SERVICE MANUAL 5C Rev B
Contents
1. 2 On the front of the temperature controller push the lt button on the left side once to verify the set temperature of 407 C 3 Push the button once more to verify the alarm mode temperature of 30 C 4 Turn off unit and unplug power cord 2 7 Over Temperature Test Warning Burn Hazard A HEATER BLOCK BECOMES HOT DO NOT TOUCH 1 Switch main power off and disconnect the power cord 2 Attach leads of VOM to thermal cut out switch terminals Set the VOM to Resistance Ohms and turn on VOM 3 Verify the VOM reads less than 1 Ohm 4 With a heat gun apply heat to top of heater block for approximately 60 seconds as shown on photo below When a CLICK is heard the thermal switch has opened stop the heat gun Repeat Step 2 and verify the VOM reading is between 5 and 6 k Ohms Press the thermal cut out switch reset button and verify the VOM reads less than 1 Ohm aes et Page 17 of 33 1800213 RevB 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 3 Adjustment and Aerosol Test Caution ESD Hazard TEMPERATURE CONTROL UNIT IS ESD SENSITIVE PERFORM THESE STEPS AT ESD WORKSTATION 1 Open fill cap and fill with approximately 0 5 cups 118 cc of clean liquid aerosol reagent Use a funnel with a strainer to eliminate particles from entering the2. at the source If regulation is above 65 psi 4 5 bar the internal pressure relief valve will open This protects the 5C from excessive pressure to the regulator see Internal Protective Devices Page 5 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc D Regulator At the gas input a pressure regulator is set to allow flow in the tank and heater block Enough flow is required to pressurize the tank so liquid will flow and to actuate the piloting actuator see Liquid Feed Valve If there is excessive flow the aerosol will be too wet The regulator is set to maintain dry aerosol at the output nozzle Gas flow is routed to the tank and to the solenoid valve input port When all conditions are met the solenoid valve has ON OFF control by the aerosol switch When energized gas is allowed to pilot the liquid feed actuator which then allows the liquid feed valve to open and liquid flow to the heater block E Internal Protective Devices 1 High Pressure Relief Valve At the gas input the 5C has a high pressure relief valve set to open at 65 Psi 4 5 bar If the gas source regulator is set higher than 65 psi 4 5 bar the valve will open and relieve excess pressure This feature protects the internal pneumatic components and the liquid reservoir 2 Low Pressure
3. 2 Page 25 of 33 1800213 Rev 05 10 10 1403 Cronridge Drive Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1 Z e 9S MIOANASSY dinor 929000 owe gt Al0d 914 sorores 9 3214140 M ONILL 331 6770 0 9 9 aoe so Sawa screen L tL aoa Sk ores o0es 4 SISSVHO 73877 L 8b aoj 2980018 e 1800213 RevB 05 10 10 Page 26 of 33 1403 Cronridge Drive Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1 Z Ne Am ISdg 9 49 3ATVA 281009 7 2910099 2 inne ta UU T3AMMS 06 14 100065 jai oid 68006 9 3ATVA 902009 xen r en 1800213 Rev B 05 10 10 Page 27 of 33 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A
4. Relief Valve Mounted at the internal regulator is a low pressure relief valve set at 6 8 psi 0 47 bar Should the internal regulator be set too high or fail to regulate the gas to the proper pressure the valve will open and relieve flow to the reservoir Normally the internal regulator is set much lower approximately 2 3 psi 0 14 to 0 2 bar 3 Thermal Cut out Switch A thermal cut out switch is mounted on top of the heater block metal panel The thermal cut out switch senses the temperature of the heater panel surface and is set to open at 148 C If the panel surface exceeds 148 C the switch opens and breaks power to the mechanical relays The temperature at the controller will drop at this point The switch has a manual reset button at the top The surface temperature will have to cool enough to allow the switch to be re set Once re set the heaters can be powered however an investigation as why the switch opened should be conducted prior to re setting 4 Tipping Switch The tipping switch is mounted to the PCB The switch opens when the 5C is tipped over in any orientation more than 30 from horizontal When the switch opens 12 VAC power is interrupted causing the mechanical relays to open and the solenoid valve to close This effectively turns off the aerosol and power to the heater cartridges If the switch closes by setting the 5C back to level position the unit will normalize An indicator of the tipping switch opening and closing i
