Caron Measurement & Controls TC-200 Bedienungsanleitung
Top Cut Sampler Model TC200 Pressurized
TOP CUT
SAMPLER
TC-200 User Manual
CARON MEASUREMENT
& CONTROLS
September 2016
Tyler Palinkas
Caron Measurement & Controls | www.caroncontrols.net
2
TABLE OF CONTENTS
CHAPTER 1SAFETY.............................................................................................................. 3
SECTION 1.1 SAFETY PRECAUTIONS ................................................................................. 3
CHAPTER 2OPTIONAL ACCESSORIES................................................................................... 4
SECTION 2.1 MOUNTING................................................................................................... 4
SECTION 2.2 FLOW SIGNAL .............................................................................................. 4
SUBSECTION 2.2.1 PNEUMATIC..................................................................................... 5
SUBSECTION 2.2.2 FLOW SWITCH ................................................................................. 5
SUBSECTION 2.2.3 DRY CONTACTS............................................................................... 5
SUBSECTION 2.2.4 DIRECT EXTERNAL PNEUMATIC ...................................................... 5
SECTION 2.3 INSULATED &HEATER ENCLOSURE............................................................. 5
CHAPTER 3TOP CUT OPERATION ........................................................................................ 6
SECTION 3.1 SCHEMATIC DRAWINGS................................................................................ 7
SECTION 3.2 INSTALLATION ........................................................................................... 10
SECTION 3.3 CALIBRATION............................................................................................. 11
SECTION 3.4 STARTUP PROCEDURE ................................................................................ 15
SECTION 3.5 PREVENTATIVE MAINTENANCE................................................................... 16
CHAPTER 4TROUBLESHOOTING......................................................................................... 17
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CHAPTER 1……………………………………………….SAFETY
SECTION 1.1 SAFETY PRECAUTIONS
-THE INTERNAL TIMER BATTERY SHOULD ONLY BE CHANGED IN A SAFE
ENVIRONMENT. VERIFY THAT AN EXPLOSIVE ATMOSPHERE IS NOT
PRESENT.
-WHEN SAMPLE IS NOT IN USE ENSURE THAT ALL SWITCHES ARE SET TO
OFF WHEN SAMPLER IS NOT IN USE. THE INTERNAL TIMER SWITCH
SETTING “0” AND THE MASS SAFETY SHUTOFF IN THE “OFF” POSITION.
-THE SAMPLER ENCLOSURE SHOULD BE VENTED INDEPENDENTLY TO A
SAFE LOCATION AND A MINIMUM OF 1.5M FROM ANY ELECTRICAL
ENCLOSURE.
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CHAPTER 2………………………….….OPTIONAL ACCESSORIES
SECTION 2.1 MOUNTING
THE TOP CUT SAMPLER CAN BE MOUNTED IN VARIOUS CONFIGURATIONS.
WALL MOUNTING TABS ARE SHIPPED WITH THE STANDARD SAMPLER
PACKAGE. OPTIONALLY AVAILABLE IS A UNIVERSAL STAND, ALLOWING
THE SAMPLER TO BE LOCATED ON ANY LEVEL SURFACE. CUSTOM BUILT
STANDS ARE AVAILABLE UPON REQUEST.
SECTION 2.2 FLOW SIGNAL
IN ORDER FOR THE SAMPLER TO ACCURATELY SAMPLE IN PROPORTION TO
FLOW, A BOOLEAN (TRUE OF FALSE) FLOW CONDITION SIGNAL CAN BE
SUPPLIED TO THE SAMPLER. THE INTRINSICALLY SAFE ELECTRONICS CAN
TAKE SIGNAL FROM ANY ISOLATED DRY CONTACT. ANY EXTERNAL
WIRING SHOULD BE DONE USING BLUE CABLE TO INDICATE INTRINSIC
WIRING, AS WELL AS MAINTAINING ISOLATION FROM ANY NON-INTRINSIC
WIRING. A CLOSED LOOP CONDITION INDICATES FLOWING, WHILE OPEN
INDICATES NOT FLOWING.
SUBSECTION 2.2.1 PNEUMATIC
OUR STANDARD SAMPLER IS EQUIPPED WITH A PNEUMATIC
PRESSURE SWITCH WHICH ACCEPTS A 30PSI SIGNAL TO INDICATE A
FLOWING CONDITION. THE SIGNAL CAN COME DIRECTLY FROM A
LEVEL CONTROLLER OUTPUT, OR VIA SOLENOID VALVE
CONTROLLED BY A PLC FOR FLOW PROPORTIONAL SAMPLING.
