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YZ Systems DynaPak DP-2010, Instructions & Operating Manual

The YZ Systems DynaPak DP-2010 is a high-performance device that ensures seamless operation in your workspace. With its advanced features and user-friendly interface, this product guarantees optimal efficiency. To make the most of your DynaPak DP-2010, simply download the Instructions & Operating Manual for free from our website, manualshive.com.

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YZ Systems Milton Roy • 201 Ivyland Road • Ivyland, Pennsylvania • USA • 18974 • P: 281.362.6500 • www.yzsystems.com  

DP-2010 ver.05-2018

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DynaPak 2000 Pump Parts List

Number Description

Part Number

D

F

K

L

1001

Set Screw

C0-0096

1002

Volume Adjustment Knob

B1-0002

1003

O-Ring

V-010

1004

Cap Screw

C0-0014

1005

Volume Adjustment Detent

B1-0030

1006

Volume Adjustment Spring

C3-0005

1007

Pneumatic Fitting

A1-0113

1008

Upper Diaphragm Housing

B1-0003

1009

Stroke Adjustment Screw Assembly

B1-0004

1010

Diaphragm

A6-0010

1011

Plunger Assembly

B1-0007

1012

Plunger Return Spring

C3-0006

1013

Lower Diaphragm Housing

B1-0010

1014

Seal

A6-0018

A6-0028

1015

Spring Retainer Bushing

B1-0011

1016

Discharge Check Valve Spring

C3-0007

1017

Discharge Check Valve Sleeve

B1-0014

1018

Discharge Check Valve Bushing

B1-0013

1019

O-Ring

A5-1108

A5-1108-90D

A5-3108

1020

Pump Body

B1-0015

1021

Male Connector

40061

1022

O-Ring

A5-1012

A5-3012

1023

Body Bushing

B1-0016

B1-0047 B1-0047

1024

Inlet Check Valve Dart

B1-0018

1025

O-Ring

A5-1006

A5-1006-90D

A5-3006

1026

O-Ring

V-014

A5-3014

1027

Inlet Check Valve Body

B1-0019

1028

Inlet Check Valve Spring

C3-0008

C3-0013

1029

Inlet Check Valve Spring Guide

B1-0020

1030

Nut

C0-0026

1031

Inlet Screen

C4-0006

NOTE: The part number column indicates parts for the standard DP-2010. The listings in the columns for other versions 

are the only parts that are different for that version. For example, a DP-2010FL has a B1-0047 body bushing and a C3-

0013 inlet spring along with all the other standard parts.

Summary of Contents for DynaPak DP-2010

Page 1: ...DynaPak Gas Sampler S Y S T E M S U P P O R T M A N U A L DP 2010 V e r s i o n s D F J K L S T D ...

Page 2: ...DP 2010 Instruction Operating Manual Version 05 2018 ...

Page 3: ...Components 4 System Flow Schematic 5 Standard Mounting Location 6 Standard System Connections 7 Section 3 Sample Vessel Installation 8 Variable Pressure Constant Volume Cylinders 8 Variable Volume Constant Pressure cylinder 8 Section 4 System Control Electronics 9 Overview 9 Section 5 Programming for Proportional to Flow Operation 10 Setting Operator Input Values 10 Section 6 Programming For Propo...

Page 4: ...tion 20 For Additional Help 20 Step by Step Resolution 20 Battery Power 21 Battery Power Troubleshooting Steps 21 Proportional to Flow Mode 22 Proportional to Flow Mode Troubleshooting Steps 22 Proportional to Time Mode 23 Proportional to Time Mode Troubleshooting Steps 23 Appendix A Illustrations 25 DynaPak 2000 Pump Assembled 25 DynaPak 2000 Pump Exploded View 26 DynaPak 2000 Pump List of Parts ...

Page 5: ...g the copy retains a hyperlink to the referenced item Measurement units are listed in italic parenthe sis text following their US standard equivalent As an example for defining a distance 15 4 5 meters is how the text will appear throughout the manual Items that require action for example the press ing of a key for programming the controller will feature the action item in sentence case Bold Text ...

Page 6: ...troke the DP 2000 pump The rate at which this occurs is a function of operator input Two 10 position switches are used to set the off time interval The number of times the solenoid output is ac tivated is recorded by the onboard LCD stroke indicator B Proportional to Flow sampling In this mode of operation the Z 65 counter operates as a dividing counter The Z 65 coun ter periodically energizes a l...

Page 7: ...ssel portable DOT approved 1800 psi maximum working pressure sample vessels Avail able in 300 500 and 1000 cc sizes KK 1 KK 2 KK 3 carrying cases for DuraSites that meet DOT requirements for transporting portable sample vessels 1 4 stainless steel tubing Dielectric Isolator Union These should be installed in every tubing line that at taches the sampler to the pipeline in any manner For example the...

