Installation, Operation, & Maintenance Manual MODEL: MHR, MJTHR

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1 Installation, Operation, & Maintenance Manual Mustang Heated Regulators MODEL: MHR, MJTHR ITS12ATEX17539 IECEx ETL X P (304) F (304) P.O. Box 490/43 Ritmore Dr. Ravenswood, WV info@mustangsampling.com Manufactured by Valtronics Solutions Mustang Sampling, LLC

2 2015 Mustang Sampling, LLC. All Rights Reserved. Revision: Issue Date: 5/1/2015 File Name: MIOM-HRGL No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of Mustang Sampling, LLC. Systems and equipment are subject of Patents: US , AU , CA , EP , US , AU , CA , CN , EP Other Patents Pending Mustang Sampling, Mustang, Pony, Certiprobe, Certicollar, Mustang Intelligent Vaporizer Sampling System, SoftView, the Mustang Sampling logo are all registered trademarks of Mustang Sampling, LLC.. All other trademarks and copyrights are the property of their respective owners. Mustang Sampling, LLC P.O. Box 490 Ravenswood, WV

3 TABLE OF CONTENTS Safety Warnings 2 Product Features 3 Technical Specifications 4 Installation Instructions 5 Operation Instructions 6 Maintenance Instructions 7 General Arrangement MHR Fig. 1 8 Product Dimensions MHR Fig. 2 9 General Arrangement MJTHR Fig Product Dimensions MJTHR Fig Electrical Schematic 120 vac Fig Wiring Diagram 120 vac Fig Electrical Schematic 208 vac Fig Wiring Diagram 208 vac Fig Electrical Schematic 230 vac Fig Wiring Diagram 230 vac Fig Electrical Schematic 24 vdc Fig Wiring Diagram 24 vdc Fig Product Dimensions & Parts Controller Fig. 13, Fig

4 SAFETY WARNINGS Failure to abide by any of the safety warnings could result in serious injury or death. Electrical power must be "OFF" before and during installation and maintenance or personal injury may result. Do not exceed any equipment pressure ratings. MHR & MJTHR surface temperature will approach temperature limit specified in technical specifications. Gloves may be required for set point adjustments. Select a mounting location so that the enclosure will not be subjected to impact by heavy objects. Impacts can damage enclosed devices. The hazardous location information specifying class and group listing of each instrument enclosure is marked on the nameplate of each enclosure. All unused conduit openings must be plugged. Plugs must be a minimum of 1/8" thick and engage a minimum of 5 full threads. Do not use Teflon tape or pipe dope on gland connection to the hazardous area rated enclosures. 2

5 PRODUCT FEATURES The Mustang Heated Regulator (MHR) and Joule-Thomson Heated Regulator (MJTHR) are designed to heat a gas sample to a customer specified temperature and pressure set point. Liquid condensation from a single-stage pressure reduction is prevented through a two-stage heating process. The regulator body houses a thermocouple and cartridge heater for precisely maintaining the gas sample temperature.. Through an innovative design comprised of a long flow path, the heated regulators provide efficient heat transfer to the gas sample which overcomes any Joule-Thomson cooling effect as a result of the pressure reduction. Temperature control of the regulator is accomplished via a Watlow temperature controller. Temperature input is from Type J thermocouple and the controllers utilize PI control to provide an output to the heater elements. Communication to the controller is via RS485 protocol. The heated regulator assemblies provide safe and reliable temperature control and pressure reduction essential to ensuring the performance of gas analyzers. Analytically Accurate design Provides continuous gas sample conditioning in any process industry Protects analyzers & helps preserve sample integrity Efficient heat transfer through pre-heat and post-heat chambers Proportional temperature control Thermal cutoff Contact us to determine heated and supercritical application needs with our Equations of State software 3

6 TECHNICAL SPECIFICATIONS Classification MAOP Outlet Pressure Range Internal Volume Control Range Thermal Cut-Off Connections Controller Power Wetted Materials Seat Material Certifications Class 1, Div 1, Group C, D, & T3 Zone 1 Group IIC, Category 2G, IP66, Ex d IIC T3 Gb MHR 3750 psig (259 60ºF (16ºC) MJTHR 6000 psig (408 60ºF (16ºC) 0-10, 2-25, 0-50, 0-100, 0-250, or psig (0-0.69, , , , , or bar) 5.0 cc C Opens at 230 F (110 C) or 266 F (130 C) (customer specified) 1/4 FNPT Process 3/4 FNPT Conduit Watlow Model PM6C1EH-2AAAAA 120 VAC 50/60 Hz, 215 W 208 VAC 50/60 Hz, 215 W 230 VAC 50/60 Hz, 215W 24 DC 24 VDC, 150W 316 SS/NACE Compliant; O-rings, Viton, Other materials available consult factory. Teflon ITS12ATEX17539 IEC Ex ETL X 4