5. not stay functional long enough see relays Therefore the failure will be noticeable at the temperature controller display Transformer output of 12 VAC can be verified and measured across the two test points on the PCB When measuring the transformer voltage the PCB assembly must be held vertical in order to keep the tipping switched closed see tipping switch Relays The 5C uses two mechanical relays to power the heater cartridges with high AC power If either high or low power drops out the relays will open and the heater cartridges will not be powered Solenoid Valve The 12 V solenoid normally closed valve controls gas flow to the liquid piloting valve When energized the valve opens and allows gas to pressurize the piloting valve which then allows liquid flow to the heater block The solenoid valve is energized by switching the Aerosol Switch to ON while low 12 VAC power is available The solenoid valve is a three way valve that vents when de energized Therefore when the solenoid valve is de energized the piloting valve closes the liquid feed Gas Flow Gas flow is controlled at the source bottle by the operator Once the source is connected to the 5C and the gas turned on gas will flow through the generator Purging is constant unless the gas is turned off at the source The inert gas line or tube is connected to the inch outer diameter tube fitting at the front panel Gas flow is initially regulated to 50 psi 3 45 bar
6. turn clockwise until gas hissing is audible Turn the aerosol switch to ON and note the green LED is illuminated Open metering valve slowly until fully opened Wait for aerosol to begin flowing and then allow 15 to 20 seconds for the aerosol to stabilize If there is no aerosol after 10 seconds slowly open the regulator knob turn clockwise until aerosol starts to appear aerosol does not appear STOP and consult the Troubleshooting Section Use long handled pliers or tongs to hold a piece of brown test paper near the aerosol output for 3 seconds Check for wetness in aerosol wetness will turn the paper dark The generator should not output wet aerosol 7 Warning Burn Hazard UNIT MAY SPRAY EXTREMELY HOT OIL FROM OUTPUT HOLD TEST PAPER WITH TONGS AND STAY CLEAR OF AEROSOL STREAM If wetness shows on the test paper close the regulator turn counter clockwise slightly and check again If the problem is not resolved consult Troubleshooting Turn off aerosol by switching the aerosol switch to OFF The unit should stop producing aerosol within 30 seconds Switch the aerosol switch to ON and unit should produce aerosol within 20 seconds Repeat wetness test from Step 19 If wetness test is satisfactory push regulator knob in to lock position While the aerosol is running turn the main power switch to OFF and verify the aerosol stops producing aerosol within 30 seconds Page 19 of 33 1800213 Rev 05 10 10 11403 Cronr
7. 63 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc Ill PREVENTATIVE and PERIODIC MAINTENANCE Warning Electrical Hazard A UNPLUG POWER CORD FROM UNIT BEFORE REMOVING THE TOP COVER OR ATTEMPTING INSPECTION OR SERVICE It is recommended that customers return their 5C for annual inspection and service At a minimum the following should be performed when receiving a 5C for this service 1 Remove the top panel and visually inspect the interior for signs of cable and tubing distress fraying kinking heat brittleness etc liquid build up and corrosion Replace cables or tubing sections that are damaged or distressed Clean wipe excess liquid buildup from interior Check and inspect condition of fuses Install new fuses as necessary Check condition of the fill cap for cracks and missing or damaged gasket Inspect the output nozzle orifice for signs of blockage Use a 0 060 0 002 inch 1 5 mm 0 05 mm diameter metal pin or wire to clean out the blockage Inspect the heater block fittings for wetness looseness or cracks in the insulation blocks If needed remove the heater block assembly from the back panel and inspect for further signs of damage Check for loose or missing hardware Tighten as necessary or replace any missing hardware Perform electrical safety mechanical and aerosol test per in Section VII Page 8 of 33 1800213 Rev 05 10 10 11403 Cronridg
