YZ Systems DynaPak DP-2020N User manual

DynaPak Gas Sampler
S Y S T E M S U P P O R T M A N U A L
DP-2020N

Version09242003
DynaPak2020N
SystemSupport
Manual

4
1. Introduction 5
2. System Components 5
3. Theory of Operation 6
4. Sampler Location 7
5. Sampler Installation 8
6. Sample Vessel Installation 9
7. Operational Check & Leak Testing 10
8. Sampler Set-Up:
proportional-to-flow sampling 13
9. Sampler Set-Up:
time-based sampling 17
10. Sampler Maintenance 18
11. Trouble Shooting 21
12. Diagrams
#1 DP-2000 pump (assembled) 25
#2 DP-2000 pump (exploded) 26
#3 YZ filter regulator (assembled) 27
#4 YZ filter regulator (exploded) 28
#5 Z-200 controller 29
#6 LinkPlus 30
#7 Z-200 installation notes/wiring
control documentation 31
#8 DuraSite portable sample vessel
instructions 32
Table Of Contents

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
5
1. Introduction
Congratulations on your purchase of the DynaPak 2020
Sampler.
Before installation, insure that all of the components are
present. You may or may not have ordered a sample
cylinder with your DynaPak System. Regardless, you will
need a cylinder during installation. If you have any ques-
tions about installation/operation, contact your YZ represen-
tative or YZ Customer Service at 936.788.5593.
2. System Components
The primary components of the DynaPak 2020 Sampler are
illustrated here.
1949
Factory
System
Approved
Mutual
Sample Discharge
DynaPak 2000 Pump
Tubing
Purge Valve
Isolation Valve
Sample Discharge
Probe Body Assembly
Note:
Filter/Regulator
YZ SYSTEMS, INC.
3101 POLLOK DRIVE CONROE, TEXAS 77303
Z-65 Controller Cable Entry Fitting Solenoid Valve
Patents 5,152,678; 4,531,895; 4,928,536
Wiring and Pneumatic Tubing Not
Shown For Drawing Clarity
Sample Inlet
8" (20cm)
6" (15cm)
DynaPak 2000N Pump
10 1/2" (27 cm)
8 1/2" (22 cm)
DP-2010N
YZ SYSTEMS, INC.
3101 POLLOK CONROE, TEXAS 77303
1949
Mutual
System
Approved
Factory
Z-200 Controller Cable Entry Fitting
Patents 5,152,678; 4,531,895; 4,928,536
N

6
DynaPak 2020 Gas Sampler
The DynaPak 2020 Sampler is a pipeline mounted system
which uses the pneumatically operated, positive
displacement DynaPak 2000N pump, the Z-200 timer/
controller, the YZ filter/regulator and a low power solenoid
valve to obtain gas samples. The 2020 has two modes of
operation:
A. Proportional-to-flow sampling: in this mode of operation, the
2020 extracts a gas sample from the pipeline at time
intervals proportional to the pipeline flow rate. The volume
of the sample is set by the operator using the volume
adjustment feature of the DP-2000 pump. The Z-200
periodically energizes a low power solenoid valve, which
allows actuation gas to stroke the DP-2000 pump.
The Z-200 operates as a recycling timer with exception that
the off time is adjusted to account for variations in pipeline
flow conditions. In the event that flow increases in the
pipeline the time between solenoid actuations will be
shortened. If the flow in the pipeline decreases the time
between solenoid actuations will lengthen. This allows the
time between solenoid actuations to be directly propor-
tional-to-flow in the pipeline.
The Z-200 controller uses a customer supplied 1 - 5 VDC
analog signal to determine the percentage of flow that is
present in the pipeline.
B. Proportional-to-time sampling: in this mode of operation, the
Z-200 controller operates as a recycling timer, energizing
the solenoid valve at an interval pre-selected by the opera-
tor. As in the other mode of operation, solenoid actuation
allows the DP-2000 pump to stroke.
In either mode of operation, the number of solenoid
actuations is recorded by the onboard LCD indicator. The
Z-200 timer/counter operates using a replaceable internal
battery pack. The battery pack condition is monitored using
two indicator LEDs. When the battery pack needs replace-
ment, 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 No.
EPO-120) consists of an AC to DC convertor and intrinsically
safe barrier to convert 120 AC 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

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
7
4.1 The sampler should be a minimum of five pipe diam-
eters 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 3-1985 ED.).
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).
4. Sampler Location
Meter Tube
Optimum Sampler Probe Locations
Differential Pressure Device
5 Ø
Flow
A B 5 Ø

