Servomex Installation Manual – Model 2700 Analyzer

SERVOMEX 335A2014 PURGE ASSY Operator Manual Part Number: Revision: Language: 335A2014-MAN 1 English Installation Manual – Model 2700 Analyzer – Purge Assembly i User and Installation Manual Ref: 335A2014/335A2010/335A1023 Order as part no. 335A2014 Installation Manual – Model 2700 Analyzer – Purge Assembly ii Table of Contents 1 INTRODUCTION……………………………………………………… 1 1.1 1.2 1.3 1.4 1.5 Warnings, Cautions and Notes…………………………………. Scope of this manual ……………………………………………. NEC/NFPA 496 Compliance ..…………………………………. General Description ……………………………………………. Hazardous Area approval and certification ……………......... 1 1 1 2 2 2 INSTALLATION/OPERATION……………………………………… 2.1 Assembly Notes ………………………………………………… 2.2 Overview of the installation …………………………………… 2.3 Operation Notes …...…………………………………………… 2.4 Confirmation of Proper Purge Operation...………………….. 2.5 Alarm output …………………………………………………… 3 3 3 4 5 6 3 MECHANICAL INSTALLATION …………………………………… 3.1 Unpacking and inspection ……………………………………… 3.2 Unit Description ………………………………………………… 3.3 Assembly notes ………………………………………………….. 7 7 7 8 4 ELECTRICAL INSTALLATION …………………………………….. 8 4.1 NEC guidelines ………………………………………………….. 8 4.2 Purge Switch connections ………………………………………. 9 5 INSTALLATION & OPERATION NOTES ………………………….. 11 6 CONFIRMATION OF PROPER PURGE SYSTEM OPERATION… 12 7 REFERENCE DRAWINGS 7.1 335A2014-REV I, ASSEMBLY DETAILS …..………………… 13 7.2 335A2010, COMPONENT IDENTIFICATION ………………. 14 7.3 335A1023, PURGE VENT RELIEF SUB-ASSEMBLY ………. 15 7.4 335A2014-REV I, ASSEMBLY FLOW SCHEMATIC...……… 16 8 CSA Certificate of Compliance …………………………………………. 17 Installation Manual – Model 2700 Analyzer – Purge Assembly iii APPENDIX A ……………………………………………………………. 19 APPENDIX A -- INDEX 1. Component specification sheets a. ASCO –TriPoint® Pressure Switches – Fixed Deadband Switch Unit and Transducer Unit Combinations – SB-Series – Form No. V5778R3 ……………………………….. 19 b. Swagelok – 40G Series Ball Valve – 3-Way Ball Valve, 0.35 Cv, 1/4in tube fittings -- Part No. SS-42GXS4…………… 26 c. Marsh Bellofram – Regulator – Type 51 960-175-203………… 27 d. Marsh Bellofram – Diaphragm Gauges – G26504...................... 30 e. Killark – E Series Sealing Fittings – ENY-1 ………………….. 34 2. Component Approval a. ASCO –TriPoint® Pressure Switches – UL, Inc. Listed – Form No. P7022R4 …………………………………………… 38 3. Component Installation & Operation Manual a. ASCO –TriPoint® Switch Unit – SB-Series – Form No. V5735R2 …………………………………………… 39 Installation Manual – Model 2700 Analyzer – Purge Assembly iv List of Figures Figure 1 Figure 2 Assembly of Pressure Switch ……………..……………… Adjustment (Signal Setting) of Pressure Switch ………….. 9 10 Installation Manual – Model 2700 Analyzer – Purge Assembly v 1. INTRODUCTION 1.1 Warnings, Cautions and Notes This manual includes WARNINGS, CAUTIONS and NOTES which provide information related to the following WARNING Hazards which could result in personal injury or death. CAUTION Hazards which could result in equipment or property damage. NOTE Alert the user to pertinent facts and conditions. 1.2 Scope of this manual This manual covers the installation and operation details of the Servomex 2700 Purge Assembly – P/N 335A2014. In addition, a section on Confirmation of Proper Purge Operation is included. About this manual Ref: 335A2014 1.3 NEC/NFPA 496 COMPLIANCE The purge assembly complies with NFPA 496-2008. Installation Manual – Model 2700 Analyzer – Purge Assembly 1 1.4 General Description The Servomex Model 2700 Purge Assembly is a purge assembly specifically designed for the Model 2700 O2/COE sensor assembly of the analyzer system. It offers the following: • • • • • 1.5 Air pressure regulation Fast purge flow for startup conditions Normal purge flow control to limit air usage and provide efficient use of air flow to maintain safe purge conditions Positive pressure purge of Model 2700 Sensor Assembly to permit installation of sensor into Class 1, Division 2 locations Alarm contact via pressure switch, for remote notification of loss of purge pressure Hazardous Area approval and certifications The assembly is designed for use on the Servomex Model 2700 sensor, to provide safe installations into Class 1, Groups B, C & D, Division 2 locations. The assembly is also CSA Certified as a safety compliant system to permit installations of the sensor WARNING The Servomex 2700 series sensor head is not suitable for use in hazardous areas/locations with out use of appropriate purge equipment or other safety precautions. WARNING If the 2700 series sensor head is installed in a hazardous area, purge assembly is required and must be installed and protected according to conditions on the relevant certificates, national wiring regulations, hazardous area codes of practice and local authority regulations. Installation Manual – Model 2700 Analyzer – Purge Assembly 2 2 INSTALLATION 2.1 Assembly Notes Purge relief assembly, Pressure Switch/Gauge and associated hardware are preassembled by Servomex. The end-user is required to provide interconnecting tubing from the Purge Assembly to the Analyzer Sensor module. Caution: Any deviation from location of connection of the Purge/Relief assembly to the analyzer enclosure will result in inadequate purging of the analyzer. Use Teflon® tape for all pipe fittings assembly. Purge relief valve must be in a vertical position with the vent port at the top of the assembly. Safety Labels must be applied as displayed on drawing 335A2014. 