O2 PPM Level Checks

Work Instruction BTU O2 PPM Level Checks

Work Instruction

Trouble shooting High PPM levels
  1. Check that N2 Pressure is set between 55-65PSI at the internal regulator.
  2. Check flow Exceeds 450-500 LPM maintaining the above pressure (Check Default recipe notes for nominal settings)
  3. Check that Purge timer is set between 30-45mins
  4. Verify analyzer operation, flow and make sure inlet tube is secure with correct fittings. 
  5. Establish baseline for the machine firstly sample only the source gas, document the value. Should be less than 20 PPM
  6. After full purge 30-45 mins sample only from Peak zone note the value after readings stabilize.
  7. Allow several cycles until reading has stabilized. Record the reading. 
  8. Verify in normal running conditions not in idle mode.
  9. PPM Should Be >500PPM on these systems

Check the following if PPM Levels are high 
  1. Analyzer operation check correct flow and fittings are secure for the incoming supply tube. validate readings with second analyzer if available
  2. Entrance and exit curtains should be present at top and bottom. (Cut to suit Product requirements.
  3. Check Main clam shell gasket seal integrity. (Not Damaged)
  4. Lift top section cooling lids and inspect the gaskets.
  5. Check both cooling box door seals are good and gaskets for excess compression
  6. Check blower motor doughnut and plug gasket seals are good for each zone.
  7. Check flux management door and drip tray gaskets are ok and not overly compressed replaced if necessary.
  8. Check flux motor gasket seal is ok.
  9. Verify no loose hose fitting connections, clamps (Input hosing to the Flux inlet)
  10. Check flux motor is running between 1-1.5 amps
  11. Check Cooling motor seals and doughnut gaskets are good.
  12. Check hose connections are secure.
  13. Check sample system solenoid and hose connections.
  14. Check sample and feed lines to zones are secure.
Testing For O2 Leaks.

  1. Document all tests and allow stability between tests, take pictures where necessary and note any parts that are suspect.
  2. With The system running with the above conditions.
  3. Disconnect Flux motor and wait for 10 mins or until stable see if PPM Value drops Record the value. Then reconnect the motor
  4. Switch on flux bypass valve on and monitor PPM Levels If this drops record value.
  5. Disconnect each cooling motor ( One at a time )and wait for 10 mins or until stable and record PPM Values. Reconnect the motor.
  6. Now individually disconnect the top and bottom Zone blower motors and monitor PPM Levels.  It is important to give the analyzer time to react after you make a change it takes time to change.
  7. By doing the above items you should be able to effect the PPM Levels to go down.  Look at the recording and work on the one that had the most effect.
  8. Document values during each test parameter 
Nominal flows, verify Default recipe notes for recommended flows specific to your machine 


Flow Meter 
Nominal Value LPM
Ent Vest
190
Zone 1
90
Zone 5
0
Zone 9/10
70
Cooler
50
Exit
50
Total Flow
450 LMP

Above is a standard setup with the minimum flows recommended for a 10 zone pyramax.

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