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Summary of Contents for Ametek Universal Analyzers 1221
- Page 1 Instruction Manual Model 1221 Distillation Sample Probe 5200 Convair Drive Carson City, NV 89706 Phone: +1 775 883 2500 • www.UniversalAnalyzers.com...
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Page 2: Table Of Contents
Instruction Manual 1221 Distillation Sample Probe Table of Contents 1.0 Notice 2.0 Definition of symbols 3.0 Theory of operation 4.0 Installation 4.1 Utilities 5.0 Probe controllers 5.1 Pneumatic controllers 5.1.1 Pneumatic controller layouts 5.1.2 Pneumatic controller operation 5.2 Electronic controllers 5.2.1 Electronic controller layouts 5.2.2 Electronic controller overview 5.2.3 HMI display and operation... -
Page 3: Notice
Instruction Manual 1221 Distillation Sample Probe 1.0 Notice This equipment is designed for industrial analytical applications. Individual installations may vary in scope. The installer should consult national, local, and plant construction codes to ensure that governing regulations are met. When installing optional electronic control equipment, as a minimum, general installation precautions should be observed: •... -
Page 4: Definition Of Symbols
Instruction Manual 1221 Distillation Sample Probe 2.0 Definition of Symbols CAUTION, RISK OF DANGER SYMBOL INDICATES INJURY MAY OCCUR IF MANUFACTURER’S INSTRUCTIONS ARE NOT ADHERED TO. PLEASE READ MANUAL CAREFULLY WHEN SYMBOL IS DISPLAYED CAUTION, HOT SURFACE SYMBOL INDICATES EXPOSED SURFACE TEMPERATURE CAN CAUSE BURNS OR PERSONAL INJURY. -
Page 5: Theory Of Operation
Instruction Manual 1221 Distillation Sample Probe 3.0 Theory of Operation All ethylene production facilities will employ some type of cracking furnace, which is used to convert saturated hydrocarbons found in the feed stock into unsaturated hydrocarbons or olefins, which are the basic building blocks used in a variety of chemicals produced downstream of the olefins plant. - Page 6 Instruction Manual 1221 Distillation Sample Probe The Model 1221EX Distillation Probe utilizes a countercurrent flow technique for cooling of the sample. Cooling medium flows in opposite direction of the process gas on the outside of the distillation column. Heat is conducted through the column wall and then transferred to the cooling medium.
- Page 7 Instruction Manual 1221 Distillation Sample Probe Various Separator Discs When the sample gas enters the first stage of the probe, the gas and separator will be at its highest operating temperature. This is due to the counter current flow design of the sample (upwards) vs. the flow of the cooling medium (downwards).
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Page 8: Installation
Instruction Manual 1221 Distillation Sample Probe 4.0 Installation Proper installation of the Model 1221 Distillation Probe will ensure optimum performance for the equipment and the analytical measurement technique of choice. For the best performance, the probe should be mounted on a horizontal process line with an isolation valve located between the process and the probe. -
Page 9: Utilities
Instruction Manual 1221 Distillation Sample Probe 4.1 Utilities The vortex air cooled probes, the following requirements apply: • Inlet air pressure > 100 psig (80 psig minimum) at the probe • Inlet air dew point recommended < -40°F • Instrument air required to power the vortex = 40 SCFM (single vortex) and 80 SCFM (dual vortex) •... -
Page 10: Probe Controllers
Instruction Manual 1221 Distillation Sample Probe 5.0 Probe Controllers The primary task of the Model 1221 Distillation Probe is to cool the sample gas to a desired temperature. The sample setpoint determines the average temperature of the sample gas and is programmed in degrees Fahrenheit. Basic operation is to enable cooling when the gas temperature is above the desired setpoint and disable cooling when it drops below the setpoint. - Page 11 Instruction Manual 1221 Distillation Sample Probe Typical Control Box Layout (Single Vortex Shown) Typical Controller Location Page 11 of 38...
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Page 12: Pneumatic Controller Operation
Instruction Manual 1221 Distillation Sample Probe 5.1.2 Pneumatic Controller Operation The pneumatic controller / vortex requires dry instrument air or N2 with a dew point of less than -40°F at a pressure of 80-100 psig. Each vortex tube requires 40 SCFM while in operation. Instrument air enters the system and is sent in two different directions. -
Page 13: Electronic Controllers
Instruction Manual 1221 Distillation Sample Probe 5.2 Electronic Controllers Electronically controlled probes have tighter accuracy around the sample setpoint than the pneumatic controllers, on average about +/- 1°C. Electric power is required, limiting the controllers to Class I, Division 2 hazardous areas and general-purpose applications. - Page 14 Instruction Manual 1221 Distillation Sample Probe Typical Remote Controlled Layout (Single Vortex Shown) Typical Local Controlled Probe Layout (Dual Vortex Shown) Page 14 of 38...