8. 800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc APPENDIX 2 ASSEMBLY DRAWINGS This section contains exploded views of the sub assemblies with parts list For clarity wire cables and tubing are not shown Refer to assembly drawing 0200341 for wiring details Heater Assembly 0600430 Liquid Reservoir Tank Assembly 0600431 Regulator Assembly 0600432 Metering Concentration Valve Assembly 0600433 Front Panel Assembly 0600434 Rear Panel Assembly 0600435 Heater Block Assembly 0600438 5C Completed Unit 0200341 Top panel Assembly 0600436 O Ou pu ct Page 24 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc EN 15 2 2200007 scREW 4 2 12 2 0009627 BRACKET HEATER RETENTION _ EE SULA FE EN 4 2200116 HER 2100009 0627 1 2200174 2200018 Pw DESCPIPTION 8 0600430 SCALE SHEET 2 oF 2 4 9 2 1 6700165 CABLE ASSY HEATER ROD PCB HEATER PANEL 5 9 aa 7 1 6 2 5 6 a 5 SUB ASSY 5 ga
9. Division of Hamilton Associates Inc DESCRIPTION 7 1 T5A0 0420 VALVE METERING 1 8 1 5100014 FTG PRLK 90 SWIVEL 28 of 33 1800213 Rev 05 10 10 1403 Cronridge Drive Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1 e Z e Nd Os WOlvin93H ASSV Ac ONIS I IL Ja Z VIV X k 95 9S T3NVd INOW4 8090004 b amp 854 OLHOLIMS Assy 87870 29 0049 W i H3TIOHINOO dW3l vri009Y 9 evita vas enis y TOMINOO J3MOd 95 ASSV 9810090 6 3lhQOW LN3 wAM 1 0069 0 1991 608009 fz ONINSWM TVORLIO3T3 38V1 606009 XH LAN 9 1800213 Rev 05 10 10 Page 29 of 33 a AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com s w wr mee jr Jess s EJERE 509904 LABEL HOT SURFACE WARNING 1 1509 ama JLABEL GROUND 1 2 DIA n s meam screw s Jone sp
10. Remote OFF GPIB 08 LCD Contrast 6 Audible Alarm Volume 4 Fail Stop ON AC Dielectric Voltage 1350V Hi Limit 25 00 mA Low Limit 0 0 mA Ramp time 2 Sec Dwell time 9 Sec Frequency 60 Hz Arc Sense 1 Arc Fail OFF Scanner Set CH 1 16 00000000000000000 Connect ON Ground Bond Current 25 0 A Voltage 8V Hi Limit 100 milliohms Lo Limit milliohms Dwell Time 2 Sec Frequency 60 Hz Scanner CH 0 Offset milliohms Connect OFF Page 13 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 2 NOTE The 5C unit should be completely assembled including the top cover 3 Using the power cord that will be shipped with the unit plug in 5C unit in at the main power to the tester See instruction sheet for connection method For the chassis return connect to the Gas Inlet Port on the front panel 4 Switch the 5C unit main power switch to ON 1 3 Test With the tester configured and connected to the 5C initiate the test by pressing the green button The tester will perform the AC Dielectric Hi Pot test first and Ground Bonding test last The test er will stop at the first failure At green light will illuminate if the unit passes At completion of the test record Pass Fail for each test and the resistance of the Ground Bond test in milllohms on the Test a
11. STE AIR Tee TERNATIONAL ns UE MD 21117 2247 USA Tel 410 363 9696 Fax 410 363 9695 1800213 SERVICE MANUAL oC GENERATOR P N 9300207 9300208 9300213 9300214 1 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc TABLE OF CONTENIS OCO 3 I FUNCTIONAL DESCRIPTION 4 II PREVENTATIVE and PERIODIC MAINTENANCE 8 SERVICE REPAIR 9 V OPARE FART 11 VI FINAL INSPECTION CHECK 12 VII TESTING and ADUUSTMENIT 13 APPENDIX 1 SERVICE and REPAIR TROUBLESHOOTING PROCEDURES Ds 22 APPENDIX 2 ASSEMBLY DRAWINGS eee 24 Page 2 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc l SCOPE The purpose of this document is to provide authorized service personnel with information necessary to service repair and test the 5C Aerosol Generator This document is intended to be
12. Using a 7 16 spanner wrench connect the test gauge ENG 20 at the Tee fitting When reading pressure hold the gauge vertical while reading as shown Page 15 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 2 3 High Pressure Test Open the test valve Using the test valve regulator SLOWLY increase the pressure until air begins to escape from the high pressure relief valve inside the test unit Note the pressure on the test valve regulator when the air begins to escape The pressure shall be between 65 Psi 4 5 bar and 80 Psi 5 5 bar Record Pass Fail and the pressure on the Test and Acceptance Record Close the test valve and the regulator so that air is relieved and the pressure is zero 2 4 Low Pressure Test po pit d 6 Fully close the unit internal regulator Adjust the test valve regulator to 50 psi 3 45 bar Open the test valve Adjust the unit s internal regulator increasing the flow until air begins to escape from the unit s low pressure relief valve Note the pressure on the test gauge at point A when the air begins to escape The pressure shall be between 6 Psi 0 45 bar and 8 Psi 0 55 bar Record Pass Fail and the pressure on the Test and Acceptance Record 2 5 System Leak Test m M dus PM Close the test valve Clos
