Super systems Dp 2000 User manual

DP2000 Portable Dew Point Analyzer Operations Manual

Super Systems Inc. Page # 1 of 30

Model DP 2000

Portable Digital Dew Point Analyzer

OPERATIONS MANUAL

Super Systems Inc.

7205 Edington Drive

Cincinnati, OH 45249

513-772-0060

Fax: 513-772-9466

www.supersystems.com

DP2000 Portable Dew Point Analyzer Operations Manual

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Super Systems Inc.

USA Office

Corporate Headquarters:

7205 Edington Drive

Shipping Address:

7245 Edington Drive

Cincinnati, OH 45249

Phone: (513) 772-0060

http://www.supersystems.com

Super Systems Europe

Unit E, Tyburn Trading Estate,

Ashold Farm Road, Birmingham

B24 9QG

UNITED KINGDOM

Phone: +44 (0) 121 306 5180

http://www.supersystemseurope.com

Super Systems México

Sistemas Superiores Integrales S de RL de CV

Acceso IV No. 31 Int. H Parque Industrial

Benito Juarez

C.P. 76120 Queretaro, Qro.

Phone: +52 442 210 2459

http://www.supersystems.com.mx

Super Systems China

No. 369 XianXia Road

Room 703

Shanghai, CHINA

200336

Phone: +86 21 5206 5701/2

http://www.supersystems.cn

Super Systems India Pvt. Ltd.

A-26 Mezzanine Floor, FIEE Complex,

Okhla Indl. Area, Phase –2

New Delhi, India 110 020

Phone: +91 11 41050097

http://www.supersystemsindia.com

 
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Contents 
INTRODUCTION –.....................................................................................................................................4 
SPECIFICATIONS ......................................................................................................................................4 
WARNINGS –.............................................................................................................................................5 
STARTUP –.................................................................................................................................................5 
OPERATION -.............................................................................................................................................6 
INSTRUMENT DAMAGE ...........................................................................................................................8 
WHAT IS DEW POINT? ............................................................................................................................10 
HOW IT WORKS –....................................................................................................................................10 
MAINTENANCE /SAFETY ISSUES –.....................................................................................................10 
FACTORY CALIBRATION –.....................................................................................................................11 
FIELD CALIBRATION –...........................................................................................................................11 
RECHARGING THE MODEL DP2000 –...................................................................................................17 
TROUBLESHOOTING -...........................................................................................................................17 
UNIT DOESN’T POWER UP:...........................................................................................................................17 
DEW POINT READING SHOWS +80°F (OR A HIGH READING)AND NEVER DROPS:..............................................18 
NO VISIBLE FLOW IS SHOWN IN THE FLOW METER:........................................................................................23 
DISPLAY APPEARS TO BE LOCKED UP AND NEVER CHANGES (NOT AT 80°F):...................................................24 
DISPLAY READS -50°F (INDICATING THAT THE SENSOR FAILED): ...................................................................24 
DISPLAY READS HIGHER THAN NORMAL AND DOES NOT MATCH OTHER DEW POINT EQUIPMENT:......................24 
RETURNING THE UNIT TO SSI –...........................................................................................................24 
WARRANTY..............................................................................................................................................26 
SPARE PARTS –......................................................................................................................................27 
APPENDIX “A” –......................................................................................................................................28 
APPENDIX “B” –......................................................................................................................................29

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INTRODUCTION –

Thank you for selecting Super Systems Inc. (SSi) and the DP2000 as your source

for accurate dew point measurements of:

●Endothermic Atmosphere

●Endothermic Generators

●Nitrogen / Methanol Atmosphere

●Nitrogen / Hydrogen Atmosphere

●Plant Air Systems

We have taken every precaution to protect this unit during shipment. It has been

packed in a customized foam carrier to protect it against mishandling during

shipment. Please retain this packing material to use when returning the

instrument to SSI for calibration or service. Carefully unpack the Model DP2000

Dew Point Analyzer, and if there are any signs of shipping damage, notify SSI and

the shipper immediately.

Keep this instruction book in a secure place and refer to it when there is a

question about the analyzer. An electronic version of this manual can be

downloaded for free from our website: www.supersystems.com.

