YZ Systems DynaPak 2010FKNX User manual

DynaPak2010FKNX
SystemSupport
Manual
Version 09242003

2
1.Introduction 3
2. System Components 3
3. Theory of Operation 4
4. Sampler Location 5
5. Sampler Installation 6
6. Sample Vessel Installation 8
7. Operational Check & Leak Testing 9
8. Sampler Set-Up: time-based
sampling 10
9. Sampler Set-Up: time-based
sampling with the DPS-2 12
10. Sampler Set-Up: proportional-
to-flow sampling 14
11. Sampler Maintenance 16
12. Trouble Shooting 20
13. Diagrams
#1 DP-2000 pump (assembled) 24
#2 DP-2000 pump (exploded) 25
#3 YZ filter regulator (assembled) 26
#4 YZfilterregulator(exploded) 27
#5 LinkPlus 28
#6 DPS-2 29
#7 Z-65controller 30
#8 Z-65installationnotes/wiring
control documentation 31
#9 DuraSite Portable Sample vessel
installation 32
Notes 34
Table Of Contents

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
3
Congratulations on your purchase of the DynaPak
2010 Series Sampler. You've made a wise
measurement investment for your company.
Before you begin installation, insure that all of the
necessary components are present. You will need
a sample cylinder(s) during the installation. If you
have questions concerning installation/operation,
contact your YZ representative or YZ Customer
Service at 936.788.5593.
2. System Components:
The primary components of the DynaPak 2010
Sampling System are illustrated here.
1. Introduction
Z-65 Controller Cable Entry Fitting Solenoid Valve

Wiring and Pneumatic Tubing Not
Shown For Drawing Clarity
Sample Inlet
10 1/2" (27 cm)
81/2"(22cm)

(CEVQT[
5[UVGO
4463:/.
/WVWCN
Sample Discharge
DynaPak 3000 Pump
Tubing
Purge Valve
Isolation Valve
Sample Discharge
Probe Body Assembly
Note:
Filter/Regulator
YZ SYSTEMS, INC.

1/2" NPT
DynaPak2000NPump
3/4" NPT
DP-2010FKNX
10 1/2" (27 cm)
8 1/2" (22 cm)

4
DynaPak 2010 Gas Sampler
The DynaPak 2010 Sampler is a pipeline mounted
system which uses the pneumatically operated,
positive displacement DynaPak 2000 pump, the
Z-65 timer/controller, the YZ filter/regulator and a
low power solenoid valve to obtain gas samples.
The 2010 provides three modes of operation:
A. Time-based sampling: in this mode of
operation, the 2010 extracts a gas sample from
the pipeline at regular time intervals. The volume
of the sample is set by the operator using the
volume adjustment feature of the DP-2000 pump.
The Z-65 controller operates as a recycling timer,
periodically energizing a low power solenoid valve.
Energizing the solenoid valve allows actuation gas
to stroke the DP-2000 pump. The rate at which
this occurs is a function of operator input. Two 10
position switches are used to set the off time
interval. The number of times the solenoid output
is activated is recorded by the onboard LCD stroke
indicator.
B. Time-based sampling with the Optional
YZ differential pressure switch (DPS-2): this
mode of operation is similar to the time-based
sampling mode, except that the DPS-2 converts a
differential pressure signal to an electrical signal
that the Z-65 timer uses to determine if flow is
present in the pipeline. In effect, the DPS allows
the Z-65 timer to shut off when flow stops in the
pipeline, and when flow starts again, the ability to
start-up and resume operation.
C. Proportional-to-flow sampling:
in this mode of operation, the Z-65 counter
operates as a dividing counter. The Z-65 counter
periodically energizes a low power solenoid valve.
As in the other two modes of operation, this allows
actuation gas to stroke the DP-2000 pump. The
rate at which this occurs is a function of operator
input as well as the host computer or other device
that inputs pulses per volume metered. The two
10-position switches on the Z-65 are used to set
the number of pulses the counter will count before
activating the solenoid output. The number of
times the solenoid output is activated is recorded
by the onboard LCD stroke indicator. Sample
volume is again controlled using the DP-2000
volume adjustment knob.
In all three modes of operation, the Z-65 timer/
counter operates using a replaceable internal
battery pack. The battery pack condition is
monitored by way of two indicator LEDs. When
the battery pack needs replacement, the red LED
will illuminate when the solenoid output is
activated. If the battery pack is good, the green
LED will illuminate when the solenoid is activated.
The External Power Option can be used in lieu
of the internal battery pack. The External Power
Option (model # EPO-120) consists of an AC to
DC convertor and intrinsically safe barrier to
convert 120 VAC power to 28 VDC to operate the
controller without the use of the internal battery
pack.
The Solar Power Option would be used in lieu of
the internal battery pack. The Solar Power
Option (model #SPO-12) consists of a 5 watt
solar panel with RM-12 charger regulator module
and internal 12V, 5 Amp hour battery pack.
3. Theory of Operation

