BE provided on the Power Circuit to the Condumax
II Hydrocarbon Dew-Point Analyzer for maintenance or servicing. Note: This switch
only isolates power to the analyser NOT any other circuits.
Minimum Cable Requirements
Power Cable 3 core, 0.75mm2 conductor area (6A)
Table 3 Minimum cable requirements, power connectors
2.3 Output Wiring Connections
Two analog 4-20 mA outputs and a Modbus RS485 digital interface are available.
Connections are made onto wires from the Outputs conduit.
Wires are marked:
HC Dew-Point Version
Wire No. Output
1 Modbus RS485 digital comms Earth
2Modbus RS485 digital comms A
3 Modbus RS485 digital comms B
4Pressure measurement current - mA2
5Pressure measurement current + mA2
6Hydrocarbon dew-point measurement current - mA1
7Hydrocarbon dew-point measurement current +mA1
Table 4 Wire Numbers, HC Dew-Point Version

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INSTALLATION
HC and Water Dew-Point Version
Wire No. Output
1 Modbus RS485 digital comms Earth
2Modbus RS485 digital comms A
3 Modbus RS485 digital comms B
4Water dew-point measurement current - mA1
5Water dew-point measurement current + mA1
6Hydrocarbon dew-point measurement current - mA1
7Hydrocarbon dew-point measurement current + mA1
Table 5 Wire Numbers, HC and Water Dew-Point Version
Recommended Minimum Cable Requirements
Communications Cable For use with 4-20mA only or Modbus only
1 pair individually and overall screened, 0.5mm2 conductors
Communications Cable For use with 4-20mA and Modbus
2 pair individually and overall screened, 0.5mm2 conductors
Table 6 Minimum cable requirements, wire connectors

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NEC Compatible IOM Manual
Michell Instruments 9
OPERATION
3 OPERATION
Operation of the Condumax II Sampling System should be carried out in conjunction
with, and referring to, the Condumax II Hydrocarbon Dew-Point Analyzer User Manual
prior to commencing the System Start-Up Procedure (Section 3.1).
Before commencing the start-up procedure it is essential to ensure that the installation
conforms to the correct hazardous area and local plant standards.
Before any gas pressure is applied, check that all gas inlet & outlet connections are fully
tightened up and that all valves and regulators are in the closed position.
Additionally, for the outdoor version, the heater/thermostat circuit will need to achieve
the set-point temperature.
BEFORE power is applied to the Sampling System check that the
Condumax II Power Isolator switch is set to the OFF position.
Apply power to the Sampling System and allow the pressure regulator temperature
to stabilize. This will prevent the possibility of condensation occurring within the gas
handling components during start-up.
There is a mandatory purge procedure stipulated as part of the
certication of the Condumax II product. This procedure must
be fully carried out prior to any power or signal connections to
the Condumax II being energized.
This procedure must also be carried out at any time following
service or maintenance periods that cause any of the Condumax
II or associated gas handling equipment sample lines to be
disconnected.
It is not necessary to carry out this procedure of, during a shut
down period, the sample lines have not been disconnected or of
the power or signal connections only have been connected.
Before commencement of the start-up procedure ensure that
all power and signal connections to the Condumax II are fully
isolated and if necessary observe the stipulated de-energization
period of 45 minutes.

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OPERATION
3.1 System Start-Up Procedure
Proceed as follows:
1. Unscrew and remove the Condumax II ameproof enclosure cover after
rst loosening the hex grub screw.
2. The user interface/display assembly uses two ¼-turn bayonet style fasteners
to secure it and are nger operated - clockwise to lock, counter-clockwise
to release. Temporarily, the user interface/display once disconnected from
the two ¼-turn fasteners, can be re-positioned on the instrument by
securing the right-hand fastener in the left-hand fastener position. This
will situate the user interface/display assembly in an overhanging position
outside of the enclosure, allowing greater access. If there is insufcient
space to accommodate the overhanging user interface/display assembly
on the left-hand side then it can be fully disconnected from the instrument
by disconnecting the ribbon cable connection to the main processor PCB.
3. Locate the solenoid valve and the manual override operating adjuster
(brass screw handle) mounted on the base of the solenoid valve body.
4. Adjust the solenoid valve to the PURGE POSITION (fully screwed in
clockwise) as shown on the label attached to the solenoid valve.
5. Ensure the Letdown Gas Vent Isolation Valve (BV3) is CLOSED.
6. OPEN the Gas Outlet Isolation Valve (BV2).
7. Slowly OPEN the Gas Inlet Isolation Valve (BV1) to allow sample gas to
enter the Sampling System.
8. Fully OPEN the Bypass Flow Letdown Pressure Regulator (PR2).
9. Adjust the Bypass Flow Flowmeter/Metering Valve (FM2) to indicate a gas
ow rate of approximately 0.4m³/hour (6.7 Nl/min) (full-scale).
10. Slowly OPEN the HCdp Pressure Regulator (PR1) to provide a purge ow
through the Condumax II (2 full turns).
11. Adjust the HCdp Flow Metering Valve (FV1) to indicate a sample gas ow
rate of approximately 0.12m³/hour (2 Nl/min) (full-scale) on the HCdp
Flowmeter (FM1).
12. Fully OPEN the H2Odp Letdown Pressure Regulator (PR3) {if tted}.
13. Adjust the H2Odp Flowmeter/Metering Valve (FM3) {if tted} to indicate a
sample gas owrate of approximately 0.2 to 0.3m3/hour (3.3 to 5 Nl/min)
mid to three-quarters full scale).
14. Allow the sample gas to purge the system for a minimum period of 3
minutes.
15. Re-adjust the solenoid valve to the Normal Operating Position (fully
unscrewed counter-clockwise) as shown on the label attached to the
solenoid valve.
16. Re-t the Condumax II user interface/display assembly and ameproof
enclosure cover.

