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Related Manuals for ABB Totalflow Cold Weather Enclosure
Summary of Contents for ABB Totalflow Cold Weather Enclosure
- Page 1 2102824-001 (AA) ® TOTALFLOW Cold Weather Enclosure and Equipment Installation for use with NGC8200 Manual ABB Inc. Totalflow Products 7051 Industrial Blvd. Bartlesville, Oklahoma 74006 Tel: USA (800) 442-3097 International 1-918-338-4880...
- Page 2 Intellectual Property & Copyright Notice ©2006 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved. Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless of any circumstances. The original US English version of this manual shall be deemed the only valid version.
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Page 3: Table Of Contents
Table of Contents INTRODUCTION........................1 Unpacking & Inspection ...................1 Sample Probe Installation ..................2 III. Freestanding Cold Weather Enclosure Installation ..........4 Pipe Mounted Cold Weather Enclosure Mounting Kit ...........5 Optional Support Leg Kit Installation..............8 Sample Probe Access Cover Installation..............9 VII. Cold Weather Enclosure (CWE) Mounting Plate ..........10 VIII. - Page 4 Table of Figures Figure 1 Typical Cold Weather Enclosure with Electric Heater ..........1 Figure 2 Sample Probe ......................3 Figure 3 Sample Probe Insertion ..................3 Figure 4 Typical CWE Stand Mount Installation ..............4 Figure 5 CWE Mounting Hardware ..................5 Figure 6 Mounting Brackets ....................6 Figure 7 Mounting Hardware Installation ................6 Figure 8 Adjustment Assembly .....................7 Figure 9 Sample Probe Access Plates .................7...
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Page 5: Introduction
INTRODUCTION This document describes the installation of the Totalflow Cold Weather Enclosure and equipment designed for use with the NGC8200 Chromatograph. These instructions are listed in the suggested installation order. Depending upon how your system was configured, some of these instructions may not apply to your installation. When optional equipment installation has been completed, refer to the “NGC8200 User’s Manual”... -
Page 6: Sample Probe Installation
2) Unpacking The NGC is shipped in a specially designed shipping carton which contains the unit, mounting brackets, parts list and wiring and interconnect diagrams. Optional equipment is shipped in a separate carton. Carefully remove all internal and external packing material. Carefully remove all items from the box. -
Page 7: Figure 2 Sample Probe
B. Installation Shut down meter run and isolate from gas source. Be sure to use proper lockout and tagging procedures. Bleed off gas from meter run Ensure installed mounting coupling is free from dirt and debris. Ensure Sample Probe threads are free from dirt and debris. Using Teflon tape or Pipe Dope, wrap or cover NPT threads of Sample Probe (see Figure 2). -
Page 8: Freestanding Cold Weather Enclosure Installation
III. Freestanding Cold Weather Enclosure Installation The following steps will typically require two people. A. Materials • 4 ea. ½-13 x 1 ¼ SST Bolt • 4 ea. ½ SST Flat Washer • 4 ea. ½” SST Split Washer • 1 ea. -
Page 9: Pipe Mounted Cold Weather Enclosure Mounting Kit
Figure 5 CWE Mounting Hardware Pipe Mounted Cold Weather Enclosure Mounting Kit If your installation includes a Pipe Mounted Cold Weather Enclosure, follow these instructions as well as the Optional Support Leg instructions if applicable, otherwise continue to the next applicable set of instructions. A. -
Page 10: Figure 6 Mounting Brackets