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SUBSECTION 2.2.2 FLOW SWITCH
A STAINLESS STEEL FLOW SWITCH CAN BE
WIRED TO THE SAMPLER TIMER TO INDICATE A
FLOWING CONDITION. THIS ALLOWS FOR A
COMPLETELY SELF CONTAINED ELECTRICAL
FLOW SIGNAL SYSTEM. NO NEED FOR
EXTERNAL POWER OR LOGIC. THE FLOW
SWITCH REQUIRES A 1-1/2”NPT CONNECTION ON THE TOP OF A
HORIZONTAL SECTION OF PIPE.
SUBSECTION 2.2.3 DRY CONTACT
THE TOP CUT SAMPLER CAN ALSO UTILIZE ANY ISOLATED DRY
CONTACT TO INDICATE FLOW. CARE MUST BE TAKEN TO FOLLOW
CEC GUIDELINES TO MAINTAIN INTRINSIC SAFETY. PLEASE
CONTACT A MEMBER OF OUR TEAM FOR MORE INFORMATION ON
THIS CONFIGURATION.
SUBSECTION 2.2.4 DIRECT EXTERNAL PNEUMATIC
A DIRECT EXTERNAL PNEUMATIC CONTROL SIGNAL CAN ALSO BE
USED TO ACTUATE THE PUMP. WITH THIS OPTION, THE UNIT WILL
BE EQUIPPED WITH A SELECTION VALVE TO ALTERNATE FROM
INTERNAL TIMER CONTROL, TO EXTERNAL CONTROL, BYPASSING
THE ELECTRONIC TIMER COMPLETELY. SEE SCHEMATICS IN
SECTION 3.1 FOR MORE INFORMATION.
SECTION 2.3 INSULATED AND HEATED ENCLOSURE
FOR OUTDOOR OPERATION THE TOP CUT SAMPLER IS AVAILABLE WITH
AN INSULATED AND HEATED ENCLOSURE. THE THERMOSTAT
CONTROLLED HEATER WILL MAINTAIN ABOVE FREEZING TEMPERATURES
INSIDE THE SAMPLER. THE HEATER REQUIRES A 120-240VA C POWER
SOURCE. PLEASE CONTACT THE SALES DEPARTMENT FOR MORE
DETAILED HEATER SPECIFICATIONS.
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CHAPTER 3…………………………………TOP CUT OPERATION
THE TOP CUT SAMPLER ELECTRONICS OPERATE ON ONE 6 VOLT PC915
ALKALINE BATTERY. OPERATING LIFE OF THE BATTERY VARIES WITH SAMPLING
FREQUENCY, BUT WILL GENERALLY LAST 6 TO 18 MONTHS.
THE SAMPLER OPERATES ON A TIME BASED INTERVAL. THE BUILT IN TIMER IS
TRIGGERED WHEN THE LOOP IS CLOSED ACROSS FLOW SIGNAL INPUT
TERMINALS (FLOW SIGNAL OPTIONS LISTED IN SECTION 2.2). THE TIMER IS
RETENTIVE IN-BETWEEN CYCLES OF THE FLOW SIGNAL INPUT. THIS MEANS
THAT IF THE SIGNAL INPUT IS OPENED BEFORE THE TIMER RUNS OUT, THE TIMER
WILL PAUSE, AND RESUME FROM THE REMAINING TIME THE NEXT TIME THE
INPUT IS CLOSED.
WHEN THE FLOW CONDITION INPUT IS CLOSED, THE TIMER BEGINS TO COUNT.
WHEN THE TIME SETTING IS REACHED, THE PULSE VALVE WILL SWITCH ON FOR
2 SECONDS, THEN OFF AGAIN FOR 2 SECONDS, AT WHICH POINT THE TIMER WILL
RESET AND START COUNTING UNTIL THE INPUT GOES OPEN. IN THE ON
POSITION, THE PULSE VALVE STROKES THE SAMPLE PUMP AND PUSHES THE
SAMPLE FLUID THROUGH THE BACKPRESSURE VALVE AND INTO THE SAMPLE
CONTAINER. WHEN OFF, THE PUMP RETURNS TO ITS RESTING POSITION,
DRAWING ANOTHER SAMPLE FROM THE PROCESS.
