AquaVolt™
Installation, Operation and Service Manual M4000 12/27/2012 Rev K
© 2001, MEECO, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of MEECO, Inc. AquaVolt™ is a trademark of MEECO, MEECO, Inc. LabVIEW® executable. LabVIEW © 1994, National National Instruments Corporation. All rights reserved. United States States Patent Nos. 4,901,221; 4,901,221; 4,914,568; 4,914,568; 5,291,587 5,291,587 and 5,301,366. Other patents pending. SmartHeap memory manager © 1991-1994, 1991-1994, Arthur D. Applegate. Applegate. All rights reserved. For service and support, please contact MEECO, MEECO, Inc., 250 Titus Ave., Ave., Warrington, PA 18976-2426, PHONE: (215) 343-6600 343-6600 or (800) 641-6478, FAX: (215) 343-4194
© 2001, MEECO, Inc. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of MEECO, Inc. AquaVolt™ is a trademark of MEECO, MEECO, Inc. LabVIEW® executable. LabVIEW © 1994, National National Instruments Corporation. All rights reserved. United States States Patent Nos. 4,901,221; 4,901,221; 4,914,568; 4,914,568; 5,291,587 5,291,587 and 5,301,366. Other patents pending. SmartHeap memory manager © 1991-1994, 1991-1994, Arthur D. Applegate. Applegate. All rights reserved. For service and support, please contact MEECO, MEECO, Inc., 250 Titus Ave., Ave., Warrington, PA 18976-2426, PHONE: (215) 343-6600 343-6600 or (800) 641-6478, FAX: (215) 343-4194
Thank You Dear Customer, We commend you on your selection of the MEECO AquaVolt™ moisture analyzer. We appreciate the time, effort and money you devoted to selecting equipment best suited to your needs. We want to assure you that you made the appropriate choice. We respect the fact that, by purchasing our equipment, you show your faith in our technology and our organization. Therefore, we pledge to repay you with exceptional quality, service and support. Founded in 1948, MEECO provides instrumentation of the highest quality and finest precision for some of industry’s toughest analytical and measurement tasks. As the field of moisture analysis grew and changed during the past few decades, MEECO led in product innovation. Thus, our second pledge to our customers is to continue to keep pace with market needs now and long into the future. As always, always, we are are working hard hard to make make our documentation documentation clear clear and complete. complete. Please Please let us know if you discover omissions, unclear explanations or inaccuracies. Your feedback will help us make necessary improvements to both the manual and the instrument. We welcome calls and faxes regarding any questions and/or comments to: VP Marketing MEECO, Inc. 250 Titus Avenue Warrington, PA 18976 Phone: (215) 343-6600 Toll Free: (800) 641-6478 FAX: (215) 343-4194 Finally, thank you for choosing a MEECO AquaVolt™ moisture analyzer. Please remember that we value your opinion as much as your patronage. We welcome your comments, questions and suggestions about our equipment. Sincerely, The MEECO Staff
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MEECO Warranty
MEECO, Inc. (“MEECO”) warrants that newly manufactured instruments will be (A) free from defects in materials and workmanship for a period of one year from the date of delivery, except for the Aquavolt+ and the Tracer-2 instruments for which the period shall be two years from the date of invoice, and (B) free from any lawful lien, security interest or encumbrance from any person claiming by, through or under MEECO, provided the full purchase price is paid in a timely fashion. MEECO warrants that any cell which it has cleaned and resensitized (“C&R”) will be free from defects in materials and workmanship for a period of 90 days from the date of completion of the C&R service. The warranties regarding defects in materials and workmanship do not apply to (i) defects, malfunction or damages arising out of or relating to improper installation, improper use, improper storage, negligence, misuse, abuse, mishandling, accident or failure to follow operating or maintenance instructions, or (ii) instruments and parts repaired, altered, modified, contaminated or serviced by anyone except a MEECO authorized service technician. If a newly manufactured instrument does not meet the warranties specified in clause (A) above and the purchaser notifies MEECO promptly, MEECO’s sole responsibility will be to repair or replace such instrument or to correct any defect in materials or workmanship that developed under proper and normal use within one year (two years in the case of Aquavolt+ and Tracer-2 instruments) from the date of invoice of such instrument. All warranties, expressed or implied in law, are subject to the requirement that repairs of the instruments are made or attempted solely by MEECO or under MEECO’s supervision, and if repairs are made or attempted to be made by any other person, all warranties, express or implied, shall terminate. Parts considered consumable or expendable, including without limitation, batteries, fuses, and filter elements, are excluded from the warranties set forth herein. THE WARRANTIES CONTAINED IN THIS SECTION ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND NO OTHER WARRANTIES WHATSOEVER, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF PERFORMANCE, MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND NO INFRINGEMENT, APPLY TO THE INSTRUMENTS, AND NO WARRANTY SHALL BE IMPLIED OR ARISE FROM ANY COURSE OF DEALING OR USAGE OF TRADE. NO EXPRESS WARRANTY OR GUARANTY, EXCEPT AS MENTIONED ABOVE, GIVEN BY ANY PERSON, WITH RESPECT TO THE INSTRUMENTS, SHALL BIND MEECO AND ALL ORAL OR WRITTEN REPRESENTATIONS MADE OR IMPLIED IN ANY MANUAL, LITERATURE, ADVERTISING BROCHURE OR OTHER MATERIALS ARE EXPRESSLY SUPERSEDED. THE PARTIES AGREE THAT THE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AGAINST MEECO SHALL BE FOR THE CORRECTION OF ANY DEFECTS IN MATERIALS OR WORKMANSHIP AS DESCRIBED IN THE FIRST PARAGRAPH ABOVE. The purchaser expressly agrees that no other remedy shall be available and that MEECO shall not be liable for delays, deprivation of use, or any other damages, direct, indirect, exemplary, moral, incidental, consequential or punitive, which may result to the purchaser because the instrument does not operate to the purchaser’s satisfaction. IN NO EVENT SHALL MEECO BE LIABLE TO THE PURCHASER OR ANY THIRD PARTY BASED UPON BREACH OF WARRANTY, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT LIABILITY OR OTHERWISE, FOR ANY INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, EXEMPLARY, MORAL OR ii
PUNITIVE DAMAGES (INCLUDING, WITHOUT LIMITATION, ANY LOSS OF PROFITS), OR DAMAGES IN THE NATURE OF PENALTIES, EVEN IF MEECO HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. In addition, it is expressly agreed between the parties that the purchaser shall use all reasonable efforts and take all reasonable steps in order to mitigate any damages or loss incurred. The purchaser assumes all risk and liability for loss, damage, injury to persons, or to the property of the purchaser or other third parties arising out of or related to the instruments purchased hereunder. The purchaser agrees to indemnify, defend and hold harmless MEECO from and against all actions, suits, claims, liabilities, damages, costs, and expenses, including without limitation, any loss of use, loss of profits, damage or injury to persons or property, attorneys’ and experts’ fees and court costs, arising out of or related to the instruments purchased hereunder, whether made or alleged by the purchaser, the purchaser’s customers or other third parties.
During the warranty period, MEECO’s obligation shall be limited to the repair or replacement of materials or the correction of any workmanship shown to its satisfaction to be defective. Please contact MEECO’s Customer Service Coordinator for a Return Authorization Number (“RA#”). All units and/or cells returned without an RA# may experience service delays. Please return units and/or cells DDP Warrington, PA, USA, to: MEECO Service Department Attention: RA# _____________ 250 Titus Avenue Warrington, PA 18976 Phone (215) 343-6600 Facsimile: (215) 343-4194 Toll Free: (800) 641-6478
[email protected] NOTE: Prior to sending instruments to MEECO, instruments must be purged, properly shut down, and properly capped. Please refer to the manual for procedures. Failure to do so may void the warranty contained herein. Instruments or cells returned are subject to review, and contaminated instruments may be returned to the purchaser at its cost without service.
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Product Registration Please fill out the information requested below to register your analyzer and return to MEECO at the address noted on the next page. Model/Type:_________________________ Serial Number _____________________________ Company: ____________________________________________________________________ Dept.: ________________________________________________________________________ User Name: ___________________________________________________________________ User’s Title: ___________________________________________________________________ Address: _____________________________________________________________________ City: _______________________________ State: ________________ Zip Code: _________ Country:____________________________ Phone: _____________________________ Fax:_____________________________________ Purchase Date: ________________________________________________________________ Type of Application:_____________________________________________________________
Yes
Was the product received in working order:
No
If No, please explain:____________________________________________________________ ____________________________________________________________________________ Was the instrument received on time?
Yes
No
Why did you purchase a MEECO Analyzer? (Please mark all that apply)
Reliability Versatility
Accuracy Durability
Speed of Readings Price
Other ____________________________________________________________
Yes
Do you presently own MEECO instruments?