8
5.1 DynaPak 2020
a. The DynaPak 2020 requires a 3/4" FNPT pipeline
connection.
b. The DynaPak 2020 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 parallel to the
pipeline.
e. Before applying pipeline pressure to the DynaPak 2020,
ensure that the isolation valve is closed.
f. After pipeline pressure has been applied to the sampler,
check the probe body/pipeline connection using a liquid
leak detector.
5. System Installation
CAUTION:
Incorrect operation of valves (over tightening)
can result in damage to the valve components
(isolation 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
throughthisportuntilthissectionofthepipeline
is shut in. Be aware of the following procedures
andinformation.
· DynaPak valves are of soft seat
designandshouldonly beclosed
or opened with fingers. No
wrenches should ever be used.
·If a valve will not seal off with
fingertightoperationthe valve
should have maintenance
performed to allow proper
operationofthevalve. Center 1/3
1/3
1/3
1/3
Center 1/3
1/3
1/3
1/3

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
9
6.1 Spun Cylinders. Spun cylinders may be installed in a
horizontal position on the DynaPak optional 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 discharge port to
the sample vessel should be arranged such that liquid
traps are not created.
6.2 Variable volume/constant pressure cylinder.
A 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 #8 for DuraSite portable sample vessel
instructions.
6.3 LinkPlus. Install the 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.
6. Sample Vessel Installation

10
7.1 When all of the tubing connections have been com-
pleted, 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)
Over 700 psig (48 Bar) 65 psig (4.5 Bar)
7.3 Turn the stroke adjustment knob on the top of the pump
counterclockwise to set the pump displacement at .4 cc/
stroke.
7.4 Set the mode switch to position #5.
7.5 Set the data switches to 00.0 to enter the diagnostic
mode of operation.
7.6 Depress the enter switch to load the value into memory.
7.7 Pump actuation will begin as the solenoid valve is
energized by the Z-200. In this mode, pump actuation
should occur every two seconds.
7.8 Each time the solenoid actuates, the LCD stroke
indicator on the Z-200 should increment.
7.9 Allow the sampler to operate until the desired stabilized
pressure is achieved at the sample discharge.
7.10 Return the mode switch to position 9 (off position).
7.11 Check all connections from the sampler discharge to
the connection on the sample cylinder and the connection
from the pump to the manifold at the discharge tubing using
a liquid leak detector.
7.12 If no leaks are found, the pump and tubing should be
considered tested and functional.
7. Operational Check &Leak Testing
Mutual
System
Approved
Factory
0
5
6
9
8
7
4
1
2
3

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
11
Sample pump displacement per stroke Number of turns open on the pump volume knob
.1cc 3
.2cc 6
.4cc 12
In order for the Z-200 controller to operate in the propor-
tional-to-flow mode of operation it will be necessary to
enter the following parameters:
8.2Lossofflowinput:
(XX.X min) Mode #7 Default 20.0 min
The loss of flow input setting is a predetermined amount of
time that the operator would like to see transpire between
pump strokes in the event that the 1 - 5 VDC flow input
signal is lost.
To set the loss of flow input:
1. Set the mode switch to position #7.
2. Set the data switches to the desired time
in minutes XX.X minutes.
Ex: 20 minutes = 20.0
3. Depress the enter switch to load the
value into memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
NOTE: Time (20.0 minutes) above corresponds to dial setting
shownfortheZ-200.1model. (FortheZ-200.10,thetimewould
be 2.00 minutes - the decimal moves one place to the left).
8. Sampler Set-Up
Proportional-to-flowsampling
In this mode of operation, the Z-200 uses two operator
inputs in conjunction with the 1 - 5 VDC flow input to vary the
time that will transpire between pump strokes.
8.1 Adjust the pump volume adjustment knob to the value
used in the calculation in step 9.1.
Mutual
System
Approved
Factory

