model111-zeroair-156file_17823

MODEL 111/111S

ZERO AIR SUPPLY

INCLUDING EXTERNAL AIR COMPRESSOR

INSTRUCTION MANUAL P/N 7734

THERMO ENVIRONMENTAL INSTRUMENTS INC. 8 WEST FORGE PARKWAY

FRANKLIN, MASSACHUSETTS 02038

TELEPHONE: (508) 520-0430 FACSIMILE: (508) 520-1460

3-4-02

Other brands and product names mentioned in this instruction manual are trademarks of their respective owners.

Copyright 2000-2002 Thermo Environmental Instruments, Inc.

Franklin, Massachusetts

�This manual is a work protected under Copyright law. Copying or other reproduction of any of its contents without the prior written consent of Thermo Environmental Instruments is expressly prohibited.�

Publications Comments Form

Document Part Number 7734 Fax 508-520-1460 Title Model 111/111S Instruction Manual

We continually seek to improve the content and usability of our technical documents. You can help us by answering the questions below and mailing this form to us.

How do you use this document? Introduction to the product Advanced programming techniques Classroom resource Operating instructions Self-study Reference Programming procedures Other

How did you get this document? Received with equipment Ordered from TEI

Do not know Received from Sales or Customer Service Representative Other

Please rate this document. Excellent Good Poor Technical Accuracy

Does the system work as described in the manual?

Readability Is the manual easy to read and understand?

Clarity Are the instructions easy to follow?

Examples Are the examples helpful and realistic? Are there enough examples?

Organization Is the organization of the manual logical? Is it easy to find what you are looking for?

Illustrations Are the illustrations clear and useful? Appearance What do you think of the layout, printing, binding, etc.?

Yes NoAre there any terms or concepts that are not defined clearly? If so, what are they? ____________________________________________________________________________________

Yes NoAfter reading this manual, are you able to use the equipment?

What errors did you find in the manual? Please include page numbers. Attach extra sheets if necessary. ____________________________________________________________________________________

Do you have any comments or suggestions? ____________________________________________________________________________________ ____________________________________________________________________________________

Name: _____________________________________ Street: ____________________________________ Title: ______________________________________ City: ____________________________________ Dept./Mail Stop ____________________________ State/Country: _____________________________ Company: _________________________________ Zip Code: _________ Telephone: ______________

Thank you for your help.

Sent by __________________________ __________________________ __________________________ Thermo Environmental Instruments, Inc. 8 West Forge Parkway Franklin, MA. 02038-3136

Attn: Technical Publications

PLACESTAMP HERE

v

TABLE OF CONTENTS CHAPTER 1 INTRODUCTION......................................................................... 1-1 Specifications ...................................................................................................................1-3 CHAPTER 2 INSTALLATION AND SETUP .................................................... 2-1 Unpacking ........................................................................................................................2-1 Assembly..........................................................................................................................2-2 CHAPTER 3 OPERATION............................................................................... 3-1 CHAPTER 4 THEORY OF OPERATION......................................................... 4-1 Gas Scrubbing ..................................................................................................................4-1 Electrical...........................................................................................................................4-3 CHAPTER 5 MODEL 111S.............................................................................. 5-1 CHAPTER 6 MAINTANENCE.......................................................................... 6-1 Weekly..............................................................................................................................6-1 Monthly ............................................................................................................................6-1 Yearly ...............................................................................................................................6-1 Compressor.......................................................................................................................6-1 CHAPTER 7 SERVICING ................................................................................ 7-1 Spare Parts........................................................................................................................7-1 Servicing...........................................................................................................................7-1 Return of Merchandise .....................................................................................................7-2 APPENDIX A WARRANTY..............................................................................A-1