Remove Nut and washers from Adjustment Assembly if necessary (see Figure 8). Insert All-Thread through round hole on adjustment side of angle iron. BOLT HOLES CHAIN HOLE 43.00 4.12 34.000 (2 1/2) 1.25 1.00 ADJUSTMENT CHAIN RETAINER ASSEMBLY HOLE MOUNTING HOLE 1.12 Figure 6 Mounting Brackets (31.00) -
Page 11: Figure 8 Adjustment Assembly
TIGHTENING CHAIN LENGTHS -001 13.00" .75 FLAT WASHER .75 SPLIT WASHER -002 19.00" .75 NUT -003 25.00" -004 32.00" MASTERLINK .75 ALL THREAD -005 38.00" Figure 8 Adjustment Assembly Place the flat washer, split washer and Nut on All Thread. Screw Nut onto All-Thread until top of Nut is level with top of All-Thread. -
Page 12: Optional Support Leg Kit Installation
(31.00) VIEW B-B VIEW A VIEW B VIEW A-A Figure 10 Pipe Mount installation Feed long flat end of Chain Retainer (see Figure 11) through middle of a chain link then move retainer lock into position where round peg fits into small round mounting hole. -
Page 13: Sample Probe Access Cover Installation
B. Instructions Set Support Leg underneath front or rear (or both if using 2 kits) of pipe mounted enclosure, oriented so that the Leg Brace is horizontal with front of enclosure (see Figure 12). Place split washer, then flat washer on one of the 1 ¼” Bolts. Insert Bolt through hole located in the angle iron into the outermost corner of the enclosure. -
Page 14: Cold Weather Enclosure (Cwe) Mounting Plate
A. Instructions Cover faceplate of Sample Probe Gauge, open end of relief valve and Probe Outlet with something similar to masking tape. This will protect lens from overspray with aerosol insulation. Spray aerosol insulation around base of installed probe and enclosure bottom. -
Page 15: Figure 14 Ngc Mounting Plate
B. Instructions Place Mounting Plate (see Figure 14) inside of the Cold Weather Enclosure, oriented horizontally so that each Bolt hole is aligned with the Mounting Tracks (see Figure 15). Move Channel Spring Nuts into position underneath slotted mounting holes. Figure 14 NGC Mounting Plate 5/16"-18 CHANNEL SPRING NUTS MOUNTING TRACKS... -
Page 16: Ngc Installation
Continue to the “NGC Installation” instructions. Method of installation must be consistent with customers company policy. VIII. NGC Installation Once the mounting system has been installed inside the Cold Weather Enclosure, these instructions should be followed to install the NGC onto the mounting pipe. Before you begin, review the procedure and the materials required for installation. -
Page 17: Sample Conditioning Module Installation
Figure 17 NGC Optional Mounting Flange Pipe If the Optional Mounting Pipe with Flange is used, insert Hex Socket Screw through hole in the welded flange into the neck bottom of unit and tighten using ¼” Hex Wrench. Repeat for all screws. Small adjustments may be made to orientation, by applying additional pressure to mounting pipe with pipe wrench, tightening mounting pipe into shelf mounted flange or pipe saddle flange. -
Page 18: Figure 18 Sample Conditioning Module Bracket
washer on Bolt. Screw Nut onto end of Bolt, finger tight. Repeat for second mounting Bolt. Tighten both Nuts. Repeat for all additional Modules. Straddle mounting pipe with U-Bolt and insert threaded ends through holes located in Bracket, so that Bracket back fits flat against pipe and Module Mounting Lip sets away from pipe (see Figure 19). -
Page 19: Sample Line Connections
Sample Line Connections Following installation of the Sample Conditioning Module(s), the sample tubing from the Sample Probe to the Sample Conditioning System and NGC Feed-Through Assembly should be installed. A. Materials • 1/8” SST Chromatography Grade Transport Tubing (Amount to be determined by technician based on distance from Sample Probe to Sample Conditioning Module and number of Sample Streams. -
Page 20: Figure 20 Sample Conditioning Module Installation
