DynaPak Gas Sampler - YZ Systems

1 DynaPak Gas SamplerS Y S T E M S U P P O R T M A N U A LDP-2010DP-2010 INSTRUCTION & OPERATINGMANUALV ersion: 02042002YZ Systems , Inc. 3101 Pollok Drive Conroe, Texas USA 77303 P: F: IDP-2010 TDP-2010 TDP-2010 TDP-2010 TDP-2010 TABLEABLEABLEABLEABLE OFOFOFOFOF C C C C CONTENTSONTENTSONTENTSONTENTSONTENTSDP-2 010 Table of Contents .. ISection 1: First Things To Know .. 1 How to Use this Manual .. 1 Typographic Conventions .. 1 Getting 1 Operation Specifications .. 2 Theory of Operation .. 3 System 4 Section 2: System Installation .. 5 Standard System Components .. 5 System Flow Schematic .. 6 Standard System Mounting .. 7 Standard System Connections .. 8 Optional DPS-2 Installation .. 9 Section 3: Sample Vessel Installation ..11 Variable Pressure/Constant Volume Cylinders.

2 11 Variable Volume/Constant Pressure Cylinders .. 11 Link Plus .. 11 Section 4: System Control & Electronics .. 13 Overview .. 13 Section 5: Programming for Proportional-to-Flow Operation .. 15 Setting Operator Input Parameters .. 15 Section 6: Programming For Proportional-To-Time Operation .. 19 Setting Operator Input Parameters .. 19 Section 7: Programming For Proportional-To-Time w/DPS-2 Operation .. 23 Setting Operator Input Parameters .. 23 Section 8: Mechanical System .. 27DP-2000 Sample Pump .. 28YZ Filter 29 Section 9: System Operation .. 31 Preparing The System For Operation .. 31 Section 10: System Maintenance ..33 Preventative Maintenance 33 Monthly 33 Semi-Annual 33 Annual 33 Recommended Spare Parts .. 33 Cleaning an Lubricating The Pump .. 34 Replacing a Depleted Battery .. 36 Section 11: System Troubleshooting .. 31 How to Use This Section .. 31 For Additional 31 Step-by-Step Resolution .. 31 Battery Power .. 32 Battery Power Troubleshooting Steps.

3 32Z-65 Counter Mode .. 33Z-65 Counter Mode Troubleshooting Steps .. 33Z-65 Timer Mode .. 34Z-65 Timer Mode Troubleshooting Steps .. 35 Appendix A: 39DP-2000 Sample Pump Assembled .. 39DP-2000 Sample Pump, Exploded View .. 40 Filter Regulator, Assembled .. 41 Filter Regulator, Exploded View .. 42 Link Plus .. 43 DuraSite Sample Vessel .. 44 Optional DPS-2 .. 45Z-65 and 46Z-65 Wiring Control Document .. 47YZ Systems , Inc. 3101 Pollok Drive Conroe, Texas USA 77303 P: F: 1DP-2010 1: F 1: F 1: F 1: F 1: FIRSTIRSTIRSTIRSTIRST T T T T THINGSHINGSHINGSHINGSHINGS T T T T TOOOOO K K K K KNOWNOWNOWNOWNOW A A A A ABOUTBOUTBOUTBOUTBOUT T T T T THEHEHEHEHE D D D D DYNAYNAYNAYNAYNAPPPPPAKAKAKAKAKHow to Use this ManualThe DP-2010 Operations Manual is a step-by-stepguide containing the procedures needed to workwith the DP-2010 DynaPak System Series of samplers implementthe most advanced technology available in theindustry.

4 It is recommended that the techniciansworking with the DynaPak Systems study themanual prior to initiating work on the system for thefirst ConventionsTo aide in readability, this manual uses severaltypographic conventions. References to illustrations,photographs, and other related content will appear initalicized text along with the location of where to find theitem in the manual. Digital versions of the manual,available in Adobe Acrobat PDF format, will behighlighted further in blue italic text indicating the copyretains a hyperlink to the referenced units are listed in italic parenthesis textfollowing their US standard equivalent. As an example,for defining a distance, 15' ( meters), is how the textwill appear throughout the that require action, for example the pressing of a keyfor programming the controller, will feature the action item insentence case Bold Text followed in normal text by theitem such as, the Up Arrow key or Main Power switch.

5 Adobe Acrobat & Acrobat Reader are trademarks of Adobe Systems , HelpThis manual provides solutions to typical questionsabout the DP-2010 system. If the answer can notbe found within this manual, contact YZ Systems at:T: : : : calling, have this manual close at calling or writing, please include in yourcommunique the following information: The serial number of the DynaPak System andthe version number of this manual. The serialnumber is located on the inside of the enclosuredoor. The version number of this manual islocated at the bottom of each page. A description of the problem and, if applicable theactions of the technical personnel when the Systems , Inc. 3101 Pollok Drive Conroe, Texas USA 77303 P: F: 2DP-2010 1: F 1: F 1: F 1: F 1: FIRSTIRSTIRSTIRSTIRST T T T T THINGSHINGSHINGSHINGSHINGS T T T T TOOOOO K K K K KNOWNOWNOWNOWNOW A A A A ABOUTBOUTBOUTBOUTBOUT T T T T THEHEHEHEHE D D D D DYNAYNAYNAYNAYNAPPPPPAKAKAKAKAKO peration SpecificationsMaximum Output:5,760 cc/day*( liters/day)Maximum Operating Pressure: 1,500 psig(124 Bar (g)Pump Displacement.)

