Laboratory Zero Air Generator ZAC-GC Series
Contents
1. MATHESON TRI GAS ask Gas Professionals LABORATORY ZERO AIR GENERATOR ZAC GC Series USER MANUAL 166 Keystone Drive Montgomeryville PA 18936 Telephone 215 641 2700 Fax 215 641 2714 Email mtgmmville matheson trigas com INT 0260 XX rev B Contents E PPP EE 2 eee 3 3 System Components eoe ette et eene en o eH ee Gen et eis 4 Ing MEMO 5 5 ONION OO ANT ITE 6 6 Installation cs UE OE UII erates ci UNDE e NO EN ele cian e OL E ies E ees 7 yx IS 11 8 Maintenaneg c o sux M UR ERREUR DEAE QR aut REDE E d RU Ruta cR 13 9 Troubleshooting Guide De UR Dena n NEU 17 10 SDOCIHCSHOFIS Heber c 18 INT 0260 XX rev B 1 of 18 1 0 Introduction NOTICE This manual is intended to provide technical guidance on the installation operation and maintenance of the ZAC GC series zero air generator Do not attempt to install or operate this product without having fully read and understood the information presented If you have questions please contact Matheson Tri Gas WARNING misuse of this product will void the manufacturer s warranty Product Description The ZAC GC series zero air generator produces laboratory grade purified air for the most precise GC FID equipment Designed with safety and convenience in mind this system will genera2. LED If the catalyst has expired the system does not enter warm up mode The processor immediately flashes the red Check System LED If the catalyst is within 2 months of expiring then the red Check System LED will flash but the system will still enter operation mode Warmup Check Pressure 5 o 5 YELLOW System check 3 seconds Blink 1 Hz Blink 1 Hz Blink 1 Hz Blink 1 Hz System fault Quickstart Mode Blink 1 Hz System check 5 seconds Blink 1 Hz La Warm up 50 minutes Blink 1 Hz Fault catalyst temperature below set point after 20 min Control Board Program Logic Table 1 Blink 1 Hz pom E pu Cal E p aim Cod per EG 7 5 Shutdown Procedure Before performing any service or maintenance to the zero air generator be sure to complete the following steps 7 5 1 Turn off power using the switch on the unit 7 5 2 Disconnect the outlet tubing and freely run air through the unit for several minutes to cool the catalyst Allow a minimum of 2 hours to cool the catalyst before replacing 7 5 3 Shut off air supply 7 5 4 De pressurize the unit and disconnect power source before servicing 12 of 18 8 0 Maintenance WARNING Before service is performed make certain that the following conditions are met 1 System shut down has been performed according to instructions above 2 Supply pressure has been shut off 3 Line pres
3. Let equipment cool completely before putting away Loop cord loosely around equipment when storing To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids To reduce the risk of electric shock do not use on wet surfaces or expose to rain Use only as described in this manual Use only manufacturer s recommended attachments ALWAYS WEAR SAFETY GLASSES when working with this equipment Everyday eyeglasses have only impact resistant lenses They are NOT safety glasses SAVE THESE INSTRUCTIONS INT 0260 XX rev B 3 of 18 3 0 System components 4 of 18 INT 0260 XX rev B 4 0 Design overview The ZAC GC series zero air generator utilizes a 3 stage process to purify ambient air into zero grade air All main components are manufactured with high grade stainless steel oriented neatly in cabinet for easy access and service 4 1 Stage 1 Prefiltration and Pressure Regulation 4 1 1 Air is initially passed through a highly efficient combination coalescing particulate pre filter to ensure quality air enters the system The pre filter removes bulk moisture and larger particulates greater than 5 microns in size The filter is supplied with an automatic float drain to remove periodic moisture build up 4 1 2 The air pressure is then regulated with a pressure regulator pre set to 100 psig 7 bar The minimum allowable pressure is 65 psig 4 5 bar 4 2 Stage 2 Hydrocarbon and CO Remo
4. Install external inlet filter 6 2 1 Apply Teflon pipe sealant tape to both sides of the supplied 1 4 NPT nipple 6 2 2 Thread the nipple to output side of the air filter assembly Do not over tighten 6 2 3 Attach air filter assembly to input side left side of the generator and secure 6 3 Check voltage setting Check the setting of the voltage selector on the side of the unit The white arrow indicates the voltage setting To change the voltage setting proceed as follows 6 3 1 Using a small screwdriver remove the voltage selector insert 6 3 2 Replace fuses Voltage setting Fuse 240 Vac 120 6 3 3 Replace the voltage selector insert so that white arrow points to the correct voltage 240 120 INT 0260 XX rev B 8 of 18 6 4 Unit positioning There are two different positions the units can be placed a Ona table Allow at least 6 in 150 mm clearance around the sides of the unit for proper ventilation RM 150 b Fixed on a wall or permanent structure Drill appropriate holes in the wall or permanent structure and insert supplied mounting screws Tighten only enough so there is approximately 1 4 extruding from the surface The mounting holes are spaced 7 7 8 200 mm apart 200 a VY Hold the generator up to the extruding screws and insert the u