13. acer a ra80 0245 GASKET GEN COLLAR TUBE NOZZLE 5C OUTPUT PLATE NOZZLE REAR 8C OUTPUT a NOZZLE FRONT 5C OUTPUT 5 7 una wor 7 320074 WASHER gt 709177 GND WIRE 26 RING LUG EZER REAR PANEL 8 t essem Jassy HEATER Page 30 of 33 1800213 Rev B 05 10 10 dk 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 e Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc BSHG REDUCING 5C HEATER BLOCK CABLE ASSY THERMOCOUPLE J TYPE DESCRIPTION 10010 2 2 T5A0 0272 WASHER GEN HEATER BLOCK 1 1000626 6 5A0 N HEATER BLOCK 1 TsA0 0274 NOZZLE GENERATOR Page 31 of 33 1800213 RevB 05 10 10 1403 Cronridge Drive Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1 Z Nous os 29 TANVd ASSY RC CINES 98 IHNvd dO ASSV r 1 sow v v s isi H in soie _ osi 1800213 Rev B 05 10 10 Page 32 of 33 Fax 410 363 9695 Te
14. e Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc IV SERVICE REPAIR Warning Burn Hazard A HEATER BLOCK BECOMES HOT DO NOT TOUCH After inspection and or repair is performed turn the unit ON and allow it get to the operating temperature of 407 C Note the time required to reach the operating temperature If it takes more than 25 minutes or temperature fails to reach the operating temperature consult the Troubleshooting Guide in Appendix 1 A Basic Instructions e Apply three wraps of 14 wide 6 3 mm commercial grade Teflon tape for sealing all NPT threads Apply to male NPT threads in a clockwise direction with the threads facing you before installing e Note direction of arrows on filters and check valve These components must be oriented in the correct direction as indicated on the exploded views No special or custom tools are required for repair service However there is special test equipment required for post repair testing e Refer to the assembly exploded views in Appendix X for disassembly and replacement of components If necessary use the trouble shooting guide to identify a problem with a unit e All repairs require re testing See Section VII B Front Panel PN 0600434 The front panel contains electrical components that may require replacement if damaged by external
15. e the unit internal regulator Plug the outlet nozzle end with the test plug 2TF AT5C 9300207 Adjust the test valve regulator to 50 psi 3 45 bar Open the test valve Adjust the unit s internal regulator increasing the pressure to 3 psi 0 2 bar on the test gauge at Point A Close the test valve Allow 10 seconds for the pressure to stabilize Page 16 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 9 Note the starting pressure 10 Start the stopwatch 11 After 2 minutes stop the test and note the final pressure on the test gauge 12 The pressure difference after 2 minutes shall not exceed 0 50 psi 34 5 millibar 13 Record Pass Fail and the final pressure on the Test and Acceptance Record 14 If unit does not pass there is an air leak in the system and must be remedied before proceeding 15 After making necessary repairs repeat test until the unit passes 16 REMOVE THE TEST PLUG AT THE OUTLET NOZZLE 17 Close test regulator to zero pressure 18 Using a 7 16 spanner wrench remove the test regulator assembly from the gas inlet fitting 19 Using a 7 16 spanner wrench remove test gauge ENG 20 and reconnect the plastic tube fitting going to the solenoid valve 2 6 Temperature Controller Settings Verification 1 Turn power switch ON
16. for the 5C to able to produce aerosol The 5C must have electrical power The main power switch must be ON The temperature controller must indicate a temperature between 337 and 437 C Adequate inert gas must be flowing through the generator The aerosol switch must be ON AND The metering valve must be open The generator must be placed on a level stable surface If any one of these conditions is not met the 5C will not produce aerosol The 5C has several internal protection devices These devices if active will prevent the 5C from producing aerosol since they affect the conditions listed above A Part Numbers There are four top level part numbers associated with 5C generators The part numbers correspond to the following Part Number 9300207 for 115 VAC and uses PAO 4 Part Number 9300208 for 230 VAC and uses PAO 4 Part Number 9300213 for 115 VAC and uses DOP Part Number 9300214 for 230 VAC and uses DOP Part numbers 9300207 and 9300208 can also be used with DOS DEHS Ondina El or mineral oil as an aerosol reagent Before starting repairs note the part number on the product label for the proper voltage and liquid aerosol reagent B Electrical System The 5C will operate at either 115 VAC or 230 VAC rating The only physical difference is the installation of the two fuses and the fuse holder inside the Power Entry Module Incorrectly setting up the fuses will produce the following e Powering a 115 V fused unit wi