No
If “Yes”, which one(s): ___________________________________________________________ How Many? _________________________ Year(s) Purchased? ________________________
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How did you hear about MEECO? (Please mark all that apply)
Advertisement (Publication Title)_______________________________________________ Article (Publication Title) _____________________________________________________
Demonstration (Location) ____________________________________________________
Recommendation (Reference) ________________________________________________
Other _____________________________________________________________________ Please send information on t he following:
Accessories/Options
Extended Warranty
MEECO Product Line
On-site Service Calls
Complete and mail to: MEECO Product Registration 250 Titus Avenue Warrington, PA 18976 Phone: (215) 343-6600 FAX: (215) 343-4194 Toll Free: (800) 641-6478
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Extended Warranty Agreement We would like to introduce you to the MEECO, Inc. Compliance 9000 Program. This extended warranty program was developed to help you meet ISO 9000 requirements on your MEECO moisture analyzer and to extend your unit’s years of optimum service. Provisions of Agreement: The one-year preventive maintenance agreement provides service and maintenance performed by qualified MEECO Inc. technicians on the equipment listed above. The agreement covers repair parts and labor (refer to the original MEECO Warranty in your instruction manual), annual electronic calibration and annual N.I.S.T. certification, routine maintenance, and the cleaning and resensitizing (C&R) of two standard electrolytic cells, or one high purity cell, per year. Repair, c alibration and routine maintenance include the f ollowing:
Electronic calibration of display meter, 4-20 mA output, mV output and alarm (if applicable); calibration performed using a N.I.S.T. traceable current source. Mass flow controller calibration against a N.I.S.T. traceable flow standard (if applicable). Verification of moisture cell response and accuracy using a certified permeation-based moisture generator (if applicable). Flush flow system and static leak check on industrial units. Determination if any part or parts require replacement, including electrolytic cells. Such parts will be replaced free of charge, with the exception of consumable/expendable items; i.e. batteries, fuses, filter cartridges or membranes, permeation devices. This maintenance should be performed at minimum once per year to ensure ultimate instrument performance and reliability and to ensure re-qualification eligibility for the next year’s Compliance 9000 extended warranty program. ANY UNAUTHORIZED MODIFICATIONS TO MEECO UNITS WILL VOID WARRANTIES
Exclusions: The Compliance 9000 Program price does not include travel expenses (food, lodging, airfare and ground transportation) for field service. If on-site service is desired, please contact the MEECO Service Department. This agreement does not cover user-related or negligent damage or items considered expendable or consumable as listed above or if unit has been serviced by anyone except a MEECO authorized Service Technician. Units returned with obvious contamination will be subject to review, and if determined hazardous the unit will be returned at customer’s expense without service. The Extended Warranty price does not include travel expenses (airfare, lodging, food, ground transportation, and related freight charges) for field service. If on-site service is desired, please contact the MEECO Service Department. Program Eligibility: If your unit is not currently under warranty, it will need to be eligibility qualified by the MEECO Service Dept. Any unwarranted unit is eligible if it has been repaired by a MEECO Service Technician within the past ninety (90) days. For customers still under warranty, in order to be eligible to renew the Compliance 9000 Program Extended Warranty Agreement, a unit must have been serviced at least once within its warranty period. To initiate an extended warranty once it has expired, or f or new warranty customers, an eligibility requalification check-up must first be performed at the normal perunit service cost, and any parts requiring repair or replacement will be at customer’s expense. Certain discounts, however, may apply; contact the MEECO Extended Warranty Administrator.
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Procedure for Returns: Customer’s units returned to MEECO’s factory for service or m aintenance will be prioritized on a firstin/first-out basis. Prior to equipment return, call MEECO Customer Service (215-343-6600) for a Return Authorization Number (RA#) and print RA# clearly on outside package label. Material sent i n without an RA# may be delayed until customer is contacted and reason for return is reviewed. Warranty customers are responsible for transportation to MEECO; MEECO will return prepaid via UPS GT.
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Table of Contents Thank You ________________________________________________________________________ i Product Registration ______________________________________________________________ iv Extended Warranty Agreement _____________________________________________________ vi Table of Figures __________________________________________________________________ x AquaVolt™ SPECIFICATIONS_____________________________________________________xi Serial Number Identification _______________________________________________________ xii Warning! Labels _________________________________________________________________ xiii
1 Installation & Startup ________________________________________________________ 1 Unpacking Instructions ____________________________________________________________ 1 Getting Started _______________________________________ ___________________________________ 2
Component Identification __________________________________________________________ 3 Front Panel __________________________________________ ___________________________________ 3 Rear Panel ________________________________________________________________________ ______4 Internal View__________________________________ __________________________________________ 5
Internal View (components)_________________________________________________________ 5 Side View ___________________________________________ ___________________________________ 6
Unit Hook-up_____________________________________________________________________ 7 Internal Pressure Regulator Adjustment ______________________________________________ 9 Basic Menu Operation ____________________________________________________________ 10 Status Display ___________________ ___________________________________________ ____________ 10 Adjusting Parameters _________________________________________ ___________________________ 11
Cell Protection___________________________________________________________________ 13 Cell Protection Below Lower Detection Limit ____________________________ _____________________ 13 Cell Protection Above Maximum Range ________________________________________ _____________ 13
2 Shutdown _________________________________________________________________ 15 Shutdown _______________________________________________________________________ 15
3 Maintenance ______________________________________________________________ 17 Cell Change Procedure ___________________________________________________________ 17 Removal and Installation of the Electrolytic Cell ___________ ____________________________________ 18 Battery Replacement Procedure ________________________________________ ____________________ 19
Software Upgrade Installation______________________________________________________ 19 Flash Reprogramming ______________________________________________________________ ______20
Changing Fuses __________________________________________________________________ 21 AquaVolt™ Spare Parts List _______________________________________________________ 22
4 General Information ________________________________________________________ 23 Pin Out Listing __________________________________________________________________ 23 Serial Port RS-232 ____________________________________ __________________________________ 23 I/O Connector ____________ __________________________________________ ____________________ 24 Alarm Relay Conn ector___________________________________________________________________ 24
5 Serial Communication ______________________________________________________ 25 General Information______________________________________________________________ 25
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Communications Protocol _________________________________________________________ 26 Communication Parameters ___________________________________________ ____________________ 26 Connector Pin Out_____________________________________ __________________________________ 26 Message Structure ____________________________________________ ___________________________ 27 Systems Commands __________________________________________ ___________________________ 27 Variable Format ______________________________________ __________________________________ 28
System Protocol__________________________________________________________________ 29 Floating Point Operations ____________________________________________________ _____________ 29 Flowchart for floating point operations__________________________________________ _____________ 30 Integer Operations_____________________________________ __________________________________ 31 Flowchart for write integers ____________________________________ ___________________________ 32 Error Handling _______________________________________ __________________________________ 33
AquaVolt™ Variable Reference ____________________________________________________ 33
Appendix 1 _________________________________________________________________ 35 The AquaVolt™ Concept __________________________________________________________ 35 Electrolytic Cell Principle _________________________________________________________ 36 Cell Construction _____________________________________ __________________________________ 36 Faraday’s Law ________________________________________________ __________________________ 38
The Delta Flow Test ______________________________________________________________ 39 General Analyzer Configuration ____________________________________________________ 41
Appendix 2 _________________________________________________________________ 43 Construction of a Sampling Manifold________________________________________________ 43
Appendix 3 _________________________________________________________________ 45 Calibration Factors When Nitrogen is Not the Calibration Gas __________________________ 45
Appendix 4 _________________________________________________________________ 49 Approvals ______________________________________________________________________ 49
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Table of Figures Figure 1 Front Panel .................................................................................................................3 Figure 2 Rear Panel ..................................................................................................................4 Figure 3 Internal View ..............................................................................................................5 Figure 4 Side View ....................................................................................................................6 Figure 5 Removing Electrolytic Cell .......................................................................................18 Figure 6 Flowchart for Read (Floating Point Variables) ....................................................... 29 Figure 7 Flowchart for Write (Floating Point Variables) ......................................................30 Figure 8 Flowchart for Read (Integer Operations) ................................................................31 Figure 9 Flowchart for Write (Integer Operation) ................................................................ 32 Figure 10 Element Cross Section ............................................................................................ 36 Figure 11 Cell Body .................................................................................................................37 Figure 12 Cell Coating ............................................................................................................ 37 Figure 13 Delta Flow ............................................................................................................... 40 Figure 14 General Arrangement of Electrolytic Cell .............................................................41 Figure 15 Sample Manifold .................................................................................................... 44
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AquaVolt™ SPECIFICATIONS Ranges: 1-1000 ppm inerts, oxygen, hydrogen Sensor: Meeco AP Style Cell Lower Detection Limit: 1 ppm Accuracy: +/- 5% of reading or 0.4 ppm, whichever is greater Unit of Measure: Field selectable choices: ppmV, ppmV, ppmW, dewpoint in Cº or Fº Power: 100 - 240 VAC, 50/60 Hz 2.5 AMP Replaceable fuse in Power Entry module Output Signal: (Field Configurable Isolated 0-5 VDC or Isolated Current Output 4-20mA, 0-20mA, or 0-24 mA) RS - 232 Communications – Standard Alarms: Standard One (1) Cell Alarm – Fixed Two (2) User Adjustable Moisture Lev el Alarms Inlet Pressure: 10-3000 psig (0.7 - 204 Bar) Ambient Temperature: 0º C to 60º C, Max. 80% RH non – condensing Flow Rate: ~ 1.1 slpm combined sample and bypass Gas Connection: 1/8" Compression tube fitting Weight: 25 lbs. (11.34 kg ) Dimension: See Section 1 Figure 2 and Figure 4
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Serial Number Identification Each AquaVolt™ contains a serial number plate located at the rear of the unit. T he identifying features of this number are as follows:
XXXXX- 41 -0 |_____| |_| | | | | Unit Serial # | Hardware Revision # Model # Please have this number available when you contact MEECO with any questions regarding service. The software version will be displayed on the initial menu when the unit i s powered up.