12
8.3Low flow shut-off:
(XX.X%) Mode #6 Default2.0%
The low flow shut-off setting allows a preset point in % of
flow to be set that the operator would like the Z-200 to stop
operating. This allows thecontroller to sense low flow
conditions that might exist in the pipeline where operation of
the Z-200 controller is not wanted. When flow again
increases above this point the Z-200 will again resume
operation.
To set the low flow shut-off:
1. Set the mode switch to postion #6.
2. Set the data switches to the desired % flow XX.X%.
Ex: 2% = 02.0
3. Depress the enter switch to load the value into memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
8.4Zero calibration:
Mode #4 (1.00VDC @ 0% of metered flow)
The zero calibration adjustment is used to calibrate the
Z-200 controller for 0% of metered flow in the pipeline
(1 VDC). The Z-200 controller is calibrated at the factory for
0% of flow to directly correspond to 1.00VDC at the flow
input terminals #4, #5.
To set zero calibration:
1. Set the mode switch to position #4.
2. Apply 1.00VDC to the terminal strip terminal #4 (+signal
input); terminal #5 (-signal input) (if a DPT is being used,
output from the transmitter should be 1.00VDC @ 0" ( 0 cm)
differential pressure).
3. Depress the enter switch to load the zero setting into
memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
8. Sampler Set-Up
Mutual
System
Approved
Factory
Mutual
System
Approved
Factory

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
13
8.5Spancalibration:
Mode #3 (5.00VDC @ 100% of metered flow)
The span calibration adjustment is used to calibrate the
Z-200 controller for 100% of metered flow in the pipeline
(5VDC). The Z-200 controller is calibrated at the factory for
100% flow to directly correspond to 5.00VDC at the flow
input terminals #4, #5.
To set the span calibration:
1. Set the mode switch to postion #3.
2. Apply 5.00VDC to the terminal strip terminal #4 (+signal
input); terminal #5 (-signal input)
(if a DPT is being used, output from the transmitter should
be 5.00VDC @ maximum range of meter. Ex.: 5.00 VDC @
100" (254 cm) water differential pressure).
3. Depress the enter switch to load the span setting into
memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
NOTE: for maximum accuracy, after setting the span, return
to zero calibration section and repeat both zero and span
procedures in that order.
8.6 Initial percentage flow:
(XX.X%) Mode #2 Default50.0%
The initial percentage flow shoud be set by the operator to
the typical or average % of metered flow that exists in the
pipeline. This should be based upon historical flow
measurement records from the metering device being
used. If the history is not known, use an anticipated value.
To set initial percentage flow:
1. Set the mode switch to position #2.
2. Set the data switches to the desired % of flow X.XX%.
Ex.: 50% = 50.0
3. Depress the enter switch to load the value into memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
8. Sampler Set-Up
Mutual
System
Approved
Factory
Mutual
System
Approved
Factory

14
8.7 Initial stroke rate:
(XX.Xmin) Mode #1 Default 20.0 min
The initial stroke rate is set by the operator to the amount of
time that would be desired to transpire between pump
strokes if the % of flow measured in the pipeline was equal
to that set in mode position #2 (initial percentage flow).
To set the initial stroke rate:
1. Set the mode switch to position #1.
2. Set the data switches to the desired time minutes X.XX
min.
Ex.: 20 minutes = 20.0
3. Depress the enter switch to load the value into memory.
NOTE: the green LED will flash if entry is accepted; the red
LED will flash if not accepted.
8.8 Run Mode: the run mode position is the position that the
mode switch should be in to start the Z-200 controller in
proportional-to-flow mode of operation. When in this mode
of operation the Z-200 controller will monitor the flow input
and adjust the time interval between pump strokes to be
proportional to the % of flow measured in the pipeline.
To start the Z-200 controller:
1. Set the mode switch to position #0.
2. Depress the enter switch to begin operation.
NOTE: if all parameters (mode #'s 7, 6, 4, 3, 2, 1) have not
been entered properly, a red LED will illuminate and stay on
and the controller will not start in the run mode position #0
when the enter switch is depressed. See the LED indicator
chart in the trouble shooting section of the manual if the Z-
200 controller does not seem to operate properly.
NOTE: Time (20.0 minutes) above corresponds to dial setting
shownfortheZ-200.1model. (Forthe Z-200.10,thetimewould
be 2.00 minutes - the decimal moves one place to the left).
8. Sampler Set-Up
Mutual
System
Approved
Factory
Mutual
System
Approved
Factory

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
15
The Z-200 controller operates as a recycling timer. The time
between solenoid actuations is set by the operator and
does not change in respect to pipeline flow conditions.
9.1 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.
9.2 Adjust the pump volume adjustment knob to the value
used in the calculations in step 9.1.
9.3 Set the mode switch to position #5.
9.4 Set the data switches to the desired time in minutes
XX.Xminutes.
Ex.: 18 minutes = 18.0
9.5 Depress the enter switch to load the time into memory to
start operation.
NOTE: see the LED indicator chart in the trouble shooting
section of the manual if the Z-200 controller does not seem
to operate properly.
NOTE: Time (18.0 minutes) above corresponds to dial setting
shownfortheZ-200.1model. (FortheZ-200.10,thetimewould
be 1.80 minutes - the decimal moves one place to the left).
9. Sampler set-up time-based sampling
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)
Mutual
System
Approved
Factory

