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Atec 8000 Operation And Maintenance Manual

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Model 8000 Automated Sampler
Operations and Maintenance Manual
Version 3.02
January 17, 2019
2019 ATEC, 9727 Cotharin Road, Malibu, CA 90265-2112

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  • Page 1 Model 8000 Automated Sampler Operations and Maintenance Manual Version 3.02 January 17, 2019 2019 ATEC, 9727 Cotharin Road, Malibu, CA 90265-2112...
  • Page 3 Limited Warranty Atmospheric Technology (ATEC) warrants to the original purchaser of the Model 8000 Toxic Air Sampler that should it prove defective by reason of improper workmanship and/or material: Parts and Labor: For one year on all components from the date of original purchase, we will repair or replace, at our option, any defective part without charge for the part.
  • Page 4 Atmospheric Technology...

  • Page 5: Table Of Contents

    RUNNING THE SYSTEM Hardware Setup Display and Function Tabs Date and Time Site Identification Cartridge Sampling Information Ozone Scrubber Temperature Abort Function Tabs PROGRAMMING THE MODEL 8000 Time/Date Setup Schedule Leak Check Data Power Failures Manual Mode Advanced LOCAL AREA NETWORK CONNECTION...
  • Page 6 Cartridge Filter Ozone Scrubber Mass Flow Controller Calibration Procedure MODEL 8000 PARTS LIST APPENDIX A SCHMATICS APPENDIX B MANUAL FOR MASS FLOW CONTROLLER Atmospheric Technology...

  • Page 7: Introduction

    1. Introduction This manual covers the installation, operation and routine maintenance of the ATEC Model 8000 Automated Sampler. This instrument is a microprocessor controlled sampler that can be programmed to draw ambient air through cartridges, filters, or sorbent tubes for specified time periods.
  • Page 8 Atmospheric Technology...

  • Page 9: System Configuration

    3. System Configuration 3.1 Hardware 3.1.1 System Specification Flowrate: Nominal 1.0 lpm with Sep-Pak cartridges. Adjustable between 0-2 lpm depending on cartridge restriction. Optional ranges available. Accuracy: ±1% FS No. of Channels: 8 ports on Channel 1. Two other single port channels with independent operation are optional.

  • Page 10: Sampler Components

    3.1.2 Sampler Components This section describes the general operation and major components of the ATEC Model 8000 Automated Sampler. Shown here is a schematic diagram of the sampler. Air enters the sampler to the inlet valve. The inlet valve is normally closed and allows leak checking of the entire flow system.
  • Page 11 used to isolate the cartridge when sampling is not occurring. The flow from the outlet solenoid valve passes through the outlet manifold to a mass flow controller (MFC) and is exhausted with a vacuum pump. Only one port for Channel 1, consisting of two solenoids and the cartridge, can be activated at a given time.
  • Page 12 24 in Hg. using two MFCs flowing at 1 lpm. 3.1.2.8 Optional 8-Port or 16-Port Expansion Module The Model 8000 can be expanded to a total of either 16 ports or 24 ports by the addition of an expansion module. The Model 8008 adds an additional 8-ports while the Model 8016 adds an additional 16-ports.
  • Page 13 Model 8000 is correctly made, the additional ports will display once the Model 8000 is turned off and then turned back on. Atmospheric Technology...
  • Page 14 Atmospheric Technology...

  • Page 15: Running The System

    When power is applied, the display will illuminate in approximately 20 seconds. The Model 8000 uses an WVGA LCD color touch screen display to show current operating status and to enter information into the computer.

  • Page 16: Date And Time

    Model 8000 Version 2.00 Time/Date Setup Schedules Data Leak Check SOP Main Manual Advanced Monday, November 26, 2005 18:58 East River Site Flow Volume Status 11.8 Cartridge Ch. 1 Port 1 Finished 11.5 Port 2 Finished Sampling Port 3 1.001 10.4...

  • Page 17: Ozone Scrubber Temperature

    Aborted—Operator terminated sampling Finished—A successful sample has been collected without errors Leak Err—Cartridge failed spedified leak rate tolerance on start-up Post Leak Err—Cartridge failed auto leak check at the end of sampling Temp Tol—Ozone scrubber temperature exceeded ±5°C Flow Tol—Specified cartridge flow rate tolerance exceeded Zero Tol—Cartridge MFC required more than 1% zero compensation Errors—Multiple errors, power outage, or sample aborted 4.6 Ozone Scrubber Temperature...
  • Page 18 Atmospheric Technology...