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Warning! Labels NOTE: Before operating the AquaVolt™, please be sure to read all warning notes which are shown throughout the manual. We have listed all of the warning notes on this page for your convenience. Read this instruction manual completely before operating your AquaVolt™. Failure to do so may cause damage to your unit.
WARNING: Oxygen Cleaning Operation is recommended for the Analyzers when used for analysis of pure Oxygen, and gas mixtures with high content of Oxygen.
•
Do not remove the cap fittings on the rear of the AquaVolt™ until you are ready to start up the unit. Leaving the AquaVolt™ open or uncapped for m ore than a few minutes causes the electrolytic cell to get very wet, resulting in a long initial drydown period, or damage to the electrolytic cell.
•
Do not disconnect the 67.5V battery! This battery is not rechargeable.
•
Avoid back pressure into the sample and bypass outlets.
•
Proper precautions must be used when venting hazardous or toxic gases.
•
•
•
•
•
•
Never access any internal components of the AquaVolt™ without first turning off the main power switch on the front panel and unplugging the unit from the AC Power Source! Be sure to read the Unpacking Instructions and Getting Started guidelines before proceeding any further. Failure to do so can result in extremely long drydown times for your instrument. Maintain the instrument on a dry gas purge when it is idle, with at least 100 sccm flow from the sample outlet on the back of the unit. When purging your MEECO system, be sure that your purge gas is within the operating range of the unit. Otherwise, please use a MEECO SMA (Standard Moisture Addition) to avoid cell dry-out and sluggish performance. NEVER service the AquaVolt™ without first disconnecting AC power; this may result in electrical shock. This high voltage symbol indicates the presence of high voltages.
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Section 1
1 Installation & Startup
PROTECT YOUR WARRANTY -- OPEN AND POWER UP IMMEDIATELY! PLEASE FLOW GAS THROUGH THE INSTRUMENT AS SOON AS POSSIBLE. The shelf life of the battery is six m onths when the instrument is not connected. MEECO strongly suggests you flow gas through the unit as quickly as possible. Spare cells should have their batteries checked and/or replaced every 90 days.
NOTE: The AquaVolt should only be used in a manner specified by the manufacturer, and therefore, requires operators to read this manual in its entirety.
Unpacking Instructions Remove the AquaVolt™ from the carton and packing material. Retain the carton and packing material for future use. The AquaVolt™ is shipped ready for use.* At the factory, we dried the analyzer to a low ppm level. To keep the system clean and dry during shipment, we capped all inlet and outlet fittings.
IMPORTANT : Do not remove the cap fittings on the rear of the AquaVolt until you are ready to startup the unit. Leaving the AquaVolt open or uncapped for more than a few minutes causes the electrolytic cell to get very wet, resulting in a long initial drydown period, or damage to the electrolytic cell. * If inlet pressure is above 600 psig, see i nternal pressure regulator adjustment section.
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Section 1 A 67.5V battery connected to the electrolytic cell keeps it dry during shipment. The battery connects internally to the electrolytic cell. When AC power is connected to the analyzer, the battery automatically disconnects from the cell. The battery resides in the holder in standby mode until a power outage or disconnection occurs. At this time, the battery then powers the cell.
IMPORTANT : Do not disconnect the 67.5V battery! This battery is not recharge-able. The battery voltage is monitored while the unit is powered. If the voltage level dips below a satisfactory level, a low battery warning will flash on the display.
Getting Started The following guidelines will help make the installation of the AquaVolt™ go smoothly. •
•
•
•
•
Choose a suitable location for the AquaVolt. The AquaVolt™ should be mounted in a 19" rack. We recommend that, in addition to the front panel mounts, you support the unit with side rails or bottom braces to evenly distribute the unit's weight. In either case, make sure that it is lev el during operation to permit accurate operation of the mass flow controller. Prepare your sample line properly by purging it before attempting to hook up the AquaVolt. This prevents prolonged exposure of the analyzer to ambient moisture levels. To construct your sampling system in a way to allow switching the AquaVolt™ between two separate samples without disconnecting the unit, please ref er to MEECO’s recommended guidelines for the construction of a sampling manifold located in Use only clean, high quality stainless steel tubing for the sample line connection. Eliminate excess components and dead legs in the sample line. When components are necessary, use only high-quality components with metal seals. Be certain an appropriately rated power cord is connected at the rear of the unit, and to use an easily accessible socket outlet no more than 3 meters from the AquaVolt. The AquaVolt™ is capable of handling inlet pressures up to 3000 psig (204 Bar). Avoid redundant regulators and other components in the sample line, which act as m oisture traps.
WARNING : Avoid back pressure into the sample and bypass outlets.
WARNING : Use proper precautions when venting hazardous or toxic gases.
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Section 1
Component Identification Front Panel
Figure 1 Front Panel (A) Alphanumeric Vacuum-fluorescent display, 2 characters high x 20 characters wide; Display displays moisture reading, units of measure, setup selections and alarm status. (B) Power Switch Main Power on/off function (C) “Menu” Key Use to access the various setup menus or to enter a selected option on the alphanumeric display (D) Arrow Keys Left and right arrow keys are used to display menu parameters for review or editing. The up and down arrow keys enable the operator to adjust the value of the parameter displayed.
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Section 1
Rear Panel
Figure 2 Rear Panel (A) Sample Inlet
1/8" compression fitting; 10-3000 psig (.7–204 Bar) inlet pressure
(B) Alarms
Connector for alarm outputs
(C) Bypass Outlet
1/8" compression bulkhead fitting
(D) Sample Outlet
1/8" compression bulkhead fitting
(E) Cell Access Panel
For removal and replacement of electrolytic cell; also for access to internal pressure regulator for pressure adjustment
(F) Power Entry Module
Connector for main power
(G) Fuses (2)
Holds two 2.5A main power fuses
(H) RS-232 Connector
Connector for serial interface
(I) I/O Connector
Connector for 0-5 V / 4-20 mA / 0-20mA / 0-24 mA output
(J) Module Screws Retains instrument module inside of chassis
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Section 1
Internal View
Figure 3 Internal View
Internal View (components) (A)
Electrolytic Cell
Senses moisture
(B)
Sample Inlet Pressure Regulator
Do not allow inlet pressures to exceed 3000 psig 204 Bar) or go lower than 10 psig (.7 Bar)
(C)
Sample Mass Flow Controller
0–200 sccm control range (100 sccm standard
(D)
Vacuum Fluorescent Display
Alphanumeric display; 2 characters high x 20 characters wide
(E)
Power Supply
±15 V DC and +5 V DC; power supply for the mass flow controller, display and main board.
(F)
Main Board
Single controller board for all logic, A/D, relay and communication functions
(G)
67.5V Battery
Provides power to cell during shipment or power loss
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for N2)
Section 1
Side View
Figure 4 Side View
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Section 1
Unit Hook-up WARNING: Be sure to read the Unpacking Instructions and Getting Started guidelines on the previous pages before proceeding any further. Failure to do so can result in long drydown times or damage to your instrument.
After placing the AquaVolt™ in the desired location: 1. Plug the socket end of the power cord into the power receptacle (Fig. 2, Item F) on the back of the AquaVolt. 2. Plug the other end of the power cord into an appropriate grounded AC outlet. 3. Press the Main Power Switch (Fig. 1, Item B) to the “ON” position. The vacuum fluorescent display will illuminate when the power is on. The following title screen will appear on the display.
After a few moments, the display will change to the standard "status display" as shown below.