vi

APPENDIX B COMPRESSOR OPERATION AND MAINTANENCE...............B-1 Installation....................................................................................................................... B-1 Disassembly..................................................................................................................... B-2 Electrical.......................................................................................................................... B-4 Assembly......................................................................................................................... B-4 Inspection ........................................................................................................................ B-5 APPENDIX C OPTIONAL HEATLESS AIR DRYER .......................................C-1 Description ...................................................................................................................... C-1 Operation......................................................................................................................... C-3 Operating Temperatures ...................................................................................... C-3 Piping .................................................................................................................. C-3 Air Connections................................................................................................... C-3 Electrical Conditions ........................................................................................... C-3 Inlet Air Preparations .......................................................................................... C-4 Solid State Timing............................................................................................... C-4 Maintenance .................................................................................................................... C-5 Parts Summary ................................................................................................................ C-7 Troubleshooting .............................................................................................................. C-8

vii

LIST OF ILLUSTRATIONS Figure Page 1-1 Zero Air Assembly ...............................................................................................1-1 1-2 Outline Drawing...................................................................................................1-2 2-1 Interior View ........................................................................................................2-2 2-2 Flow Schematic ....................................................................................................2-2 2-3 Option 006 for H2S Permeation ...........................................................................2-3 4-1 Model 111 Flow Schematic..................................................................................4-1 4-2 Component Layout ...............................................................................................4-2 4-3 Wiring Diagram....................................................................................................4-3 4-4 Temperature Controller Schematic ......................................................................4-4 5-1 Model 111S Flow Schematic ...............................................................................5-1 B-1 Compressor � Dimensional Data......................................................................... B-1 B-2 Standard Model 111 Compressor Motor � Exploded View................................ B-2 B-3 20 LPM Option Compressor Motor � Exploded View ....................................... B-3 C-1 Heatless Air Dryer............................................................................................... C-1 C-2 Accumulator � Outline Dimensions.................................................................... C-2 C-3 Dryer Electrical Connections .............................................................................. C-3 C-4 Cycle Timer......................................................................................................... C-4 C-5 Heatless Air Dryer � Exploded View.................................................................. C-6

1-1

CHAPTER 1 INTRODUCTION

The Model 111 Zero Air Supply is a convenient system for the generation of pollutant free zero gas for NO, -NOx, -O3, -SO2, -CO, and hydrocarbon monitoring requirements. The Model 111 uses an external compressor; the pressure regulators, chemical scrubbers, reactor and temperature controller are all contained in a single convenient case (see Figure 1-1 and Figure 1-2). The Model 111 has been designed for any application where pollutant free levels of NO, -NOx, -O3, -SO2, -CO and hydrocarbons are required, with flows up to 20 liters per minutes at pressures of 30 PSI.

Figure 1-1. Zero Air Assembly

Chapter 1 Introduction

1-2

Figure 1-2. Outline Drawing

Chapter 1 Introduction

1-3

SPECIFICATIONS Power 115V 50/60 Hz

Power Consumption 120 Watts

Dimension 12 ¼� H x 19� W x 15� D (suitable for rack mounting)

Weight 17 pounds

2-1

CHAPTER 2 INSTALLATION AND SETUP

The installation of the Model 111, Zero Air Supply (ZAS) includes unpacking the instrument, connecting the compressor, connecting the gas flow lines, and attachment to suitable AC power.

UNPACKING The Model 111 Zero Air Supply is shipped in two containers. If, upon receipt of the supply there is obvious damage to the shipping container, notify the carrier immediately and hold for his inspection. The carrier, and not Thermo Environmental Instruments Inc., is responsible for any damage done during shipment. In addition to the basic unit, an instruction manual is included in the shipping container. Use the following procedure to unpack the instrument: 1. Remove the Model 111 from the shipping container and set on a table or bench,

which will allow easy access to both the front and rear of the instrument. 2. Remove the Model 111 cover from the main frame of the unit, thus exposing the

internal components of the instrument. 3. Check for possible damage during shipment, and then reinstall the cover. 4. Remove compressor from shipping container, unbolt from pallet, and then identify

the coalescing filter and pressure regulator. 5. Check for possible damage during shipment.

Chapter 2 Installation and Setup

2-2

ASSEMBLY Use the following procedure to assemble the instrument: 1. Connect the coalescing filter and pressure regulator to the output of the compressor. 2. Using 1/4" Teflon tubing, connect the outlet of the pressure regulator located on the

compressor to the input of the Model 111. 3. Using 1/4" Teflon tubing, connect the outlet of the Model 111 to the device requiring

"zero air" under pressure.