SPECIFICATIONS

Dew Point Range: 0 to 80°F (-18 to 27°C)

Temperature Range:

0 to120°F (-18 to 49°C)

Power Supply:

Factory set to 115 or 240 VAC

Display Type:

LED Digital

Display Resolution:

+/- 1°F (+/- 0.1°C)

Retransmission Output:

4-20 mA (range is -50 to 80°F)

Battery Specifications:

12V Rechargeable

Battery Life:

Approx. 8 hours

Size (Closed Case):

11” x 10” x 7”

Weight:

8.2lbs (3.7 kg)

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WARNINGS –

Although it is intended for use in an industrial environment, the DP2000 is a

sensitive piece of analysis equipment. Care should be taken not to drop the

analyzer or to operate it in a manner inconsistent with its intended use.

Open all sample ports and remove all soot and/or moisture from the lines

prior to attaching the sample tubing.

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

four hours prior to operation.

When the unit is to be returned to SSI for service or any other reason, it

should be shipped in its original protective packaging. If this packaging is not

available, protect the instrument with at least four inches of foam or other

impact-absorbing material.

For maximum battery life, do not charge the unit until the “battery low”

indicator on the display is illuminated.

This unit is not designed to measure the dew points in corrosive gases, such

as ammonia (NH3), sulphur trioxide (SO3), chlorine (Cl), and hydrochloric acid

(HCl).

Please read and understand this Operations Manual before operating the

unit.

Failure to comply with these conditions may cause damage to the unit that will

not be covered under the warranty. Super Systems, Inc. is not responsible for

damage to this unit caused by disregard of these warnings, neglect, or misuse.

STARTUP –

The DP2000 Dew Point Analyzer has been calibrated and fully charged before it

was shipped from Super Systems, Inc. You can begin typical operation as soon as

the unit has been allowed to stabilize in a temperature similar to the

temperature in the heat-treating department. This is particularly important for

units that may have been sitting overnight in a delivery van in sub-zero weather,

since the rapid temperature change can cause condensation on the sensor which

will cause the unit to temporarily display inaccurate readings.

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OPERATION -

The use of the DP2000 is somewhat dependent upon the application. Although

they are fundamentally alike, the operation procedures are different for sampling

heat treating furnaces and endothermic generators.

Flip the POWER switch to the on position. A green POWER ON light should

illuminate indicating that the unit is turned on. The LED display should also

illuminate showing “SSi” (Figure 1) followed by a dew point reading given in

degrees Fahrenheit (Figure 2).

Figure 1 Figure 2

Connect a sampling tube/hose to the barb fitting located on the side of the

DP2000 (Figure 3). Make sure that the hose or tubing fits over the fitting properly

and does not allow air to leak into the sampling line. A tubing and filter assembly

is supplied with the DP2000 (SSI P/N A20315 –Figure 5), which is designed to fit

the hose barb properly. Also, make sure that the sample gas is flowing through

the filter in the right direction. There is an arrow on the filter to indicate which

direction the gas should flow (Figure 4).

Figure 3 Figure 4

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If the system from which gas is being sampled is under pressure, there should

be visible flow in the flow meter. Adjust the flow through the meter using the

adjusting knob on the meter.

If there is no visible flow after the sampling line is connected, the pump will need

to be turned on to “pull” a sample through the DP2000. Flip the PUMP switch to

turn on the sampling pump. The green PUMP ON light should illuminate when

the pump is on (Figure 6). You should also be able to hear the pump running

(depending on the noise level at your location).

Figure 5

Figure 6

Regardless of the application, allow the DP2000 to sample gas for two to three

minutes before recording any data. This assures that the sensor has achieved

equilibrium in the sample gas. Also, make sure that the in-line filter (P/N 31033

or equivalent) is clean and functional. Not only will this ensure that the sample

reading is not abnormally high (since soot tends to trap moisture), but it will also

prevent soot and other contaminants from entering the unit and damaging the

sensor.

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The optimum flow rate of the sample gas

should be between 1.5 and 2.0 cubic feet per

hour (CFH) (Figure 7), although a flow rate as

low as 1.0 CFH is acceptable. If the unit is

reading less than 1.0 CFH, verify that there are

no obstructions to the flow such as a clogged

sample line or a poorly adjusted knob on the

DP2000’s flow meter. If these conditions do

not exist, the unit may need to be returned to

SSI for replacement of the pump. The pump’s life is dependent upon how

frequently it is used as well as the cleanliness of the sample gas. Insufficient

filtration will significantly reduce the operating life of the pump.