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
5
4.1 The sampler should be a minimum of five
pipe diameters from any device which could cause
aerosols or significant pressure drops.
4.2 The sampler should not be located within the
defined meter tube region (AGA 3 manual).
A = The number of unobstructed, straight pipe
diameters upstream (see AGA - 3 manual).
B = The number of unobstructed, straight pipe
diameters downstream (see AGA - 3 manual).
Meter Tube
Optimum Sampler Probe Locations
Differential Pressure Device
5 Ø
Flow
A B 5 Ø
4. Sampler Location

6
5.1 DynaPak 2010
a. The DynaPak 2010 requires a 3/4" FNPT
pipelineconnection.
b. The DynaPak 2010 sampler should be
mounted vertically in a horizontal run of the
pipeline.
c. The end of the sampler probe should penetrate
the center 1/3rd of the pipeline.
d. The end of the sample probe should be cut
paralleltothe pipeline.
e. Before applying pipeline pressure to the
DynaPak 2010, ensure that the isolation valve and
purge valve are closed.
f. After pipeline pressure has been applied to the
sampler, check the probe body/pipeline connection
using a liquid leak detector.
g. 1/4" stainless steel tubing must be connected
from a source of supply actuation gas with a
minimum pressure of 65 psig to the external gas
supply connection for the Filter Regulator located
on the left side of the sampler enclosure.
CAUTION
Incorrect operation of valves (over tightening) can
result in damage to the valve components (isola-
tion valve bonnet assembly) which might result in
the valve stem being screwed out of the probe
body. This of course results in product at pipeline
pressure being vented continually through this port
until this section of the pipeline is shut in. Be aware
of the following procedures and information.
· DynaPak valves are of soft seat
design and should only be closed
or opened with fingers. No
wrenches should ever be used.
· If a valve will not seal off with
finger tight operation the valve
should have maintenance
performed to allow proper
operation of the valve.
5. System Installation
Center 1/3
1/3
1/3
1/3
Center 1/3
1/3
1/3
1/3
Maximum Pipeline Pressure 1500 psig.
External
GasSupply
Connection

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
7
5.2 Optional DPS-2
Maximum Pipeline Pressure 1500 psig with this
option.
a. With the low pressure supply valve and the high
pressure supply valve closed, connect the DPS-2
to the orifice connection tubing.
b. Open the equalization valve.
c. Open the low pressure supply valve or the high
pressure supply valve.
NOTE: Do not open either the low pressure
supply valve or the high pressure supply valve
without ensuring that the equalization valve is
open. Failure to do so may damage the
DPS-2's internal components.
d. Open the other supply valve.
e. Close the equalization valve.
f. Run the free end of the DPS-2 cable through the
cable entry connector located on the upper left
side on the DynaPak 2010 enclosure.
g. Connect the DPS-2 cable as shown in the
diagram.
h. Tighten the cable entry connector, allowing for
enough cable length to open the enclosure. High Pressure Supply Valve
Orifice Connection
Equalization Valve
Low Pressure Supply Valve
Flow
Low Pressure
High Pressure
(CEVQT[
4463:/.
5[UVGO
/WVWCN
Clear
Black
5. System Installation
Maximum
Pipeline
Pressure
1500 psig.