• If the compressor's power cord has not been installed at the factory, remove the controller's cover on the compressor. Connect power cord to the screw terminals provided. Be sure to connect the ground wire, the line, and the common. Replace the cover. For further instructions on the compressor, refer to Appendix C, �Compressor Operation and Maintenance.�

• If an optional auto drain is being used, remove the stopcock on bottom of tank

and install the auto drain option. 4. Plug the AC line cord into an appropriate power source. Check the voltage and verify

before connecting to the power. For 220 VAC operation, a step-down transformer is installed internally in the Model 11�s case. The compressor is operated directly off the line voltage, 115 V or 220 V. Check the plate on the pump motor to determine the correct voltage and frequency prior to plugging in the compressor.

3-1

CHAPTER 3 OPERATION

Once the Model 111 has been unpacked and assembled, you can use the following procedure to power up and operate the instrument. 1. Close the manual valve on the output of the compressor and plug in the compressor.

The pressure in the tank should gradually increase to 80 to 90 psi. At that point, the pump shuts off.

2. Open the manual valve and adjust the pressure regulator downstream of the

coalescing filter for 70 psi. 3. Adjust the pressure regulator on the Model 111 case for the desired pressure

(typically 10 to 30 psi). 4. Turn the dial on the optional CO reactor temperature controller to 350o C. Turn on the

instrument. The internal cooling fan starts blowing and the temperature controller light is on.

5. After approximately one hour, the indicating light on the temperature controller is

cycling on and off indicating that the reactor is up to temperature. The Model 111 is now ready for use.

6. The compressor�s motor will cycle on and off, with the tank pressure is controlled

between 80 and 90 psi.

4-1

CHAPTER 4 THEORY OF OPERATION

This chapter explains the gas scrubbing and the electronics of the Model 111.

GAS SCRUBBING The purpose of the Model 111 is to supply pollutant-free air (zero air) from the ambient air to allow for proper zeroing, and to provide clean diluent air for spaning ambient air analyzers. The components to be removed are SO2 NO, NO2, CO and hydrocarbons. There is no consensus as to what extent zero air should have water vapor removed. Since many analyzers have longer response times if super dry air (dew point less than -30o C) is used for zero and span, and since water vapor is not a pollutant, the Model 111 does not have a drying system. However, the dew point is reduced as a result of compression of the ambient air. Figure 4-1 is the gas flow schematic for the Model 111. Room air enters the compressor, where it is raised to a pressure of approximately 80 to 90 psi (4560 mm). At 25o C the saturation water vapor pressure is approximately 24 mm. Therefore, most of the water condenses out, and falls to the bottom of the tank. Out of the 4560 mm of pressure in the tank, only 24 mm is due to water vapor. When this air is later expanded to atmospheric pressure (760 mm) the water vapor pressure is reduced to approximately 4 mm. This corresponds to a dew point of slightly less than 0o C. To keep any condensation from occurring in the tubing between the compressor and the Model 111, the output of the compressor contains coalescing filter and a pressure regulator where the pressure is reduced to 70 psig.

Figure 4-1. Model 111 Flow Schematic

Chapter 4 Theory of Operation

4-2

Inside the main case of the Model 111, the compressed air is further reduced to the final desired pressure (10 to 30 psi). The air then passes into a column of Purafil (potassium permanganate on alumina), which oxidizes NO to NO2. The air then passes through a column of iodated charcoal, which removes NO2, and S02. Finally, the air goes into the reactor where it is heated to 375 o over a catalytic surface, which oxidizes CO to CO2, and hydrocarbons including methane, to CO2 and water. Figure 4-2 shows the layout of these components.

Figure 4-2. Component Layout


4-3

ELECTRICAL Figure 4-3 is an electrical schematic of the Model 111 Zero Air Supply. The transformer is installed for 220 volt operation. If the transformer is not installed, a jumper package is installed. Figure 4-4 is the electronic schematic of the temperature controller.