5. screws 1 and 2 and remove the right side plastic cover screws 3 8 3 9 Carefully disconnect the two compression air fittings 1 and 2 to remove the cooling spiral 3 INT 0260 XX rev B 15 of 18 INT 0260 XX rev B 8 3 10 8 3 11 8 3 12 8 3 13 8 3 14 8 3 15 Remove the heater and thermocouple wires from the control board and the ground wire from the oven Unscrew the two screws to remove the aluminum plate from the metal heat shield covering the catalyst chamber When the catalyst chamber is cool to the touch extract the catalyst chamber from the unit Install the new catalyst chamber assembly using the reverse process Connect the heater and thermocouple wires to the control board and connect the ground wire to the oven Pressurize the system and check thoroughly for leaks 16 of 18 9 0 Troubleshooting Guide 1 Fault table Warmup Check Pressure Fault CD EBENEN temperature below set point after 20 min System can be reset to initial condition L Turn off unit to reset system L Turn on unit and check for LED configuration 2 Leaks Apply leak check solution to all external fittings and look for air bubbles Tighten any leaky connections Additional Teflon tape may be required in some cases INT 0260 XX rev B 17 of 18 10 Specif
6. when the catalyst has fully heated 5 2 Monitors critical system parameters the control board continuously checks for proper catalyst temperature to insure zero air purity specifications are always met 5 3 Digital thermostat the control board limits the maximum temperature to 650 C to preserve the life of the heating element Without a thermostat temperatures would often exceed this limit especially if the air supply were interrupted With the control board you never have to worry about overheating 5 4 Catalyst life alarm the control board reminds you when the 3 year life of the catalyst is exceeded After 3 years the red external check system LED begins to flash From this time the operator has 60 days to replace the catalyst or the control board disables the system INT 0260 XX rev B 6 of 18 6 0 Installation 1 Air inlet 2 Air outlet 3 Inlet air filter 4 LED membrane 5 Door lock 4 Power button and fuse location for appropriate voltage setting Items supplied with the unit 1 2 lt lt 4 lt Model ZAC GC series zero air generator completely assembled and is ready for installation One 1 high quality inlet air filter assembly is supplied with each system to remove particulates and bulk moisture before entering your unit One 1 power cord Two 2 fuses One 1 installation kit One 1 pipe nipple to
7. attach your inlet filter to the unit Two 2 machine screws with matching nuts and split lock washers to mount your unit Two 2 door keys to lock your unit One 1 user manual Items not included with the unit 1 3 Air supply shut off valve placed upstream of the unit This is required for safe and easy installation and for any needed maintenance Bleeder valve installed between the shut off valve and the inlet of the unit NOTE The inlet air filter assembly supplied with your unit can also be used to de pressurize your system by pushing the pin valve in the base of the filter housing Additional filtration may be required depending on the quality of your air supply The pre filter of the unit INT 0260 XX rev B 7 of 18 will remove nominal amounts of moisture and particulates If the air supply has excessive moisture oil or particulates then additional filters should be installed 4 Tube fitting to install to the supplied pre filter The exact type will depend on the supply tubing or hose from air source A hose clamp is recommended if flexible tubing is used 5 Tube fitting to install into the bulkhead fitting on the output of your unit The exact type will depend on the transport tubing or hose to your analyzer A hose clamp is recommended if flexible tubing is used CAUTION Remove plastic wrap inside unit before applying power 61 Unpack unit and open cover Remove plastic inlet amp outlet port plugs 6 2
