ZeroAir
Contents
1. element The filter element will still be attached to the filter main body to remove it unscrew it anti clockwise ocrew on the new replacement filter element with the small o ring before it Ensure the large o ring is in place and the spring is in line Then screw the filter bowl back into the filter main body by hand again do not use any tools to tighten it just make it hand tight 11 5 Troubleshooting Flow Chart Is the Red switch on Switch it on the rear of the unit in the on position Check the fuse in the drawer below the IEC Is the Red switch on the rear of the unit illuminated socket Is the Green switch on the front panel labelled Heater in the on position Switch it on Is the Green switch on the front panel labelled Heater illuminated Suspect switch No Yes Is the fan operating can be viewed through the rear panel air should be drawn in through rear panel and blown out Suspect fan Yes To check heater If there is a resistance across the heater then Can heat be felt from the air being blown out of the vents and or on Disconnect Power open enclosure Suspect heater the Solid State relay will Remove the two power be the problem wires feeding the heater and measure the resistance if the reading is between 10 100 ohms the heater is OK the top pa2. the ZeroAir using the 4 BSP thread see diagram below 4 Put IEC cable into socket at the back of the ZeroAir and turn on the red switch on the socket see diagram below Plug into wall outlet Air Inlet ZeroAir Outlet This is the compressed air inlet This is the Hydrocarbon Free Air Air compressor units are Outlet available from Texol specifically for ZeroAir and are supplied with all fittings If you are using an existing air supply then please ensure your air supply is compatible The thread on this port is 1 4 female of type Rc This should be connected to your application with suitable piping the thread is 1 4 female Hc Attach the pipe to the equipment requiring Hydrocarbon free air Power Socket A power cable is supplied with a socket to attach to this IEC Chassis Plug Main Power Switch This switches the supply of power for the whole system on off Fuse Holder This holds a fuse to protect the ZeroAir generator 5 Turn on the power switch at the front of the ZeroAir which should illuminate green Power Switch 6 After 5 minutes you should be able to get the results from the ZeroAir for the application Compressed Air Supply Compressed Air Supply Compressed Air Supply System Setup Pressure Flow ZeroAir Application Regulator Controller Pressure ZeroAir Regulator Flow Application Controller Flow App
3. ZeroAir User Manual Tel 44 0 141 530 7417 PR utm TEXGL Email info texol co uk This document is the property of Texol Gasgen Itd and is delivered on the express condition that it is not to be disclosed reproduced in whole or in part or used for manufacture for anyone other than Texol Gasgen Ltd without its written consent and that no right is granted to disclose or so use any information contained in said document 2009 Texol Gasgen Ltd All rights reserved Manual Revision Record of Revision 19110105 This manual contains technical information to enable operation maintenance troubleshooting and repair of the system In all communications with Texol please quote the serial number of the system you are referring to The serial number can be found on the CE Services label attached to the rear of the enclosure For easy reference copy the serial numbers into the boxes below Generator Model Type Serial Number Disclaimer Texol Gasgen Ltd has written this manual to be an easy to use guide for the Zero Air generator range All statements technical information recommendations in this manual and in any associated guides or related documents are written in good faith However the accuracy and the completeness thereof are not guaranteed or warranted They are not intended to be nor should they be understood to be representations or warranties concerning the products described This generator has been s