Figure 4-3. Wiring Diagram


4-4

Figure 4-4. Temperature Controller Schematic

5-1

CHAPTER 5 MODEL 111S

The Model 111 is also available for continuous duty when it is supplied with a heatless air dryer. This dryer, normally installed before the Model 111, is designed to remove water, CO2 and some pollutants from the compressed air supply. This provides dry, relatively pollutant free air to the Model 111 for the conversion of CO and removal of NO, NO2, SO2 and hydrocarbons. This will significantly extend the life of the Purafil and charcoal canisters under continuous, around the clock usage. Figure 5-1 illustrates the flow schematic for the Model 111S. An optional compressor can be used to supply the higher air flow rates often required in continuous systems. Customer supplied compressed air may also be used, but caution must be taken to ensure that liquid water and oil be completely removed prior to the heatless air dryer or the Model 111. The Model 111 output pressure is normally set to 60 psig under continuous operating conditions. This pressure can be reduced in certain situations as required. It is important to note that the supply pressure to the heatless air dryer should be 80 to 100 psig. The heatless air dryer will not operate within specifications below 60 psig.

B50P802

Figure 5-1. Model 111S Flow Schematic

6-1

CHAPTER 6 MAINTENANCE

The Model 111 Zero Air Supply has been designed with ease of maintenance as an important criterion. Components and sub-assemblies have been selected for high performance, excellent stability, and long life. The exact lifetimes of the scrubbing material is hard to predict. It is dependent upon flow, pressure, and level of contaminate. For most applications the following recommendation should be followed:

WEEKLY If optional automatic drain valve is not installed, open the stop cock on the bottom of the tank and drain water.

MONTHLY Check the condition of the Purafil. Fresh Purafil is purple. It becomes brown when it is used up. Replace when the purple color represents less than 20% of the volume. To replace, turn off power and unplug, wait until the reactor cools down (approximately 10 minutes with air flowing). Shut off the air supply so that the Model 111 pressure drops to 0.0 psig. Remove the cartridge holding Purafil. Slowly unscrew the cap, allowing any remaining pressure to vent, empty out the used Purafil and discard. Replace with fresh Purafil. Screw on cover and replace cartridge.

YEARLY Replace the charcoal. The procedure is the same as replacing Purafil, outlined above.

COMPRESSOR When it is observed that the pump is having difficulty keeping the pressure, rebuilding may be necessary. For directions, refer to Appendix C, �Compressor Operation and Maintenance.�

7-1

CHAPTER 7 SERVICING

The Model 111 has been designed with ease of maintenance as an important criterion. Electric components have been packaged in sealed subassemblies for rapid fault isolation and replacement. Components and subassemblies have been selected for high performance, excellent stability and long life.

SPARE PARTS The following list includes the recommended spare parts for the Model 111:

Part Number Description Quantity 4510 Main Fuse 1

4510 Temperature Controller Fuse 1

7075 Purafil 5 lbs.

4157 Charcoal 5 lbs.

8193 Service Kit for Standard Compressor 1

8221 Service Kit for 20 LPM Compressor 1

SERVICING Thermo Environmental Instruments Inc. provides spare parts and servicing from the locations listed below:

Thermo Environmental Instruments Inc. 8 West Forge Parkway Franklin, MA 02038 Tel: (508) 520-0430 Fax: (508) 520-1460

Thermo Environmental Instruments Inc.

325 E. Arrow Hwy., suite # 506 San Dimas, California 91773

Tel: (909) 394-2373 Fax: (909) 394-2367

Chapter 7 Servicing

7-2

RETURN OF MERCHANDISE All equipment returns require an authorization to speed response. Before shipping material to the factory, obtain a return authorization number from the Service Department. The number must appear on the outside of shipping container.