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Section 1 If the AquaVolt™ is turned off without going through the shutdown sequence or in the case of a power failure, the system will return to the mode it was in prior to the loss of power and all user programmable settings will be saved. saved. This feature is especially useful useful when quickly moving the system from from one location to another. For initial hook-up, hook-up, however, the moisture values, mode and other information information displayed at this time are not meaningful. A detailed description of the the displayed data is provided in Section 1, "Basic Operation," and should be reviewed after initial hook-up. 4. Uncap the Sample Sample Inlet Inlet (Fig. 2, Item A) , and quickly connect connect a closed closed gas source of between between 10-3000 psig (.7-204 Bar) to the sample inlet. See internal pressure regulator adjustment section if inlet pressure exceeds 600 psig. 5. Uncap the Bypass Outlet (Fig. (Fig. 2, Item C) C) 6. Enable the gas source to allow allow a gas flow from the source, source, through the the Bypass Outlet, to purge the source line. This process should continue for 5 minutes. 7. When the instrument instrument moisture reading is on scale and and decreasing decreasing in value, uncap the Sample Outlet (Fig. 2, Item D). 8. Select the proper gas gas type under the Measure mode menu selection. The AquaVolt™ is now ready for operation.
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Section 1
Internal Pressure Regulator Adjustment The inlet pressure should be within 10-3000 psig (.7-204 Bar) and the unit is factory set for 5 psig. This range is specified f or the protection of the electrolytic cell, and other components of the AquaVolt. An optional pressure pressure measurement kit (P/N (P/N L1487) can be purchased purchased for use with the AquaVolt™ AquaVolt™ and would become necessary if the inlet pressure were to ex ceed 600 psig. The kit consists of a 0-10 psig pressure gauge, 12" length of 1/8" OD PTFE tubing, a 1/8" compression nut and ferrule fitting. To adjust the internal pressure regulator: 1. Make sure the AquaVolt™ is connected to the gas supply, following the hook-up procedures on the previous pages, and that the m oisture readings are on scale. 2. Open the cell/regulator cell/regulator access door on the back back of the instrument to gain gain access to the regulator. 3. To prevent damage to the gauge, turn the regulator regulator to its its lowest lowest setting. Looking from the bottom bottom of the instrument, turn the knob fully counter-clockwise. 4. Connect the pressure gauge to the sample sample outlet. outlet. 5. Adjust the regulator until the gauge gauge pressure pressure measures measures 5 psig psig (.35 Bar). 6. Remove the pressure gauge and close the cell/regulator access door.
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Section 1
Basic Menu Operation Operation of the AquaVolt™ is designed to be simple. After start-up and the brief display of the title screen, the main "status display" appears. A sample "status display" is shown below, along with a description of the information it contains:
Status Display
(A) Moisture Reading
This reading represents the measured moisture content of the sample gas.
(B) Mode Indicator
S – Service M – Measure
(C) Flow Rate Indication
This area of the display will show the sample flow rate in sccm.
(D) Alarm State
1 - User Set 2 - User Set C - Cell Alarm F - Flow Alarm Alarm
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Section 1
Adjusting Parameters Normally the Status Display will be shown on the vacuum fluorescent display. Pressing the 'M' key while the Status Display is shown will change the display to parameter adjustment mode. Once in the parameter adjustment mode, the keys have the following functions: Up
Increment the value of the currently displayed parameter. On parameters with wide numeric ranges, holding the Up key depressed will rapidly increment the parameter's value.
Down
Decrement the value of the currently displayed parameter. On parameters with wide numeric ranges, holding t he Down key depressed will rapidly decrement the parameter's value.
Left
Go to the previous parameter without saving any changes made to the currently displayed parameter.
Right
Go to the next parameter without saving any changes made to the currently displayed parameter.
M/Enter Information
Access the parameter list when viewing the Status Display; save the changes made to the currently displayed parameter and go to the next parameter when viewing parameters.
When changing a parameter's value, the previously saved value will be preceded by an asterisk. This is only to show the previously selected value. If twenty seconds pass without any key being pressed, the display will revert back to the Status Display and any changes to the currently displayed parameter will be lost. To regain access to the parameter list, press the 'M' key. The following table displays the parameters, along with their ranges, in the order in which they are accessed. Display Text Operating Mode:
Moisture Units Sample Gas Type:
K-fac for User Gas:
Communications ID#:
Range of Value Measure, Service Shutdown
PPMv, PPBv, DewPoint º C, # / MMSCF DewPoint º F, Air, Argon, Carbon Dioxide, Helium, Hydrogen, Methane, Neon, Nitrogen, Nitrus Oxide, Oxygen, Xenon, Other Gas 0.50 to 3.00
0 to 15
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Definition or Usage Measure Mode measures moisture under default parameters, whereas Service Mode parameters may be altered.
The type of gas being analyzed. This is required so that the mass flow controller can adapt for differing molecular weights. K factor, for mass flow controllers, when using a gas not listed in the Gas Type parameter. This menu is shown only when gas type = OTHER. (see Appendix 3) Aquavolts adress for serial communications.
Section 1 Display Text
Range of Value 0-5 Vdc, 4-20 mA, 0-20 mA, 0-24 mA
Definition or Usage The selection of recorder output signal.
Recorder Scale:
1 - any value up to the upper limit of the unit.( 2 ppm increments)
Level Alarm Type:
1 or 2 (ENABLED or DISABLED)
Level Alarm Value:
Upper limit of unit (user set) to lower detection limit of unit.
The range of values to provide full scale output of the recorder output. The effect of the derived moisture level on the alarm output relay. Alarms will always be displayed in the Status Display regardless of this setting. The value at which point the derived moisture level is considered to be an alarm. Alarm will trigger when the reading is below the lower detection limit. The effect of flow deviation on the alarm output relay. Alarms will always be displayed in the Status Display regardless of this setting. The amount of deviation from set point at which to be considered a flow alarm. Software version and release date of the installed software. Duration that the unit has been powered up.
Recorder Output MODE:
Cell Alarm:
Always Enabled
Flow Alarm Type:
ENABLED, DISABLED (Default 5%)
Flow Alarm Deviation:
3 to 25 (% of scale deviation)
Software Revision:
Read only, not adjustable
Uptime:
Read only, not adjustable
Pressing the LEFT arrow key when viewing the "Operating Mode:" parameter or the RIGHT arrow key when viewing the software revision will return you to the STATUS display. Pressing the left arrow key when viewing the "Operating Mode" parameter or the right arrow key when viewing the software revision will return you to the status display. If you wish to just review the settings, use the RIGHT arrow key to step through the list. This will prevent accidentally changing a parameter.
12
Section 1
Cell Protection Cell Protection Below Lower Detection Limit The AquaVolt™ is equipped with a cell protection feature which will aid in preventing a cell from drying out. If the cell reading drops to 200ppb, power to the cell is removed. After 5 minutes, power is reapplied and the cell level checked. If the measurement is now greater than 200ppb, the unit will return to normal operation. If the measurement is still below 200ppb the testing process will continue an additional 5 minutes. During this wait period, the display will flash "Cell Protection" and the time remaining in cell protection mode.
Cell Protection Above Maximum Range The AquaVolt™ comes equipped with a cell protection feature which will aid in preventing a cell from saturation. This feature can be enabled or disabled by use of the menu. When the f eature is enabled and moisture readings are above the User Selected Limit, the AquaVolt™ automatically reduces the fl ow rate in the sample line. Compensation for this reduction is made for the display output and may have an effect on accuracy. The level at which this feature is deployed can be set through the menu.
13
Section 1
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14
Section 2
2 Shutdown
Shutdown MEECO recommends that you maintain the AquaVolt™ on a dry gas purge (dry gas not l ess than 1 ppm) with AC power applied when not in use. This way the instrument will be in good condition when you go to use it again. Since the complete shutdown procedure includes removing the AquaVolt™ from the sample and capping the instrument, generally a small amount of moisture will enter the unit. This will cause you to wait through an initial drydown period again upon the next startup. Therefore, maintaining the instrument on a slight purge is better than taking the instrument completely off line. IMPORTANT: Maintain the instrument on a dry gas purge when it is idle, with at least 100 sccm flow. Of course, if you need to move the AquaVolt, disconnection from the sample is unavoidable. Please follow the shutdown procedure step by step to limit the analyzer’s exposure to moisture. To shut down the AquaVolt, follow the instructions on the display to perform the following steps: 1. Cap the Sample Outlet (Figure 2, Item D). 2. Cap the Bypass Outlet (Figure 2, Item C).
WARNING: Do not perform the next step until the sample inlet pressure is reduced to a safe level. Also, do not leave the instrument capped and connected to a pressurized sample line for extended periods. Regulator leakage can allow the internal instrument pressure to rise to the level of the inlet pressure which could damage the unit.
3. Disconnect the Sample Inlet (Figure 2, Item A) and cap with a 1/8" compression plug fitting. You should also plug the sampling system. 4. Turn off the power by pressing the Power Switch on the front panel (Figure 1, Item B). If you remove power to the unit, the cell will automatically switch to the 67.5 V DC battery located inside of the unit. Since the 67.5 V battery can run down, only use it when you ship or t ransport the unit. Otherwise, keep the AquaVolt™ connected to an AC source and powered on. NOTE: The AquaVolt will automatically switch on/off the 67.5 V battery when connected or disconnected from AC source.