17. idge Drive e Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http Awww atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc Holding brown test paper in aerosol stream 16 Turn the main power switch back to ON and verify the aerosol starts again 17 Switch aerosol switch to OFF and fully close the metering valve 18 Turn off the unit at the power switch Warning Fire Hazard A DO NOT TURN OFF INERT GAS UNTIL UNIT HAS BEEN PURGED OF RESIDUAL AEROSOL 19 Wait a minimum of 60 seconds to clear residual aerosol from the heater block and then turn off the inert gas at the source regulator Allow the gas to de compress bleed off through the unit 20 Disconnect hoses and power cord keep the cord with the unit Turn off vacuum testing station 21 Replace the inch tube ferrule back on fitting at unit inert gas inlet 22 Inspect the interior of the generator for leakage 23 Record results Pass Fail 24 Cool for approx 1 hour Temperature may be monitored by switching unit on momentarily temperature control unit will display current temperature The unit may be moved safely when the temperature drops below 100 C and may be empti ed safely when temperature drops below 80 C Warning Fire Burn Hazard A MOVING UNIT BEFORE SUFFICIENTLY COOL MAY CAUSE IGNITION OR SPRAYING OF EXTREMELY HOT OIL 25 Look inside oil reservoir if oil is burnt or contaminated di
18. it to reach the operating temperature Connect the insert gas line and turn on the compressed insert gas Turn the Aerosol Switch to ON Fully turn the metering valve knob counterclockwise Allow the previous liquid aerosol reagent left in the unit to purge out until the there is only insert gas flowing Fully close the concentration valve and turn OFF the aerosol switch The 5C is ready for use with a different liquid aerosol reagent DIE S wes Page 21 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc APPENDIX 1 SERVICE and REPAIR TROUBLESHOOTING PROCEDURES Symptom Cause Resolution Check wiring terminal No Display on Controller Controller wiring not installed correctly installation is correct and or after switch main power ON or faulty wiring harness replace wiring harness to temperature controller Check fuse amp replace if Fuses blown or not installed Check power module wiring harness for damage or loose connections Controller is defective Replace temperature controller Wait a minimum of 25 30 minutes for temperature stabilization Power Input module wiring not properly contacting or may be damaged Unit does not warm up temperature does not Not enough time allowed for the unit to increase within 30 warm
19. l 410 363 9696 MD 21117 2247 USA 1 AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1403 Cronridge Drive e Owings Mills http www atitest com 1 Z e NOLLdIH2S30 25 T3NVd JHM OND 1800213 RevB 05 10 10 Page 33 of 33 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 1800213 Rev 05 10 10
20. lfunctioned H Liquid Feed Valve The Liquid Feed Valve controls liquid flow from the metering valve to the heater block The liquid feed valve is gas pressure piloted controlled A piloting actuator activates the liquid feed valve when gas pressure is applied When liquid flow is needed the aerosol switch turns on the solenoid valve which then pilots the liquid feed valve Therefore no liquid flow will occur if the gas pressure is too low or the solenoid valve is de energized see solenoid valve l Temperature Controller OMRON E5CSV R1T The temperature controller is set up to indicate temperature in degrees Celsius The set point is 407 C The 5C uses the controller s alarm relay output to allow the solenoid valve to open and allow liquid flow The alarm is set to output at 30 above and below the set point temperature The controller must therefore indicate a temperature between 377 and 437 C before the solenoid valve can be energized If inspecting or replacing the temperature controller refer to the set up procedure in Section V J Output Collar The output collar has a perforated tube between the collar and the rear panel The perforations provide quench air to the aerosol stream The design allows the operator to clamp an un vented hose to the output collar and maintain quench air to the vapor stream Page 7 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 3