6 2 - .4 cc/StrokeOperating Temp Range:0 to 140 degrees F.(17 C to 60 C)Power Supply:Internal Battery Pack*Flow SignalDry Contact orVoltage PulseNote: at temperatures below 32 F (0 C), condition-ing of the actuation gas supply may be the actuation gas supply has a high watercontent and/or a low hydrocarbon dew point, addi-tional actuation gas filtration or heating of the actua-tion gas supply may be necessary. Bottled nitrogencan also be used during cold operating conditions toavoid condensation in the actuation gas supply addition, operation at extreme temperatures willaffect seal and diaphragm performance. To prolongthe service of seals and diaphragm, adequate heatshould be provided to maintain an operating environ-ment above 30 F (-1 C).* The External Power Option can be used inlieu of the internal battery pack. The ExternalPower Option (model # EPO-120) consists of anAC to DC convertor and intrinsically safe barrierto convert 120 VAC power to 28 VDC to operatethe controller without the use of the internalbattery Systems , Inc.

7 3101 Pollok Drive Conroe, Texas USA 77303 P: F: 3DP-2010 1: F 1: F 1: F 1: F 1: FIRSTIRSTIRSTIRSTIRST T T T T THINGSHINGSHINGSHINGSHINGS T T T T TOOOOO K K K K KNOWNOWNOWNOWNOW A A A A ABOUTBOUTBOUTBOUTBOUT T T T T THEHEHEHEHE D D D D DYNAYNAYNAYNAYNAPPPPPAKAKAKAKAKT heory of OperationThe DynaPak 2010 Sampler is a pipelinemounted system which uses the pneumaticallyoperated, positive displacement DynaPak 2000pump, the Z-65 timer/controller, the YZ filter/regulator and a low power solenoid valve toobtain gas samples. The 2010 provides threemodes of operation:A. Time-based sampling: in this mode ofoperation, the 2010 extracts a gas sample fromthe pipeline at regular time intervals. The volumeof the sample is set by the operator using thevolume adjustment feature of the DP-2000pump. The Z-65 controller operates as a recy-cling timer, periodically energizing a low powersolenoid valve.

8 Energizing the solenoid valveallows actuation gas to stroke the DP-2000pump. The rate at which this occurs is a func-tion of operator input. Two 10 position switchesare used to set the off time interval. The numberof times the solenoid output is activated isrecorded by the onboard LCD stroke Time-based sampling with the YZdifferential pressure switch (DPS-2): thismode of operation is similar to the time-basedsampling mode, except that the DPS-2 convertsa differential pressure signal to an electricalsignal that the Z-65 timer uses to determine ifflow is present in the pipeline. In effect, the DPSallows the Z-65 timer to shut off when flow stopsin the pipeline, and when flow starts again, theability to start-up and resume Proportional-to-flow sampling:in this mode of operation, the Z-65 counteroperates as a dividing counter. The Z-65 counterperiodically energizes a low power solenoidvalve. As in the other two modes of operation,this allows actuation gas to stroke the DP-2000pump.

9 The rate at which this occurs is a func-tion of operator input as well as the host com-puter or other device that inputs pulses pervolume metered. The two 10-position switcheson the Z-65 are used to set the number of pulsesthe counter will count before activating thesolenoid output. The number of times the sole-noid output is activated is recorded by theonboard LCD stroke indicator. Sample volume isagain controlled using the DP-2000 volumeadjustment all three modes of operation, the Z-65 timer/counter operates using a replaceable internalbattery pack. The battery pack condition ismonitored by way of two indicator LEDs. Whenthe battery pack needs replacement, the red LEDwill illuminate when the solenoid output isactivated. If the battery pack is good, the greenLED will illuminate when the solenoid is Systems , Inc. 3101 Pollok Drive Conroe, Texas USA 77303 P: F: 4DP-2010 1: F 1: F 1: F 1: F 1: FIRSTIRSTIRSTIRSTIRST T T T T THINGSHINGSHINGSHINGSHINGS T T T T TOOOOO K K K K KNOWNOWNOWNOWNOW A A A A ABOUTBOUTBOUTBOUTBOUT T T T T THEHEHEHEHE D D D D DYNAYNAYNAYNAYNAPPPPPAKAKAKAKAKS ystem Accessories The External Power Option can be used in lieu ofthe internal battery pack.

10 The External PowerOption (model # EPO-120) consists of an AC toDC convertor and intrinsically safe barrier toconvert 120 VAC power to 28 VDC to operate thecontroller without the use of the internal batterypack. The Solar Power Option would be used in lieu ofthe internal battery pack. The Solar Power Option(model #SPO-12) consists of a 5 watt solar panelwith RM-12 charger regulator module and internal12V, 5 Amp hour battery pack. DuraSite, portable DOT approved constant pres-sure sample vessels. Available in 150, 300, 500,800, and 1000 cc sizes. SC-Spun Vessel, portable DOT approved (1800 psimaximum working pressure), sample in 300, 500, and 1000 cc sizes. KK-1, KK-2, & KK-3: carrying cases for DuraSitesthat meet DOT requirements for transportingportable sample vessels. 1/4" stainless steel tubing Dielectric Isolator should be installed in every tubing line thatattaches the Sampler to the pipeline in anymanner.