Model 111 Zero Air Supply - User Manual
Contents
1. 2 3 Model 111 Flow Schematic it Bene 4 Component LAY OU rn unse 4 2 Winne Drastan Liceo aee o aetna REA coven qol af dans NG 4 3 Temperature Controller Schema 4 4 Compressor Dimensional B 1 Standard Model 111 Compressor Motor Exploded B 2 20 LPM Option Compressor Motor Exploded B 3 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 SO 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 NO O3 SO CO and hydrocarbons are required with flows up to 20 liters per minutes at pressures of 30 PSI Thermo ELECTRON CORPORATION Model 111 Zero Air Supply Figure 1 1 Zero Air Assembly 1 1 Chapter 1 Introduction Figure 1 2 Outline Drawing 1 2 SPECIFICATIONS Power Power Consumption Dimension Weight 115V 50 60 Hz 120 Watts 12W H x 19 W x 15 D suitable for rack mounting 17 pounds 1 3 Chapter 1 Introduction CHAPTER 2 INSTAL2. Model 111 Instruction Manual Zero Air Supply Including External Air Compressor Part Number 7734 20Dec2007 2007 Thermo Fisher Scientific Inc All rights reserved Specifications terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermo com aqi Thermo Fisher Scientific WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive are available at www thermo com WEEEROHS WEEE Compliance TABLE OF CONTENTS CHAPTER 1 INTRODUCTION nnne 1 1 SIE Cl Pe EOIN A E Cato be etd eu e assumes 1 3 CHAPTER 2 INSTALLATION AND 2 1 Unpackins uc pisos eredi ee i tacitae Pei diat i te t
3. 7075 Purafil 5 lbs 4157 Charcoal 5 lbs 8193 Service Kit for Standard Compressor 1 8221 Service Kit for 20 LPM Compressor 1 Chapter 6 Servicing SERVICE LOCATIONS For additional assistance Environmental Instruments Division has service available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information 866 282 0430 Toll Free 508 520 0430 International Thermo Fisher Scientific Appendix A Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller s published specifications and be free from defects in material and workmanship when subjected to normal proper and intended usage by properly trained personnel for the period of time set forth in the product documentation published specifications or package inserts Ifa period of time is not specified in Seller s product documentation published specifications or package inserts the warranty period shall be one 1 year from the date of shipment to Buyer for equipment and ninety 90 days for all other products the Warranty Period Seller agrees during the Warranty Period to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with said published specifications provided that a Buyer shall promptly notify Seller in writing upon the discovery of any defect which notice shall include the product
4. 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 P N 8187 110V P N 8188 220V Description 1 inter Fitter Assembly hal s uu RM Safety Valve Part Qnty Cylinder Head lasi Head Gasket 26 vw cure bilem BEN Cylinder Gasket WR or e 1a Piston noa Anemon real Gounterweigne gt gt Lis fr ru Denotes parts included in service kit Figure B 2 Standard Model 111 Compressor Motor Exploded View B 2 Appendix B Compressor Operation and Maintenance P N 8216 110V P N 8206 220V Ref Part Description Qnty Inlet Filter Assembly a NM aj arc d e6 Valve Outlet OO No 28 Valve niet 2 9 Gasket Cylinder 10 Cylinder 412 Piston
5. 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 Appendix B Compressor Operation and Maintenance 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 65 to 75 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 A WARNING To prevent explosive hazard do not pump combustible liquids or vapors with these units It is usually quickest and least expensive to send the motor in for repair Authorized service facilities are located at Gast Manufacturing Co Ltd Gast Manufacturing Corp Halifax Road Cressex Estate 2550 Meadowbrook Road High Wycombe Bucks HP123SN Ben
6. model and serial number if applicable and details of the warranty claim b after Seller s review Seller will provide Buyer with service data and or a Return Material Authorization RMA which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replacement Products shall be made in accordance with the Delivery provisions of the Seller s Terms and Conditions of Sale Consumables including but not limited to lamps fuses batteries bulbs and other such expendable items are expressly excluded from the warranty under this warranty Notwithstanding the foregoing Products supplied by Seller that are obtained by Seller from an original manufacturer or third party supplier are not warranted by Seller but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier to the extent such assignment is allowed by such original manufacturer or third party supplier In no event shall Seller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear and tear ii accident disaste
7. the layout of these components CHARCOAL FILTER TRANSFORMER 220 110 OPTION REACTOR TERMINAL BOARD PRESSURE TEMPERATURE REGULATOR CONTROL MOUNTED OUTSIDE Figure 4 2 Component Layout 4 2 Chapter 4 Theory of Operation 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 Ti 220 Et 27T 2 HOT Figure 4 3 Wiring Diagram JUMPERS Chapter 4 Theory of Operation L SEE NOTE IN amp 5 40 INDIC LI ono 46 R14 NOTE SEE NOTE y ALL VOLTAGE READINGS ARE REFERENCED TO SEE NOTE FE COMMON C4 6 Bpf 20 VDC ADDEO TO REDUCE VOLTAGE AD SPIKE TO IC2 PIN 3 TO ELIMINATE Ki CHATTER 6 0 R2 56K V Gia Figure 4 4 Temperature Controller Schematic 4 4 CHAPTER 5 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
