MKS 2480HS Instructions for use

2480HS High-Speed
Sampling Cart
Installation & Use Manual
PRELIMINARY

MKS MultiGas High-Speed Gas Sampling Cart
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Copyright © 2010-2011 by MKS Instruments, Inc.
All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be
expressly permitted in writing by MKS Instruments, Inc.
MultiGas™ is a trademark of MKS Instruments, Inc., Wilmington, MA
National Instruments™is a trademark of National Instruments, Austin, TX
Windows®95 is a registered trademark of Microsoft Corporation, Redmond, WA
Swagelok®is a registered trademark of Swagelok Company, 29500 Solon Road, Solon, OH
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MKS MultiGas High-Speed Gas Sampling Cart
Contents
Safety...............................................................................................................................5
SymbolsUsedinThisInstructionManual ................................................ 5
SymbolsFoundontheSystem................................................................. 6
SafetyProceduresandPrecautions ......................................................... 7
AdditionalSafetyInformationfortheMultiGasCart ............................... 8
General Information .................................................................................................9
Introduction............................................................................................ 9
HowThisManualisOrganized ................................................................ 9
CustomerSupport ................................................................................... 9
System Overview.....................................................................................................10
SystemComponents...............................................................................11
OperatingPrinciple ................................................................................13
Installation .................................................................................................................14
SafetyNotice..........................................................................................14
FacilityRequirements.............................................................................14
Cabinet System Dimensions........................................................................................................................15
InstallationProcedure ............................................................................17
Required Equipment/Tools.........................................................................................................................17
Step 1: Unpack the Crate............................................................................................................................17
Step 2: Check The Filter Assembly............................................................................................................19
Step 3: Check the Power Cords and Connections ...................................................................................20
Step 4: Install the MultiGas Unit .............................................................................................................21
Step 5: Install the Extended Dewar...........................................................................................................22
Step 6: Install the Computer (if packaged separately)............................................................................23
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MKS MultiGas High-Speed Gas Sampling Cart
Step 7: Connect Facility Nitrogen, Span Gas, and Exhaust Lines.........................................................23
SystemOperationSummary...................................................................25
SetupforSpan/N2 ...............................................................................26
ConnectSampleline...............................................................................27
PowerUp ...............................................................................................29
CartDailyUse.........................................................................................32
Maintenance ..............................................................................................................33
Replacingthefilterelement ...................................................................33
Installingthe5LiterextendedDewar.....................................................34
Fillingthe5LiterDewar .........................................................................37
AccesstotheElectronicsBox..................................................................38
AccesstotheHeatedBox .......................................................................38
Settingthethermalcontrollers...............................................................39
Troubleshooting......................................................................................................39
ReplacingPumpDiaphragmsandValvePlates .......................................40
Required Tools and Materials....................................................................................................................40
Required Parts.............................................................................................................................................40
Parts Drawing ID: .......................................................................................................................................41
Preparation ..................................................................................................................................................42
Removing the pump head...........................................................................................................................42
Changing diaphragms.................................................................................................................................42
Changing valve plates..................................................................................................................................43
Mounting pump head..................................................................................................................................43
Reference Drawings...............................................................................................44
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MKS MultiGas High-Speed Gas Sampling Cart
Safety
In the event of an emergency, seek safety / medical treatment immediately.
Contact MKS Instruments, Inc. 1-800-227-8766 to obtain information.
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SymbolsUsedinThisInstructionManual
Definitions of WARNING, CAUTION, and NOTE messages used throughout the manual.
Warning
The WARNING sign denotes a hazard to personnel. It calls attention to
a procedure, practice, condition, or the like, which, if not correctly
performed or adhered to, could result in injury to personnel.
Caution
The CAUTION sign denotes a hazard to equipment. It calls attention to
an operating procedure, practice, or the like, which, if not correctly
performed or adhered to, could result in damage to or destruction of all
or part of the product.
Note
The NOTE sign denotes important information. It calls attention to a
procedure, practice, condition, or the like, which is essential to highlight.
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MKS MultiGas High-Speed Gas Sampling Cart
SymbolsFoundontheSystem
The following table describes symbols that may be found on the unit.