2.2 Overview of Installation The Model 2700 Sensor and Control should be installed per Servomex Installation Manual, reference 02700/005C/0. All safety guidelines, warnings and cautions must be observed and followed appropriately per local safety requirements. The Purge Vent/Relief Sub-Assembly must be installed local to the 2700 sensor assembly, reference Item 17 of Drawing 335A2014-H1. This sub-assembly must be installed in a vertical position with the vent port located at the top of the final installation. Purge Vent should discharge into well ventilated areas only. The Purge Panel should be installed locally to the 2700 sensor assembly so that visual indication of the purge is provided local to the installation. It is imperative that the user installs the purge pressure switch and wires it to an appropriate alarm/warning device. (Reference the pressure switch literature in the Appendix Section for wiring details of the device.) Refer to the purge code, NFPA 496, for additional details. If the pressure switch (Ref. Item 18) is located in a hazardous area, it must be installed using an approved conduit seal on the electrical port(s). Ports unused must be properly plugged to maintain the explosion proof rating of the switch. Instrument quality air must be supplied to the Instrument Air supply port per ISA S7.3 at a pressure of 30-100 psig. Interconnecting tubing is required between the Purge Panel and the 2700 Sensor. Tubing is required between the Purge Air Supply to the Purge/Relief Valve sub-assembly. This tubing supplies the purge air to the 2700 sensor. Tubing is also required between the Purge Vent Port on the 2700 sensor and the Vent Return port on the Purge Panel. Tubing should be leak checked for proper installation. The user must properly install the purge hardware (including the wiring of the purge pressure switch) and operate the system as described in this document. Installation Manual – Model 2700 Analyzer – Purge Assembly 3 2.3 Operation Notes WARNING Power shall not be applied to the instrument until the interior of the probe is known to be safe and the output from the pressure switch is connected to an appropriate alarm/warning device. Set the output of the Instrument Air Pressure Regulator (Ref Item 3) to 20-22 psig and turn the purge valve to the FAST FLUSH position to obtain a purge flow rate of 10 CFH into the purged case. The interior of the probe shall be safe after the case has been completely closed, fastened and purged with four (4) volumes of instrument quality air. Purging the analyzer case for 30 minutes at 10 CFH will assure that the atmosphere inside the case is safe. Turn the purge Valve to the NORMAL position to obtain a minimal flow rate (approximately 450 cc/min) while maintaining a positive purge pressure on the purged case. The local purge pressure indicator (gauge) (Item 13) should display between 3 and 12 in W.C. NOTE Proper purge pressure is within the range of 3.0 to 12 in W.C. NOTE Pressure switch will activate when the enclosure pressure falls below 1-2 in W.C. WARNING Purge/Relief Vent should discharge into well ventilated areas only. Installation Manual – Model 2700 Analyzer – Purge Assembly 4 WARNING Hot components are inside the module, after power is supplied. Interior surfaces may reach 1270 ºC , unless area is known to be non-hazardous, enclosure shall not be opened until power has been turned off for 80 minutes during which proper purge pressure is maintained. 2.4 Confirmation of Proper Purge Operation Check that the purge pressure indicator (guage) (Item 13) reads “0 psig” with the probe enclosure open. Check that the purge supply regulator (Item 3) is set to 20-22 psig, adjust if necessary. Purge pressure indicator gauge (Item 13) must be in the range of 3-12 inches W.C., when the purge valve is in the “NORMAL” position. Pressure switch should activate the alarm when enclosure pressure falls below 1-2 in W.C., as the probe enclosure seal is broken. Adjust if required. Installation Manual – Model 2700 Analyzer – Purge Assembly 5 WARNING The 2700 Series Probe assembly with this type “Z” Purge accessory is suitable for use in nonhazardous or Class 1, Division 2, Group B, C or D areas. Additionally, the temperature rating for this probe assembly is T Internal = 800 ºC, T External = T3C Temperature Class (160ºC). WARNING Use of this purge accessory is subject to the following limitations: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 2.5 The interconnecting wiring is in compliance with NFPA 70 (NEC). The gas vapors in the analyzer environment are compatible with the temperature rating of the analyzer. The user properly installs the purge hardware (including the wiring of the purge pressure switch) and operates it as described in this document. The analyzer has not been modified in any fashion. This purge system and associated hardware is applicable