15
Section 3
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16
Section 3
3 Maintenance WARNING: When purging your MEECO system, be sure that your purge gas is within the operating range of the unit. Otherwise, please use a MEECO SMA (Standard Moisture Addition) to avoid cell dry-out and sluggish performance.
Cell Change Procedure If you suspect a problem with the electrolytic cell in your AquaVolt, contact MEECO before you attempt to service your unit. What may appear to be a cell problem could, in fact, be something else. MEECO service personnel can assist you in troubleshooting. If the problem is identified as a faulty cell and you have a replacement from MEECO, the following procedure will assist you in removing the defective cell and replacing it with a new one. Before performing the cell change procedure, turn off the sample gas source. Failure to do so may result in excessive venting of your sample gas.
WARNING: NEVER service the AquaVolt™ without first disconnected AC power.
17
Section 3
Removal and Installation of the Electrolytic Cell 1. Ensure that all power sources are disconnected and all switches are off. 2. Open the Cell Access Door on the rear of the unit (Figure 2, Item E). Inside the door, you will see the electrolytic cell as shown below.
Figure 5 Removing Electrolytic Cell 3. Carefully disconnect the cell leads by unplugging the connector (Figure 5, Item A). 4. Loosen the cell nuts (Fig. 5, Item B) at the top and bottom of the cell with a 7/8" wrench. 5. Remove the cell retaining strap (Fig. 5, Item C) 6. Remove the cell along with the PTFE gaskets from the top and bottom fittings. 7. Install new PTFE gaskets in the top and bottom fittings. 8. Remove the red plastic end caps from the new cell. 9. Install the new cell in the holder and install the cell retaining strap. 10. Connect the new cell leads to the connector. 11. Tighten the cell top and bottom nuts about 1/8 turn beyond finger tight. 12. Install the red end caps on the cell which was removed. 13. Return the old cell to MEECO for servicing.
18
Section 3
Battery Replacement Procedure
WARNING: NEVER service the AquaVolt™ without first disconnected AC power.
1. Power off and then disconnect the AC power cord from the AquaVolt 2. Remove the AquaVolt™ module from the chassis by removing rear screws (Fig. 2, Item K) and then sliding module out of the c hassis (the sample line may need to be disconnected from the inlet for this step). 3. Remove the 15 top cover screws (1/16" hex head) then remove the cover from the AquaVolt. 4. Remove the battery electrical connection clip from the battery terminals. 5. Remove the two nuts and washers that fasten the battery bracket to the AquaVolt™ chassis. 6. Lift the battery to clear the two threaded studs, and then move it forward to allow removal of the battery. 7. Remove and replace the 67.5 Vdc NEDA 200 battery (MEECO P/N L0027 Replacement Battery). 8. Reverse the above steps to reassemble your AquaVolt™ and return it to service. 9. It is not necessary to change the battery if the unit is powered.Software Upgrade Installation
Software Upgrade Installation * If problems are encountered uploading or downloading the software line or character, delays may need to be added under the ASCII setup. As MEECO continues to add features and make improvements to the AquaVolt, we will make available new versions of the operating software. The following procedure will guide you through the installation of new AquaVolt™ software. The pre-procedures for upgrading the newest AquaVolt™ software: (S1) Find out the current software version you are using: Press “M” at center of front panel; then press right arrow “” continuously till the version information is displayed; write down the version information. (S2) If the version number is v2.11 or below, or xxb.xx, you need to choose our latest software version B for upgrading, for example “v2b.18”. If the version number is v2.15 or above, you need to choose our regular latest software version for upgrading, f or example “v2.18”.
19
Section 3
Flash Reprogramming To reprogram the flash memory of the AquaVolt, the following procedure should be followed. 1. Obtain the latest software for theAquaVolt™ from MEECO Inc. 2. Turn power to the AquaVolt™ off. 3. Connect a 1 to 1 nine pin cable from the serial port of a computer to the serial connection on the rear of the AquaVolt. 4. Run a terminal program on the computer such as “Hyperterminal” with communications settings* of: 9600 bits per second No parity 8 data bits 1 stop bit Be sure flow control is set to none. 5. Power the AquaVolt™ on. 6. Once the AquaVolt™ is powered on there is a 10 second opportunity to type “CTRL Z”, which will bring up the “bootloader” program. If you miss the opportunity, recycle the power and repeat. 7. A menu of choices will appear on the display. a) Menu of choices S = Save your current firmware U = Update your firmware X = Exit program mode 8. It is recommended that you save your present configuration first before trying to update. 9. To save your present firmware, press the “S” key. 10. Use the transfer option of the communications program to receive a file using xmodem. 11. Enter a file name and a folder to store your existing software. 12. When the file is finished being saved you will see a transfer complete and the previous menu choices repeated. 13. To upload the new firmware press “U” to update the AquaVolt. After pressing “U” the operator is given the choice of continuing or aborting. Press “C” to continue. 14. Use the transfer option of the communications program to send a file using xmodem. 15. Choose the file with the new firmware for the AquaVolt. 16. At the end of the transmission a menu will appear. Press “X” to reset the AquaVolt™ with the new code.
20
Section 3
Changing Fuses There are two 2.5 Amp IEC fuses mounted in a removable fuse holder on the rear of the AquaVolt™ (see Figure 2, Item G). If the AquaVolt™ has no power indications with the power switch on and AC power connected, there may be a problem with the fuses. To remove and replace these fuses:
WARNING: NEVER service the AquaVolt™ without first disconnected AC power.
1. Switch the AquaVolt™ power off and disconnect the AC power cord from the AC source. 2. Remove the fuse holder cap of the power entry module. 3. Remove the fuses from the fuse holder and examine for an open fuse. If necessary, use an ohmmeter to check for continuity across each fuse. 4. If the fuse is open, replace with a fast-acting, 250V/2.5A IEC fuse (MEECO P/N L3380). 5. Replace the AC power cord at the rear of the unit. Power the unit back on and check for normal operation. This completes the Fuse Replacement procedure.
21
Section 3
AquaVolt™ Spare Parts List Part # L3380 L6538 L3240 L3795 T6046 T6051 T6053
Description FUSE, 2.5 AMP Battery 15 Volt Power Supply PCB Assembly APR Cell (Inert Gas Only) APO Cell (Oxygen and Inert Gas) APRH Cell (Hydrogen and Inert Gas)
22
QTY 2 1 1 1 1 1 1
Section 4
4 General Information
Pin Out Listing Serial Port RS-232
Female - DB-9 1. 2. 3. 4. 5. 6. 7. 8. 9.
Not used TX signal RX signal Not used Signal ground Not used Not used Not used Not used
23
Section 4
I/O Connector
Male - DB-9 1. 2. 3. 4. 5. 6. 7. 8. 9.
0-5Vdc Signal Out 0-5 Vdc Common 4-20 / 0-20 / 0-24 Common 4-20 / 0-20 / 0-24 Signal Out
Alarm contact ratings: 48Vac/2A non-inductive
Alarm Relay Connector Alarm contact ratings: 30 Vdc / 1A nc com no -
Normally Closed Common Normally Open
Female - DB-9 5. com - Low Level Alarm 4. nc - Low Level Alarm 9. no - Low Level Alarm 1. com - Level Alarm1 2. nc - Level Alarm 1 6. no - Level Alarm1 8. com - Level Alarm 2 3. nc - Level Alarm 2 7. no - Level Alarm 2
24
Section 5
5 Serial Communication
General Information The Serial Communication feature allows you to monitor the instrument from a host computer via an RS232 connection. You can read integer and floating point data to and from memory locations inside the AquaVolt. Access to these memory locations allows complete monitoring of the instrument.
25
Section 5
Communications Protocol The communication protocol functions in the following sequence. The host initiates an exchange of data by sending a command byte to a network of instruments. This command byte consists of a one bit field that distinguishes command bytes from data bytes, a three-bit field that contains the commands op-code, and a four bit field that contains the address of the receiving instrument. The addressed instrument responds by echoing the command byte back t o the host. The host sends a data byte containing a seven bit operand address referring to a lookup table of internal AquaVolt™ variables. A list of these variables and their addresses is provided in the AquaVolt™ Variable Reference portion of this section. The instrument acknowledges receipt of this operand byte by echoing it back to the host. If the command was a request for an integer or floating point number, the AquaVolt™ sends a series of data bytes to the host, each being echoed back to the AquaVolt™ for verification. If the command was a write integer or write floating point command, the host sends a series of data bytes t o the AquaVolt, each being echoed back to the host for verification. Refer to the flowcharts in the following text for the choreography of this exchange.
Communication Parameters The AquaVolt™ uses the f ollowing communication parameters: Baud Rate: Data Bits: Start Bits: Stop Bits: Parity:
9600 Baud 8 1 1 None
Connector Pin Out The AquaVolt™ used a 1 t o 1,9 pin serial (male/female) cable.