16
10.1 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 monthly.
d. Test the system for leaks each time a fitting or connection
has been made.
10.2 Cleaning and lubricating the DP-2000 pump
a. Close the isloation valve.
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 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, 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 and plunger assembly. The
diaphragm chamber should not be disassembled unless
one of these items needs replacing.
g. Remove the internal bushings and o-rings from the pump
body by inserting a non-metallic 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.
10. Sampler maintenance
11.2 g
10.2g
10.2 d
10.2 c
10.2 a
10.2 e
10.2 f
10.2 b

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
17
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.
k. Insert all other bushings, springs, and o-rings in their
respective sequence on the plunger shaft.
l. Carefully install the diaphragm housing into the top of the
pump body.
NOTE: apply a light coat of assembly grease on the plunger
shaft prior to installation.
m. Install the pump assembly on the inlet valve assembly.
Tighten firmly by hand.
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 strokes adjustment knob to its original setting.
q. Pressure test the pump as previously described for
proper operation.
10. Sampler maintenance
11.2 j
11.2 k
10.2k
10.2j

18
10.3 Battery Test: with the mode switch in the mode
position #5, depress the test switch. When the solenoid
fires, the green LED signifies a good battery. The red LED
signifies a depleted battery.
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 terminal
strip.
2. The battery is located in the lower left hand corner of the
Z-200 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-200 enclosure.
5. Return the mode switches to their original positions.
6. Send your depleted battery to:
YZ Industries Inc.
206 Lubbock Hwy.
Snyder, TX 79549 USA
10.4 Recommended spare parts for the
DynaPak 2020 gas sampler:
Part NumberDescription Qty Location
D3-0002 DP-2000 pump seal kit 1 diagrams #1, #2
D3-0003 YZ filter/regulator repair kit 1 diagrams #3, #4
D3-0004 filter element 1 diagrams #3, #4
D3-0142 Z-65/200 fuse replacement kit 1 diagram #5
E3-2001 battery pack 1 diagram #5
10. Sampler maintenance
Battery Pack

DynaPak 2020N 09242003 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
19
timer mode #5
Proportional-to-time
A. Set the mode switch to position #5.
B. Set the data switches to 00.0 to enter the diagnostic
mode of operation.
C. Depress the enter switch to load the value into the
memory.
D. This mode of operation enables the operator to increase
the solenoid output rate to one actuation every two seconds.
NOTE: the LCD stroke indicator should increment each
time the solenoid actuates.
LED Indicator Chart (proportional-to-time only)
green red condition
on off solenoid on, good battery
off on solenoid on, low battery
NOTE: on means for approximately one half second.
To test the LED indicators, depress the test switch located
on the front of the controller.
Timer Setting
A. Z-200/6.1 - all time settings are xx.x minutes
B. Z-200/6.10 - all time settings are x.xx minutes.
11. Troubleshooting

20
Proportional-to-flow:runmode#0
A. Refer to the controller set-up section in the manual and
make sure the following parameters have been set:
1. mode #7 loss of flow input (XX.X min)
(X.XX min for Z-200.10)
2. mode #6 low flow shut off (XX.X%)
3. mode #4 zero calibration (1.0V @ 0% flow)
4. mode #3 span calibration (5.0V @ 100 % flow)
5. mode #2 initial percentage flow (XX.X%)
6. mode #1 initial stroke rate (XX.X min)
(X.XX min for Z-200.10)
NOTE: if all parameters have not been entered properly, a
red LED will illuminate and stay on and the controller will not
start in run mode position #0 when the enter switch is
depressed.
B. After these inputs have been re-entered, depress enter
switch to start operation.
LED indicator chart (proportional-to-flow mode only)
Green Red Condition
on off solenoid on, good battery
off on solenoid on, low battery
blink off lowflow shut off imposed
off blink loss of flow input alarm
NOTE: on means for approximately one half second. Blink
means on for approximately 20 milliseconds.
To test the LED indicators, depress the test switch located
on the front of the controller.
11. Troubleshooting