Heat Treat Furnace Sampling:

A gas sample may be extracted from a process

using the built-in pump. The sample tube from which the sample is taken out of

the furnace should extend into the furnace past the HOT face of the refractory.

For accurate results, a designated sample port should be used to extract the

sample. SSI offers a sample port assembly (part number 20263) which is ideal

for this purpose. If a designated sample port is not available, then a clean “burn-

off” port on an SSi Gold Probe, an industry leading oxygen sensor for

atmosphere control, can be used. Readings taken from the burn-off port on a

probe may be artificially high due to the presence of soot in the probe sheath.

Endothermic Generator Sampling:

For applications under pressure, the pump

should be switched off and the flow controlled by the small restriction valve on

the flow meter. A flow rate between 1.5 and 2.0 CFH is ideal. The sample should

be taken from the endothermic gas manifold after the gas has been cooled.

NOTE: Allow the sample port to blow out any soot and / or water before

connecting the sample tube. Failure to do so will result in inaccurate readings

and expose the sensor to potential damage.

INSTRUMENT DAMAGE

The two main causes of damage to the DP2000 are the ingestion of soot and

water. Both of these contaminants will cause erroneous readings in the short

term, and cause long-term damage to the sensor and internal components.

Soot / Particulate Contaminants

When taking a sample from a furnace or a generator, care should be taken to

reduce the amount of soot that enters the instrument. The in-line filter will trap

these particles, but cleaning the sample line before attaching the DP2000 will

Figure 7

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increase the life of the filter. Furnace ports can be burned off by pumping air

through them while hot, or by removing them from the heat and mechanically

cleaning them. Generator ports should be opened before the instrument is

attached to allow any particulate buildup to be blown out. It is also helpful to tap

on the port while it is being blown out to eject any loose particles before the

instrument is attached.

If soot is allowed to collect on the dew point sensor in the instrument, it could

result in higher readings. This soot will also retain moisture than can corrode

the sensor over time. The sensor tip can be cleaned by carefully removing it

from the sample block (see Section 2.3 of the Field Calibration instructions) and

rinsing it in isopropyl alcohol. The power should be off while this is done, and the

power should remain off for at least 30 minutes after this procedure to allow all

of the alcohol to completely evaporate.

Water / Moisture Contamination

When a furnace or generator is being started up or cooled down, the resulting

gas will contain unusually high amounts of carbon dioxide and water. When the

gas cool, moisture will precipitate out and become condensation inside the

sample tubing assembly. Even if the furnace or generator is operating normally,

residual moisture may still be present in the sample tube or plumbing system.

In the same way that the ports are checked for soot (see above) they should be

checked for moisture before attaching the instrument. This is especially

important when taking a sample from a generator, since the sample port is

usually preceded by a significant amount of plumbing. All traces of moisture

should be eliminated before attaching the instrument. Failure to do so will result

in erroneous measurements and could result in damage to the analyzer.

The first signs of moisture in the instrument will be visible condensation in the

sample tubing and an unusually high dew point. The upper range of the sensor is

+80°F (27°C), so if that value is displayed on the instrument it is probably due to

the presence of moisture. If this moisture is not removed, it will cause the

sensor tip to corrode and will eventually require the sensor to be replaced.

To remove moisture from the instrument, the sample tubing and filter should be

removed from the instrument since they will probably be wet. A dry and inert gas

such as nitrogen or argon should then be flowed through the instrument (with

the pump off) for as much time as it takes to dry out. This dry-out time will

depend on the amount of moisture present in the instrument. The condition of

the sensor can be monitored by periodically reading the dew point from the

display and watching the value decrease over time. To test if it is operating

properly, verify the ambient dew point against a web-based weather station that

will report the ambient dew point for your area. If the displayed reading is within

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three degrees (3°) of the reported dew point when the instrument is taken

outside, then all of the moisture has probably been successfully removed. The

wet filter and sample tubing can be re-attached after they have been completely

dried out.

To prevent the possibility of moisture damaging the instrument, be sure that the

measured dew point is below ambient levels before it is stored. If necessary,

nitrogen or argon can be used to dry out the instrument after use.

WHAT IS DEW POINT?

Dew point can be defined as the temperature at which the water vapor pressure

of the gas equals the saturated water vapor pressure. In other words, it is the

temperature at which condensation will just begin to occur as the gas is cooled.