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MKS MultiGas High-Speed Gas Sampling Cart
SafetyProceduresandPrecautions
The following general safety precautions must be observed during all phases of operation of this
instrument. Failure to comply with these precautions or with specific warnings elsewhere in this
manual violates safety standards of intended use of the instrument and may impair the protection
provided by the equipment. MKS Instruments, Inc. assumes no liability for the customer’s failure to
comply with these requirements.
DO NOT SUBSTITUTE PARTS OR MODIFY INSTRUMENT
Do not install substitute parts or perform any unauthorized modification to the instrument. Please
contact MKS for service and repair to ensure that all safety features are maintained.
SERVICE BY QUALIFIED PERSONNEL ONLY
Operating personnel must not attempt component replacement and internal adjustments. Any service
must be made by qualified service personnel only.
DO NOT OPERATE IN AN EXPLOSIVE ENVIRONMENT
To avoid explosion, do not operate this product in an explosive environment unless it has been
specifically certified for such operation.
USE PROPER FITTINGS AND TIGHTENING PROCEDURES
All instrument fittings must be consistent with instrument specifications, and compatible with the
intended use of the instrument. Assemble and tighten fittings according to manufacturer’s directions.
OPERATE AT SAFE INLET PRESSURES
Never operate at pressures higher than the rated maximum pressure (refer to the product
specifications for the maximum allowable pressure).
KEEP THE UNIT FREE OF CONTAMINANTS
Do not allow contaminants to enter the unit before or during use. Contamination such as dust, dirt,
lint, glass chips, and metal chips may permanently damage the unit or contaminate the process.
ALLOW THE UNIT TO WARM UP
Sample should not be applied before the unit has completely warmed up. Use a positive shutoff
valve to ensure that no erroneous flow can occur during warm up.
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MKS MultiGas High-Speed Gas Sampling Cart
AdditionalSafetyInformationfortheMultiGasCart
CAUTION! LIFTING HAZARD! Two people are required to perform this
procedure due to size, position, and/or weight of a component.
This symbol indicates that a component is considered a “Heavy Object” and
requires a two-person lift. Please take caution in lifting the device and have
appropriate assistance when doing so. In addition, the NIOSH Lifting Formula
should be used in a Manual Handling Worksheet to evaluate the final installation
location of a component or equipment for the in-use location determined by the
end-user. This should be used to determine if the component could exceed the two-
person lift limitations and require a lift assist in order to position or remove it. Refer
to center of gravity drawings.
WARNING: BURN HAZARD! Allow system components to cool as directed
prior to performing maintenance to avoid personal injury.
Caution: Toxic vent must be connected prior to use. Using a 7/8 line, connect the toxic vent of
the sample cart to facility vent or vented outside of your facility.
Caution: Toxic Pressure relief vent line must be connected prior to cart use. Using a 1/2 in
line, connect the pressure relief line to facility vent or vented outside of your facility.
NOTE: Toxic Vent and Toxic Pressure relief should not be plumbed together. They must
remain dedicated lines up to the facility exhaust.
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MKS MultiGas High-Speed Gas Sampling Cart
General Information
Introduction
The MultiGas High-Speed Gas Sampling Cart provides a complete portable sampling system for
MG2030HS gas analyzers. This manual describes the basic installation, operation, maintenance and
troubleshooting of the system.
HowThisManualisOrganized
This manual provides instructions on how to set up, install, and operate the MKS MultiGas High-
Speed Gas Cart.
Before installing the system or operating it, familiarize yourself with all precautionary notes in the
Safety Messages and Procedures section at the front of this manual. Observe and obey all WARNING and
CAUTION notes in the manual.
General Information, (this section) introduces the product and describes the organization of the manual.
Overview, provides a brief description of the instrument and its functionality.
Installation, explains the environmental requirements and how to install the system.
Operation, describes how to use the instrument and explains all the functions and features.
Maintenance, lists maintenance required to keep the instrument in good working condition.
Troubleshooting, provides basic troubleshooting guidance.
Appendix A, System Schematics, includes basic schematics for the system.