26
Section 5
Message Structure
Command Byte: XXX = command field
0 = Read integer 1 = Read floating point 2 = Write integer 3 = Write floating point 4 = Reversed 5 = Reversed 6 = Reversed 7 = Error acknowledge 0-15 = AquaVolt™ address (Each AquaVolt™ should be assigned its own unique address)
YYY = address field
Data Byte: XXXXXXX = data or operand
Systems Commands Write Integer
Writes a 16 bit integer value to the specified AquaVolt™ variable.
Write Floating Point
Writes a 32 bit single precision floating point number to the specified AquaVolt™ variable.
Read Integer
Retrieves a 16 bit integer value from the specified AquaVolt™ location.
Read Floating Point
Retrieves a 32 bit single precision floating point number from the specified AquaVolt™ memory location.
Error Acknowledge
Issued by an AquaVolt™ to alert the host that the echo character received by an AquaVolt™ did not match the character that was sent by that AquaVolt™ during a read integer or read floating point operation.
27
Section 5
Variable Format Since data bytes can only carry seven bits of usable data, integer and floating point variables are represented in the following fashion:
Floating Points:
Byte 1:
Byte 2:
Byte 3:
Byte 4:
Byte 5:
s = sign bit Ex = expoment Mx = manitissa
Integers: Byte 1:
Byte 2:
Byte 3: Dx= integer data
28
Section 5
System Protocol Floating Point Operations The following flowcharts indicated the order of operations the host computer must perform for proper transfer of floating point data to and from theAquaVolt. Flowchart for read floating point v ariables: Loop Counter =0
Send command byte to Aquavolt
No
Receive echo before time out
Process
Error
Yes
Send operand byte to Aquavolt
No Receive echo before timeout?
Process
Error
Process
Error
Yes
Receive data byte before ti meout ?
No
Yes Echo data byte
Increment loop counter
Receive error character ?
Yes Process
Error
No
Loop counter =5
No
Yes
Process da ta bytes
. Figure 6 Flowchart for Read (Floating Point Variables)
29
Section 5
Flowchart for floating point operations Loop Counter = 0
Send command byte to Aquavolt
No
Receive echo before timeo ut
Process Error
Yes
Send operand byte to Aquavolt
No Receive echo before time out?
Process Error
Ye s
Send data byte
No
Receive echo before tim eout ?
Process Error
Yes Increment loop counter
Loop counter = 5
No
Yes
T ransfer Compl ete
Figure 7 Flowchart for Write (Floating Point Variables)
30
Section 5
Integer Operations The Following flowcharts indicated the core of operations the host computer must perform for proper transfer of integer data to and from the Aquavolt™. Flowchart for read integer operations: Loop Counter = 0
Send command byte to Aquavolt
No
Receive echo before timeout
Process Error
Ye s
Send operand byte to Aquavolt
No Receive echo before timeout?
Process Error
Ye s
Receive data byte before timeout ?
Process Error No
Ye s Echo data byte
Increment loop counter
Receive error character ?
Ye s Process Error
No Loop counter = 3
No
Ye s
Process data bytes
Figure 8 Flowchart for Read (Integer Operations)
31
Section 5
Flowchart for write integers: Loop
Counter = 0
Send command byte to Aquavolt
Receive echo bef ore timeout
No Proc ess
Error
Y es
Send operand byte to Aquavolt
Receive echo bef ore timeout?
No Proc ess
Error
Proc ess
Error
Yes
Send data
byte
Receive echo bef ore timeout ?
No
Yes Increment
Loop
loop
counter
counter = 3
No
Yes Trans f er
Complete
Figure 9 Flowchart for Write (Integer Operation)
32
Section 5
Error Handling When an error acknowledge (see item on command bytes in preceding section on Message Structure) is received by the host, the current data exchange is terminated and the data is lost. The exchange m ust be reiterated by the host from the beginning with the retransmission of the command byte. In addition, the host computer is responsible for establishing the proper time-out periods referred to in the decision boxes of the preceding flowcharts. This time-out period should be in the neighborhood of 50 milliseconds or greater for effective error trapping. ASCI Mode (Software Rev. 2.13 and above) The AquaVolt™ may be queried with an ASCII terminal when configured for RS-232 operation. Simply send the following formatted command to the AquaVolt™ Do not sent the '<' and '>' characters.
Where: Type is "i" or "I" for integer values and "f" or "F" for floating point values. Index # is the index of the variable being queried. CR is the carriage return character. No special setup is required to operate in ASCII mode. The AquaVolt™ will automatically recognize an ASCII query or a binary query and return a message in the appropriate format.
AquaVolt™ Variable Reference Floating point variables:
Type
F0
Moisture value in ppb with gas correction assuming 100 sccm flow rate.
R
F1
Moisture value in ppb with gas and flow correction
R
F5
Moisture value shown on display
R
F8
Sample MFC setpoint
R/W
Integer variables: I0
Software revision
R
I3
1= Flow reduction enable
0 = Flow reduction disabled
R/W
I4
2 = Measure mode
3 = Service mode
R/W
I7
Gas Type
4 = Shutdown mode
R/W
I10 Cell alarm Enable/ Disable
R/W
I11 Level alarm 1 1 = Enable
2 = Disable
R/W
I12 Level alarm 2 1 = Emable
2 = Disable
R/W
I14 Flow alarm 1 = Enable
2 = Disable
R/W
33
Section 5
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34
Appendix 1
Appendix 1
The AquaVolt™ Concept The AquaVolt™ is the newest member of MEECO’s trace moisture analyzers for industrial and high-purity monitoring applications. Simply put, the AquaVolt™ provides higher reliability, easier operation, a simpler design and lower maintenance than any other moisture analyzer in its class. In keeping with contemporary needs, the output signal is no w microelectronics-based. The instrument comes standard with both an RS232 serial communications port and a 0-5 Vdc, 4-20 mA, 0-20 mA, or 024 mA (isolated) output. You no longer need to request that the f actory preset the concentration range. Simply enter in the desired scale on the front keypad to m atch your recorder or data acquisition system voltage or current input. Based on the electrolytic principle, the AquaVolt™ is modular in design and can accommodate one or two units in a single 19” rack m ount. The instrument can be used on the bench, i n a plant control room or in a standalone panel. The lower detection limit of the AquaVolt™ is 1 ppm over a 0-1000 ppm scaleable output range. The AquaVolt™ provides precise, on-line trace m oisture monitoring for: • • • • • • • •
Industrial process gas production in air-separation plants Industrial gas at various stages of product purification Trailer and cylinder filling operations Instrument air used in pneumatic systems Shielding gases used in welding Specialty gas applications Mobile cart application Research/scientific labs
Much of the success of the AquaVolt™ derives from a time proven electrolytic cell design (see Figure 15).
35
Appendix 1
Electrolytic Cell Principle Before you can fully appreciate what makes the AquaVolt™ and other MEECO analyzers unique, you need to understand the principle of operation of the electrolytic cell, the heart of all MEECO analyzers
Cell Construction The electrolytic cell consists of a hollow glass tube about four inches long, with an outside diameter of about 1/8"(2.5 mm) of an inch and about 1/16" (1mm) of an inch inside diameter. Two metal electrode wires run parallel in a double spiral along the inside of the tube. These wires are partially imbedded in the glass, fixing their position. This assembly, called the element, is shown in Figure 10.
Figure 10 Element Cross Section The element is then assembled into a protective metal body, before being plumbed into the moisture analyzer. Within the body, as shown in Figure 11, a seal surrounds the element so that gas can only flow through the element. The electrode wires extend from the bottom end of the element and pass through insulated feedthrough to the outside of the body to separate terminals. A voltage can then be applied to the terminals. At this point, they register no current since the electrodes never contact each other.
36
Appendix 1
Figure 11 Cell Body Next, the inside of the element is covered with a t hin coating of phosphorous pentoxide (P2O5) as shown in Figure 12. One of the m ost hygroscopic materials known, P2O5, is often used in driers or as a desiccant.
