AADCO 737 Series Manuel utilisateur

OPERATING INSTRUCTIONS

AADCO 737-SERIES

PURE AIR GENERATORS

737-1 & 737R-1

(1-LPM)

AADCO INSTRUMENTS, INC.

145 South Miami Ave.

Village of Cleves, OH 45002

U.S.A.

Telephone: (513) 467-1477

Fax: (513)467-9009

737-1 and 737R-1 PURE AIR GENERATORS

TABLE OF CONTENTS

Section Page

LIST OF ILLUSTRATIONS............................................................................iii

0.0 DAMAGED AND/OR LOST IN SHIPMENT PROCEDURE.............................1

1.0 INTRODUCTION..............................................................................................2

2.0 INSPECTION UPON RECEIPT.......................................................................3

3.0 INSTALLATION................................................................................................4

4.0 OPERATION.................................................................................................... 6

5.0 PRINCIPLE OF OPERATION........................................................................11

6.0 PURIFICATION REACTORS.........................................................................12

7.0 METHANE REACTORS.................................................................................14

8.0 PERFORMANCE SPECIFICATIONS............................................................16

9.0 PREVENTIVE MAINTENANCE.....................................................................18

10.0 TROUBLESHOOTING...................................................................................20

11.0 COMPONENT REPLACEMENT....................................................................26

12.0 ABBREVIATED OPERATING INSTRUCTIONS

...........................................

13..0 PARTS LIST...................................................................................................29

ILLUSTRATIONS........................................................................30 THRU 46

WARRANTY................................................................................................. 47

737-1 AND 737R-1 PURE AIR GENERATORS

LIST OF ILLUSTRATIONS

Figure Page

1 FRONT PANEL...............................................................................................30

2 REAR PANEL WITH “HOUSE” AIR ADAPTER.............................................31

3 INSIDE TOP VIEW......................................................................................... 32

4 INSIDE BENCH-MOUNTED, COMPRESSOR SIDE VIEW

..........................

5 ELECTRICAL TERMINAL STRIP VIEW

........................................................ 34

6 FRONT PANEL, RACK-MOUNTED UNIT..................................................... 35

7 INSIDE RACK-MOUNTED, COMPRESSOR SIDE VIEW.............................36

8 INSIDE RACK-MOUNTED, METHANE REACTOR VIEW

............................

9 WIRING DIAGRAM.........................................................................................38

10 PNEUMATIC DIAGRAM.................................................................................39

11 MOISTURE OUTPUT VERSUS TIME FOR REACTORS

.............................

12 GAS CHROMATOGRAPHIC APPLICATION OF “B” REACTOR

.................

13 “TEE” BLEED VALVE INSTALLATION..........................................................42

14 “B” REACTOR VERSUS CYLINDER FID RESPONSE.................................43

15 CHROMATOGRAMS-METHANE REACTOR EFFICIENCY

.........................44

16 “A” VERSUS “C” REACTOR C02 OUTPUT................................................... 45

17 FLOW NOMOGRAPH.................................................................................... 46

0.0 DAMAGED AND/OR LOSS IN SHIPMENT PROCEDURE.

0.1 SHIPMENTS FOB FACTORY. This shipment was thoroughly inspected prior to

delivery to the carrier. Our responsibility for this shipment has now ended.

Therefore, you should make a thorough inspection upon its arrival.

0.2 In the event any portion of the shipment is damaged or missing, do not sign the bill

of lading or express receipt until the freight or express agent makes appropriate

notation on the receipt.

0.3 “Concealed damage” means damage which may not be apparent until after the

items are unpacked and tested. In the event of such damage, you should file a

written request within fifteen days of delivery with the carrier for inspection. Delay in

making this request may provide grounds for refusal of your claim. Be certain to

retain all papers, packing materials, etc., until the carrier has made his inspection.

Keep in mind that concealed damage can occur from rough handling even though

the shipment shows no evidence of external damage.

0.4 The carrier may request you to return the damaged item to AADCO Instruments,

Inc. for inspection and repair. In this event, we will repair or replace the item and

invoice you for the costs involved. This invoice then becomes part of your claim

upon the carrier.