Figure 20 Sample Conditioning Module Installation If necessary, install reducer into Sample Probe output fitting. Install ferrule and Nut onto one end of the sample tubing. Insert tubing with ferrule into Reducer/Sample Probe output fitting. Move Nut down onto ferrule, screw onto fitting and tighten. Install ferrule and Nut onto other end of the sample tubing. -
Page 21: Cwe Optional Pwr/Comm Outlet Box Assembly
Make necessary bends in tubing to ease installation of tubing into the required fittings on the end of Sample Conditioning Module Purge Coil. When all connections are complete, apply aerosol insulating foam from inside the enclosure pointing toward the outside of boot, ensuring that the overspray falls outside the enclosure. -
Page 22: Figure 22 Cwe Access Panel Removed
B. Instructions Remove left side access plate from enclosure (see Figure 22). Gain access to rear Termination Panel by loosening the Countersunk Hex Socket Locking Set Screw in the rear end cap using a 1/16” Hex wrench, then unscrewing the end cap. INTERNAL CONNECTION ASSY ACCESS OPENING... -
Page 23: Figure 23 Power Communication Outlet Box Assembly
DC POWER SWITCH INTERNAL NGC CONNECTION ASSEMBLY OUTLET BOX ASSEMBLY FLEXIBLE CABLE ASSEMBLY Figure 23 Power Communication Outlet Box Assembly Remove cover from Outlet Box Assembly. Feed wires through Outlet Box elbow and out past the wiring panel, moving assembly up to the threaded end of the cable. Begin threading the Outlet Box Assembly onto end of Flexible Cable Assembly, rotating entire Outlet Box Assembly Clockwise until snug and in a vertical (360 ) position. -
Page 24: Figure 24 Assembled Power/Communication Assembly
INSULATED ENCLSOSURE WALL DC POWER SWITCH FLEXABLE CABLE ASSEMBLY NGC8200 MOUNTING BRACKET CONDUIT SEAL-TO BE COMPLETED BY CUSTOMER OUTLET BOX ASSEMBLY LOCKING GASKET Figure 24 Assembled Power/Communication Assembly POWER Figure 25 Power Wiring Diagram Remove Power Field Termination J3 Connector from Outlet Box Panel. Using the Wiring Instructions in Figure 25, install each wire into the correct terminal and replace connector on board. - Page 25 NOTES: Optionally, Communication wires maybe run directly to the spare Conduit Hub located on the bottom of the Outlet Box Assembly. Please follow local codes. For the purpose of this manual, we will assume that communication wiring will be included with the power wiring in one conduit run. Tape 3’...
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Page 26: Figure 26 Suggested Rs-232 Wiring Instructions
NGC 8200 TERMINATION BOARD 2102080-XXX 1 2 3 1 2 3 SW PWR SW PWR 10 10 J8 COMM PORT 1 J10 COMM PORT 2 11 11 12 12 Figure 26 Suggested RS-232 Wiring Instructions NGC 8200 TERMINATION BOARD 2102080-XXX 1 2 3 1 2 3 SW PWR... -
Page 27: Cwe Carrier Gas Bottle Rack Installation
NGC 8200 TERMINATION BOARD 2102080-XXX 1 2 3 1 2 3 SW PWR TXD+ TXD - RXD+ RXD- SW PWR TXD+ 10 10 TXD - J8 COMM PORT 1 J10 COMM PORT 2 RXD+ 11 11 RXD- 12 12 Figure 28 Suggested RS-422 Wiring Instructions XII. -
Page 28: Carrier Gas Regulator Installation
Figure 29 Dual Bottle Rack Assembly Figure 30 Dual Bottle Rack Installation XIII. Carrier Gas Regulator Installation These instructions assume that the Carrier Gas bottle has previously been installed and are valid for all installations. NOTE: DO NOT connect a low pressure switch directly to the NGC. A. -
Page 29: Cwe Calibration Gas Bottle Installation
Figure 31 Carrier Gas Pressure Regulator with Relief Valve B. Instructions Remove protective cap from High Pressure Inlet if required. Insert Ferrule on Regulator High Pressure Inlet into Carrier Gas Bottle Outlet. Screw Nut onto thread and tighten Check for leaks. XIV. -
Page 30: Calibration Gas Regulator Installation