Page 8: ...roller Sample Pump Probe mounted pneumatically actuated DP 2000 Sample Pump Filter Regulator Stainless Steel regulator ca pable of reducing pressure from line pressure of up to 1500 psi down to system supply pressures in one step Low Power Solenoid Provides interface between the Z 65 Electronic Controller and the Pump Pneumatic actuation Controller Provides control functions for the DynaPak Sample...

Page 9: ... Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 5 Section 2 System Installation System Flow Schematic figure 2 EPO 120 SPO 120 ...

Page 10: ...h could cause aerosols or significant pressure drops 2 The sampler should not be located within the defined meter tube region AGA 3 manual A The number of unobstructed straight pipe diameters upstream see AGA 3 manual B the number of unobstructed straight pipe diameters downstream see AGA manual A The number of unobstructed straight pipe diameters upstream see AGA 3 manual B The number of unobstru...

Page 11: ...ewed out of the probe body This of course results in product at pipeline pressure being vented continually through this port until this section of the pipeline is shut in DynaPak valves are of soft seat design and should only be closed or opened with fingers Wrenches should never be used If a valve will not seal off with finger tight operation the valve should have maintenance performed to allow p...

Page 12: ...cal position Piping from the sam pler discharge port to the sample vessel should be arranged so that liquid traps are not created Variable Volume Constant Pressure cylinder The free floating piston cylinder DuraSite figure 35 on page 31 may be installed in a horizontal position on an optional vessel rack Free floating piston cylinders should NOT be installed on the DynaPak BackRack vessel rack Ins...

Page 13: ...are when performing maintenance on Sampling Systems Always take necessary measures to assure that electrical classification in the area is considered before and during all repairs and that necessary steps are taken to maintain proper electrical proce dures for the classification of the area The control package requires you to configure the Z 65 controller to operate in a Proportional To Flow mode ...

Page 14: ...e host computer or output device that will give an input pulse to the Z 65 controller 1 Determine if the incoming input is either a dry contact or voltage pulse 2 If the input is a dry contact a Terminate the incoming connections to the Z 65 terminal strip see illustration b Turn mode switches 1 3 to ON and 2 4 to OFF OR 3 If the input is a voltage pulse a Terminate the incoming connections to the...

Page 15: ...ost flow meters to the desired rate If the calculated counter setting is less than 1 increase the pulses per volume metered If the calculated counter setting is greater than 99 decrease the pulses per volume metered figure 8 1 Your pump displacement from 1 to 4cc s a 2 Your sample cylinder volume in cc s 300cc 500cc etc b 3 Average flow rate MMCF per day or MCM per day c 4 Sample period in days d ...

Page 16: ...to the dial setting shown for the Z 65 model with the timer range setting in the factory position jumper on the two left pins See section 10 Timer Range Setting Page 24 figure 9 Example Number of turns open on pump stroke knob Sample pump displacement per stroke Sample cylinder volumes 1000 cc 500 cc 300 cc 3 100 4 9 15 6 200 9 18 30 9 300 13 27 45 12 400 18 36 60 Sample rate minutes 3 Adjust the ...

Page 17: ...systems com DP 2010 ver 05 2018 Page 13 Section 7 Mechanical System Overview The DynaPak mechanical system as shown below is composed of the sample pump and filter regulator These components of the system are shown here and described in the following pages figure 11 3 4 standard 1 2 J version ...

Page 18: ...e period is achieved by the controller This pump has internal pressure balancing capabilities that allows the pump to func tion properly when the pipeline pressure is greater than the sample vessel pressure or when the sample vessel pressure is greater than the pipeline pressure Each time the pump strokes product pre viously captured in the pump chamber is forced towards the sample cylinder As the...

Page 19: ...rclockwise to set the pump displacement at 4 cc stroke refer to Section 7 page 14 4 Move all of the mode switches on the Z 65 to their OFF positions as shown 5 Move both timer counter dials to the 0 position 00 minutes as shown 6 Move mode switches 1 2 and 3 to ON position The pump will begin stroking once every 2 seconds in a diagnostic test mode as shown 7 Allow the sampler to operate until the ...

Page 20: ...e application of the sampler Many of these considerations include the weather envi ronment the condition of the actuation gas the product condition and quality and the pump stroke frequency All of these issues must be considered when establishing a preventative maintenance schedule Recommended Maintenance Schedule Monthly Inspection 1 Verify system pressure 2 Check for leaks 3 Test the battery 4 T...