CustomerSupport
Standard maintenance and repair services are available through MKS. Should any difficulties arise
in the use of your system, or to obtain information about companion products MKS offers, contact
any authorized MKS Calibration and Service Center. If it is necessary to return the instrument to
MKS, please obtain a Return Material Authorization (RMA) Number from MKS before shipping.
The RMA Number expedites handling and ensures proper servicing of your instrument
The inside back cover of this manual lists MKS Calibration and Service Centers.
Warning
All returns to MKS Instruments must be free of harmful, corrosive,
radioactive, and toxic materials.
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MKS MultiGas High-Speed Gas Sampling Cart
System Overview
The MultiGas High-Speed Gas Sampling Cart provides a complete sampling system for
MG2030HS gas analyzers. The MultiGas Cart provides the MultiGas Analyzer with a portable,
fully-functional sampling system including:
•heated gas box to properly heat sample gas and calibration gases for processing
•regulators and rotameters for gas pressure control
•purge and span gas plumbing and control
•Temperature controllers for sample lines, required to maintain the sample at 191°C, as
required for precision gas composition analysis
•quick-connection for sample gas inlet line
•portable unit with standard electrical connections and on-board control electronics and
software for data collection and analysis
The system allows in-situ zero and span check of the instrument (without disconnecting and
reconnecting fittings).
The system allows the user to regulate the flow of gas to the MultiGas analyzer at a constant
1 atma ± 0.05 atma, and at a sample temperature of 191°C. The system is compatible with an optional
pre-filter.
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MKS MultiGas High-Speed Gas Sampling Cart
SystemComponents
FSAM-1
Filter element access
Temperature controllers
On/Off switch for pumps
Sampling back pressure regulator
FM1Exhaust flow rotameter
FM2
Flowmeter N2or Span
Inlet flow to system
MV2
Valve to switch between
N2and Span Gas
PRV SG (Span Gas) regulator
MV1
Valve to Select allow
Span/N2, or Sample
Gas to flow into system
Monitor and
Keyboard
Drawers
Main power on/off
Breakers and Fuses
FM1 valve
PRV N2 regulator
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MKS MultiGas High-Speed Gas Sampling Cart
Inlet gas connector release
Inlet gas quick-disconnect port
Liquid Nitrogen Dewer
MultiGas Analyzer
Computer
Toxic vent
Toxic Pressure Relief
Span gas supply
Nitrogen supply
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MKS MultiGas High-Speed Gas Sampling Cart
OperatingPrinciple
The MultiGas Sampling Cart system is a stand-alone system designed to provide properly
conditioned sample to an MKS MultiGas Analyzer. The flow path is as follows:
1. Sample inlet gas to be analyzed flows through a heated inlet line into the “heated box” at the
top of the system.
2. The sample gas flows through a particulate filter and then through two pumps in the heated
box.
3. The heated sample gas flows into the MKS MultiGas Analyzer for analysis.
Backpressure regulators allow adjustment of proper gas flows through the system.
Nitrogen and span gas inlets and flow paths with regulators, rotometers, and manual flow selector
valves are provided to provided span (calibration) and purge flows as required. A low flow of
nitrogen is maintained at all times through the MultiGas Analyzer to protect the system optics.
A simplified gas flow schematic is provided below. Please refer to the system plumbing and
instrumentation drawing (P&ID) for complete details.
N2
Span Gas
Heated Inlet Line
Gas Sample
MKS MulGas
Analyzer
Heated Box
FM2 Rotameter
FM1 Rotameter
To TOXIC VENT
Backpressure Regulator
PRVN2
Pressure
Regulator
Pressure
Regulator
PRVSG
MV2
Manual
Gas Selector Valve
MV1 Manual
Gas Selector
Valve
Filter FSAM-1
Pumps
Baffle Tank
Relief Valve Connecon
Simplified Gas Flow Schematic
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MKS MultiGas High-Speed Gas Sampling Cart
Installation
SafetyNotice
Warning
All users of the equipment must read and understand all safety
information before installing or working on the MultiGas High-Speed
Gas Sampling Cart.
FacilityRequirements
Refer to the system dimensional drawings and center –of–gravity drawings provided with the
system.