21. means The front panel also contains the pneumatic assembly components C Rear Panel PN 0600435 1 The rear panel contains the heater assembly PN 0600430 and the output collar assembly 2 Inspect output collar items 6 through 11 for looseness Tighten hardware as necessary D Heater Assembly PN 0600430 1 Remove heater block assembly from rear panel Save all hardware Page 9 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 2 Inspect insulation blocks items 11 and 12 for cracks 3 If necessary to replace insulation blocks disassemble the heater 4 Replace insulation pads items 9 and 10 if they are wet or contaminated E Heater Block Assembly PN 0600430 1 If heater block fittings are to be removed or replaced clean threads of all residue Discard old washers part number T5A0 0272 and replace with new washers Use Resbond 907 5 high temperature thread locking compound when assembling heater block fittings Check the shelf life expiration date on the Resbond 907 5 container Only use a container that has not expired 2 Tighten heater block fittings to 70 to 80 ft lbs 9 7 kg m to 11 kg m torque 3 Inspect thermocouple cable for thermal stress or fraying Replace if needed F Metering Valve Assembly PN 0600433 1 Remove the metering val
22. nd Acceptance Record Mechanical Tests 2 1 Tools and Equipment Required Small flathead screwdriver 7 16 spanner wrench Brown test paper Approximately 0 5 cup 118 cc of liquid aerosol reagent See part number for correct type High pressure Nitrogen inert gas 5Opsig 5 psig 3 45 bar 0 35 bar training required Vacuum testing station training required Long handled pliers or tongs Stop watch ATI test gauge ENG 20 ATI test valve no TF AT5C 9300207 ATI test plug no 2TF AT5C 9300207 Heat air gun Standard Volt Ohm Multi Meter VOM 2 2 Set Up Hemove the top panel part number 0600436 from the unit and save along with all the hardware screws Remove inch tube ferrule from unit inert gas inlet and save ferrule for replacement at end of all testing Fully close the test valve assembly TF AT5C 9300207 regulator and close the test valve Connect test valve regulator to shop air Make sure the regulator gauge indicates zero pressure Connect the end fitting of the test valve plastic tube to the gas inlet fitting at the font panel shown below Page 14 of 33 1800213 Rev B 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http Awww atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 6 Using a 7 16 spanner wrench remove threaded fitting and plastic tube at the Tee at Point A located as shown below 7
23. output nozzle is clear of carbon build up Output collar hardware are securely fastened The handle foot pads and other hardware are securely fastened All labels are legible and undamaged Liquid level sight tube is clear and transparent The fill cap gasket is intact and undamaged No leaks around the tank drain plug All electrical components are securely attached There are no frayed wires on any cable All wire connections are securely fastened no loose terminals All pneumatic fitting connections are properly tightened All pneumatic tubing is free of kinks or other distress Test and adjust unit per Section VII Page 12 of 33 1800213 Rev B 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc Vil TESTING and ADJUSTMENT Warning Electrical Hazard A RECEIVE TRAINING IN PROPER USE OF ELECTRICAL SAFETY TEST EQUIPMENT AND TESTING AREA STAY CLEAR OF UNIT WHILE TEST IS IN PROCESS 1 Electrical Safety Tests HiPot and Ground Bond Leakage 1 1 Tools and Equipment Required e AC DC HiPot with Insulation Resistance Tester Quadcheck Model 7564SA Electrical oafety Compliance Analyzer or equal with calibration a Set Up 1 Set up the AC DC HiPot tester with insulation resistance tester 2 Configure the tester as follows Test Parameter Setting System parameter PLC
24. reservoir 2 Place unit on testing station and plug in the power cord equipped with a GFI NOTE The power cord with is required for this testing DO NOT proceed until the proper cord is available NOTE Use the proper voltage source according to the unit configuration 115V or 230V Warning Personal Injury Hazard RECEIVE TRAINING IN PROPER USE OF HIGH PRESSURE GAS EQUIPMENT AND THE TESTING STATION CHECK TO ENSURE THE CENTRAL VENTILATION SYSTEM IS ON gt Plug cord back into unit Turn power switch ON Wait approximately 20 minutes for temperature to stabilize at 407 C TURN ON vacuum testing station switch is located on the left side of the machine Warning Explosion Hazard te gt FOLLOW HIGH PRESSURE GAS SAFE HANDLING PROCEDURES Page 18 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 10 11 12 13 14 15 Attach hose from inert gas source to the gas inlet fitting at the front panel Open inert gas source regulator and if needed adjust regulator to 50 psig 5 psig 3 45 bar 0 35 bar Warning Fire Hazard N INERT GAS MUST FLOW AT ALL TIMES WHEN MAKING ADJUSTMENTS OR PRODUCING AEROSOL Pull out the unit internal regulator knob Tighten counter clockwise completely Slowly open the regulator