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Page 15: Electronic Controller Overview
Instruction Manual 1221 Distillation Sample Probe 5.2.2 Electronic Controller Overview All electronic controllers are based on the IDEC microSmart FC6A PLC. Input Connections SD Card and ON/OFF Switch Status Indicators Power Connection Output Power Connection Output Connections RTDs are connected to the PLC via an FC6A-J4CN1, 4 channel input module, located to the right of the PLC. Sensors are connected to the module as follows: Module Power Connection... -
Page 16: Hmi Display And Operation
Instruction Manual 1221 Distillation Sample Probe 5.2.3 HMI Display and Operation The IDEC FC6A-PH1 provides local control and display, and is located on the left side of the PLC. The Ethernet port located on the bottom side of this module is programmed at the factory: 192.168.1.25. This connection may be used to view and control the PLC from a remote computer but does not communicate Modbus values and is not practical for usage by most customers. -
Page 17: Network And Status Display
Instruction Manual 1221 Distillation Sample Probe 5.2.4 Network and Status Display The FC6A-PH1 has an internal system menu, which displays current information for registers, as well as network. To access the system menu, press [ESC-HOLD] + [OK-HOLD] at the same time. The [ESC] button should be pressed slightly before the [OK] button is pressed. -
Page 18: Sample Isolation Valve Manual Operation Screen
Instruction Manual 1221 Distillation Sample Probe 5.2.6 Sample Isolation Valve Manual Operation Screen The sample isolation valve in an electronically controlled probe is a normally closed valve. It requires both power/signal from the PLC and the required air pressure to open the valve to allow sample to flow. The valve will close with loss of either power or air pressure. -
Page 19: Sample Temperature Setpoints Screen
Instruction Manual 1221 Distillation Sample Probe ° SAMPLE 70.6 PROCESS 206.7 °F COOL EXH 73.8 °F SAMPLE VALV FORCED CLOSD FORCED CLOSED may not be enabled when FORCED OPEN is currently enabled. Enabling FORCED OPEN when FORCED CLOSED is currently enabled will disable FORCED CLOSED. CAUTION: If FORCED OPEN is enabled, the PLC cannot automatically shut off the sample flow to avoid a high temperature liquid carryover. -
Page 20: Process Temperature Setpoints Screen
Instruction Manual 1221 Distillation Sample Probe Sample Temperature - Cooling Cycle with Hysteresis Sample Setpoint Hysteresis Cooling Below Setpoint Cooling Warming All the temperature setpoints on this screen are configured with exponential notation. To change any setpoints on this screen, press [OK-HOLD], [DOWN] to the desired setpoint, [OK], [RIGHT] to the appropriate numeral, [UP] or [DOWN] to the desired setting, [OK]. -
Page 21: Coolant Dwell Timer Operation Screen
Instruction Manual 1221 Distillation Sample Probe PROCESS TEMPERATURE ALARM 1400 ISOLATE 1500 To change any setpoints on this screen, press [OK-HOLD], [DOWN] to the desired setpoint, [OK], [RIGHT] to the appropriate numeral, [UP] or [DOWN] to the desired setting, [OK]. Changing the Alarm Setpoint from 1400°F to 250°F is shown below: SAMPLE SET PROCESS TEMPERATURE... - Page 22 Instruction Manual 1221 Distillation Sample Probe The COOLANT ON timer should be set to expire while the sample temperature is still above the sample setpoint. The sample temperature should continue to drop below the sample setpoint. Once the COOLANT ON timer expires, the COOLANT OFF timer begins. It is expected that the sample temperature drops below the sample setpoint before the COOLANT OFF timer expires.
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Page 23: Enclosure Temperature Screens
Instruction Manual 1221 Distillation Sample Probe 5.2.10 Enclosure Temperatures Screens The enclosure temperature RTD monitors the ambient temperature around the PLC. This is most applicable when the PLC is mounted in the field with locally controlled (LC) probes. This measurement can be critical if ambient temperatures fall outside the operating temperature range of the PLC. -
Page 24: Temperature Units With Box Cool/Heat
Instruction Manual 1221 Distillation Sample Probe 5.2.11 Temperature Units with Box Cool/Heat The units displayed on the controller may be changed from °F to °C. To change units to °C, navigate to the screen shown, press [OK-HOLD], [OK], [RIGHT] to the last numeral, [UP] once to change the value to “1”, [OK]. To change back to °F, repeat the above commands except change the last numeral to “0”. -
Page 25: Reset Factory Register Screen
Instruction Manual 1221 Distillation Sample Probe 5.2.12 Reset Factory Register Screen Unless otherwise specified on the PO when ordered, the electronic controllers are set to specific factory default values. These values are programmed into every unit, and are as follows: Parameter Value Units... -
Page 26: Changing Ip Address And Slave Number
Instruction Manual 1221 Distillation Sample Probe 5.2.13 Changing IP Address and Slave Number Scroll [DOWN] to the Home Screen. Press [ESC-HOLD] + [OK-HOLD] to access the system menu. The [ESC] button should be pressed slightly before the [OK] button is pressed. The network settings and slave number may only be changed with the PLC stopped. - Page 27 Instruction Manual 1221 Distillation Sample Probe SAMPLE SET SAMPLE SET SAMPLE SET Slave Number Port 1: HYSTERSIS HYSTERSIS CPU Network Settings HYSTERSIS HMI Network Settings ALARM BAND ALARM BAND ALARM BAND ISOLATE HI ISOLATE HI ISOLATE HI SAMPLE SET Port 1: SAMPLE SET Port 1: HYSTERSIS...