Dew point and relative humidity are not the same measurement. Relative

humidity is the amount of water vapor in the air compared to the amount the air

could hold if it was totally saturated, and it is expressed as a percentage, not a

temperature. To determine dew point, two main variables are required: relative

humidity and temperature. The DP2000 measures both variables to compute the

displayed dew point.

HOW IT WORKS –

The dew point sensor is a “dielectric ceramic” that varies its electrical

capacitance with changes in relative humidity. The sensor is mounted in a short

probe, which is installed in a T-fitting that allows the sample gas to flow past the

sensor. The tip of this probe contains the dielectric ceramic relative humidity

(RH) sensor, as well as a built in temperature sensor to determine its dry bulb

temperature. Information from both of these sensors is used to compute the

resultant dew point, which is displayed on the digital LED display.

MAINTENANCE / SAFETY ISSUES –

One of the added features of the DP2000 is the ability to monitor the sensor’s

operating temperature through the built-in thermistor in the probe tip. The

temperature of the sample gas can be determined by pressing the switch labeled

“Sensor Temp”. It is spring loaded, so it will automatically return to displaying

dew point.

Maintaining proper sensor temperature will prevent the premature failure of the

sensor. The operating temperature of the sensor should remain below 140F

(60C) at all times. Periodic checks of the sensor temperature will verify that the

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sensor is not being exposed to excessive heat. If these periodic checks show a

high sensor temperature, then the length of sample tubing should be increased

to allow for adequate cooling of the sample before it passes the sensor tip.

Continuous operation of the DP2000 Dew Point Analyzer will lead to premature

failure, since many the internal components are not designed for uninterrupted

use. If continuous monitoring of Dew Points is required, please contact Super

Systems, Inc. at 513-772-0060 to inquire about products intended specifically for

this application.

FACTORY CALIBRATION –

Factory calibration is recommended every six months if the unit is used

regularly. SSI’s calibration is NIST traceable and includes a numbered

“Certificate of Calibration”. This certificate also indicates the accuracy of the

analyzer before and after calibration. Please contact Super Systems, Inc. at 513-

772-0060 for more information regarding this service.

FIELD CALIBRATION –

It is also possible to calibrate the DP2000 in the field, which will require the

optional calibration kit (Part Number 31030). The instructions for a field

calibration are shown here, however please feel free to contact Super Systems at

513-772-0060 if you would like to review the process with us before you begin.

The calibration kit consists of two bottles of saturated salt solution in which each

bottle generates a precise relative humidity percentage (R.H. %) value. One

bottle is 11.3% R.H., and the other is 75.3% R.H. These two specific calibration

points are already pre-programmed into the microprocessor board.

1.0 Open the unit

1.1 Remove the aluminum faceplate of the DP2000 by removing the

single allen-head cap screw located at the bottom front of the

faceplate. After the screw has been removed, carefully lift the front of

the faceplate and slide it towards you about an inch. After the

faceplate has been removed, it can temporarily be rested in the lid of

the open case, to allow access to the components inside. This plate

will still be connected to the interior circuit boards, so care should be

taken to maintain all existing connections.

2.0 Locate the key components within the unit

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

This board contains three very small buttons that are used for

calibration. Two are next to one another, and they are marked “75.3%”

and “11.3%”, while the other has no label. The unmarked button is the

“Calibrate” button. The approximate locations of each button are

shown on this diagram:

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

It is the gray rectangular box with brass barb fittings on either side

with a black plastic gland protruding from the center.

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

is held in place by the nut on the black plastic gland.

3.0 Remove the sensor probe from the sensor sampling chamber.

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

out through the airtight seal. Care must be taken when removing this

sensor probe, since the tip is very delicate and can be easily damaged

if it is mishandled. Note that the probe has white mark at the wire

entry point, which must be aligned with corresponding white mark in

plastic gland when it is re-inserted in the sampling chamber.

4.0 Install the sensor probe into the 75.3% salt solution.

4.1 Slip the black sensor gland (supplied in the calibration kit) over the

sensor probe with the sensor tip protruding from the threaded end of

the gland and the sensor wires being flush with the top of the rubber

SPAN

BUTTON

(75.3)

ZERO

BUTTON

(11.3)

CAL

BUTTON

Dew Point Microprocessor Board

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o-ring in the gland. Tighten the gland around the sensor. This does

not need to be done with a wrench or other tools, but it does need to be

tight enough to prevent ambient air from contaminating the humidity

level of the sampling chamber.