Figure 12 Cell Coating
37
Appendix 1
Faraday’s Law In operation, the sample gas enters the element and the P2O5 absorbs 100% of the water molecules present in the gas flow. A voltage, applied across the electrode terminals, electrolyzes moisture in the film. Once equilibrium is reached, the rate at which water molecules enter the cell will exactly match the rate that molecules are electrolyzed. Each electrolyzed water molecule displaces two electrons from the anode to the cathode. The electrolysis current (Amps) gives the electrical charge (Coulombs) displaced per second. Consequently, since the elementary charge of an electron is known, you can determine the rate that water molecules enter the cell by current measurement. When the rate of water molecules entering the cell is known, the moisture reading is expressed in parts-per-million (ppm) by comparing the rate of water molecules to the rate of total gas molecules entering the cell. The rate of total gas molecules entering can be determined by controlling the flow rate through the cell. The relationship between measured current and moisture concentration in the electrolytic cell is governed by these absolute principles of Faraday’s Law without any need for calibration versus a moisture standard. You can derive the relationship numerically as follows: In this example, assume a standard 100 cc/minute flow of gas through the element. “Standard” means at standard temperature and pressure, which are 25° C (298.16° K) and 1.0 atm (14.7 psi). Also assume a moisture concentration of 1 ppm. Calculate first, the total number of moles of gas that flow through the element per minute by using the Ideal Gas Law. PV = nRT where,
P = Pressure [atmosphere] V = Volume [liter] T = T emperature [Kelvin] R = 0.08205 [atmosphere liter Kelvin-1 mole-1] n = number of moles of gas [mole]
Therefore, since.
n=
P x V ( R x T )
n=
1.0 x 0.1 (0.08205 x 298.16) -3
n=
4.0851 x 10 moles 23
Per definition, a mole of gas contains 6.022 x 10 molecules of gas. Therefore, the total number of molecules of gas that flow through the element per minute is: -3
23
21
4.0851 x 10 moles x 6.022 x 10 molecules = 2.46 x 10
molecules
Since the gas contains 1 ppm of moisture (one out of a million molecules is a water molecule), the number of water molecules that enter the element per minute is: 21
15
2.46 x 10 molecules = 2.46 x 10 water molecules 6 1 x 10
38
Appendix 1 As mentioned earlier, to electrolyze one water molecule, two electrons have to be transported from one -19 electrode to the other. Also, an electron represents one elementary charge or 1.6022 x 10 Coulombs(C). Therefore the total amount of charge due to electrolysis flowing through the electrodes per minute is: 15
2.46 x 10
-19
x 2 electrons x 1.6022 x 10
-4
C = 7.85 x 10 C
Current is measured in units of amperes (Amps). One ampere (A) is defined as one Coulomb per second. Since you know the total charge per minute (in Coulombs), you can determine the charge flowing per second, which is: -4
-6
7.85 x 10 C = 13.138 x 10 C 60 This corresponds to a current of 13.138 microAmpere. Thus, by principle of Faraday’s Law (and as deriv ed here), a gas containing 1 ppm of m oisture flowing through the element at 100 cc per minute, standard conditions, results in an electrolysis current of 13.138 microAmpere. Then again, for the theoretical to hold true in practice, certain conditions must hold true. These are: a) Accurate flow rate through the element. b) Accurate current measurement. 2 5 c) All moisture passing through the element is absorbed by the P O . MEECO’s test procedures are documented in a test record, detailed later in this manual, that you receive with the unit. With regard to a) and b) li sted above, MEECO uses NIST traceable test equipment to insure the accuracy of the flow and current measurements in the AquaVolt. Assumption c) requires additional discussion.
The Delta Flow Test Every measuring device has a specific operating range. This means that there are restrictions on the usability of the instrument at values higher than the upper limit of the range and lower than the lower limit (often the detection limit). The electrolytic cell is no exception. As an exaggerated example, at the high end of the range, some liquid moisture is injected into the cell (do NOT allow this to happen!). Of course, the thin phosphoric acid film is unable to absorb and electrolyze all of the i ncoming water. This effect tells us that somewhere at high concentrations (outside of the operating range) the electrolysis signal is no longer proportional with the rate of incoming moisture. The response curve flattens and continues toward some saturation value for v ery high concentrations. The delta flow test allows you to check that the high end of the operating range of t he hygrometer is sufficiently far away from the point where the response curve starts to flatten. In the following, the Delta Flow and low detection limit tests are described. These tests verify that the specified range of the instrument is correct. The Delta Flow Test should be done using nitrogen or another inert gas. The Delta Flow test insures that the upper limit of the operating range of the electrolytic cell is in agreement with the specification. As discussed above, at some point the response curve will flatten for very high concentrations. The test is performed as follows: First, you provide a stable higher concentration of moisture to the hygrometer, that is operating at 100 cc/minute and take the reading (when stable). Then you reduce t he flow rate to 50 cc/minute and take the reading (again, when stable).
39
Appendix 1 Fi
Figure 13 Delta Flow Now suppose, as in Figure 13, that you are in the part of the curve where it starts to flatten. In this case, the reading at 100 cc/minute is too l ow while the 50 cc/minute reading is not affected. You will not find the 100 cc/minute reading to be twice the 50 cc/minute reading as it should. Had the test been conducted at a lower concentration within the operating range, the 100 cc/minute reading would be twice the 50 cc/minute reading due to being on the linear scope of response. Note 1:
When performing the Delta Flow at very low concentrations, the flow-independent background has an impact on the result. This effect should not be interpreted in terms of flattening of the response curve.
Note 2:
There is a proportionality of the electrolysis current with the flow rate of the sample gas through the element. Increasing to higher and higher flow rates will ev entually result in diffusion limited behavior. At some point, the residence time of a moisture molecule in the element becomes too short to guarantee that it is going to be absorbed with a 100% probability. The chosen flow rate of 100 cc/minute is a very safe v alue for cells of the geometry that MEECO produces. Attempts to interpret results at higher flow rates should be regarded in the context of this effect.
Note 3:
The onset of the effect discussed in Note 2 causes all Delta Flow tests, in practice, to fall short of 100%, when the 50 cc/minute moisture measurement, doubled, is compared to the 100 cc/minute measurement.
Note 4:
Use "SERVICE MODE" to adjust MFC output.
40
Appendix 1
General Analyzer Configuration The general arrangement of the electrolytic cell in the analyzer is shown in Figure 14. The critical sample flow rate is controlled downstream of the cell by a mass flow controller just before the sample outlet. MEECO analyzers also utilize a bypass flow. The exact rate of the bypass flow is not critical, but it is typically set at about ten times the rate of the sample flow. The bypass flow allows a much higher throughput between the sample point and the c ell. This allows for faster equilibration of the analyzer and the sampling system. Without the bypass, the entire flow through the sampling system would only be the 100 sccm of the sample flow. Also, the bypass helps to dilute the effect of small contributions of moisture from the sampling system t hat may interfere with the true moisture reading.
Figure 14 General Arrangement of Electrolytic Cell
41
Appendix 1
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42
Appendix 2
Appendix 2
Construction of a Sampling Manifold There are often applications for which it is desirable to switch the AquaVolt™ between two separate samples. You may, for instance, want to switch between a sample of unknown moisture content and a dry, “zero” gas or a sample with a known moisture content from a moisture generator. You also may want to be able to do this quickly and efficiently without disconnecting the analyzer and introducing ambient moisture into the system. MEECO recommends that you use the following guidelines for the construction of a sampling manifold that will allow you to switch between samples. This technique ensures the interferences with moisture measurements due to dead volumes or equilibration of moisture within the sample tubing are kept to a minimum. A schematic diagram for the manifold is shown in the figure that follows. You may alter the geometry of the manifold somewhat to suit your specific needs and to m aintain access to certain items on the rear panel of the AquaVolt, but schematically this configuration should be adhered to. •
•
•
•
Use high-quality, stainless steel tubing for all parts of the manifold between the sample inlets and up to the inlet connection of the AquaVolt. Avoid using NPT threaded components as they do not provide the necessary leak integrity. Use only high-quality, low dead volume shut-off valves for valves #1 and #2. These may be 1/4 turn valves. The branches for the purge vents should be 2" from either side of the tee to prevent back diffusion. This is dimension “A” in the diagram The flow meters and needle valves need not be of high quality as long as they are located at least 2" from the sample line (dimension “B” in the diagram). Their only purpose is to control a small, continuous purge of about 100 sccm.
43
Appendix 2 To introduce Sample #1, simply open valve 1, keeping v alve 2 closed. Both purge vents should be open, allowing a slight, continuous bleed from both vents. The purge through the v ent closest to valve 2 insures that no moisture trapped in the dead space between valve 2 and the tee can contaminate the sample. Similarly, to introduce Sample #2, simply close valve 1 and quickly open valve 2. In this configuration, it is also desirable that the pressures of Sample #1 and Sample #2 be the same in order to prevent pressure spikes that might force moisture from the dead spaces past the purge branches to the analyzer.