Page 21: ...w the pump body by hand from the inlet check valve assembly Separation at this point is recommended to maintain proper tubing location and alignment between the pump body and the probe body Do not remove the inlet check valve body from the manifold unless cleaning is necessary To replace the inlet check valve o ring carefully cut the o ring off the head of the dart and stretch the new o ring over ...

Page 22: ...he body bushing into the bottom of the pump body as shown 11 Insert all other bushings springs and o rings in their respective sequence on the plunger shaft as shown 12 Carefully install assembly into the top of the pump body and screw the actuator assembly onto the pump body Tighten firmly by Hand ONLY 13 Install the pump assembly on the inlet valve assembly Tighten firmly by Hand ONLY 14 Connect...

Page 23: ...umb screws over plate and orange terminal connector 2 The battery is located in the lower left hand corner of the Z 65 controller assembly 3 Unclip the battery plug from the battery receptacle 4 Replace the depleted battery with a fresh battery pack part No E3 2001 Refer to figure 20 to assure proper battery wire placement in the Z 65 enclosure 5 Return the mode switches to their original position...

Page 24: ... 6500 International Calls E techsupport yzhq com SAFETY NOTES Always use extreme care when performing maintenance on Sampling Systems Always take necessary measures to assure that electrical classification in the area is consid ered before and during all repairs and that necessary steps are taken to maintain proper electrical procedures for the classification of the area Take special care when dis...

Page 25: ...the Battery needs changing Battery Power Troubleshooting Steps 1 Set the mode switches 1 2 and 3 to ON position as shown 2 Set the time switches to the 01 position This will set the solenoid output rate to one actuation every one minute based on the factory set time range for the Z 65 model refer to figure 28 page 24 3 Depress the test switch to test the battery A green LED will illuminate if the ...

Page 26: ...ses are being received at the count input ter 3 A Dry Contact Input Mode switch 4 should be in the off position as shown Depress the test switch and hold A red LED should illuminate When the dry contact input is received at the counter input ter 3 the green LED will turn on and off and the red LED will illuminate again This will normally occur very quickly and give the appearance that the green LE...

Page 27: ...e solenoid output rate to one pulse every two seconds Figure 25 3 Unscrew the thumbscrews and remove the six position terminal strip and cover This will expose the battery pack and the three position configuration jumper located in the lower right corner of the Z 65 controller assembly 4 Set the configuration jumper to the far right position marked stroke indicator test as shown 5 This will cause ...

Page 28: ...he timer setting dials 1 Range Setting xx minutes Set the configuration jumper to the far left position factory setting as shown 2 Range Setting x x minutes Set the configuration jumper to the center position as shown NOTE To obtain maximum battery life choose the longest solenoid stroke rate possible Figure 28 Figure 29 Jumper switch location for 1 99 counts xx factory positioned Jumper switch lo...

Page 29: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 25 Appendix A Illustrations DynaPak 2000 Pump Assembled Figure 30 ...

Page 30: ...on Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 26 Appendix A Illustrations DynaPak 2000 Pump Exploded View Figure 31 DP 2000 Pump Seal Kit P N D3 0002 ...

Page 31: ...ing Retainer Bushing B1 0011 1016 Discharge Check Valve Spring C3 0007 1017 Discharge Check Valve Sleeve B1 0014 1018 Discharge Check Valve Bushing B1 0013 1019 O Ring A5 1108 A5 1108 90D A5 3108 1020 Pump Body B1 0015 1021 Male Connector 40061 1022 O Ring A5 1012 A5 3012 1023 Body Bushing B1 0016 B1 0047 B1 0047 1024 Inlet Check Valve Dart B1 0018 1025 O Ring A5 1006 A5 1006 90D A5 3006 1026 O Ri...

Page 32: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 28 Appendix A Illustrations YZ Filter Regulator Assembly Figure 32 ...

Page 33: ... Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 29 Appendix A Illustrations YZ Filter Regulator Exploded View Figure 33 V 214 ...

Page 34: ...Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 30 Appendix A Illustrations Link Plus Figure 34 A8 0067 A8 0060 A8 0048 A8 0058 ...

Page 35: ...stems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 31 Appendix A Illustrations DuraSite Sample Vessel Figure 35 P N C6 1040 P N C6 1041 ...

Page 36: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 32 Appendix A Illustrations Z 65 and Solenoid Figure 36 D3 0142 ...

Page 37: ...YZ Systems Milton Roy 201 Ivyland Road Ivyland Pennsylvania USA 18974 P 281 362 6500 www yzsystems com DP 2010 ver 05 2018 Page 33 Appendix A Illustrations Z 65 Wiring Control Document Figure 37 ...

Page 38: ...201 Ivyland Road Ivyland PA 18974 P 800 653 9435 P 281 362 6500 E sales yzhq com www yzsystems com ...

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