Thermo Scientific PRO902C User manual

PRO902C
Instruction Manual
Dilution Probe Conditioning Assembly &
Remote Probe Controller Assembly
Part Number 111981-00
16Au
g
2007

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Air Quality Instruments
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PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 ii
1.0 PRODUCT DESCRIPTION
1.1 Introduction ..................................................................................................... 1-1
1.2 PRO902 description ........................................................................................ 1-1
1.3 Dilution probe conditioning assembly hardware ................................................ 1-2
1.3.1 Probe enclosure ................................................................................... 1-2
1.3.2 Enclosure heater .................................................................................. 1-2
1.3.3 Valve manifold and dilution air regulator............................................... 1-3
1.3.4 Heated filter, dilution eductor, and probe barrel assembly...................... 1-3
1.3.5 Heat exchanger and drain valve assembly ............................................. 1-4
1.3.6 TEI O2analysis system ......................................................................... 1-4
1.3.6.1 O2eductor .............................................................................. 1-5
1.3.7 Power, purge and temperature control .................................................. 1-5
1.3.7.1 Power distribution.................................................................. 1-5
1.3.7.2 Valve controller (watchdog) module ...................................... 1-5
1.3.7.3 Heated filter control module................................................... 1-5
1.3.7.4 Heat exchanger control module .............................................. 1-6
1.3.8 Absolute pressure transducer ................................................................ 1-6
1.4 Tubing and wiring umbilicals ........................................................................... 1-6
1.4.1 Tubing umbilical .................................................................................. 1-6
1.4.2 Wiring umbilical ................................................................................... 1-6
1.5 Remote probe controller assembly ................................................................... 1-6
1.5.1 Remote probe controller enclosure ....................................................... 1-7
1.5.2 Interface printed circuit assembly and O2meter display ........................ 1-7
1.5.3 Temperature controllers........................................................................ 1-7
1.6 Specifications ................................................................................................... 1-8
2.0 THEORY OF OPERATION........................................................................................ 2-1
2.1 General ............................................................................................................ 2-1
2.2 Gas Flow functional description........................................................................ 2-1
2.2.1 Sampling mode..................................................................................... 2-2
2.2.2 Purge mode .......................................................................................... 2-3
2.2.3 Calibration mode................................................................................... 2-4
3.0 INSTALLATION AND OPERATION ........................................................................ 3-1
3.1 Site location and preparation ............................................................................ 3-1
3.2 Limitations at the probe site.............................................................................. 3-2

PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 i
Claims for Damaged Shipments
A. The PRO902C and remote probe controller assembly are shipped ready for operation.
Immediate inspection of the PRO902C and remote probe controller assembly should follow upon
receipt. Inventory of the container should be checked against the enclosed packing list. If there is a
shortage of items, the operator should immediately contact TFS. If the contents are damaged, the
carrier and the project manager at TFS should be notified immediately.
B. The following documents are necessary to support claims:
1. Original freight bill and bill of lading.
2. Original invoice or photocopy of original invoice.
3. Copy of the packing list.
4. Photographs of damaged equipment and container.
NOTICE
Material contained in this manual is proprietary information of TFS. The TFS manual is to be used
only for the installation, understanding, and servicing of this product. For further information or
assistance contact:
Thermo Fisher Scientific
All rights reserved. No part of this publication may be reproduced or stored in a retrieval system or
transmitted in any form or by any means, electronic, mechanical photocopying, recording, or
otherwise, without the prior written permission of TFS.
REVISION HISTORY
Revision
No.
Revision Made Pages Affected Revision Date
1.1 Revise document to Word format/update All June 25, 1999
2.0 Revised document All October 13,
2000
3.0 Changed Logo & TEI All April 12, 2001
4.0 Changed O2 analyzer All Sept 28, 2006
5.0 Changed List of Drawings 6-1 Aug 16, 2007
6 Added Schematics 6-1, 6-9 Jan 4, 2008

PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 ii
1.0 PRODUCT DESCRIPTION
1.1 Introduction ..................................................................................................... 1-1
1.2 PRO902 description ........................................................................................ 1-1
1.3 Dilution probe conditioning assembly hardware ................................................ 1-2
1.3.1 Probe enclosure ................................................................................... 1-2
1.3.2 Enclosure heater .................................................................................. 1-2
1.3.3 Valve manifold and dilution air regulator............................................... 1-3
1.3.4 Heated filter, dilution eductor, and probe barrel assembly...................... 1-3
1.3.5 Heat exchanger and drain valve assembly ............................................. 1-4
1.3.6 O2analysis system ......................................................................... 1-4
1.3.6.1 O2eductor .............................................................................. 1-5
1.3.7 Power, purge and temperature control .................................................. 1-5
1.3.7.1 Power distribution.................................................................. 1-5
1.3.7.2 Valve controller (watchdog) module ...................................... 1-5
1.3.7.3 Heated filter control module................................................... 1-5
1.3.7.4 Heat exchanger control module .............................................. 1-6
1.3.8 Absolute pressure transducer ................................................................ 1-6
1.4 Tubing and wiring umbilicals ........................................................................... 1-6
1.4.1 Tubing umbilical .................................................................................. 1-6
1.4.2 Wiring umbilical ................................................................................... 1-6
1.5 Remote probe controller assembly ................................................................... 1-6
1.5.1 Remote probe controller enclosure ....................................................... 1-7
1.5.2 Interface printed circuit assembly and O2meter display ........................ 1-7
1.5.3 Temperature controllers........................................................................ 1-7
1.6 Specifications ................................................................................................... 1-8
2.0 THEORY OF OPERATION........................................................................................ 2-1
2.1 General ............................................................................................................ 2-1
2.2 Gas Flow functional description........................................................................ 2-1
2.2.1 Sampling mode..................................................................................... 2-2
2.2.2 Purge mode .......................................................................................... 2-3
2.2.3 Calibration mode................................................................................... 2-4
3.0 INSTALLATION AND OPERATION ........................................................................ 3-1
3.1 Site location and preparation ............................................................................ 3-1
3.2 Limitations at the probe site.............................................................................. 3-2

PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 iii
3.2.1 Stack temperature extremes .................................................................. 3-2
3.2.2 Ambient temperature extremes.............................................................. 3-2
3.2.3 Process pressure ................................................................................... 3-2
3.3 General installation........................................................................................... 3-2
3.3.1 Dilution probe conditioning assembly.................................................... 3-2
3.3.2 Air supply............................................................................................. 3-5
3.3.3 Sample and calibration gas lines ............................................................ 3-5
3.3.4 Vent line ............................................................................................... 3-5
3.3.5 Power................................................................................................... 3-5
3.3.6 Control and data lines ........................................................................... 3-6
3.4 Dilution probe conditioning assembly Start-up
(City Technology O2) ....................................................................................... 3-6
3.5 4-20 mADC current output calculation............................................................. 3-9
3.6 City Technology O2sensor alignment ..............................................................3-10
3.7 Absolute pressure transducer checkout procedure............................................3-11
3.8 Remote probe controller interface board setup procedure ................................3-11
4.0 MAINTENANCE........................................................................................................ 4-1
4.1 General ............................................................................................................ 4-1
4.2 Required maintenance equipment...................................................................... 4-1
4.3 Heated filter replacement.................................................................................. 4-1
4.4 Quartz orifice replacement................................................................................ 4-2
4.5 Probe head removal.......................................................................................... 4-2
4.6 Orifice holder assembly removal ....................................................................... 4-3
4.7 Eductor jet body removal ................................................................................. 4-3
4.8 Probe head leak Test ........................................................................................ 4-4
4.9 Probe Head Flow test ....................................................................................... 4-5
4.10 Eductor vacuum test......................................................................................... 4-5

PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 iv
4.11 Trouble Shooting ............................................................................................. 4-6
4.11.1 Zero drift – full system.......................................................................... 4-6
4.11.2 Span drift –full system........................................................................... 4-6
4.11.3 Low sample flow rate............................................................................ 4-6
4.11.4 High sample flow rate ........................................................................... 4-7
4.11.5 Low flow rate at the eductor exhaust .................................................... 4-7
4.11.6 High flow rate at the eductor exhaust.................................................... 4-8
4.11.7 Low eductor vacuum ............................................................................ 4-8
4.11.8 Low span reading.................................................................................. 4-8
4.11.9 High span reading ................................................................................. 4-9
5.0 ASSEMBLY REPAIR................................................................................................. 5-1
5.1 Obtaining replacement parts ............................................................................. 5-1
5.2 Spare parts list, CTL902C................................................................................ 5-1
5.3 Spare parts list, PRO902C................................................................................ 5-2
5.4 Extended Parts List, PRO902C......................................................................... 5-3
5.5 Recommended tools ......................................................................................... 5-5
6.0 LIST OF DRAWINGS ................................................................................................ 6-1
LIST OF FIGURES
1.3 Dilution probe assembly ................................................................................... 1-4
2.2 Probe head flow diagram.................................................................................. 2-3
3.1 Enclosure mounting diagram ............................................................................ 3-1
3.3 Probe barrel assembly....................................................................................... 3-4
3.4 Probe controller front panel.............................................................................. 3-6
3.8-1 Remote probe controller interface board setup.................................................3-12
3.8-2 Remote probe controller assembly, top view....................................................3-12
3.8-3 Remote probe controller electronics ................................................................3-13
4.8 Probe head leak test configuration .................................................................... 4-4

PRO902C MANUAL TFS
Rev 6.0 August 16, 2007 v
4.9 Probe head flow test configuration.................................................................... 4-5
4.10 Eductor vacuum test configuration ................................................................... 4-6
LIST OF TABLES
1.4.2 Wiring umbilical table....................................................................................... 1-6
3.4.1 Setup menu parameters .................................................................................... 3-7
3.4.2 Operation setup menu....................................................................................... 3-8