A-1

APPENDIX A WARRANTY

Subject to the exceptions stated below, Thermo Environmental Instruments Inc. agrees to correct either by repair or at our option, by replacement, any defects in materials or workmanship which develop within one year from the date of delivery not to exceed eighteen (18) months from date of shipment, parts and labor supplied free of charge. The exceptions mentioned above are: (1) All defective items must be returned to Thermo Environmental Instruments Inc., transportation charges prepaid, and will be shipped prepaid and charged to the customer unless the item is found to be defective and covered by the warranty in which case Thermo Environmental Instruments Inc will pay all surface transportation charges; (2) Thermo Environmental Instruments Inc. agrees to extend to the customer whatever warranty is given to Thermo Environmental Instruments Inc. by suppliers of component items purchased by Thermo Environmental Instruments Inc. and incorporated into products sold to the customer; (3) Thermo Environmental Instruments Inc. shall be released from all obligations under this warranty in the event repairs or modification are made by persons other than its own authorized service personnel, or service personnel from an authorized representative, unless such repair is minor, merely the installation of a new plug-in component; (4) if any model or sample was shown to Purchaser, such model or sample was shown merely to illustrate the article and not to represent that any article delivered hereunder would conform to the model or sample, and (5) Spare parts are warranted for ninety (90) days. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, IMPLIED, OR STATUTORY. SELLER DOES NOT WARRANT MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE, OR MAKE ANY OTHER WARRANTY OR AGREEMENT EXPRESSED OR IMPLIED WITH RESPECT TO ANY ARTICLES COVERED HEREUNDER. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THOSE EXPRESSLY STATED IN THIS CONTRACT.

APPCO

INS

ENDIX B MPRESSOR OPEARTION AND MAINTENANCE This appendix explains proper operation and maintenance of the compressor.

TALLATION If this compressor is being installed in a system where it will be periodically required to start against any form of system back pressure, a positive sealing one way check valve should be installed in the air line between the system and the compressor. Check valves are provided as standard equipment on all Gast tank mounted compressor assemblies (see Figure B-1 for dimensional data.

A B C D E 17 1/4 16 5/8 5 5/8 4 10

Standard Model 111

A B C D E 26 20 7/8 13 1/2 11 1/2 16

20 LPM Option

Compressor CIM Free Air

Model HP @ Open @ 70 psig @100 psig

Standard 1/6 2246 1037 864

20 LPM Option 1/3 4147 2246 1901

! CAUTION: Never lubricate this dry oil-less piston pump. The Teflon filled rings areself-lubricating and require no oil. The motor bearings are grease packed for the life ofthe bearing.

B-1

Figure B-1. Compressor � Dimensional Data

Appendix B Compressor Operation and Maintenance

B-2

DISASSEMBLY It is not necessary to remove the filters from the cylinder head as metal chips could be dislodged and enter the unit. Remove the shroud, cylinder head, and valve components. Do not rearrange the valve components. Remove the cylinder and rings. Make sure all parts are clean before reassembling. Refer to Figure B-2 for the Standard Model 111 compressor and Figure B-3 for the 20 LPM Option.

Note: Do not use any chlorinated solvents to clean valves, or any liquids to flush units. The stainless steel valves can be cleaned with water. All parts, except the valves, can be cleaned with any industrial, non-flammable, non-toxic cleaning solvent.

Figure B-2. Standard Model 111 Compressor Motor � Exploded View

TEI P/N 8187 (110V) TEI P/N 8188 (220V)

* Denotes parts included in service kit.


B-3

Figure B-3. 20 LPM Option Compressor Motor � Exploded View

* Denotes parts included in service kit.

TEI P/N 8216 (110V) TEI P/N 8206 (220V)


B-4

ELECTRICAL Remove the plate covering the electrical terminal for wiring instructions.

ASSEMBLY Use the following steps to assemble the compressor: 1. Install piston seals, piston rings, and rider rings on the piston. 2. Locate ring joints approximately opposite each other and attach cylinder to bracket

with the cylinder screws and lock washers. 3. Tighten screws finger tight. 4. Move pistons to top dead center position and adjust each cylinder flush with top of

piston and torque cylinder screws to 150 to 160 psi. 5. Re-torque second time. 6. Stack the valve components in order as shown in the detail. The valve leaf is pre-bent

and should not be adjusted in any way. 7. Install the cylinder head, lock washers, and head screws. The exhaust ports in the

cylinder head are marked, omitting the ends of two of the fins. Do not tighten head screws at this time.