4.2 Remove the cap of the 75.3% salt solution and install the sensor

gland (with the sensor) into the salt solution. To increase the life of the

calibration salts, an effort should be made to minimize the amount of

time that the salt solution is exposed to the ambient air.

5.0 Allow the sensor to reach equilibrium with the calibration salt.

5.1 With the power to the unit still turned off, leave the sensor in the

calibration salt for a minimum of eighteen (18) hours. It is acceptable

to leave the sensor in the salt solution for a longer period of time, even

a few days, if desired.

6.0 Begin the 75.3% (Span) calibration process.

6.1 After leaving the sensor in the salt for at least eighteen (18) hours,

turn the unit on. The reading on the display is not important at this

point.

6.2 Simultaneously press the “75.3%” and “Calibration” buttons on the

microprocessor board.

7.0 Verify the 75.3% (Span) calibration.

7.1 Do not be concerned if the unit does not display 75.3, since it is not

supposed to match the value of the calibration salt.

7.2 Use the “Sensor Temp” switch on the faceplate of the unit to

determine and record the sensor temperature.

7.3 Look up this temperature on the “Theoretical Dew Point Values for

Calibration Verification” chart located in the back of this manual.

Appendix “A” will show the temperature values in Fahrenheit, and

Appendix B will show the temperature values in Celsius.

7.4 Next to the appropriate temperature, note the number in the

corresponding column titled “75.3%”. This should match with the dew

point that is shown on the display of the DP2000.

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8.0 Determine the acceptability of the reading.

8.1 The value printed on the chart in Appendix A is a theoretical value,

and some variation can be expected. When a calibration is performed

at SSI, we certify (in writing) that the unit displays within +/- 1 degree

of the theoretical value after it has been calibrated. We would not

consider a calibration to be successful unless it is within +/- 1 degree,

however in the case of a field calibration, this degree of accuracy may

or may not be required. The degree of accuracy that is acceptable is

determined by the policy of the person performing the calibration.

NOTE: Keep in mind that the DP2000 only displays even numbers, and

not tenths of a degree. Therefore, a reading of 65°F could be as low as

64.50 or as high as 65.49.

9.0 Allow the sensor to achieve equilibrium at ambient atmosphere.

9.1 After the 75.3% (Span) calibration has been completed, remove the

sensor from the calibration salt and replace the cap on the salt.

9.2 Leave the sensor probe in the gland and while the unit is still on,

allow it to achieve equilibrium at the ambient atmosphere in the room.

This is accomplished by simply leaving the sensor exposed to ambient

air for between two and three minutes. You will know when this has

been accomplished when the numbers on the display begin to stabilize.

10.0 Install the sensor probe into the 11.3% salt solution.

10.1 Remove the cap of the 11.3% salt solution and install the sensor

gland (with the sensor) into the salt solution. To increase the life of the

calibration salts, an effort should be made to minimize the amount of

time that the salt solution is exposed to the ambient air.

10.2 Turn the unit off.

11.0 Allow the sensor to reach equilibrium with the calibration salt.

11.1 With the power to the unit still turned off, leave the sensor in the

calibration salt for a minimum of 24 hours. It is acceptable to leave the

sensor in the salt solution for a longer period of time, even a few days,

if desired.

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12.0 Begin the 11.3% (Zero) calibration process

12.1 After leaving the sensor in the salt for at least twenty-four (24)

hours, turn the unit on. The reading on the display is not important at

this point.

12.2 Simultaneously press the “11.3%” and “Calibration” buttons on the

microprocessor board.

13.0 Verify the 11.3% (Zero) calibration

13.1 Do not be concerned if the unit does not display 11.3, since it is not

supposed to match the value of the calibration salt.

13.2 Use the “Sensor Temp” switch on the faceplate of the unit to

determine and record the sensor temperature.

13.3 Look up this temperature on the “Theoretical Dew Point Values for

Calibration Verification” chart located in the back of this manual.

Appendix “A” will show the temperature values in Fahrenheit, and

Appendix B will show the temperature values in Celsius.

13.4 Next to the appropriate temperature, note the number in the

corresponding column titled “11.3%”. This should match with the dew

point that is shown on the display of the DP2000.

14.0 Determine the acceptability of the reading

14.1 The value printed on the chart in Appendix A is a theoretical value,