8
6.1 Variable pressure/constant volume cylinders.
Spun cylinders may be installed in a horizontal position
on the DynaPak BackRack vessel rack. Avoiding traps
in the line, install stainless steel tubing and fittings from
the sample discharge port of the sampler to the product
end of the sample cylinder.
300cc and 500cc spun cylinders may also be installed
in a vertical position. Piping from the sampler dischage
port to the sample vessel should be arranged so that
liquid traps are not created.*
6.2 Variable volume/constant pressure cylinder.
The free-floating piston cylinder (DuraSite) may be
installed in a horizontal position on an optional vessel
rack. Free-floating piston cylinders should NOT be
installed on the DynaPak BackRack vessel rack.
Install 1/8" tubing from the sample discharge port of the
manifold to the product end of the vessel. Avoid traps in
this line.
See diagram #9 for DuraSite portable sample vessel
instructions.
6.3 LinkPlus. Install the optional LinkPlus directly into
the sample discharge port of the sampler. Use
stainless steel tubing and fittings to connect the
LinkPlus outlet to the product end of the sample
cylinder.
*Standard configuration for this option package.
6. Sample Vessel Installation

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
9
7.1 When all of the tubing connections have been
completed, close the purge valve on the front of the
sampler probe body. Open the sample probe supply
valve to allow pipeline pressure into the sampler.
Check all connections using a liquid leak detector.
7.2 Adjust the filter/regulator from the following
ranges:
Pipeline Pressure Actuation Pressure
Under 700 psig (48 Bar) 50 psig (3.5 Bar)
700-1500 psig (48-103 Bar) 65 psig (4.5 Bar)
1500-2160 psig (103-149 Bar) 75 psig (5.2 Bar)
7.3 Turn the stroke adjustment knob on the top of the
pump counterclockwise to set the pump
displacement at .4cc/stroke.
7.4 Move all of the mode switches on the Z-65 to their
off positions.
7.5 Move both timer/counter dials to the 0 position
(00 minutes).
7.6 Move mode switches 1, 2 and 3 to the on position.
The pump will begin stroking once every 2 seconds in
a diagnostic test mode.
7.7 Allow the sampler to operate until the pipeline
pressure plus 100 psi (6.9 Bar) is achieved at the
sample discharge.
7.8 Return the mode switches to their off positions.
7.9 Check all connections from the sampler
discharge to the connection on the sample cylinder
using a liquid leak detector.
7.10 If no leaks are found, the pump and tubing
should be considered tested and functional.
NOTE: BlackindicatesNOTE: Blackindicates
NOTE: BlackindicatesNOTE: Blackindicates
NOTE: Blackindicates
theswitchposition.theswitchposition.
theswitchposition.theswitchposition.
theswitchposition.
/WVWCN
5[UVGO
4463:/.
(CEVQT[
7. Operational Check & Leak Testing

10
8.1 Calculate the sampling rate using the
following 30 day chart:
NOTE: To obtain maximum battery life, choose
the longest time interval and the largest pump
displacement setting possible.
18minutes
Example
8.2 Set the timer dials on the Z-65 to the sample
rate from step 8.1.
NOTE: The time (18 minutes) above corresponds
to the dial setting shown for the Z65 model with the
timer range setting in the factory position (jumper
on the two left pins). See section 12.4 Timer
Range Setting.
3
2
0
9
6
8
7
1
3
2
5
4
0
9
1
6
7
8
5
4
12 .400 18 36 60
913 27 45
3
6
4
918
915
30
.300
.200
.100
Numberofturns
openonpump
strokeknob
sample
pump
displacement
perstroke 1000 cc 500 cc 300 cc
Sample cylinder volumes
Sample
rate
(minutes)
8. Sampler Set-Up - Time-based sampling