Note: Do not tighten head screws at this time.

8. Install manifold and nuts and seals on the manifold and assemble into the other

cylinder head and manifold. Torque all head screws to 85 to 95 psi. 9. Re-torque again. 10. Position manifold and tighten manifold nut 1/2 to 3/4 turns beyond hand tight.

WARNING: The motor might be thermally protected and can automatically

restart when the protector resets. Always disconnect the power source before servicingthe instrument.

!


B-5

INSPECTION If the pump or motor show evidence of overheating or excessive noise, stop immediately for repairs. Regular inspection can prevent expensive repairs. The rider thickness can be an indication of when rings need replacing. If a rider ring measures .05511 or less in thickness, a change of all rings should be made. For a unit operating at sea level, in fairly clean air, at an ambient of 65º to 75º F, relative humidity of approximately 35 percent, and at maximum advertised duties, it is suggested that 4,000 hours of operation be used as an initial inspection point. As operating conditions on your particular application improve or worsen, your own experience can be used to determine whether this 4,000-hour figure can be lengthened or should be shortened.

Note: If your pump is equipped with plastic plugs in the exhaust or intake ports, remove them before starting the unit.

It is usually quickest and least expensive to send the motor in for repair. Authorized service facilities are located at: Gast Manufacturing Co., Ltd. Halifax Road, Cressex Estate High Wycombe, Bucks HP123SN England High Wycombe 23571

Gast Manufacturing Corp. 2550 Meadowbrook Road Benton Harbor, MI 49022 (616) 926-6171

Wainbee, Ltd. 121 City view Drive Rex dale, Ontario Canada M9W 5A9

Gast Manufacturing Corp. 505 Washington Ave. Carlstadt, NJ 07072 (201) 933-8484

Wainbee, Ltd. 215 Brunswick Blvd. Ponte Clair, Montreal Canada H9R 4R7 (514) 697-8810

Brenner-Fielder & Assoc. 16210 Gundry Ave. Paramount, CA 90723 (213) 636-3206

WARNING: To prevent explosive hazard, do not pump combustible liquids or

vapors with these units.

!

C-1

APPENDIX C OPTIONAL HEATLESS AIR DRYER

This appendix provides the following details for Heatless Air Dryer:

• Description • Operation • Maintenance • Parts • Troubleshooting

DESCRIPTION The heatless air dryer provides clean dry air with minimal carbon dioxide to provide zero air for ultra sensitive analyzers. The function of the dryer is to first remove moisture from compressed air, and second, to remove the desiccant chambers due largely to the multiple layering of special adsorbent materials (see Figure C-1 and Figure C-2).

Note: All units are equipped with a power cord.

Model Chamber Lengths (inches)

A B C D Weight (pounds)

Standard Option 12� 17� 11.5� 5� 10

Optional 20� 25� 11.5� 5� 19 ¼�

Figure C-1. Heatless Air Dryer

Appendix C Optional Heatless Air Dryer

C-2

Figure C-2. Accumulator � Outline Dimensions


C-3

OPERATION Operating Temperatures The heatless air dryer can operate at maximum ambient temperatures of +100o F. (38 o C) and a maximum inlet air temperature of +125 o F (52o F). However, the recommended operating temperature is +70 o F (21 o C) ambient and inlet air conditions. Piping The heatless air dryer is designed for wall mounting, with the desiccant chambers always up. Air Connections The inlet and outlet connections are 1/4" female NPT. When connections are made directly into unit, a pipe compound should be used to prevent galling of the threads. 3/8" tubing with 1/4" pipe connections should be installed at the input and output for maximum flow. Larger lines are recommended to avoid pressure drop where long piping runs are encountered. After connecting the piping or tubing to the unit, use a soap solution to check the connections for air leaks. An upstream inlet filter is recommended to remove particulate matter 20 microns and larger and liquid water. If oil in liquid form or mist form is present in the air stream, an oil coalescing filter must be used. The dryer should not be operated in a corrosive atmosphere. Electrical Conditions Before wiring, check the nameplate for electrical requirements. Standard electrical characteristics are CDAl-115VAC, 50/60 Hz, 36 watts. 230 VAC units are available (see Figure C-3).