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NEC Compatible IOM Manual
Michell Instruments 11
OPERATION
17. After the ameproof enclosure cover has been retted the Condumax II is
ready for power up.
18. Switch on the power to the Condumax II using the Condumax II Power
Isolator switch located on the Power Circuits junction box.
19. Re-adjust the HCdp Pressure Regulator (PR1) to set the HCdp gas analysis
pressure. Pressure is indicated on the main display of the Condumax II.
It is normal practice for an analysis pressure of 391 psig (27 barg) to
be set for the analysis of hydrocarbon dew point, as it is the recognized
cricondentherm condition (pressure at which the highest hydrocarbon
dew-point temperature will exist).
NOTE: The water dew-point gas analysis pressure is set at full
line pressure and has no adjustment.
20. Re-adjust the hydrocarbon dew-point sample gas ow rate to approximately
0.06m³/hour (1 Nl/min) using the HCdp Flow Metering Valve (FV1).
21. Re-adjust the water dew-point sample gas owrate to approximately
0.2m3/hour (3.3 Nl/min) using the H2Odp Flowmeter/Metering Valve (FM3)
{if tted}.
22. Re-adjust the bypass ow rate to approximately 0.4m³/hour (6.6 Nl/min)
using the Bypass Flow Flowmeter/Metering Valve (FM2).
23. Close the cabinet door and allow the temperature to stabilize for at least
one hour before monitoring a measurement.
Refer to the Condumax II Hydrocarbon Dew-Point Analyzer User’s Manual for further
operating instructions.
3.2 System Shut-Down Procedure
There is a mandatory de-energization time period of 45 minutes
stipulated in the certication of the Condumax II product. This
special condition must be fully carried out prior to removing the
cover of the Condumax II ameproof enclosure.
Proceed as follows:
1. Isolate the Sampling System from the sample gas supply line by CLOSING
the Gas Inlet Isolation Valve (BV1).
2. Allow a short time for the Sampling System to vent/depressurize before
attempting to carry out any work on the system.
3. Depressurize the Sampling System by CLOSING the Gas Outlet Isolation
Valve (BV2) and OPENING the Letdown Gas Vent Isolation Valve (BV3).
4. Ensure the Condumax II Power Isolator switch is in the OFF position.
5. After power down a minimum period of 45 minutes must be observed
before removing the cover of the Condumax II.

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OPERATION
3.3 Pressure Regulator Temperature Control
WARNING
This operation will expose electrical parts operating at high
voltage. Therefore, isolate the power supply from the Sampling
System before making adjustments.
The heated pressure regulator contains an adjustment for the temperature control
set point (factory-set to approximately +40°C (+104°F)). It may need adjustment to
increase/decrease the heat requirements to the regulator dependent on the high/low
inlet gas pressure.
This can be identied by the manufacturer markings:
CSA version GO HPR-2 markings
CSA Version - GO HPR-2 Pressure Regulator
To adjust the setting proceed as follows:
1. Unscrew and remove the cover of the junction box after rst loosening the
hex grub screw.
2. Adjust the heater output by turning the potentiometer clockwise to increase
and anti-clockwise to decrease.
3. The seven markings around the potentiometer equate to an approximate
temperature value for the heater of:
1 = +75°F (+24°C) Recommended setting
2 = +80°F (+27°C)
Other settings may be advised by Michell
Instruments, dependent upon application
3 = +85°F (+29°C)
4 = +95°F (+35°C)
5 = +110°F (+43°C)
6 = +130°F (+54°C) Should not be set
7 = +175°F (+79°C)
Table 7 Potentionmeter markings - CSA Version
4. Screw back the junction box cover and tighten the hex grub screw.