8. he outlet The 1 8 FPT output fitting of the zero air generator is located on the right side of the unit In order to maintain the purity of the air from your zero air generator stainless steel tubing or instrument grade Teflon tubing should be used to connect the generator to the analyzer zero port All plastic hose should be instrument grade and free of contaminants so that it will not out gas any hydrocarbons or other pollutants over time SS WARNING Do not use PVC or any other non instrument grade plastic tubing anywhere in your system Many plastics will out gas hydrocarbons and will contaminate your purified air 6 7 Leakcheck Before powering the unit perform a leak check on the external plumbing to the unit 6 7 1 Slowly open the supply air valve to pressurize to the system 6 7 2 Apply a leak test solution to all external fittings and look for air bubbles 6 7 3 Tighten any leaky connections Additional Teflon tape may be required in some cases INT 0260 XX rev B 10 of 18 7 0 Operation 7 1 Connect power and start up unit 7 1 1 Insert the female end of the supplied power cord to the power supply connection on the left side of the zero air generator and plug the male end into a properly grounded socket 7 1 2 Turn the power on to the unit 7 1 3 For the first 3 seconds all panel LEDs illuminate This verifies proper operation of the control board firmware and LEDs 7 2 Warming up After power up the system en
9. ications Outlet Hydrocarbon Concentration Outlet Carbon Monoxide Concentration Outlet Particles lt 0 5 microns removed Outlet Air Temperature Max Inlet Hydrocarbon Concentration Max Inlet Carbon Monoxide Concentration Max Inlet Temperature Inlet Pressure Range regulated to 100 psig 7 bar Pressure Drop max Flow Rate Maximum Outlet Pressure Startup Time for Specified THC Concentration Inlet Port Outlet Port Electrical Requirements System Dimensions H x W x D Generator Weight INT 0260 XX rev B lt 0 1 ppm lt 0 1 ppm 99 99 Ambient 27 F 15 C 100 ppm 50 ppm 104 F 40 C 65 145 psig 4 5 10 bar 15 psig 1 bar 94 psig 6 5 bar 50 minutes 1 4 FPT 1 8 FPT 115 230 VAC 16 x 18 5 x 10 41 x 47 x 25 cm 25 Ibs 11 kg 18 of 18
10. nding on the quality of the air supply Alternately more filtration can be applied upstream of the zero air generator 8 2 X Annual High Grade In line Particulate Filter Replacement The high grade in line particulate filter is the final component before the outlet The filter body is clear plastic and is held by the inlet and outlet lines 8 2 1 Disconnect the filter 1 from the push in connector 2 of the air line 8 2 2 Replace the used filter with the new one Make certain the flow direction indicated on the filter housing points in the upward direction toward the outlet pressure regulator on the unit INT 0260 XX rev B 14 of 18 8 3 Three Year Catalyst Chamber Replacement The catalyst chamber used in the ZAC GC series zero air generator should be replaced every 3 years to maintain carbon monoxide and hydrocarbon specifications 8 3 1 system should be shut down as described above prior to replacement 8 3 2 Allow the unit to cool for a minimum of 2 hours before replacement 8 3 3 If unit has been powered recently and catalyst is hot turn off the power DO NOT turn off the air at this time 8 3 4 Remove the outlet connection and allow the outlet air to flow freely for 2 hours to cool the catalyst 8 3 5 After 2 hours of cool down disconnect the air supply 8 3 6 Depressurize the system by depressing the pin at the bottom of the inlet filter housing 8 3 7 Open front panel with door key 8 3 8 Loosen
11. nit over the screws through the keyholes Let the unit slide downward as the screws slide up into the keyhole slots WARNING DO NOT TIGHTEN SCREWS FULLY THE ZAC GC SERIES GENERATOR IS NOT DESIGNED TO BE PERMANENTLY MOUNTED TO A WALL OR OTHER PERMANENT STRUCTURE IT MUST BE POSSIBLE TO REMOVE THE UNIT WITHOUT THE USE OF TOOLS INT 0260 XX rev B 9 of 18 6 5 Connect the air supply The zero air generator requires a continuous supply of dry compressed air between 65 and 145 psig 4 5 and 10 bar for proper operation WARNING MAXIMUM INLET PRESSURE 145 psig 10 Bar The air pressure is regulated with an internal pressure regulator pre set to 100 psig 7 bar It is important that the air supply be maintained at room temperature and dew point and free of oils hydrocarbons and particulates If the compressed air supply for the generator has excess moisture oil or particulates the inlet filter may need premature replacement and the unit may be damaged Install extra coalescing and particulate filtration upstream from the unit if necessary WARNING The catalyst chamber can be contaminated by high concentrations of lead sulfur phosphorous compounds heavy metals chlorinated solvents and chlorinated hydrocarbons Extra care should be taken to avoid introducing such compounds to the system Any contamination from oil water or any of the substances mentioned above will void the warranty on your unit 6 6 Connect to t