  • Page 19: Programming The Model 8000

    Advanced tab. 5.1 Time/Date The time and date that is stored in the Model 8000 can be changed using the Time/Date tab. When this tab is touched, the operating system data and time selection screen will appear. Once the changes have been made, pressing the OK button in the upper right corner of this window will bring back the main screen that should show the correct day of the week, date, and time.
  • Page 20 Ch.2 MFC Set Point The sampling flow rate for the Channel 2 cartridge is specified in this box Flow Leak Limit The flow leak limit is the maximum flow rate that is allowed for a cartridge to pass either manual or automatic leak check. This value has the same units as the flow rate.

  • Page 21: Schedule

    Touching the site label box brings up an alphanumeric keypad that can be used to input a site specific label (e.g. East River Site No. 2) that appears on the main screen. TouchScreen Pressing the TouchScreen button brings up the touchscreen calibration routine. The screen is calibration by touching five crosses that appear at different places on the sceen.

  • Page 22: Leak Check

    entered for each cartridge. This label will appear with the data to identify each sample. If only one cartridge is to be sampled, the Done button is pressed and the sampler will return to the main screen. If additional channels are to be sampled, The Next button must be pressed to display the schedule for the next port.

  • Page 23: Data

    If the Next button is pressed after checking the last cartridge channel, a total system leak check can be performed. This checks the entire cartridge sampling path from the outlet of the inlet valve to the vacuum pump. This is especially important when maintenance is performed, and the Teflon filter or ozone scrubber has been replaced.
  • Page 24 Post Run Leak Check Flow Limit Exceeded The entire data set can be downloaded to a jump drive inserted into one of the USB connectors below the screen. The following jump drives are known to work with this sampler: Lexar JumpDrive Sport 256MB Lexar JumpDrive Sport 512MB SanDisk Cruzer Micro 256MB Other jump drives may work with the samplers, but only those shown above have...

  • Page 25: Power Failures

    0.994 1423.90 50.1 The Next button on the 8000 Data screen will advance to the next data screen or Exit can be used to return to the main screen. 5.6 Power Failures If a power failure occurs during sampling, the sampler will resume sampling based on the programmed sampling schedule.

  • Page 26: Advanced

    Advanced tab. This portion of setup should only be used by individuals familiar with the operation and calibration of components used in the Model 8000. Changing the values in the Advanced Setup will alter the accuracy of the instrument.

  • Page 27: Local Area Network Connection

    6. Local Area Network Connection If the sampler is to be connected to a local area network (LAN), the following steps will need to be taken to enable communication between the sampler and a PC or tablet on the same LAN. 6.1 Initial Network Setup Before communication is started, the IP addresses of the sampler and the remote PC/tablet must be determined.
  • Page 28 4. If the Local IP Address is invalid or needs to be changed, select the “Change IP Address” button and do the following (you will need a USB keyboard plugged into the USB port below the screen): a. Select the ENET1 icon. b.
  • Page 29 8. Press the “OK” button to proceed. 9. The following screen will appear: 10. Press the “Continue” button and connection will be made. The “Setup” screen of the sampler should now be appearing on the PC/Tablet. These steps do not have to be done again. If a different PC/Tablet is to be used, the “Remote IP Address”...
  • Page 30 Atmospheric Technology...

  • Page 31: Maintenance

    7. Maintenance This section describes routine maintenance procedures for the Model 8000 Automated Sampler. All other repair work should be performed by trained personnel. 7.1 Vacuum Pump To remove the vacuum pump from the sampler, remove the top and side covers.

  • Page 32: Cartridge Filter

    interchangeable. Clean them with water. When replacing the outlet valve, place the new valve in location and note there is a retaining bar near the machine screw hole. This retaining bar holds the valve in position. When replacing the inlet valve, note that the valve holder is marked with an X in one corner.

  • Page 33: Mass Flow Controller Calibration Procedure

    The calibration of the mass flow controllers can be changed by entering the appropriate slope and intercept for each mass flow controller. The calibration of the flow controllers in ATEC samplers with software version 5.0 or higher requires a special calibration procedure because the analog-to-digital...
  • Page 34 converters in the embedded computer do not read negative voltages. Therefore, to detect MFC negative zero drift, a zero bias needs to be applied to the MFC. Once the zero is established, the slope is applied to adjust the MFC span to agree with a certified flow standard referenced to EPA standard conditions of 25°C and 760mm It is important to understand that the flow values shown on the Manual Screen can be referenced to two conditions, either the MFC manufacturer’s reference condition...
  • Page 35 4. Attach a certified calibrator in series with the MFC to record the flow rate. For calibrating the Channel 1 MFC attach the calibrator to one of the port outlet tubes. For calibrating the Channel 2 MFC, attach the calibrator to the Channel 2 outlet tube.
  • Page 36 +/- 1% of the range of the MFC. At this point, ATEC recommends that the MFC be mechanically zeroed to eliminate excessive software compensation which may be a cause of a MFC malfunction.