8. LATION 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 Electron Corporation 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 l 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 Remove the Model 111 cover from the main frame of the unit thus exposing the internal components of the instrument Check for possible damage during shipment and then reinstall the cover Remove compressor from shipping container unbolt from pallet and then identify the coalescing filter and pressure regulator Check for possible damage during shipment 2 1 Chapter 2 Installation and Setup ASSEMBLY Use the following procedure to assemble the instrument 1 Using 1 4 Teflon tubing connect the outlet of the pressure regulator located on the compressor to the input of the Model 111 Note An optional compr
9. Sea 13 Piston Rod Assembly t4 Rider Ring 15 Eis Manifold Sleeve Denotes parts included in service kit Figure B 3 20 LPM Option Compressor Motor Exploded View B 3 Appendix B Compressor Operation and Maintenance ELECTRICAL Remove the plate covering the electrical terminal for wiring instructions A WARNING The motor might be thermally protected and can automatically restart when the protector resets Always disconnect the power source before servicing the instrument 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
10. TATEMENT SELLER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT A 2 Warranty Thermo Fisher Scientific APPENDIX B COMPRESSOR OPEARTION AND MAINTENANCE This appendix explains proper operation and maintenance of the compressor CAUTION Never lubricate this dry oil less piston pump The Teflon filled rings are self lubricating and require no oil The motor bearings are grease packed for the life of the bearing INSTALLATION 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 Standard Model 111 17 1 4 16 5 8 5 5 8 4 10 A B D E 20 LPM Option 26 20 7 8 13 1 2 11 1 2 16 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 Figure B 1 Compressor Dimensional Data Appendix B Compressor Operation and Maintenance
11. aba con o puts 2 1 O sa RA tpm idus eru anal 2 2 CHAPTER 3 OPERATION aaa ken 3 1 CHAPTER 4 THEORY OF OPERATION 4 2 1 4 1 Gs Scrubbing nn nenne Ben 4 1 Electrical ds 4 3 CHAPTER 5 5 1 Weekly e O Ed 5 1 PA OBYEN a Saree e er 5 1 bil ky sap ky die bay ka kad a soa A e dodo a kok da ii 5 1 baka aka 5 1 CHAPTER 6 SERVICING sum on aaa na se kons pote 6 1 Spare Pas nase eben ehe 6 1 Service LOCAS li Pat a ei A l equ 6 2 APPENDIX A WARRANTY 2 ux ana aia A 1 iii APPENDIX B COMPRESSOR OPERATION AND MAINTANENCE B 1 A e EE cua case B 1 Disassembly en EEE B 2 Electrical O B 4 Assembly aco diuo ceca ire oe AAA ae Ai ea e ak es B 4 Inspectii ka du sed kab ran esegue testas detta yad da piki poke dedistis ab aaa ted asd eati B 5 Figure 1 1 1 2 2 1 2 2 2 3 4 1 4 2 43 4 4 B 1 B 2 B 3 LIST OF ILLUSTRATIONS Page LEN AO ot lud cn edi ce tet e ec 1 1 Outline Dawn char oe su Ebo tete oed eu beki 1 2 Interior VIO Sese o NA E se 2 2 Flow Schmale sus ee repair a m AM a TUAM DUM 2 2 Option 006 for H2S
12. 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 B Compressor Operation and Maintenance 5 1 CHAPTER 6 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 l
13. essor 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 Model 111 Using 1 4 Teflon tubing connect the outlet of the Model 111 to the device requiring zero air under pressure 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 Note 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 B Compressor Operation and Maintenance 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 sh
14. ir 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 25 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 0 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 COMPRESSOR PURAFIL CHARCOAL PRESSURE REGULATOR FILTER REGULATOR Figure 4 1 Model 111 Flow Schematic 4 1 Chapter 4 Theory of Operation 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 NO The air then passes through a column of iodated charcoal which removes NO and 502 Finally the air goes into the reactor where it is heated to 350 C over a catalytic surface which oxidizes CO to CO and hydrocarbons including methane to CO and water Figure 4 2 shows
15. r or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which Warranty 1 they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage and handling of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty Buyer shall pay Seller therefor at Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMENT TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY S
16. ton Harbor MI 49022 England 616 926 6171 High Wycombe 23571 Wainbee Ltd Gast Manufacturing Corp 121 City view Drive 505 Washington Ave Rex dale Ontario Carlstadt NJ 07072 Canada M9W 5A9 201 933 8484 Wainbee Ltd Brenner Fielder amp Assoc 215 Brunswick Blvd 16210 Gundry Ave Ponte Clair Montreal Paramount CA 90723 Canada H9R 4R7 213 636 3206 514 697 8810 B 5
17. uts 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 350 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 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 SO NO NO 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 30 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 a
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