12. sure has been released 4 Unit has been shut off and isolated from electrical power Annual Maintenance Kits The ZAC GC series zero air generator is designed to operate continuously for an entire year before service is required An annual maintenance kit will be available as spare part This kit will include all required parts Specifically each kit will include 1 New pre filter element ZAC EXT CART 2 New high grade particulate final filtration ZAC INT CART 3 year Catalyst Replacement Kits A catalyst kit will also be available as spare part for its 3 year replacement The catalyst must be replaced every 3 years to insure the removal of CO and HC to 0 1 ppm levels WARNING ONLY QUALIFIED PERSONNEL SHOULD PERFORM SERVICE ON THIS PRODUCT ANY DAMAGE DONE TO THIS PRODUCT AS A RESULT OF IMPROPER MAINTENANCE PROCEDURES WILL VOID THE WARRANTY INT 0260 XX rev B 13 of 18 8 1 Annual Pre filter Element Replacement 8 1 1 Remove the filter bowl Fig 1 pos 1 pressing on the lever and turning the bowl counter clockwise until the arrow are aligned 2 Unscrew the filter element base and remove element Fig 1 pos 3 Insert the new element and reassemble the filter in reverse order 8 1 8 1 turn unscrew estract and replace element filter Fig 1 Pre filter disassembling for element filter replacement NOTE More frequent replacement of the inlet filter may be required depe
13. te purified air from an existing in house oil free compressed air supply The ZAC GC series zero air generator will remove hydrocarbon pollutants to less than 0 1 ppm Operation of the generator requires low levels of air consumption and electrical power This complete turnkey system is engineered with the highest quality components is easy to install and requires only minimal annual maintenance INT 0260 XX rev B 2 of 18 2 0 Safety instructions When using your zero air generator basic safety precautions should always be followed including the following 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 Read all instructions Care must be taken as burns can occur from touching hot parts N WARNING A HOT SURFACE INSIDE CONTACT MAY CAUSE BURN ALLOW TO COOL BEFORE SERVICING Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified serviceman Do not let cord hang over edge of table bench or counter or come in contact with hot manifolds or moving fan blades If an extension cord is necessary a cord with a current rating equal to or more than that of the equipment should be used Cords rated for less current than the equipment can overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Never use the cord to pull the plug from the outlet Grasp the plug and pull to disconnect
14. ters a warm up cycle 7 2 1 The yellow Warm up Check Pressure LED flashes at 1 Hz indicating the system is in warm up mode If the catalyst temperature is above the minimum level of 485 C and no faults are present the system will go immediately to operation mode This quick start feature is for customer convenience when power is interrupted only for brief periods and a full warm up cycle is not required The warm up cycle takes 50 minutes NOTE The ZAC GC series zero air generator is designed to run continuously Continuous operation preserves the life of the catalyst Shutdown should only be performed for maintenance 7 2 2 Verify that the POWER green LED is on 7 2 3 Verify that the WARM UP yellow LED is flashing 7 3 Normal operation When the unit comes out of warm up 7 3 1 yellow LED will turn off 7 3 2 green System Ready LED will illuminate 7 3 3 Verify that the POWER green LED is 7 3 4 Verify that the READY green LED is on INT 0260 XX rev B 11 of 18 INT 0260 XX rev B 7 4 Startup Troubleshooting If there are any improper conditions detected by the control board the unit will not come out of warm up The panel LEDs will indicate fault conditions Any of the following conditions will prevent the unit from going to operation mode If catalyst heater temperature is still below the minimum threshold then a low temperature fault is indicated by the red Check System
15. val 4 2 1 Air is next channeled into a stainless steel catalyst chamber where any background hydrocarbons or carbon monoxide are oxidized This chamber is filled with a highly efficient platinum catalyst heated to very high temperatures to insure hydrocarbon removal to less than 0 1 ppm 4 2 2 Catalyst temperature is a critical factor the purification process The temperature is monitored and controlled with a digital thermostat on the control board A type K thermocouple is embedded in the catalyst chamber to provide the temperature measurement Any time the catalyst temperature is outside of specified limits appropriate LEDs are illuminated 4 3 Stage 3 Final Filtration A final high grade filter is used to remove 99 99 of particulates greater than 0 5 microns in size This will insure that no harmful particles will be able to enter your gas analyzers during zero calibration 4 4 Stage 4 Flow Regulation A flow regulator is used to limit maximum flow rate on the outlet The setting cannot be changed by users WARNING DON T ADJUST THE OUTLET FLOW REGULATOR ADJUSTMENT OF THE OUTLET FLOW REGULATOR CAN DAMAGE THE UNIT ANY DAMAGE DONE TO THIS PRODUCT AS A RESULT OF IMPROPER MAINTENANCE PROCEDURES WILL VOID THE WARRANTEE INT 0260 XX rev B 5 of 18 5 0 Control board The control board performs the following functions 51 Controls the warm up of the unit the control board tells user if catalyst is warming up properly and
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