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
11
8.4 Turn mode switch 1 to on.
8.5 Turn mode switch 2 to on.
8.6 Turn mode switch 3 to on.
8.7 Turn mode switch 4 to off.
8.8 Press the test button once to initiate the timer
sequence.
8.3 Adjust the pump volume adjustment knob to
the value used in the calculations in step 8.1.
Numberofturnsopenonthepumpvolumeknob
3
6
12
Samplepump displacementperstroke
.1cc
.2cc
.4cc
5[UVGO
/WVWCN
4463:/.
(CEVQT[
8. Sampler Set-Up - Time-based sampling

12
9.1 Calculate the sampling rate using the following 30 day chart:
9.2 Set the timer dials on the Z-65 to the
determined time from step 9.1. Example
18minutes
NOTE: To obtain maximum battery life, choose
the longest time interval and the largest pump
displacement setting possible.
NOTE: The time (18 minutes) above
corresponds to the dial setting shown for the Z65
model with the timer range setting in the factory
position (jumper on the two left pins). See section
12.4 Timer Range Setting.
3
2
0
9
6
8
7
1
3
2
5
4
0
9
1
6
7
8
5
4
12 .400 18 36 60
913 27 45
3
6
4
918
915
30
.300
.200
.100
Numberofturns
openonpump
strokeknob
sample
pump
displacement
perstroke 1000 cc 500 cc 300 cc
Sample cylinder volumes
Sample
rate
(minutes)
9. Sampler set-up -
time-based sampling with the Optional DPS-2

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
13
9.3 Adjust the pump volume adjustment knob to
the value used in the calculations in step 9.1.
9.4 Turn mode switch 1 to on.
9.5 Turn mode switch 2 to on.
9.6 Turn mode switch 3 to off.
9.7 Turn mode switch 4 to off.
9.8 Press the test button once to initiate the timer
sequence.
NOTE: For the Z-65 to operate the DP-2010
System, a minimum pressure differential of 3" of
water must exist between the high pressure and
low pressure ports of the DPS-2.
Numberofturnsopenonthepumpvolumeknob
3
6
12
Samplepump displacementperstroke
.1cc
.2cc
.4cc
5[UVGO
/WVWCN
4463:/.
(CEVQT[
9. Sampler set-up -
time-based sampling with the Optional DPS-2

14
Inthis mode of operation,the Z-65 controlleris used
as a dividing counter to control the rate at which the
pump is actuated. The desired time between pump
strokes is controlled by the host computer or output
device that will give an input pulse to the Z-65
controller.
10.1 Determine if the incoming input is either a dry
contact or voltage pulse.
10.2 If the input is a dry contact:
a.Terminate the incoming connections to the
Z-65 terminal strip (see illustration).
b.Turn mode switch 1 to on.
c.Turn mode switch 2 to off.
d.Turn mode switch 3 to on.
e.Turn mode switch 4 to off.
OR
10.3 If the input is a voltage pulse:
a.Terminate the incoming connections to the
Z-65 terminal strip (see illustration).
b.Turn mode switch 1 to on.
c.Turn mode switch 2 to off.
d.Turn mode switch 3 to on.
e.Turn mode switch 4 to on.
Dry contact or
duration min.)
open collector
(20 mSec
+
_
(CEVQT[
4463:/.
5[UVGO
/WVWCN
duration min.)
+
_
Voltage pulse
5-24 VDC
(20 mSec
(CEVQT[
4463:/.
5[UVGO
/WVWCN
10. Sampler set-up - proportional-to-flow sampling