0.5 SHIPMENTS FOB DESTINATION. In the case of damage in transit on shipments

made “FOB Destination”, we will gladly handle filing of the claim provided you

furnish us with an acceptable inspection report from the carrier. In the event that

our claim is disallowed because of your negligence in obtaining the report, it will be

necessary to bill you for the repair or replacement charges.

0.6 RETURNS TO AADCO INSTRUMENTS. If your property, while being returned to

AADCO Instruments, Inc. is damaged in transit, it will be your responsibility to file a

claim with the carrier. To assist you, we will secure an inspection report from the

carrier and forward it to you.

0.7 Prior to shipment to AADCO Instruments, Inc. you must call or write notifying us of

your intent. In addition, include some identifying note or letter with the item. This

note/letter should include the name of your contact person and the nature of the

damage.

1.0 INTRODUCTION.

1.1 The 737-1 (one-liter per minute) pure air generator is unique in the 737-series of

pure air generators. It is the only unit which is completely self-contained. All

components of the system, the air source and purification system, are within one

cabinet.

1.2 Incorporating all components within one enclosure limits the maximum output of this

instrument to one-liter per minute. Since all of the components must be able to

accommodate the air volume and perform the purification functions as well, there is

a compromise in component size.

1.3 The user must be aware of this limitation in capacity and select only those

applications whose requirements do not exceed this limitation. FAILURE TO DO

SO WILL COMPROMISE THE PURITY OF THE AIR ISSUING FROM THE UNIT.

1.4 When application is made to those situations which remain within the one-liter per

minute capacity, the air quality will be equal to any and all of the larger 737-series

pure air generators.

1.5 The 737-1 pure air generator is available either in bench-mounted or rack-mounted

units. All components are common to both and are readily interchangeable.

1.6 Figures 1 thru 5 are referenced to the bench-mounted units, Figures 6 thru 8 refer

to the rack-mounted units, and Figures 9 thru 11 are common to both.

1.7 The SOURCE SELECTOR valve, Figure 1 (5), and the EXTERNAL SOURCE

bulkhead connector, Figure 2 (4), are not a part of the rack-mounted units since the

use of “house” air as a source for this unit is very uncommon. Both of these

components, shown in Figure 10, should be ignored when addressing the rack

mounted systems.

2.0 INSPECTION UPON RECEIPT.

2.1 Remove unit from shipping container WITHOUT INVERTING.

2.2 For both bench-mounted (Figure 1) and rack-mounted (Figure 6), remove cover.

2.3 WITHOUT INVERTING, place unit between two level surfaces so that the bottom is

exposed.

2.4 Remove the two red screws underneath the chassis which held the compressor,

Figure 4 (14), stationary during shipment. (Hold these for possible future use.)

Screw removal is best accomplished by turning each screw a few turns, alternating

between screws rather than completely removing one screw and then the other.

The compressor is spring-mounted and removing one screw completely before

attempting to remove the other will cause difficulty with removal of the second

screw.

2.5 After removing the two red screws, remove blocking material from under

compressor and retain with screws for later use.

2 6 Check that the compressor rides freely on its shock mounts and that none of the

mounts is damaged.

2.7 Inspect for damage that column of the purification reactor, Figures 5 and 8 (1),

which is immediately adjacent to the outlet fitting of the compressor. Damage to the

column may occur during shipment if the compressor is not securely retained by the

shipping screws, thus allowing the compressor outlet fitting to pound against the

column. This could damage either or both the compressor outlet fitting and/or

purification column.

2.8 If all appears in order, replace the cover.

2.9 Remove the shipping plugs from all bulkhead fittings on the rear wall of the unit.

The unit is now ready for operation.

3.0 INSTALLATION.

3.1 THE FOLLOWING INSTRUCTIONS ARE TO BE FOLLOWED ONLY AFTER

SECTION 2.0 HAS BEEN COMPLETED.

3.2 FOR BENCH-MOUNTED UNITS UTILIZING “HOUSE” AIR AS THE PRIMARY AIR

SUPPLY TO THE PURE AIR GENERATOR, connect the “house” air adapter,

Figure 2 (1), to the EXTERNAL SOURCE fitting on the rear of the pure air

generator, as shown in Figure 2. The stainless steel tubing supplied with the

“house” air adapter will support the adapter rigidly when all fittings are properly

tightened.