THE INTERVAL TIME SETTING IS SELECTABLE FROM THE 8 POSITION SWITCH
INSIDE THE SAMPLER TIMER BOX. SETTING 0 IS RESERVED FOR THE OFF
POSITION, WHILE 1 THROUGH 7 ARE PROGRAMMABLE SET POINTS. THE SET
POINTS ARE SET UP CUSTOM FOR EACH UNIQUE INSTALLATION AND ARE
MARKED IN SHIPPING HOURS PER DAY. THE TIMER CHIPS ARE FIELD
REPLACEABLE TO ACCOMMODATE CHANGES IN PROCESS CONDITIONS. FOR
MORE INFORMATION PLEASE CONTACT OUR SUPPORT TEAM.
TIME SETTING SHOULD BE SET TO FILL THE SAMPLE CONTAINER WITH 7.2L OF
FLUID AT THE END OF THE CHOSEN SAMPLE PERIOD. A SAFETY SHUTOFF VALVE
IS USED TO DISABLE THE SAMPLE PUMP WHEN THE SAMPLE CYLINDER REACHES
7.2L. BECAUSE THE SAFETY SHUTOFF USES WEIGHT OF THE SAMPLE CONTAINER
TO GAUGE ITS CONTENTS, IT NEEDS TO BE CALIBRATED TO ACTUAL SAMPLE
DENSITY (SEE SECTION 3.3.1).
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SECTION 3.1 SCHEMATIC DRAWINGS
ITEM
DESCRIPTION
1
PROGRAMMABLE SAMPLER TIMER
2
SAMPLE PUMP
3
7.2L SAMPLE CONTAINER
4
SAMPLE PUMP CONTROL SOLENOID
5
SAFETY SHUTOFF VALVE.DISABLES SAMPLE PUMP WHEN SAMPLE CONTAINER
REACHES A CERTAIN WEIGHT.
6
BACKPRESSURE REGULATING VALVE.PREVENTS SAMPLE FROM FREE FLOWING
THROUGH PUMP.
7
SAMPLE DIVERT VALVE.SELECT SAMPLE TO OPERATING OR TEST CONTAINER.
8
FLOW SIGNAL INPUT DEVICE (STANDARD PNEUMATIC SHOWN.SEE SECTION 2.2
FOR MORE OPTIONS)
9
SAMPLE INLET FILTER
10
OPTIONAL DIRECT EXTERNAL CONTROL 3-WAY VALVE
FIGURE 3.1.1
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FIGURE 3.1.2
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FIGURE 3.1.3
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SECTION 3.2 INSTALLATION
PROPER INSTALLATION IS INTEGRAL TO RELIABLE AND ACCURATE OPERATION
OF YOUR TOPCUT SAMPLER. THE FOLLOWING INFORMATION IS MEANT TO
ASSIST YOU IN SETTING UP THE SAMPLER FOR OPTIMAL OPERATION.
FIRST STEP IS TO FIND AN APPROPRIATE LOCATION FOR THE SAMPLE POINT. IT IS
IMPORTANT TO SELECT A SAMPLE POINT WHERE THE PRODUCT WILL BE WELL
MIXED. WE RECOMMEND THE USE OF A STATIC MIXER UPSTREAM OF THE
SAMPLE POINT FOR MOST APPLICATIONS. VARIOUS SIZES AND STYLES OF MIXER
ARE AVAILABLE; CONTACT OUR SALES DEPARTMENT FOR MIXER AND SAMPLE
QUILL OPTIONS. WHEN INSTALLING THE SAMPLE QUILL, THE BEVELED EDGE
SHOULD FACE UPSTREAM, AGAINST FLOW. IDEALLY THE QUILL SHOULD BE
MOUNTED OFF THE TOP OF THE PIPE. SEE FIGURE 3.2.1 BELOW.
FIGURE 3.2.1
ANOTHER POINT TO CONSIDER WHEN SELECTING A SAMPLE POINT LOCATION IS
THE SAMPLER ITSELF. FIND A SECURE MOUNTING LOCATION FOR THE SAMPLER
AS CLOSE TO THE SAMPLE POINT AS POSSIBLE.
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