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
15
10.4 Calculate the counter setting using the
following chart:
1. your pump displacement (from .1 to .4cc’s) = a.__________
2. your sample cylinder volume in cc’s (300cc, 500cc, etc.) = b.__________
3.averageflowrate (MMCFper dayorMCMperday) = c.__________
4. sample period in days = d.__________
5.pulses/volumemetered(pulses/MMCForpulses/MCM) = e.__________
6. counter setting = a x c x d x e
(b)
Example #1:
English Gas Flow
Units
Example #2:
Metric Gas Flow
Units
10.5 Adjust the pump volume adjustment knob to
the value used in the calculation in step 10.4.
Samplepump displacementperstroke
.1cc
.2cc
.4cc
Numberofturnsopenonthepumpvolumeknob
3
6
12
10.6 Turn the counter dials to the appropriate num-
ber of pulses you want to count before the sample
pump strokes.
Example: 20 pulses; turn dials to 20.
Press the test button once to load the value into the
memory.
NOTE: If the calculated counter setting is less than 1 or greater
than 99, the pulses per volume metered will need to be adjusted.
This can be programmed in most flow meters to the desired rate.
If the calculated counter setting is less than 1, increase the pulses
per volume metered. If the calculated counter setting is greater
than 99, decrease the pulses per volume metered volume.
3
2
0
9
6
8
7
1
3
2
5
4
0
9
1
6
7
8
5
4
pumpdisplacement (a.) = .2cc .2cc
sample cylinder size (b.) = 300cc 300cc
averageflowrate (c.) = 10 MMCF per day 10MCM/day
sampleperiod (d.) = 30 days 30 days
pulsespervolumemetered (e.) = 100pulses/MMcf 100pulses/MCM
Example #1
counter setting = .2cc x 10 MMcf per day X 30 days X 100 pulses per MMcf = 20 pulses
300 cc
Example #2
counter setting = .2cc x 10 MCM per day X 30 days X 100 pulses per MCM = 20 pulses
300 cc
10. Sampler set-up - proportional-to-flow sampling

16
11.1 Recommended preventative maintenance
schedule
Every sampling situation is unique. Below are our
recommendations for average conditions. A
higher BTU content will necessitate more frequent
pump/filter maintenance.
a. Clean and lubricate the sample pump every six
months.
b. Check the filter element every six months,
replacing as necessary.
c. Test the battery every month.
d. Test the system for leaks each time a fitting or
connection has been made.
11.2 Cleaning and lubricating the DP-2000
pump:
a. Close the isolation valves. (Note the isolation
valve to the GPA Separator that supplied gas to
the Filter Regulator must also be closed)
b. Disconnect the plastic tubing from the solenoid
valve to the pump diaphragm housing by
depressing the tubing release sleeve on the
diaphragm housing fitting while pulling out the
tubing. It is not necessary to remove the fitting
from the diaphragm housing.
c. Remove the sample discharge (1/8" stainless
steel tubing) from the pump body.
d. Screw the stroke adjustment knob all the way
down to the 0 cc/stroke setting.
e. *Unscrew the pump body by hand from the inlet
check valve assembly. Separation at this point is
recommended to maintain proper tubing location
and alignment between the pump body and the
probe body. Do not remove the inlet check valve
body from the manifold unless cleaning is
necessary. To replace the inlet check valve o-ring,
carefully cut the o-ring off the head of the dart and
stretch the new o-ring over the head of the dart
using a light coat of assembly grease.
f. Remove the diaphragm housing from the pump
body by unscrewing the diaphragm housing and
carefully pulling the plunger out of the pump body.
Inspect the plunger shaft for damage or wear. The
diaphragm chamber houses the diaphragm, return
spring, stroke adjustment screw and plunger
assembly. The diaphragm chamber should not be
disassembled unless one of these items needs
replacing.
*Screwthestrokeadjustmentscrewalltheway
down.
11. Sampler maintenance
11.2 a
11.2 c
11.2 e
11.2 f
11.2 d
11.2 b