  • Page 37: Model 8000 Parts List

    8. Model 8000 Parts List Components of the Model 8000 are shown in the following Parts List. This list does not include common parts such as fuses, fittings, or fasteners. Chassis 8000-100-1 Front Panel 8000-100-2 Rear Panel 8000-100-3 Mass Flow Controller (Specify Range)
  • Page 38 GPIO Cable Set 8000-700-5 Rear Panel Output Cable Set 8000-700-7 Interface Board Ribbon Cable Set 8000-700-8 Vacuum Pump Relay Cable 8000-700-10 Atmospheric Technology...

  • Page 39: Appendix A Schmatics

    Appendix A Schmatics Atmospheric Technology...
  • Page 40 Atmospheric Technology...

  • Page 55: Appendix B Manual For Mass Flow Controller

    Appendix B Manual for Mass Flow Controller Atmospheric Technology...
  • Page 57 TELEDYNE HASTINGS INSTRUMENTS INSTRUCTION MANUAL 200/202 SERIES FLOWMETERS/CONTROLLERS I S O 9 0 0 1 C E R T I F I E D...
  • Page 58 Manual Print History The print history shown below lists the printing dates of all revisions and addenda created for this manual. The revision level letter increases alphabetically as the manual undergoes subsequent updates. Addenda, which are released between revisions, contain important change information that the user should incorporate immediately into the manual.
  • Page 59 Table of Contents GENERAL INFORMATION............................4 1.1................................4 EATURES 1.2. HFM-200 ..........................5 PECIFICATIONS 1.3. HFC-202 ..........................5 PECIFICATIONS 1.4. 4-20 .......................6 PTIONAL URRENT UTPUT 1.5............................6 THER CCESSORIES 1.5.1. Hastings Power supplies..........................6 1.5.2. Interconnecting Cables ...........................7 INSTALLATION AND OPERATION ........................8 2.1............................8 ECEIVING NSPECTION 2.2.

  • Page 60: General Information

    1. General Information The Hastings HFM-200 mass flow meter and HFC-202 flow controller are designed to accurately measure and control mass flow over the range of 10 sccm to 30 slm, without corrections or compensations for gas pressure and temperature with an accuracy of better than ±1% FS. Hastings mass flow instruments do not require any periodic maintenance under normal operating conditions with clean gases.

  • Page 61: Specifications Hfm-200

    1.2. Specifications HFM-200 Accuracy and Linearity ........................±1% F.S. Repeatability ............................. ±0.05% F.S. Standard Pressure Rating ........................500 psig Pressure Coefficient................-0.0067%/psi (0 - 1000 psig N2) typical High-Pressure Option ....................Proof tested to 1500 psig Leak Integrity ..........................< 1x10 sccs Temperature Coefficient ..................

  • Page 62: Optional 4-20 Ma Current Output

    1.4. Optional 4-20 mA Current Output An option to the standard 0 - 5 VDC output is the 4 - 20 mA current output that is proportional to flow. The 4 - 20 mA signal is produced from the 0 - 5 VDC output of the flow meter. The current loop output is useful for remote applications where pickup noise could substantially affect the stability of the voltage output or long cable runs where cable resistance would cause a voltage signal to decay.

  • Page 63: Interconnecting Cables

    1.5.2. Interconnecting Cables Cables are available from Hastings, in various lengths, to connect from the 15 pin "D" connector on the back of the Power Pod directly to any of the 200 series and 300 series flow instruments (including digital versions).

  • Page 64: Installation And Operation

    2. Installation and Operation This section contains the steps necessary to install a new flow meter/controller into operation as quickly and easily as possible. Please read the following thoroughly before attempting to install the instrument. 2.1. Receiving Inspection Carefully unpack the Hastings HFM-200/HFC-202 series instrument and any accessories that have also been ordered.

  • Page 65: Mechanical Connections

    2.4. Mechanical Connections 2.4.1. Standard Configuration The flow meter may be mounted in any position as long as the direction of gas flow through the instrument follows the arrow marked on the bottom of the flow meter case label. The preferred orientation is with the inlet and outlet fittings in a horizontal plane (if operating with a dense gas or at high pressures the instrument must be installed horizontally).

  • Page 66: Electrical Connections

    EXAMPLE: Suppose a 4” LFE is selected. The length of 4” diameter tubing or pipe, upstream of the sensor inlet tap, will be a minimum of 20“. The minimum length of 4” tubing or pipe downstream from the sensor outlet tap will be 4”. The length of additional 4” inlet tubing required for the 4”...