only to the 2700 Analyzer Probe/Sensor. The analyzer is never to be used to measure gases in a stream which contains flammable constituents. The purge hardware, as described in this document, must be protected from direct exposure to chemicals, liquids, excessive heat and ice. The user assumes full responsibility for making changes to this hardware, wrongful installation and/or misapplication. The user may need to modify the conduit seals and/or the purge relief assembly. In certain probe mounting orientations the relief valve on the relief assembly must always be in a vertical position. The conduit seal must located so they can be properly poured. Instrument quality air must be used for this accessory. Other gases are not acceptable. Alarm Output This purge assembly provides an alarm output via a pre-set pressure switch. This device utilizes a snap action switch that is Normally Open during a fail safe condition. Therefore, the switch is Normally Closed during safe purge conditions. If the pressure should drop to below 1-2 in WC, the switch opens the circuit to provide a status change remote to the installation site. (For additional details on this switch, refer to the Asco Installation & Maintenance Instructions in Appendix A.) Installation Manual – Model 2700 Analyzer – Purge Assembly 6 3 MECHANICAL INSTALLATION 3.1 Unpacking and inspection Remove the Purge Assembly from their packing and inspect for any damage due to transit. Observe and note any visual damages to the assembly If damage has occurred, inform Servomex or its agent immediately. Retain all packing and shipping information and materials. Check that the parts agree with the purchase specification. NOTE The Purge Assembly contains two sub-assemblies and various ship loose parts. Compare the parts to the documented Bill Of Materials located in the List of Figures. NOTE The Purge Vent/Relief Sub-Assembly is to be installed be installed local to the 2700 sensor assembly, reference Item 17 of Drawing 335A2014. This sub-assembly must be installed in a vertical position with the vent port located at the top of the final installation. Purge Vent should discharge into well ventilated areas only. 3.2 Unit Description The 2700 Analyzer Purge Assembly is provided in two major sub-assemblies. The Purge Vent/Relief Sub-Assembly consists of a pipe cross with (1) relief valve attached, (2) tubing connection to sensor head, (3) ¼ in tube connector, and (4) ¼ in cap. The end of the tubing connection contains a SS Mesh that is rolled tightly and installed into the end of the tubing that is connected to the Purge Out connection on the sensor head. The other major sub-assembly is a panel mounted set of hardware containing (1) Instrument Air Regulator, (2) Fast/Normal Purge flow selection valves, (3) the Purge Pressure Switch and local pressure gauge, and (4) conduit seal for signal connection to the Pressure Switch. Tags describing connections, set points, and valve selections are mounted on this panel for ease of operation. Installation Manual – Model 2700 Analyzer – Purge Assembly 7 3.3 Assembly notes Panel Sub-Assembly should be mounted to a secure surface or pipe stand to provide rigid installation and support of the panel. This should be oriented prior to installing field tubing and wiring connections that are required. Purge relief assembly, Pressure Switch/Gauge and associated hardware are preassembled by Servomex. Customer to provide interconnecting tubing from Purge Assemble to Analyzer Sensor module. Caution: Any deviation from location of connection of the Purge/Relief assembly to the analyzer enclosure will result in inadequate purging of the analyzer. Use Teflon® tape for all pipe fittings assembly. Purge relief valve must be in a vertical position with the vent port at the top of the assembly. Safety Labels must be applied as displayed on drawing 335A2014. 4. ELECTRICAL INSTALLATION 4.1. NEC guidelines CAUTION It is a condition of certification that the unit and associated subassemblies be installed following the appropriate national or international legislation or codes of practice. In particular, the correct electrical fittings, conduit and seals must be installed as required. To retain certification, the unit must not be modified, mechanically or electrically. Additional connections must not be made into any part of the unit’s flow schematic. WARNING The installation must conform to relevant safety requirements, National Electrical Code and any local regulations. The installation must be safe for any extremes of operating conditions which may occur in the operating environment of the analyzer system. Installation Manual – Model 2700 Analyzer – Purge Assembly 8 4.2. Purge Switch connections/adjustments Pressure switch electrical connections are to be made via wiring through the conduit seal and into the head of the switch. The switch cover must be removed first to install the wiring. The wires are then to be terminated at the proper terminals inside the head of the Pressure Switch. The Pressure Switch terminals have C (Common), NC (Normally Closed) and NO (Normally Open) stamps just below the terminal connections. The G (Ground) connection