7 NOMENCLATURE INSTALLATION INSTRUCTIONS MAOP Maximum Allowable Operating Pressure BTU British Thermal Unit TCO Thermal Cut Off Watlow Controller temperature controller for the heated regulator Regulator adjustment screw pressure set point adjuster Terminal Strip location of internal wire landing points Thermocouple type of temperature sensor implemented TOOLS REQUIRED Flat or Phillips Head Screwdriver The Mustang Heated Regulator assembly can be mounted in any position. Preferred position is with the heater block at the bottom so heat can rise into the body of the regulator. Mount the Model MHR assembly in accordance with previous cautions and warnings. Perform the electrical hook up with de-energized conductors. Verify the unit that you are hooking up to matches voltage wise with the power supply that you are connecting. Damage to the unit can occur if the wrong source power is applied. A seal fitting is required for the power input connection to the controller enclosure to maintain its electrical hazard classification rating. For 120 volt single phase input power: Connect the hot wire to wiring terminal #1. Connect the Neutral wire to wiring terminal #2. Connect the earthing (ground) wire to the green screw in the bottom of the enclosure. For 208 or 230 volt single phase input power: Connect one hot wire to wiring terminal #1. Connect the Neutral to wiring terminal #2. Connect the second hot wire to wiring terminal #3. Connect the earthing (ground) wire to the green screw in the bottom of the enclosure. For 24 vdc input power: Connect the positive wire to wiring terminal #1. Connect the negative wire to wiring terminal #2. Connect the earthing (ground) wire to the green screw in the bottom of the enclosure. 5

8 A seal fitting is required between the controller enclosure and the MHR heater block. Externally connect earthing (grounding) conductors from assembly to equipment ground connections. Connections from the controller to the heater block are pre-wired from the factory. If replacement or troubleshooting is required, refer to the electrical schematic supplied with the unit. ADJUST THE TEMPERATURE SET POINT. The temperature controller comes from the factory set to 120 F unless otherwise specified. If a different temperature is required, refer to the Watlow Temperature Controller operation manual for the complete setup and adjustment procedures. SET REGULATOR PRESSURE Apply input pressure and adjust the regulator adjustment screw until the desired output pressure is attained. The nut on the adjustment screw may be used to secure the adjustment screw at its set point. OPERATION INSTRUCTIONS Close the cover on the controller enclosure. Turn on the electrical supply to the controller. Allow a few minutes for the system temperature to stabilize. The pressure set point may have to be adjusted once the temperature has stabilized. Seal the seal fittings if the controller is functioning as desired. Verify that the sample stream supply is shut off. Verify that the power to the controller is off. Install the Watlow supplied software (EZ-Zone Configurator) on a laptop or other computer. Connect to the Watlow controller using a RS-485 adapter (B&B Electronics Model 485SD9 TB or equal). Plug the adapter into the serial port. Select the serial port on the computer to be used (i.e. COM 1-COM17). The other end connects to the RS-485 terminals. 6

9 On the computer, start program EZ-Zone Configurator. Turn power on to the controller. Establish communication with the Watlow controller. Set its address to 1 or user preference. Set the regulator temperature set point to the recommended temperature. Initially set the regulator temperature at F ( C). For all other Watlow parameter settings, refer to the EZ-Zone User s Manual. Slowly turn in the sample fluid low to full open to the regulator. Adjust the regulator adjusting screw to obtain the desired output pressure. Once sample fluid is being regulated, monitor the regulator temperature to verify that the controller is maintaining the set point temperature. Verify the pressure and flow to the remote gas chromatograph or analyzer. Once the flow is correctly established to the analyzer or gas chromatograph, document the flow value. Do not adjust the flow value unless a calibration check is made on the analyzer. Do not leave power on for extended periods of time without flow through the unit. MAINTENANCE INSTRUCTIONS Once system is operational, no routine maintenance is required. Monitoring of flow and temperature values is recommended at least annually. 7

10 GENERAL ARRANGEMENT MHR ADJUSTING SCREW REGULATOR TEMPERATURE CONTROLLER IN CLASS 1 DIV 1 & 2 ENCLOSURE HEAT EXCHANGE CHAMBER 8

11 PRODUCT DIMENSIONS MHR FRONT VIEW TOP VIEW 9

12 GENERAL ARRANGEMENT MJTHR ADJUSTING SCREW MULTI-STAGE REGULATOR TEMPERATURE CONTROLLER IN CLASS 1 DIV 1 & 2 ENCLOSURE HEAT EXCHANGE CHAMBER 10

13 PRODUCT DIMENSIONS MJTHR FRONT VIEW TOP VIEW 11

14 ELECTRICAL SCHEMATIC 120 VAC 12

15 WIRING DIAGRAM 120 VAC 13

16 ELECTRICAL SCHEMATIC 208 VAC 14

17 WIRING DIAGRAM 208 VAC 15

18 ELECTRICAL SCHEMATIC 230 VAC 16

19 WIRING DIAGRAM 230 VAC 17

20 ELECTRICAL SCHEMATIC 24 VDC 18

21 WIRING DIAGRAM 24 VDC 19

22 PRODUCT DIMENSIONS & PARTS CONTROLLER Fig. 13 DWG# MST-UPH-##WTL

23 Specification for Temperature Controller Enclosure Mustang Sampling Outlet box for hazardous locations Class 1, Groups B, C, D CE Ex 11 2 g Ex d llc. T6-30 Max, T5-40 Max Gb IP66 CAUTION: TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES, DISCONNECT THE EQUIPMENT FROM THE SUPPLY CIRCUIT BEFORE OPENING. OUVRIR LE CIRCUIT AVANT D;ENLEVER LE COUVERCLE KEEP ASSEMBLY TIGHTLY CLOSED WHEN IN OPERATION. GARDER LE COUVERCLEBIEN FERME TANT CUE LES CIRCUITS SONT SOUS TENSION. Fig. 14 DWG# MST-UPH-WTLRG-AI

INSTRUCTION MANUAL (ATEX / IECEx)

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