25. s the aerosol switch green LED turning on and off when the switch is left on see Aerosol Switch F In line filters There are two 40 micron fluid in line filters in the 5C The first is at the gas input between the high pressure relief valve and the internal regulator This filters out impurities from the inert gas source Page 6 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc The second filter is located at the liquid feed line between the reservoir and the concentration metering valve This filter prevents impurities in the liquid from reaching the metering valve or heater block If problems are occurring with aerosol production or low concentration is noticed the filters should be inspected or changed G Aerosol Switch The aerosol switch located on the front control panel controls aerosol production ON and OFF The switch is functional only when all the conditions for aerosol production are met The switch can be used before or after setting the metering valve Once the metering valve is set the switch provides ON OFF control of aerosol production without changing concentration If the low 12 V power see transformer is functional the LED will illuminate when the switch is ON If the switch does not illuminate the switch assembly or the transformer has ma
26. settings for correct Controller internal settings incorrect adjustment No Aerosol Output Liquid reservoir is empty ne Move the Aerosol Switch to the Aerosol Switch in OFF position ON position Verify that 50 psi of inert gas is Improper inert gas pressure being supplied to the unit Tank fill cap is leaking Check valve wires for proper installation Check temperature on controller is with operating oolenoid valve is not opening range 399 415 C Inconsistent Aerosol Check for leakages and tighten There is a gas leak in the system fittings as necessary Verify that 50 psi 3 45 bar of Improper inert gas pressure Inert gas is being supplied to the unit Internal regulator is not adjusted Adjust regulator per Section correctly III 3 in this document Check for leakages and tighten There is a gas leak in the system fittings as necessary Verify that 50 psi 3 45 bar of Improper inert gas pressure inert gas Is being supplied to the unit Internal regulator is not adjusted Adjust regulator per Section 3 in correctly this document Unit was not adequately purged before Purge out liquid in flow hood disconnecting inert gas using inert gas Smoke or aerosol is generated when unit is hot Inspect heater assembly for Liquid is leaking around the heater leaks in fittings Disassemble block heater assembly of replace heater block and fittings Page 23 of 33 1
27. spose of oil properly Otherwise place unit on top of catch pan and open drain plug underneath the unit Allow the unit to empty all liquid reagent from reservoir back into the bottle designated as Testing Liquid Reagent Place back and tighten the drain plug Page 20 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 26 Use a permanent black marker and write PAO or DOP on the top of the oil reservoir 2 Assemble top enclosure to unit Ref drawing 0200341 with saved hardware 28 Wipe off excess oil and clean the exterior with isopropyl 4 Changing and Adjusting the 5C for Different Liquid Aerosol Reagents The 5C may be changed over for DOP or PAO 4 if the customer has requested this However the exterior of the unit must be marked to reflect this No temperature adjustment is necessary An adjustment to the internal regulator is required when changing from PAO 4 plus DOS DEHS Ondina EL and mineral oil to DOP or the opposite Follow the instructions for Adjustment and Aerosol Test in Section 3 for changes to liquid aerosol reagents Before changing to a different liquid aerosol reagent perform the following purging procedure Drain all previous liquid aerosol reagent from reservoir Replace drain plug and tighten Turn the unit ON and allow the un
