Sunset Laboratory OCEC Filter Replacement (Rev: 1.3)

 

Purpose:  To remove and replace the quartz sample filter & leak check the inlet.

 

Required Tools:   Sunset filter removal tool

                                Sunset filter punch

                                Sunset flat forceps or filter tweezers

                                Inlet cap

 

Required Supplies:  37mm baked Quartz filter (same as used for PCM3)

                                      Latex/vinyl gloves

 

Reference:  “Initial Installation of Sunset Lab OCEC Field Instrument”, “Installation Notes” section 2, part h “Filter Installation/removal”, page 4.   “Install-RT3.ppt” PowerPoint presentation.  RealTimeOCECManualv8.

 

Overview: The Sunset control software (RTOCEC888) will be stopped, the filter glassware removed & the filter replaced, the software restarted and the inlet capped to check for leaks, the oven cleaned, and finally the software set to normal sample collection mode.

 

Stopping the Software:

1.      To prevent excess data loss only stop the analyzer just after a new sample has started - samples start on the hour, so 1 to 15 minutes after the hour is ideal.

2.      In the Sunset “Semi-continuous Real-time Carbon Analysis” window, in the upper right hand corner, click the “Cancel this run” button.

3.      The “VERIFY DATA LOSS” window will open, and then click the “Yes” button.

4.      The software is now stopped.

5.      Reboot the computer to clear all operating system buffers.

 

Filter Removal and Replacement:

1.      Open the “Filter installation & access port” door,

Filter access cover
 
         

2.      Remove the “Filter access cover” by pulling up on the locking knob and sliding the cover out.

 

 

3. To gain access to the filter:

a)       First loosen the “gland nut” and slide it back.

b)       Then loosen the Nylon nut holding the photodetector and slide the photodetector & Nylon nut off the quartz tube.

Stainless steel nut, called “gland nut”
 

Nylon fitting
 

photodetector
 
       

 

Note: Do not touch the quartz insert tube with your fingers - ware gloves.
 

Quartz insert tube Nylon locking nut.
 

Quartz insert tube
 

Note o-ring
 
       

 

c)       Use gloves whenever handling the quartz insert tube.

d)       Loosen (do not remove) the quartz insert tube Nylon locking nut and carefully slide out the quartz insert tube.

Note: The slotted portion of the tube goes into the oven tube.

 

 

 


4.      Get the filter removal tool and remove the protective rubber cap from the “harpoon” tip.

5.      Carefully insert the harpoon tip end of the tool into the oven quartz tube until it just touches the filters.

6.      Now give the tool a quick jab so that the harpoon tip punches through the filters (there are two filters).

7.      Carefully pull the tool out along with the two harpooned filters.  In the unlikely event that the filters cannot be harpooned and they get pushed past the shoulder in the oven quartz tube, they will have to be “fished” out with the hooked end of the filter tool or a hooked tipped wire - they cannot be left in the inner oven cavity.

Caution: When “fishing” for the filters, be careful not to damage the oven thermocouple.

Quartz filters

after removal

from the internal

oven seat
 

8.      Replace the protective cap back on the harpoon tip of the filter tool and put it away.

9.      Get out the filter cutting tool.

10.   You will cut two filters from one 37mm PCM3 baked quartz filter.

11.   Place the 37mm filter on a piece of aluminum foil placed on top of a firm, but not hard, pad - a Post-it pad works fine.

Note: Do not cut the filters on a hard surface, like a counter top; it will damage the cutting edge of the tool.

12.   Put the filter punch on the filter near the edge, but not over the edge, and press down firmly to cut through the filter and not the aluminum foil.

13.   Leave the cut filter in the tool and place the tool on the uncut area of the 37mm filter and cut out the second filter.

Quartz filters and filter punch
 

14.   Carefully remove the filters from the punch and, using tweezers, place them in the opening of the oven quartz tube.

 

New quartz

filters ready for

insertion using

the quartz insert

tube
 

15.   Position the filters so that they are vertical in the oven quartz tube.

16.   Put on a clean pair of gloves and wipe the quartz insert tube to remove any finger prints, lint, filter fragments, etc.

17.   Carefully insert the quartz insert tube (slotted portion goes into oven) and push the filters in until they are firmly seated against the oven shoulder.

Quartz insert tube Nylon locking nut.
 

Filters vertical and being pushed into place with the quartz insert tube.
 

18.   While holding the filters firmly in place against the oven shoulder, tighten the Quartz insert tube Nylon locking nut.

IMPORTANT:  Hand tighten only.  Do Not use any tools to tighten any of the nuts.

19.   Reinstall the photodetector w/Nylon nut back on the quartz insert tube - do not tighten.

20.   Attach the “gland” nut to the photodetector and hand tighten - make sure the o-ring is in place.

21.   Let the photodetector align itself on the quartz insert tube and then hand tighten the Quartz insert tube Nylon locking nut.

 

    

22.   Carefully make sure that all nuts are firmly hand tight.

23.   Re-install the “Filter access cover”.

24.   Close and secure the “Filter installation & access port” door.

 

Leak Check:

1.      In the Sunset “Semi-continuous Real-time Carbon Analysis” window, in the top center, click (to uncheck) the “Use Sample File Times”

2.      Then click “Start Analysis” in the upper right hand corner of the window.

3.      You should hear the “Ball Valve” operate and approximately “8.00” should display in the  “Sample Flow L/min” field of the “RT1 GAS FLOWS AND ABSOLUTE PRESSURE” window, indicating that the sample flow is on.

4.      Cap the inlet.

5.      The sample flow should drop to approximately .16LPM or lower (2% of 8 LPM).

6.      If not, move the inlet cap to the “Sample Inlet” port on the back of the analyzer.

7.      If the leak check is good, then there is a leak somewhere in the inlet, find and resolve the leak before restoring the analyzer to normal operation.

8.      If the leak check is still bad, then there is a leak somewhere in the sample circuit inside the analyzer.

9.      Re-check all of the tubing connections for tightness.

CAUTION: Hand tighten only - do not use any tools to tighten any of the connections.

10.   Make sure all of the plastic ferrules and o-ring are in place.

11.   If you cannot resolve the leak, contact Plano for assistance.

12.   After the system is leak tight, remove the cap, and restore all inlet connections.

 

Clean the Ovens:

1.     In the Sunset “Semi-continuous Real-time Carbon Analysis” window, in the upper right hand corner, click the “Cancel This Run” button.

2.     The “VERIFY DATA LOSS” window will open, click the “Yes” button

3.     In the Sunset “Semi-continuous Real-time Carbon Analysis” window, in the upper left hand corner click on “Run”, in the drop down menu click on “Clean Oven”

4.     The ovens will now run through a cleaning cycle that takes approximately 6 minutes.

 

Restoring Analyzer to Normal Operation:

1.     In the Sunset “Semi-continuous Real-time Carbon Analysis” window, Click (to check) the “Use Sample File Times”

2.     Click “Start Analysis”

3.     In the “RT1 Status” window the “Start Collection Time” field will display the start time of the next sample, usually on the hour, every hour.

4.     The analyzer is now set to normal operation

 

Finish Up:

1.     In TrackOps record activity & close the “Sunset EC/OC Filter Change” ticket.

2.     In the SiteLog record activity.

*********************   Procedure Complete   *****************************