Figure 15 Sample Manifold
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Appendix 3
Appendix 3
Calibration Factors When Nitrogen is Not the Calibration Gas The AquaVolt™ uses mass fl ow controllers to maintain a constant calibrated flow for the moisture measurement. A standard AquaVolt™ uses a mass flow controller calibrated for Nitrogen use, in addition to the manufacturer’s conversion factors for use on gases other than Nitrogen. These conversion factors are normally automatically applied when a different gas is chosen from the sample gas type m enu. When an AquaVolt™ is used with a flow controller calibrated on a gas other that Nitrogen the standard method of choosing a gas from the sample gas menu must be ignored and the f ollowing procedure followed. 1) When using a flow controller which has not been calibrated for Nitrogen the gas type must always be other. The sample gas type must be set to other with a K-fac of 1.00 as long as the mass flow controller calibrated gas is flowing. 2) If a new gas is going to be applied to the AquaVolt™ a new K-fac must be applied to get the proper flow rate. To do this you will need to obtain the sensor factors of both the original calibration gas and the new gas from the manufacturer supplied flow controller manual. To calculate the new K-fac, use the equation below. 3) New K-fac = factor of new gas factor of cal gas ex. Original cal gas = NF 3 (Sensor factor = 0.501) New gas = SF6 (Sensor factor = 0.270) New K-fac = 0.270 0.501 = 0.54 4) Enter this value into the K-fac for user gas. C2H3
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Appendix 3 Conversion Factors (Nitrogen Base) GAS NAME
FORMULA
Acetylene Air Allene Ammonia Argon Arsine Boron Trichloride Boron Trifluoride Bromine Pentafluoride Bromine Trifluoride Bromotrifluoroethylene Bromotrifluoromethane f-13B1 1,3-Butadiene Butane 1-Butene CIS-2-Butene Trans-2-Butene Carbon Dioxide Carbon Disulfide Carbon Monoxide Carbon Tetrachloride Carbon Tetrafluoride f-14 Carbonyl Fluoride Carbonyl Sulfide Chlorine Chlorine Dioxide Chlorine Trifluoride 2-Chlorobutane Chlorodifluoromethane f-22 Chloroform (Trichloromethane) Chloropentafluoroethane f-115 Chlorotrifluoroethylene Chlorotrifluoromethane f-13 Cyanogen Cyanogen Chloride Cyclobutane Cyclopropane Deuterium Diborane Diboromodifluoromethane f-12B2 1,2-Dibromotetrafluoroethane f-114B2 Dichlorodifluoromethane f-12 Dichlorofluoromethane f-21 Dichlorosilane 1,2-Dichloroethane 1,2-Dichlorotetrafluoroethane f-114 2,2 Dichloro 1,1-Difluoro-1-Chloroethane 1,1-Difluoroethane 1,1-Difluoroethylene Diethylsilane Difluoromethane f-32 Dimethylamine Dimethylether 2,2-Dimethylpropane Disilane Ethane Ethanol Ethylacetylene Ethyl Chloride Ethylene Ethylene Oxide Fluorine Fluoroform f-23
C2H2 Mixture C 3H 4 NH 3 Ar AsH3 BCl3 BF 3 BrF 5 BrF3 C 2BrF3 CBrF 3 C 4H 6 C 4H 10 C 4H 8 C 4H 8 C 4H 8 CO 2 CS 2 CO CCl 4 CF 4 COF 2 COS Cl2 ClO 2 ClF 3 C 4H9Cl CHClF 2 CHCl 3 C 2ClF5 C 2ClF3 CClF 3 (CN)2 ClCN C 4H 8 C 3H 6 D 2 B2H6 CBr 2F2 C 2Br 2F4 CCl 2F2 CHCl 2F SiH2Cl2 C 2H4Cl2 C 2Cl2F4 C2HC12F3 C 2H3ClF2 CH 3CHF2 CH 2CF2 C 4H12Si CF 2H2 (CH 3)2NH (CH3)2O C(CH3)4 Si2H6 C 2H 6 C 2H 6O C 4H 6 C2H5Cl C 2H 4 C 2H 4O F 2 CHF 3
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SENSOR FACTOR 0.615 0.998 0.478 0.786 1.395 0.754 0.443 0.579 0.287 0.439 0.326 0.412 0.354 0.257 0.294 0.32 0.291 0.773 0.638 0.995 0.344 0.44 0.567 0.68 0.876 0.693 0.433 0.234 0.505 0.442 0.243 0.337 0.43 0.498 0.618 0.387 0.505 0.995 0.448 0.363 0.215 0.39 0.456 0.442 0.382 0.231 0.259 0.341 0.415 0.458 0.183 0.627 0.37 0.392 0.247 0.332 0.49 0.394 0.365 0.408 0.619 0.589 0.924 0.529
Appendix 3 Conversion Factors (Nitrogen Base)cont. GAS NAME Germane Germanium Tetrachloride Halothane (R-123B1) Helium Hexafluoroacetone Hexaflorobenzine Hexafluoroethane f-116 Hexafuoropropylene (HFP) Hexamethyldisilane (HMDS) Hexane Hydrogen Hydrogen Bromide Hydrogen Chloride Hydrogen Cyanide Hydrogen Fluoride Hydrogen Iodide Hydrogen Selenide Hydrogen Sulfide Iodine Pentafluoride Isobutane Isobutene Isopentane Krypton Methane Methylacetylene Methyl Bromide 3-Methyl-1-butene Methyl Chloride Methyl Fluoride Methyl Mercaptan Methyl Silane Methyl Trichlorosilane (MTS) Methyl Vinyl Ether Monoethanolamine Monoethylamine Monomethylamine Neon Nickel Carbonyl Nitric Oxide Nitrogen Nitrogen Dioxide Nitrogen Trifluoride Nitrogen Trioxide Nitrosyl Chloride Nitrous Oxide Octofluorocyclobutane Oxygen Oxygen Difluoride Ozone Pentafluorethane f-125 Pentane (n-Pentane) Perchloryl Fluoride Perfluorobutane Perfluoro-2-Butene Perfluoromethyl-vinylether Perfluoropropane Pentane (n-Pentane) Phosgene Phosphine Phosphorous Pentafluoride Phosphorous Trifluoride Propane (same as CH3CH2CH3) Propylene (Propene)
FORMULA GeH4 GeCl4 C2HBrClF3 He F 3CCOCF3 C 6F6 C 2F6 C 3F6 (CH2)6Si2 C6H14 H 2 HBr HCl HCN HF HI H 2Se H 2S IF C 4H 10 C 4H 8 C 5H12 Kr CH 4 C 3H 4 CH 3Br C 5H 10 CH 3Cl CH 3F CH 4S CH 6Si CH 3Cl3Si C3 H 6 O C 2H7NO C 2HH5NH2 CH 3NH2 Ne Ni(CO)4 NO N2 NO2 NF3 N 2O 3 NOCl N2O C 4F8 O 2 OF2 O 3 C 2HF5 C 5H12 ClO3F C 4F10 C 4F8 PMVE C 3F8 C 5H12 COCl2 PH 3 PF 5 PF 3 C 3H 8 C 3H6
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SENSOR FACTOR 0.649 0.268 0.257 1.386 0.219 0.632 0.255 0.249 0.139 0.204 1.008 0.987 0.983 0.744 0.998 0.953 0.837 0.85 0.283 0.26 0.289 0.211 1.382 0.763 0.473 0.646 0.252 0.687 0.761 0.588 0.393 0.267 0.377 0.305 0.359 0.565 1.398 0.212 0.995 1 0.758 0.501 0.443 0.644 0.752 0.169 0.988 0.672 0.738 0.287 0.212 0.448 0.738 0.268 0.296 0.179 0.212 0.504 0.783 0.346 0.495 0.343 0.401
Appendix 3 Conversion Factors (Nitrogen Base)cont. GAS NAME
FORMULA
Rhenium Hexafluoride Silane Silicon Tetrachloride Silicon Tetrafluoride Sulfur Dioxide Sulfur Hexafluoride Sulfur Tetrafluoride Sulfur Trioxide Sulfuryl Fluoride Tetrachloromethane Tetrafluoroethylene (TFE) Tetrafluorohydrazine Trichlorofluoromethane f-11 Trichlorosilane Trimethyloxyborane (TMB) 1,1,2-Trichloro-1,1,2-Triflouroet f-113 Trimethylamine Tungsten Hexafluoride Uranimum Hexafluoride Vinyl Bromide Vinyl Chloride Vinyl Fluoride Water Vapor Xenon
ReF6 SiH4 SiCl4 SiF4 SO2 SF6 SF4 SO3 SO2F2 CCl4 C2F4 N2F4 CCl3F SiHC3 B(OCH3)3 C2Cl3F3 (CH3)3N WF6 UF6 C2H3Br C2H3Cl C2H3F H2O Xe
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SENSOR FACTOR 0.23 0.625 0.31 0.395 0.728 0.27 0.353 0.535 0.423 0.344 0.361 0.367 0.374 0.329 0.3 0.231 0.316 0.227 0.22 0.524 0.542 0.576 0.861 1.383
Appendix 4
Appendix 4
Approvals CE Certification of AquaVolt™ MEECO Inc. 250 Titus Ave. Warrington PA 18976 U.S.A. Reference: CE Certification of AauaVolt. Report # NY2249-01 The MEECO Inc. AquaVolt™ bearing the CE mark has been successfully tested to the regulations of the Electro Magnetic Compatibility directive (EMC directive 89/336/EEC). Special attention is required however when selecting the power and signal cables to be used with CE marked equipment. A cable, which is overall completely screened with a 100% shield, should be used. The shield should be terminated to an earth ground. Use of a ferrite clamp (238 ohms @ 100 Mhz) on the voltage output cable is required to meet the directive. For pin configuration, please refer to the instruction manual.
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