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5. ladium coated ceramic disc 3 Heat Exchanger 5 Outlet Filter 0 1 micron Electrical Summary Thermocouple reads heater temperature PCB sends OFF signal to SSR to SSR SSR energises Heater SSR de energises Heater PCB showing thermocouple input and temperature control knob Thermostats and SSR Solid State Relay PCB sends ON signal Thermostats Temperature Control Knob Thermocouple input SSR Solid State Relay 10 4 Maintenance Servicing This section describes how to maintain your ZeroAir Generator to give optimum performance for years to come The filter element within the filter should be renewed once a year The compressed air filters are fitted at the back of your generator Please contact your local dealer quoting Part Number TPL SP0006 Ensure that your air Filter in supply is switched off Main body before any Filter Bowl maintenance work is carried out Any pressure left in the line can be drained by pushing in the auto drain Filter Main Body O Ring Plastic Diffuser The filter can be opened while still attached to the Generator Support the filter main body and unscrew the filter bowl with your hand there is Filter Element Plastic Retainer Filter Element Retainer Screw no need for any tools Spring as they could damage U Filter Bowl When opened you will Auto Drain find two o rings a spring and a filter
6. lication Controller ZeroAir Pressure Regulator Compressor Hook up and Piping ONLY USE AIR FROM AN OIL FREE OIL LESS COMPRESSOR OR THE QUALITY OF THE AIR FROM THE COMPRESSOR AFTER FILTERING IS BETTER THAN THAT DEMANDED FOR BREATHING AIR BY BSENI2021I OIL LUBRICATED AIR WILL PERMANENTLY DAMAGE YOUR GENERATOR The compressed air requirements of the ZeroAir generator are the same as the hydrocarbon free air requirement of the instrument e g if an instrument requires 8 l min at 5 bar 72 5 psi of hydrocarbon free air then the compressed air requirement will be 8 l min at 5 bar 72 5 psi The maximum inlet pressure of the ZeroAir generator is 10 145 psi If a compressor is being used with a higher outlet pressure than 10 145 psi then the pressure out of the compressor must be regulated down to 10 145 psi or less The piping used with the ZeroAir generator is standard compressed air pipe this pipe must be clean as any oil or grease would contain and give off hydrocarbons The pipe must be specified to have a working pressure equal to or higher than the maximum pressure of the compressor usually 10 bar 145 3 Operation Operation Summary pu m Stainless Steel Chamber with Air In Catalytic Discs Inlet HEAT Filter j dj Cooling Fan Heat Exchanger Hydrocarbon Outlet Free Air Filter acri rar Pneumatic Summary Inlet Filter 0 1 micron 2 Catalyst ceramic disc Catalyst Pal
7. nel No Yes Does the cabinet seem too hot Disconnect Power open enclosure Check that insulation is intact Yes Still Problem Contact Texol 12 either the control PCB or 6 Appendices Spare Parts Texol Part Number Part Description Qty Replacement Period TPL SP0006 Service Pack for ZeroAir W Tool List e 2 5mm Allen Key e 12mm amp 13mm Spanners Type K Thermocouple amp Thermocouple meter e Filter Removal Tool or Plumbers pliers with protected teeth e Small Flat electrical screwdriver e Detector Threads The table below specifies which types of threads are compatible with the inlet and outlet ports on the rear of the ZeroAir Thread Applicable Standard Compatible Flank Male or Taper or Angle Female Parallel aii od 1956 obsolescent previously 1940 mom BSPT BS21 1938 nomenclature changed 1957 s 2 1986 1986 unu DINAS i DIN259 ee i 1287 BS2779 mmm KP emi eem or 1 ep E B 1985 5 7 1 DIN 3852 Male 14 7 Warranty Limited Warranty LIMITED WARRANTY TEXOL GASGEN LTD TEXOL warrants that the ITEMS LISTED BELOW shall be free from defects in material and workmanship for the stated period of time commencing from date of shipment or as stated below TEXOL GAS GENERATOR SYSTEM One 1 year from customer receipt Repair or re
8. old subject to the limited warranties set forth in the warranty statement Further Texol reserves the right to make changes in the specifications of the products described in this manual at any time without notice and without obligation to notify any person of such changes This laboratory gas generator is designed for operation only by trained personnel familiar with the use of similar equipment and with safety requirements for the use of nitrogen and other industrial gases Before operating this equipment make sure to read and understand this information provided herein If you have any questions please contact Texol Gasgen Ltd or your generator supplier Texol Gasgen Ltd Elderpark Workspace Glasgow G51 3TR Web www texol co uk How to Use This Manual This manual is designed to be user friendly The format includes several symbols Placed next to text they give you visual cues about the contents This text is part of a checklist If you want to learn helpful hints pay attention to this symbol NIZ e Warning sure to read the important text next to this symbol V For further information on the subject refer to the areas suggested next to this symbol Table of Contents INTRODUCTION SE d Warnings INSTALLA FION eme Material Listing Quick Start Guide System Setup Compressor Hook Up amp Piping OPERATION e P Operation Summary Pneumatic S