RequirementSpecification
Recommended Installation/
Use Space Minimum System Dimensions
Height: 71”
Width: 26”
Depth: 41”
Recommended Installation Space to allow for Connections, Service, and Operation:
Height: 77”
Width: 74”
Depth: 113”
System Power
115VAC, two (2) 15A circuits
The system requires two 115 VAC grounded outlets for power connections.
The outlets must supply a minimum of 10 Amps each.
Use of appropriate power extensions cords are required for the power load and the installation
work environment.
Nitrogen: 1 slpm, 0-20 psig, high purity
Gas Requirements
Calibration Span Gas: 1 slpm, 0-20 psig
Exhaust Requirements
A toxic vent and toxic pressure relief is required for handling the system exhaust gases as
necessary to prevent damage to personnel and equipment. Follow all local, national, and
applicable gas handling and exhaust requirements and regulations.
The toxic vent should be connected to a 25 ft 7/8” diameter exhaust line to minimize back
pressure on the system. The connection is located on the lower rear panel
A ½ in Toxic Pressure Relief exhaust line should be used to vent the pressure release valve in
the event of system over pressure. The connection is located on the lower rear panel
Operation and Storage
Conditions
Operating Temperature: 18 - 30°C
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MKS MultiGas High-Speed Gas Sampling Cart
Cabinet System Dimensions
71”
(inclusiveof
wheels)
25.5”
(inclusiveofwheel
e
x
te
n
s
i
o
n
s)
41”
(inclusiveofwheel
extensions)
Cart Approximate Dimensions – With Drawers Closed
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MKS MultiGas High-Speed Gas Sampling Cart
CART SYSTEM
Service Space
113”
74”
Approximate Work/Service Space Dimensions
Note: Service space can be shared with other equipment.
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MKS MultiGas High-Speed Gas Sampling Cart
InstallationProcedure
Required Equipment/Tools
None required.
Step 1: Unpack the Crate
1. Visually inspect the crate on arrival to ensure no damage occurred during shipping. Check the
shock and tilt indicators. If an indicator has been triggered, contact the shipping company
immediately.
2. The front door of the crate also acts as a ramp to safely remove the cart from the crate. Turn
the four latches to remove the front cover/ramp.
3. Lower the ramp to the floor and secure to the bottom of the crate.
4. Remove the foam lined cross supports.
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MKS MultiGas High-Speed Gas Sampling Cart
5. Unlock the wheels and carefully roll the cart from the crate. Retain the crate for future use.
Caution
The sampling cart is top-heavy. Guiding the cart from the crate
will require 2 people to ensure the cart will not tip over.
Note
Save the crate.If the cart needs to be shipped back to the factory, it
must be shipped in the original shipping crate or the warranty is void.
6. Lock wheels when positioned at final destination.
7. Inventory accessories:
ItemPNQuantity
Swagelok®Quick Connect SS-QC8-S-810 1
Black Box Keys 2
8. Close the crate and secure the front cover. Store in a dry, safe location.
9. Perform a general inspection of the sampling cart:
Check for loose screws and wires.
Note: DO NOT PLUG IN THE CART AT THIS TIME.
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MKS MultiGas High-Speed Gas Sampling Cart
Step 2: Check The Filter Assembly.
1. To remove the Filter Assembly, push in the handle of the filter holder and rotate counter
clockwise (CCW) to disengage the locking mechanism.
2. Remove the filter assembly from the housing. Visually inspect the filter. If the filter is
discolored or missing, replace the filter element.
Replacing a filter element:
a. Unscrew the Stainless screw end from the filter holder.
b.Slide a new filter onto the filter holder.
c. Replace the stainless steel end cap and tighten down to hold the filter in place
d.Slide the filter holder back into the cart. Push the filter holder and turn clockwise (CW)
to engage the locking mechanism.
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MKS MultiGas High-Speed Gas Sampling Cart
Step 3: Check the Power Cords and Connections
1. Make sure the power switch for the pump power is in the off position.
2. Verify that all power cords are plugged into power strips.
3. Check that all fuses and breakers are engaged.
4. Push in all fuses and switch on all circuit breakers (6 Fuses and 2 Breakers) on the front panel.
Main power
On / Off
Circuit breakers Pump On / Off
Fuses (6)
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