NGC8200 CAL BLEND REGULATOR ASSY CAL BLEND CYLINDER WORM GEAR CLAMP RIGHT SIDE CUT-AWAY VIEW Figure 32 Calibration Bottle Location Calibration Gas Regulator Installation The following instructions are valid for all installations. NOTE: DO NOT connect low pressure switch directly to the NGC. A. -
Page 31: Carrier Gas And Calibration Gas Connections
Figure 33 Calibration Gas Pressure Regulator with Relief Valve XVI. Carrier Gas and Calibration Gas Connections The following procedures describe the steps for connecting the external Carrier Gas and Calibration Gas lines from the respective regulators to the Feed-Through Assembly on the NGC. -
Page 32: Figure 34 Carrier And Calibration Gas Connections
Make necessary bends in tubing to ease installation of the tubing into NGC and Pressure Regulator. NOTE: Tube, Ferrule and Nut should always enter connection perpendicular. Install reducer into Carrier Gas Regulator. Insert tube with ferrule into reducer/Pressure Regulator output fitting. Move Nut down onto ferrule, screw onto fitting and tighten. -
Page 33: Vent Line Connections
Insert tube with ferrule into Calibration Gas Input Port (S4) on Feed-Through Assembly. Move valco Nut down onto ferrule, screw into port and tighten. NOTE: Leak test ALL gas connections when completed. XVII. Vent Line Connections The following procedure provides general steps for connecting the external Vent Lines from the respective output ports on the Feed-Through Assembly. -
Page 34: Cwe Optional Catalytic Heater Installation
NOTE: All 4 Vents MUST be open. Position Vent tubing in a downward direction so that moisture does not accumulate in the tubing. Vent lines DO NOT need to be extended outside of CWE. XVIII. CWE Optional Catalytic Heater Installation The following procedures describe the steps for installing a Catalytic Heater for the Cold Weather Enclosure. -
Page 35: Figure 37 Catalytic Heater Assembly
Apply Teflon tape to threads male end of T Assembly (see Figure 37 Catalytic Heater Assembly). Screw threaded end of T Assembly into ¼” female fitting located on the factory installed Catalytic Heater, by turning entire Assembly clockwise until tight (see Figure 38). THERMOSTAT REGULATOR REGULATOR... -
Page 36: Figure 39 Regulator Assembly Installed
Remove Ferrules and Nut from the Thermostat end of the Thermostat Assembly. Apply Teflon Tape to Threads. Insert Tube end of Thermostat Assembly through exterior wall on the side of the CWE (see Figure 38). Place Nut, Front Ferrule and Back Ferrule onto end of 3/8” bent Tubing inside of the CWE. -
Page 37: Cwe Optional Electric Heater Installation
Figure 40 Temperature Probe Installation Using the wiring instructions shown in Figure 41 and Manufacturers Instructions enclosed with Heater, make external connections. ELECTRICAL PREHEAT CONDUIT BOX 12 VDC POWER SOURCE POSITIVE NEGATIVE Figure 41 Electrical Pre-heater Wiring Instructions XIX. CWE Optional Electric Heater Installation The following procedures describe the steps for wiring an Electric Heater for the Cold Weather Enclosure. -
Page 38: Figure 42 Electric Heater Installed In Cwe
HEATER, 400 WATT 120 VAC or HEATER, 400 WATT 230 VAC BOTTLE RACK OPTION DC POWER & COMMUNICATION OPTION NGC8200 THERMOSTAT SAMPLE PROBE OPTION CALIBRATION BLEND BOTTLE Figure 42 Electric Heater Installed in CWE B. Instructions Using the wiring instructions shown in Figure 43 and Manufacturers Instructions enclosed with Heater, make external connections. -
Page 39: Dc Power Installation
DC Power Installation These instructions assume that all external wiring has been completed to point where connections have been made to field termination connector, but the connector has not been plugged into the Termination Panel. A. Instructions Apply power: If installation includes the CWE Optional Pwr/Comm Outlet Box Assembly: •...