9. placement parts for Texol Gas Generator System Ninety 90 days from customer receipt EXCLUDED FROM THIS LIMITED WARRANT Y The following shall be excluded from the Limited Warranty e Parts and items considered consumable in normal operations including those parts and items supplied with the Texol Gas Generator System System for maintenance e Any System and its parts that are not installed operated and maintained in accordance with the unit s manual supplied with the System e Damages due to accident abuse acts of God acts of terrorism misuse or negligence or which result in whole or in part from improper or unauthorized use or repair of the System or use of the System in a manner for which it was not designed or by causes external to the System such as but not limited to power or air conditioning failure or voltage irregularities REMEDY BUYER S sole and exclusive remedy in the event of defect and the liability of TEXOL hereunder is limited to the adjustment repair or replacement of the defective item or part with a similar item or part free of defect Such adjustments repairs or replacements will be made at TEXOL s Dundee Scotland plant or by agreement of both parties at the site of the System if BUYER so elects All costs for shipping equipment or parts shall be on the account of the BUYER whether to or from the point of manufacture Labour costs associated with travel expenses and subsistence costs for field se
10. rvices shall be on the account of the BUYER VOIDING OF THE LIMITED WARRANTY This Limited Warranty is immediately void upon e THE OPENING OR DISASSEMBLY OF THE SYSTEM CABINET OR ANY PART THEREIN OR e THE SALE ASSIGNMENT OR ANY OTHER TRANSFER OF TITLE BY BUYER OF THE ITEMS OR PARTS OTHERWISE COVERED UNDER THIS LIMITED WARRANTY WAIVER OF ALL OTHER WARRANTIES THE LIMITED WARRANTY PROVIDED HEREUNDER AND THE RIGHTS AND REMEDIES OF THE BUYER HEREUNDER ARE IN LIEU OF AND BUYER EXPRESSLY WAIVES ALL OTHER WARRANTIES GUARANTEES OBLIGATIONS LIABILITIES OR REMEDIES EXPRESSED OR IMPLIED ARISING BY LAW OR OTHERWISE INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND NON INFRINGEMENT IMPLIED WARRANTIES ARISING FORM THE COURSE OF DEALING OR USAGE OF TRADE AND IMPLIED WARRANTIES OF SUITABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY THE REMEDIES PROVIDED IN THIS LIMITED WARRANTY ARE EXCLUSIVE AND TEXOL SHALL IN NO WAY BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER INCLUDING WITHOUT LIMITATION LOSS OF USE REVENUE OR PROFIT 15 8 Service Contacting Texol Gasgen Service Department Texol provides worldwide engineering and technical field service support for its products Field Service representatives are available for contact at the addresses below Texol Gasgen Ltd Elderpark Workspace Glasgow G51 3TR Scotland UK Tel 44 0141 530 7417 www texol co uk servi
11. ummary Electrical Summary MAINTENANCE m AKTER M Servicing EE eS ZI elegi cene Flow Chart Electrical Diagram lid PILe llf Spare Parts Tool List Threads WARRANTY deve Limited warranty SERVIC ue Contacting Texol Gasgen Service Department I Introduction Warnings NIZ When required to open the enclosure for repair or maintenance ensure that the unit is disconnected from the electrical mains supply 2 No unqualified or untrained personnel should operate repair or maintain the system 3 Texol shall not be liable for damages to the customer s own equipment which is the result of the contravention of the products specifications warnings cautions and notes and the common sense of good engineering practice 4 Do not disconnect or exchange any pipes or cables while the system is powered 5 t is the user s responsibility to observe all safety rules and observe the system product specifications 2 Installation Material Listing After unpacking your Generator you should have the following components Zero Air Unit 1 off V itc Power Cable 1 off This user manual 1 off ZeroAir Quick Start Guide Take the unit out of the packaging 2 Connect air supply to the INLET filter at the back of the ZeroAir using the 4 BSP thread see diagram below 3 Connect the application s supply to the OUTLET filter at the back of
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