is a green colored terminal mounted onto the base assembly of the switch. The Ground connection also displays a “Ground Symbol” next to this connetion point. Reference Figure 1 below (an extract from the Installation and Maintenance Instructions provided in Appendix A.) for additional details on the pressure switch assembly. In addition, refer to the Installation and Maintenance Instructions provided in Appendix A for reference. Figure 1. Assembly of Pressure Switch Installation Manual – Model 2700 Analyzer – Purge Assembly 9 4.2. Purge Switch connections/adjustments (cont) The pressure switch is tested and pre-set at the factory to provide an alarm if the air pressure falls below 1-2 in WC. If the sensor should require adjustments in the field, refer to Figure 2 below and the Installation and Operation Maintenance Instructions for the pressure switch, which are supplied in Appendix A for reference. Figure 2. Adjustment (Signal Setting) of Pressure Switch Installation Manual – Model 2700 Analyzer – Purge Assembly 10 5 INSTALLATION & OPERATION NOTES Power shall not be applied to the instrument until the interior of the probe is known to be safe and output from the pressure switch is connected to an appropriate alarm/warning device. The interior of the probe shall be safe after the case has been completely closed, fastened and purged with four (4) volumes of instrument quality air. NOTE: Purging the analyzer case for 30 minutes at 10 CFH will assure that the atmosphere inside the case is safe. Set the output of the purge supply pressure regulator (Reference Item 3) to 20-22 psig and turn the purge valve (Reference Valve corresponding to Item 6 Sub-Assembly) to the FAST FLUSH position to obtain a purge flow rate of 10 CFH into the purged case. NOTE: Proper purge pressure is within the range of 3 to 12 in WC. CAUTION Hot components are located inside the analyzer sensor enclosure. Interior surfaces may reach 800ºC. Unless area is known to be non-hazardous, enclosure shall not be opened until power has been turned off for 80 minutes, during which proper purge pressure is maintained. It is imperative that the user install the purge pressure switch and wire it to an appropriate alarm/warning device. Refer to the purge code, NFPA 496, for additional details. If the pressure switch (Reference Items 18) is located in a hazardous area, it must be installed using an approved conduit seal on the electrical port(s). Any port(s) that are unused must be properly plugged to maintain the hazardous electrical rating of the switch. In addition, the purge vent should discharge into well ventilated areas only. NOTE Pressure switch (Reference Items 18) will activate when the enclosure pressure falls below 1-2 in W.C. Installation Manual – Model 2700 Analyzer – Purge Assembly 11 6 CONFIRMATION OF PROPER PURGE SYSTEM OPERATION First, check that the purge pressure indicator (gauge) (Ref. Item 13) reads “0” with the probe enclosure open. Next, check that the purge supply regulator (Ref. Item 3) is set to 20-22 psig and adjust, if necessary. The purge pressure indicator gauge, must be in the range of 3-12 inches WC, when the purge valve (Ref Item 6 of corresponding Sub-Assembly) is in the “NORMAL” position. Then confirm that the pressure switch (Ref. Item 18) actuates the alarm output when the enclosure pressure falls below 1-2 in WC. This may be tested by simply breaking the probe enclosure seal. If the purge pressure switch does not actuate appropriately, the switch will need to be adjusted per the procedure sated above (Section 4.3). WARNING The 2700 Series Probe assembly with this type “Z” Purge accessory is suitable for use in nonhazardous or Class 1, Division 2, Group B, C or D areas. Additionally, the temperature rating for this probe assembly is T Internal = 800 ºC, T External = T3C Temperature Class (160ºC). WARNING Use of this purge accessory is subject to the following limitations: 1. The interconnecting wiring is in compliance with NFPA 70 (NEC). 2. The gas vapors in the analyzer environment are compatible with the temperature rating of the analyzer. 3. The user properly installs the purge hardware (including the wiring of the purge pressure switch) and operates it as described in this document. 4. The analyzer has not been modified in any fashion. 5. This purge system and associated hardware is applicable only to the 2700 Analyzer Probe/Sensor. 6. The analyzer is never to be used to measure gases in a stream which contains flammable constituents. 7. The purge hardware, as described in this document, must be protected from direct exposure to chemicals, liquids, excessive heat and ice. 8. The user assumes full responsibility for making changes to this hardware, wrongful installation and/or misapplication. 9. The user may need to modify the conduit seals and/or the purge relief assembly. In certain probe mounting orientations the relief valve on the relief assembly must always be in a vertical position. The conduit seal must located so they can be properly poured. 10. Instrument quality air must be used for this accessory. Other gases are not acceptable. 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