Note: No overload protection is provided in the dryer. The attached 8-foot wire power cord must be plugged into a properly protected outlet.

Figure C-3. Dryer Electrical Connections


C-4

Inlet Air Preparations Air entering the dryer must be free of dirt, rust, oil vapors, condensation, and scale that might accumulate in the piping or compressor. Solid State Timing The cycle timers are of solid state design and are equipped with a one hour minimum memory circuit that restarts the timers at the same point in the timing cycle, as when the power was interrupted (see Figure C-4). The timers feature DC electrical outlets for the DC solenoid valves. The dryer will automatically begin re-pressurizing the purging desiccant chamber before switching chambers. The re-pressurization period is 3.75 seconds and the purging-period is 26.25 seconds. Re-pressurization helps to minimize outlet pressure fluctuation as the flow switches from one desiccant chamber to the other. Further reduction in outlet pressure swings can be obtained by installing a surge reduction tank between the dryer outlet and the outlet pressure regulator. This tank is provided in systems, supplied by Thermo Environmental Instruments Inc. when necessary.

Figure C-4. Cycle Timer


C-5

MAINTENANCE If the unit is installed in accordance with these instructions, field adjustments are unnecessary. No lubrication is required on this instrument. It is recommended that at six-month intervals the unit be thoroughly inspected. Inspection should include audible inspection for proper solenoid valve operation, purge and visual inspection for excessive dirt or oil fouling, and for desiccant attrition. This involves removal of the air manifold covers and the desiccant chambers. Annual inspections should be more thorough and need to include removal of the solenoid valves, and the purge orifice glands to inspect for excessive wear or deterioration of valve parts or the check valve balls, and possible plugging of the purge orifices (see Figure C-5).

Note: Orifices are critical parts in determining the performance of a dryer. Therefore do not, in any way, increase the size of the orifice. Orifices of the appropriate size can be obtained from the factory.

Purge orifice glands are screwed into the manifold beneath the desiccant chambers. To change orifices, unscrew the chambers and remove the orifices with a standard 7/8" socket wrench. The cycle timer can be replaced in the field.

Note: Improper packing of the desiccant chambers can cause channeling of the gas stream and unsuitable purification. For this reason, do not attempt to repack desiccant chambers in the field. Replacement chambers must be obtained from your local authorized distributor.


C-6

Figure C-5. Heatless Air Dryer � Exploded View


C-7

PARTS SUMMARY The following list includes a summary of parts for the Heatless Air Dryer:

Item No. Description Quantity 1 Desiccant Chamber 12" Inc. Item 2 Consult Factory

Desiccant Chamber 20" Inc. Item 2 Consult Factory N/A

2 O-Ring- 1.720 I.D. X 0.118W 2 3 O-Ring- 0.362 I.D. X 0.103W 2 4 Purge Orifice Assembly (includes No. 3 and No. 5) 2 5 O-Ring -0.644 I.D. X 0.0878W 2 6 Ball, Check Valve 1 7 Plug, Hex 1

7A Moisture Indicator 1 8 O-Ring _ 351 I.D. X 0.072W 1 9 Name Plate 1 10 Drive Screw, #4 X 3/6" Type Urnd. hd. st. st. 2 11 Screw #10-24 X 5/8", Pan hd. 6 12 Pipe Plug, 1/4" - 8" Socket hd. 2 13 Mounting Bracket 2 14 O-Ring _ 0.731 I.D. X 0.0103W 4 15 Air Manifold 1 16 O-Ring _ 0.850 I.D. X 0.0115W 2 17 Solenoid Valve 53 VDC (for 120 V, 50/60 Hz units)