NOTE: SINCE MOST “HOUSE” AIR SUPPLIES ARE FROM OIL-PUMPED

SOURCES, IT IS MANDATORY THAT THE AADCO INSTRUMENTS’

“HOUSE” AIR ADAPTER, AND ONLY THIS ADAPTER, BE USED. This

is an oil-indicating filter and dramatically indicates when depletion is

imminent. Use of this filter avoids contaminating the purification reactor

and jeopardizing the purity of the output air.

3.3 If a source selector valve, Figure 1 (5), is present, place it in its downward position

indicating EXTERNAL SOURCE. If not present, unit is ready for connection to the

air source.

3.4 Connect the “house” air to the lower inlet, Figure 2 (3), of the “house” air adapter

utilizing 1/4 inch swage connectors. Admit the “house” air to the “house” air adapter

and open the shutoff valve, Figure 2 (3), so that the “house” air enters the pure air

generator and registers its pressure on the INPUT PRESSURE gauge, Figure 1 (6).

NOTE: THE MINIMUM ACCEPTABLE PRESSURE FOR THE INPUT AIR IS 50-

PSIG AND THE MAXIMUM PERMISSIBLE PRESSURE IS 95-psig. Any

pressure lower than the minimum will compromise the effluent air purity

and any pressure greater than 95-psig will exceed the working capacity

of the inlet solenoid valves.

3.5 At this time, check for leaks using soap solution on all connecting fittings. Tighten

as required.

NOTE: The horizontal shutoff valve, Figure 2 (3), at the base of the “house” air

adapter serves as a shutoff to the air supply so that the pure air

generator may be moved and, should the need arise, the filter element

may be changed without shutting off the main air supply.

3.6 Connect the power cord to a suitable outlet observing voltage and power

requirements as shown on the rear of the unit, Figure 2 (7). The instrument is now

ready for operation.

3.7 FOR BENCH-MOUNTED UNITS UTILIZING THE INTERNALLY MOUNTED

COMPRESSOR AS THE PRIMARY AIR SUPPLY, place the source selector valve,

Figure 1 (5), in its upright position indicating INTERNAL PUMP.

3.8 Connect the power cord as in Section 3.6. The instrument is now ready for

operation.

NOTE: It is not uncommon to connect “house" air to those units which contain

their own internal compressors and to operate the units with “house” air

as the primary source, utilizing the internal compressor only during those

periods when the “house” air compressor is undergoing repairs or

maintenance. To make the conversion from “house” air to the internal

compressor, it is only necessary to turn the source selector valve to the

correct position and depress the PUMP switch, Figure 1 (3).

SPECIAL NOTE: AADCO Instruments, Inc. offers an automatic source selector for

those unattended installations where both “house” air and the internal compressor

are both available at the same unit. This device will automatically select between

the two sources and provide that source which is available should the other source

fail.

3.9 FOR RACK-MOUNTED UNITS (Figure 6), install in the electronics rack the slides

provided, correcting the alignment until the unit moves freely and the front panel

seats squarely when fully inserted within the cabinet.

3.10 Remove the two red screws underneath the chassis as in Section 2.4.

3.11 Connect the power cord to a suitable outlet observing voltage and power

requirements as shown on the rear of the unit, Figure 2 (7). The instrument is now

ready for operation.

NOTE: At no time should the DUMP fitting, Figure 2 (6), be restricted nor the

flow impeded in any way. The operator may attach a large bore 1/4 inch

o.d. tubing to this fitting and lead the exhaust into a space where the

exhaust noise will be inaudible; e.g., desk drawer, suspended ceiling, etc.

3.12 When “house” air is being admitted as the air source through the “house” air

adapter, Figure 2(1), ANY ACCUMULATED WATER MUST BE BLED DAILY via

the water bleed valve, Figure 2 (8).

4.0 OPERATION.

4.1 Once the instructions outlined in Sections 3.0 thru 3.6 have been followed, whereby

the air source has been connected to the pure air generator, leak checked, and the

power cord inserted into a proper outlet, the BENCH-MOUNTED unit utilizing

“house” air as the primary air supply is ready for operation.

NOTE: AT THIS TIME THERE SHOULD BE NO EQUIPMENT CONNECTED

TO THE PURE AIR GENERATOR.