28. th 230 V will overheat the transformer and open the transformer s protective thermal switches If the switches open power to the heater cartridges will cease and the generator must cool down until the switches re set Page 4 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc C Powering a 230 V fused unit with 115 V will under power the heater cartridges and the temperature controller will show a slow rise in the temperature Normally it would take 20 minutes for the temperature to reach the correct level Under this condition it will take more than an hour Transformer The 5C uses a transformer to convert line AC voltage to low 12 VAC to power the two mechanical relays The transformer mounted on the circuit board is protected from high temperature caused by incorrect line voltage by two thermal cut outs The cut outs are located on top of the primary coil and connected to the circuit board If there is a short failure at the transformer or if the fuses are configured for 115 V and 230 V power is applied the cut outs will open and break power to the transformer The cut outs are set to 70 C Once the transformer cools sufficiently the cut outs self reset The temperature controller will not be able to reach the operating temperature because the transformer will
29. up minutes Cartridge Heater s is defective Replace cartridge heater s Temperature Cut out switch is not Check temp cut out wires installed correctly or wires are Replace temp cut out if damaged necessary Check thermocouple wiring termination Replace thermocouple wire if necessary Fuses are not correctly installed Check fuses for correct y installation Press switch re set button or Thermal cut out switch is open replace switch if it does not reset Thermocouple wire damaged or incorrectly installed Check voltage at test points PCB transformer has failed 12 V power not present replace PCB Aerosol switch is damaged or has Replace aerosol switch cable failed assembly Controller internal settings incorrect Check settings for correct 9 adjustment Wait a minimum of 25 30 minutes for temperature stabilization Unit takes too long to Not enough time allowed for the unit to warm up warm up Cartridge Heater s is defective Replace cartridge heater s Page 22 of 33 1800213 RevB 05 10 10 AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc 11403 Cronridge Drive Owings Mills MD 21117 2247 USA Tel 410 363 9696 e Fax 410 363 9695 http www atitest com Temperature Cut out switch is not Check temp cut out wires installed correctly or wires are Replace temp cut out if damaged necessary Check thermocouple wiring Thermocouple wire incorrectly installed Check
30. used in conjunction with information found in the Documents List below In the event that two documents contain conflicting information or instructions the document with the highest authority shall be considered correct The order of precedence is provided in the Documents List Document List The following documents shall be used in addition to following the instructions in this procedure HA Drawing 0200341 Complete Bill of Material for 0200341 in Decade HA Drawing 1700173 Electrical Schematic Final Assembly and Test Procedures IAT 106 WI IAT 107 WI 108 OR IAT 109 WI whichever applies 5C Test and Acceptance Record Doc 110 FM e 5C Operators and Maintenance Manual Part Number 1600806 REVISION HISTORY O 0709 DraftforReview 1 0 0 0 O 05 10 Alarm temperature changed to 30 deg C Thermal Cut out Switch temperature changed to 148 deg C Revise update test procedures o Page 3 of 33 1800213 Rev 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc Il FUNCTIONAL DESCRIPTION The 5C uses heat to vaporize liquid aerosol reagent under an inert gas flow to produce aerosol To achieve this the heater block is required to be heated to 407 C Inert gas must be used in this process There are several conditions that must be met in order
31. ve assembly from the front panel Save all hardware 2 Disconnect tubing from fittings 3 Remove the piloting actuator item 2 and inspect the feed valve item 3 plunger for ease of movement If the valve is sticking replace the valve 4 Remove and replace the in line 40 micron filter item 1 G Regulator Assembly PN 0600432 1 Remove the regulator valve assembly from the front panel Save all hardware 2 Disconnect tubing from fittings 3 Remove and replace the in line 40 micron filter item 1 Page 10 of 33 1800213 RevB 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc V SPARE PARTS LIST The follow list includes parts that are commonly used for maintenance or repair refer to Appendix 2 for exploded views of the assemblies Part Number Operation and Maintenance Manual Liquid Fill Cap 3500123 Liquid Fill Cap Gasket 1480 1368 11 of 33 1800213 Rev B 05 10 10 11403 Cronridge Drive e Owings Mills MD 21117 2247 USA e Tel 410 363 9696 Fax 410 363 9695 http www atitest com AIR TECHNIQUES INTERNATIONAL A Division of Hamilton Associates Inc VI FINAL INSPECTION CHECK LIST The following inspections shall be performed after all service and repair work and before re attaching the top panel to the unit 10 11 12 13 The
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