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
17
g. Remove the internal bushings and o-rings from
the pump body by inserting a nonmetallic rod
(larger than 1/4", smaller than 1/2") into the top of
the pump body. Gently tap to remove all bushings
and o-rings out the bottom of the pump body.
h. Clean and inspect all components. Replace if
necessary.
NOTE: Normal service generally requires only
the replacement of the o-rings and seal. A seal
repair kit (part number D3-0002) is available from
YZ.
i. Apply a light coat of non-soluble assembly
grease on all o-rings and bushings to prevent
damage.
j. Install the body bushing into the bottom of the
pump body.
NOTE: Apply a light coat of assembly grease on
the plunger shaft prior to installation.
k. Insert all other bushings, springs, and o-rings in
their respective sequence on the plunger shaft.
l. Carefully install assembly into the top of the
pump body, and screw the actuator assembly onto
the pump body. (Tighten firmly by Hand ONLY)
m. Install the pump assembly on the inlet valve
assembly. (Tighten firmly by Hand ONLY).
n. Connect the 1/8" stainless steel tubing to the
pump body and 1/8" plastic tubing to the
diaphragm housing.
o. Open the isolation valve.
p. Adjust the stroke adjustment knob to its original
setting.
q. Pressure test the pump as previously described
for proper operation.
11.2 j
11.2 k
11.2 g
11. Sampler maintenance

18
11.3 Battery Test:
a. Set the mode switches as follows:
1. Position 1, 2 and 3 on
b. Set the time switches to the 01 position.
NOTE: Time switches must not be in 00 position
to test the battery.
This will set the solenoid output rate to one
actuation every one minute (based on the
factory set time range for the Z-65 model).
c. Depress the test switch to test the battery. A
green LED will illuminate if the battery is good and
a red LED will illuminate if the battery is low.
NOTE: The solenoid must be connected to test
the battery condition. Battery condition cannot
be tested with a volt meter.
Replacing a Depleted Battery:
1. Remove the four thumb screws, cover plate and
orange terminal connector.
2. The battery is located in the lower left hand
corner of the Z-65 controller assembly.
3. Unclip the battery plug from the battery
receptacle.
4. Replace the depleted battery with a fresh battery
pack (part No. E3-2001).
NOTE: Follow the illustration to assure proper
battery wire placement in the Z-65 enclosure.
5. Return the mode switches to their original
positions.
Battery Pack
11. Sampler maintenance

DP-2010FKNX Version 09242003
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
19
11.4 Recommended spare parts for the
DynaPak 2000 Series gas samplers.
Part Number Description Qty. Location
C4-0004 Filter element 1 see diagrams #3 and #4
D3-0002K DP-2000 pump seal kit 1 see diagrams #1 and #2
D3-0003 YZfilter regulatorrepairkit 1 see diagrams #3 and #4
D3-0142 Z-65/200 fuse replacement kit 1 see diagram #7
E3-2001 Battery pack 1 see diagram #7
11. Sampler maintenance

20
12.1 Mechanical Operation Test:
A. Set the mode switches as follows:
1. Positions 1, 2 and 3 on.
2. Position 4 off.
B. Set the time switches to 00 to enter the
diagnostic mode. This mode enables the user to
increase the solenoid output rate to one pulse
every two seconds.
12.2 DPS-2 Test
A. Set the mode switches as follows:
1. Position 1 and 2 on.
2. Position 3 and 4 off.
B. Set the time dials to 00 to enter the
diagnostic mode.
C. This mode enables the operator to determine if
the DPS is operating properly. This is
accomplished by depressing and holding the test
switch. If the DPS is sensing flow in the pipeline,
the green LED should illuminate. If flow is not
present, the red LED should illuminate.
12.3 LCD Stroke Indicator Test Mode:
A. To test the stroke counter, set the mode
switches as follows:
1. Positions 1, 2 and 3 on.
2. Position 4 off.
B. Set the time switches to 00.
C. Unscrew the thumbscrews and remove the six
position terminal strip and cover. This will expose
the battery pack and the three position
configuration jumper (located in the lower right
corner of the Z-65 controller assembly).
D. Set the configuration jumper to the far right
position marked stroke indicator test.
12.3 d - Jumper switch location
/WVWCN
4463:/.
(CEVQT[
5[UVGO
(CEVQT[
4463:/.
/WVWCN
5[UVGO
/WVWCN
4463:/.
5[UVGO
(CEVQT[
(CEVQT[
5[UVGO
4463:/.
/WVWCN
12. Troubleshooting - Timer Mode