4.2 The INPUT PRESSURE gauge, Figure 1 (6), should indicate the source air

pressure which must be not less than 50-psig nor more than 95-psig. See Section

3.4.

4.3 Depress the POWER SWITCH, Figure 1 (1). The POWER lamp should light, there

should be an audible “click” of the inlet solenoid valve of the purification reactor

followed immediately by a momentary decrease of input pressure and the

METHANE HEAT lamp, Figure 1 (12), if present, should light.

4.4 If no methane reactor is present, within one-minute (one full purification cycle) the

unit is ready to deliver clean air. The operator now may adjust the output pressure

to his needs by turning the OUTPUT PRESSURE REGULATOR, Figure 1 (9),

clockwise until the desired pressure appears on the OUTPUT PRESSURE GAUGE,

figure 1 (8).

4.5 To determine the proper output pressure from the pure air generator, it is necessary

to ascertain the greatest pressure required by any or all of the using instruments.

For example, if there are five instruments and the highest pressure requirement for

any or all of the instruments is 30-psig, then the output pressure can be set no

lower than 40-psig. This 10-psig pressure differential is mandatory for proper

operation of any differential pressure regulator. The 40-psig accommodates not

only that instrument with the 30-psig requirement but all of the others as well.

4.6 The pressures and flows at each of the using instruments should now be set

according to the recommendations of the manufacturer. If snubbers are present as

flow regulation devices, only proper pressure settings are required. If pressure and

flow settings are both required, set the pressure and then establish flow using

bubble towers or mass flow meters for accurate settings.

NOTE: Any instrumentation which is sensitive to even slight variations in oxygen

concentration; e.g., flame ionization detectors or flame photometric

detectors, etc.; all require incorporation of a mixer-receiver, Figures 5

and 8 (10), within the pure air generator prior to use by the above

mentioned detectors. NDIR, chemiluminescent, photoionization,

4.6 Continued.

and electrochemical sensors are unaffected by slight variations in oxygen

concentration and, therefore, do not require mixer-receivers.

4.7 At this time, since there is no equipment connected to the unit which may be used

to regulate the flow of pure air from the pure air generator, the operator must be

certain that the capacity of the unit is not being exceeded. To do so, the OUTPUT

FLOW ADJUST knob, Figures 1 and 6 (10), must be adjusted so that the indicated

flow is some value between 1.0 and 10.0 as perceived on the rotameter, Figure 1

(7). It is unnecessary to establish an exact flow during this “burn-in” interval but it is

important to maintain a positive flow of clean air, especially if there is a methane

reactor, Figure 5 (2), within the unit.

4.8 If there is no methane reactor in the unit, allow the pure air generator to operate for

about a half hour without connecting any equipment to the PURE AIR fitting, Figure

2 (5), located on the rear of the unit.

4.9 Following the half hour interval, connect the equipment which is to receive the pure

air to the PURE AIR fitting. Connections must be made with 1/4 inch large bore

tubing from the pure air generator to the using equipment. The using equipment

should be located as close to the pure air generator as possible. Great lengths of _

inch or small bore 1/4 inch tubing should be avoided because of the back pressure

exerted on the system by the restrictive tubing.

4.10 If connections at the using equipment are _ inch swage type, use 1/4 inch large bore

tubing from the pure air generator to the using equipment and then reduce to _

inch, keeping the _ inch length as short as possible. All “tees” should be 1/4 inch

also.

4.11 Open the OUTPUT FLOW ADJUST knob completely counter clockwise. Close all

valves at the using equipment. Within a minute or two the rotameter ball should

drop to zero indicating that the entire system is leak tight. If the rotameter ball does

not drop to zero but remains upscale, there is a leak. Check all connections with

soap solution and tighten as required until the rotameter ball does indicate zero. It

is imperative that all leaks be detected and remedied before putting the system into

full operation.

4.12 Once a leak free system has been established, set the required flows at each of the

receiving instruments after calculating that the aggregate flow does not exceed the

capacity of the unit.

4.13 If there is a methane reactor in the unit and the instructions in Sections 4.1 thru 4.5

have been followed, allow the unit to operate for about four hours without

connecting any equipment to the PURE AIR fitting located on the rear panel.

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