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Page 28: Sd Memory Card Data Logging And File Transfer
Instruction Manual 1221 Distillation Sample Probe 5.2.14 SD Memory Card Data Logging and File Transfer An SD memory card is provided with each PLC. This card is loaded at the factory with the current programming file and the current system software (firmware) file, which are combined into one file with a .ZLD extension. Some data logging may also have been stored on the card during quality assurance testing. - Page 29 Instruction Manual 1221 Distillation Sample Probe To eject the SD card, it’s first recommended to disable data logging with the sequence above, then enter the system functions and stop access to the card. To stop the PLC from accessing the card, start at the home screen, then press [ESC-HOLD] + [OK-HOLD] to access the system menu.
- Page 30 Instruction Manual 1221 Distillation Sample Probe Running Stop External Memory Device Monitor 2018/APR/26/THU Status Monitor 15:39:18 Do you want to Stopped stop PLC? 2018/APR/26/THU 15:40:43 SD Card Edit Program External Memory Configurations Stop Access Download Format Upload Recipe Program Filename (.zld) : DP1221V0418r0.zld After the PLC program has been updated, run the “Reset Factory Register”...
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Page 31: System Clock And Battery
Instruction Manual 1221 Distillation Sample Probe 5.2.15 System Clock and Battery The system clock will be set from the factory and will not update for Daylight Savings Time. If the battery is replaced or the system clock needs to be corrected due to other reasons, “Stop” the PLC from the System menu, then select “Configurations”... - Page 32 Instruction Manual 1221 Distillation Sample Probe Output Coil Statuses Coil Description Status Comment PLC Address 00001 Cooling Solenoid Valve 0 = Closed, 1 = Cooling Enables Probe Cooling Q0000 00002 Sample Solenoid Valve 0 = Closed, 1 = Open Enables Sample Flow Q0001 00003 General System Alarm...
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Page 33: Start-Up
Instruction Manual 1221 Distillation Sample Probe 6.0 Start-Up This procedure should be followed when starting up a Model 1221EX Distillation Probe with vortex cooling. Proper startup procedures can take anywhere from 2 to 6 hours under normal conditions. Initialization times may vary depending on ambient conditions, process composition and temperature, and cooling medium quality. -
Page 34: Maintenance
Instruction Manual 1221 Distillation Sample Probe UNIVERSAL ANALYZERS 7.0 Maintenance It is recommended that each probe be installed with a gate valve to isolate from process for all maintenance activities. Gate Valve PROCESS PIPE The coalescing separator is designed to condense and wash the heavy components in the sample back into the process along with any deposited solids avoiding the regular ‘plugging’... -
Page 35: Troubleshooting
Instruction Manual 1221 Distillation Sample Probe 8.0 Troubleshooting • Ensure that vortex cooled probes are supplied with 40 SCFM air at 80-100 psig. Measurements to ensure this should be made at the probe, not at the supply header. Consider loss in pressure due to supply lines which may be inadequately sized diametrically and/or too long. -
Page 36: Drawings And Spare Parts
Instruction Manual 1221 Distillation Sample Probe 9.0 Drawings and Spare Parts For the current revision of all Model 1221EX drawings and spare parts, visit the Universal Analyzers website. https://www.universalanalyzers.com/ Navigate to: Products -> Gas Sample Probes -> Model 1221/1221EX Links to all current drawings and spare parts for standard probe configurations are provided at the bottom of the page. -
Page 37: Standard Terms And Conditions Of Sale And Warranty
Instruction Manual 1221 Distillation Sample Probe 10.0 Standard Terms & Conditionsof Sale and Warranty Please visit our website for the current version of our Terms & Conditions of Sale and Warranty. https://www.universalanalyzers.com/product-documentation/tcs Page 37 of 38... - Page 38 Universal Analyzers is a leading supplier of gas sample extraction, transport and conditioning systems for CEM (Continuous Emissions Monitoring) and process measurement. It is a wholly owned subsidiary of AMETEK. AMETEK has 18,500 Global workforce, 150 Operating locations in 30 countries comprised of 175 brands.
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