Solenoid Valve 106 VDC 2 (for 240 V, 50/60 Hz units) 2

18 Core Assembly 2 19 Base Assembly 2 20 Coil, 53 VDC, Coil, 106 VDC 2 25 Screw, #6 - 32 X 1/8" Pan hd. 4 26 Air Manifold Cover 1 27 Timer S.S 1 min cycle 120 VAC Re-pressurization

Timer S.S 1 min cycle 240 VAC Re-pressurization 1

28 Nut Keps -8-32 2 29 Screw, 8-32 X 1" BH 2 30 Screw, 6-32 X 1/4" BH 2 31 Screw, 6-32 X 1/2" BH 2 32 Plate, Adapter - S.S. Timer Bracket 1 33 Bracket - S.S. Timer 1 34 Cover -Terminal 1 35 Decal -Terminal Cover 1 42 Spring - Check Ball 2


C-8

TROUBLESHOOTING In the event of an instrument malfunction, the following troubleshooting guide enables you to determine the problem. Contact your local authorized distributor for replacement parts.

MALFUNCTION POSSIBLE CAUSE ACTION

Instrument delivers wet air or a high concentration of carbon dioxide.

Improper operating conditions.

Adjust operating conditions.

Solenoid core spring is broken.

Remove solenoid valve and inspect core assembly. Spring should be seated on core and broken. Replace if necessary.

Purge orifice plugged. Remove, inspect, and clean orifice. Do

not force wires through critically drilled holes. Use air to clean.

Solenoid coil burned out. Remove cover, place iron or steel

material (screwdriver or nail) on exposed end of solenoid base to feel the magnetic effect indicating proper operation. Note: Each adsorber coil should be energized for 33.75 seconds. Check the improper operation of cycle timer before replacing coil.


C-9

MALFUNCTION POSSIBLE CAUSE ACTION Improper operation of

cycle timer. 1. Check the power supply. If the

correct voltage is not present between L1 and both of the L2 terminals, check the wiring and protective devices supplying power to the dryer.

2. Dryers with DC solenoid valves

between L2 and DC1 and between L2 and DC2. Replace the timer if voltage is present at either DC terminal continuously or not at all. Timer input 120 VAC/Timer Output 53 VDC. Timer Input 240 VAC/Timer Output 106 VDC.

3. Refer to Solid State Timers section

for timing cycle information. Desiccant contamination

or attrition. 1. Check inlet and outlet filters and

outlet air line for indication of oil. 2. Remove the desiccant chambers

from the air manifold. If the perforated disc at open end of the chambers can be depressed more than 1/4" from the retaining ring, replace chamber, or have it repacked.

Excess drop in outlet pressure.

Improper operating conditions.

Adjust operating conditions.

Solenoid coil burned out. Remove cover, place iron or steel

material (screwdriver or nail) on exposed end of solenoid base to feel the magnetic effect indicating proper operation. Note: Each adsorber coil should be energized for 33.75 seconds. Check for plugged air passages before replacing coil.


C-10

MALFUNCTION POSSIBLE CAUSE ACTION Improper operation of

cycle timer. 1. Check the power supply. If the

correct voltage is not present between L1 and both of the L2 terminals, check the wiring and protective devices supplying power to the dryer.

2. Dryers with DC solenoid valves

between L2 and DC1 and between L2 and DC2. Replace the timer if voltage is present at either DC terminal continuously or not at all. Timer input 120 VAC/Timer Output 53 VDC. Timer Input 240 VAC/Timer Output 106 VDC.

3. Refer to Solid State Timers section

for timing cycle information. Check valve balls seated

improperly. Remove check balls and springs and inspect for excessive wear or damage. Replace if necessary.

Plugged air passages. Check inlet and outlet air passages and

piping for blockage. Desiccant contamination

or attrition. 1. Check inlet and outlet filters and

outlet air line for indication of oil. 2. Remove the desiccant chambers

from the air manifold. If the perforated disc at open end of the chambers can be depressed more than 1/4" from the retaining ring, replace chamber, or have it repacked.

Solenoid valve chatter.

Solenoid valve defective. 1. Solenoid valve connected to AC terminal on solid-state timer.

2. Voltage too low.

model111-zeroair-156file_17823

Documents