  • Page 67: Operation

    24 Volt Connections Refer to the diagram to the right when connecting 24 Volt units. Connect the positive lead of the power supply to pin 7 of the DE-9 connector and negative lead to pin 4. The supply input is diode protected such that reversing the input polarity will not damage the instrument.

  • Page 68: Zero Check

    2.6.2. Zero Check Turn the power supply on if not already energized. Allow for a 1 hour warm-up. Stop all flow through the instrument and wait 2 minutes. Caution: Do not assume that all metering valves completely shut off the flow. Even a slight leakage will cause an indication on the meter and an apparent zero shift. For the standard 0 - 5 VDC output, adjust the zero potentiometer located on the lower outlet side of the flow meter until the meter indicates zero.

  • Page 69: Operation With A Power Supply Other Than A Hastings

    The “COMMAND” pot adjusts the Analog command signal sent to the flow controller. The setting for each controller connected to the power supply can be observed. (Depending on how the power supply was set up, the display could indicate in flow units or percent of full scale). Hastings Power Supply Feature Guide Feature Model 40...

  • Page 70: Operation With An External Sensor (Fig. 2.2)

    2.7.3. Operation with an external sensor (Fig. 2.2) In some instances, it might be desirable to use an external Fig 2.2 sensor to provide process information to the control circuitry in the flow controller. For example, you might want to control the pressure in a vacuum system by adjusting the rate at which the system is backfilled with a gas.

  • Page 71: Range Changing

    controller circuit establishes control at the new command point. This jumper does not affect the system gain and will not dampen out oscillations. To adjust the response, you need a means of producing a step change in the command voltage from 10% of full scale to 100% of full scale.

  • Page 72: Theory Of Operation

    3. Theory of Operation This section contains a functional description of Hastings flow controllers. Detailed schematics and parts lists can be obtained by contacting Hastings using the contact information found at the end of this document. In this section and other sections throughout this manual, when a power supply is mentioned, it is assumed that the customer has a Hastings Power Supply.

  • Page 73: Electronics

    relatively constant over wide ranges of temperature and pressure, the flow meter may be calibrated directly in mass units for those gases. Changes in gas composition usually only require application of a simple multiplier to the air calibration to account for the difference in heat capacity and thus the flow meter is capable of measuring a wide variety of gases.

  • Page 74: Valve

    3.5. Valve The control valve is an “automatic metering solenoid” valve. While most solenoids operate in either the fully open or fully closed state, the automatic metering solenoid valve is designed to control flow (see Figure 3.5). A spring, connected to the plunger assembly, holds a magnetic plunger tightly against an orifice to shut off flow.

  • Page 75: Maintenance

    4. Maintenance This section contains service and calibration information. Some portions of the instrument are delicate. Use extreme care when servicing the flow controller. 4.1. Authorized Maintenance With proper care in installation and use, the flow controller will require little or no maintenance. If maintenance does become necessary, most of the instrument can be cleaned or repaired in the field.

  • Page 76: Adjustments

    CAUSE: Plugged orifice. ACTION: Verify the presence of a 10-50 psig pressure across the instrument. If present, shut off gas supply and power supply. Remove orifice per Section 4.9. Examine orifice. If plugged, clean or replace as applicable. Reassemble valve. SYMPTOM: Flow meter reads other than 0.00 VDC with no flow, or there is a small flow when flow meter reads 0.00 VDC.

  • Page 77: Miscellaneous Adjustments

    4.3.2. Miscellaneous adjustments Periodically, during normal operation, the ZERO should be checked and adjusted when required. If the instrument is not shutting completely off when the Valve Override CLOSE function is active, or a command of zero flow has been given, then the orifice may require approximately 1/8 turn clockwise. 4.4.

  • Page 78: Hfc-202 Orifice

    B) If P >2P , use formula 1; otherwise use formula 2. C) Use a consistent set of units for pressure, flow, and density (i.e all lengths, masses, times in the same units, cm, ft, kg, sec etc.) 1 liter/minute = 1.667 x 10 /sec, 1 gm/liter = 1 kg/m , 1 psia = 6895 kg/m*sec...
  • Page 79 Lubricate the O-rings slightly with a silicone based grease, and the threads with anti-galling compound. Push the orifice into its hole and screw it in until it is flush with the instrument base. Apply pressure to the inlet side of the instrument. Enable the Valve Override CLOSE function or unplug the instrument.

  • Page 80: Warranty And Repair

    5. Warranty and Repair 5.1. Warranty Repair Policy Hastings Instruments warrants this product for a period of one year from the date of shipment to be free from defects in material and workmanship. This warranty does not apply to defects or failures resulting from unauthorized modification, misuse or mishandling of the product.

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