UHP Range of Zero Air Generators User Guide
Contents
1. 0 56000 64000 72000 80000 lv Power On Light BJ ee eee eee C Y I7 v v Y domnick hunter ltd and its distributors offer a comprehensive range of preventative maintenance programmes for further details contact your local domnick hunter distributor 4 Installation or domnick hunter ltd direct tel 44 0 191 402 9000 for further details 4 1 Unpacking Care should be taken during unpacking to ensure that the Zero Air Generator is not damaged 4 2 Installation Guidelines 4 3 Operation 1 Ensure that the zero air generator is correctly sized for the application Once the Zero Air generator is installed the operating procedure is very simple 2 Identify a suitable location for the zero air generator ensuring the following a Environmental restrictions refer to section 3 1 Technical Specification are taken e into consideration b The zero air generator should be located as close to the application as possible c There is at least 150mm 6 clearance on both sides and rear of the zero air generator for ventilation d Isolation valves should be fitted to the system these must be accessible when the zero air generator is installed N B It is recommended that a suitably rated pressure gauge is installed upstream of any i isolation valve e The mounting surface is capable of supporting the weight of the zero air generator refer to section 3 2 Dimensions 3 Ensure the inlet air supply is pre treat2. 2 31 EEC Standards used including number title issue date and related documents Generally In accordance with ASMEVIII Div 1 2004 and Pressure Equipment Directive essential safety requirements EN61000 6 1 2001 EN61000 6 3 2001 EN61000 3 2 2000 EN61000 3 3 1995 EN61010 1 2001 Conformity Assessment Route PED Article 3 3 SEP Name of authorised representative Barry Wade Position of authorised representative Business Systems Improvement Manager Declaration declare that as the authorised representative the above information in relation to the supply manufacture of this product is in conformity with the standards and other documents following the provisions of the above Directives Signature of authorised representative Contents 1 Safety Warnings 2 Description 3 Technical Specification 4 Installation 5 Service 6 Troubleshooting T Warranty Declaration of Conformity Page No 10 1 Safety Warnings Do not operate this generator until the instructions in this manual have been read and understood by all personnel concerned Retain this user guide for future reference Caution The operator of this unit is advised that if the equipment is used in a manner not specified in this manual the protection provided by the equipment may be impaired When handling installing or operating this unit personnel must employ safe engineering practices and observe all related regulations health amp safety proced
3. 8 17 9 17 9 17 9 17 9 UHP 150ZA 115 V 60Hz 606272296 Width mm 342 342 342 342 342 342 faeo 199 iss ts 195 15 ts UHP 150ZA 230V 50Hz 606272298 UHP 200ZA 115V 60Hz 606272300 UHP 200ZA 230V 50Hz 606272302 C UHP 10 200ZA 115V 60Hz 606260740 UHP 10 200ZA 230V 50Hz 606260742 N B Ensure that zero air generator is fully depressurised electrically isolated and allowed to cool down before carrying out any service activities Depth mm 400 400 400 400 400 400 Weight kg 10 8 10 8 16 1 16 1 16 1 16 1 3 8 5 Service 3 3 Configuration 5 1 Service Intervals Description Of Maintenance Required Typical Recommended Maintenance Interval Controller Check POWER ON indicator located on control panel is illuminated Controller Check HEATER ON indicator located on control panel illuminates intermittently Cooling Fan Check fan rotation Filtration Open manual drain valve to drain any collected condensate Pipework Check pipework for leaks erp ppp Generator Check condition of electrical supply C cables and conduits Filtration Replace inlet and outlet filters Recommended Service A Generator Replace catalyst assembly Recommended Service B Cooling Fan Replace cooling fan Recommended Service C C Check R Replace Outlet Inlet On Off Switch Electrical Connection Temperature Display Heater On Light Typical Recommended Maintenance Intervals Run Hours 8000 16000 24000 32000 40000 4800
4. ading falls well below department switch off electrical 420 C power to the unit if the surface temperature of the outer case exceeds 60 C Amber LED will not Faulty Lamp Consult domnick Note this LED will illuminate hunter service intermittently department illuminate during normal operation Consult domnick hunter service department Consult domnick hunter service department Hydrocarbon level Faulty temperature gt 0 1ppm controller Faulty catalyst heater Flow rate too high Set flow rate correctly E Consult domnick hunter service department Inlet air supply Install pre dryer and hydrocarbon level too high filtration Inlet air supply not to Install pre dryer and Consult domnick ISO 8573 1 2001 filtration hunter service class 3 2 1 department If condensate is drained from the pre filter then inlet air supply is not to required quality Consult domnick hunter service department Excessive downstream Cooling fan not operating replace cooling fan 2 Description domnick hunter zero air generators are designed to produce a supply of hydrocarbon free air from a pre treated ISO 8573 1 2001 class 3 2 1 low pressure compressed air system so eliminating the need for high pressure gas storage and disruption due to bottle changes and subsequent recalibrations The inlet compressed air first passes through a 1 0 micron filter to remove any particulate After pre filtration the air is passed over a heated palladium cata
5. dh domnick hunter OIL X and Pneudri are registered trademarks of domnick hunter limited domnick hunter limited has a continuous policy of product development and although the Company reserves the right to change specifications it attempts to keep customers informed of any alterations This publication is for general information only and customers are requested to contact our Industrial Division Sales Department for detailed information and advice on a products suitability for specific applications All products are sold subject to the Company s standard conditions of sale www domnickhunter com a member of the domnick hunter group plc 150 9001 2000 Q 05240 AN domnick hunter scientific domnick hunter limited Dukesway Team Valley Trading Estate Gateshead Tyne and Wear England NE11 OPZ Tel 44 0 191 402 9000 Telefax 44 0 191 482 6296 Copyright domnick hunter limited 2004 Stock No 176270554 Rev 001 ch domnick hunter scientific NM NN UHP Range of Zero Air Generators User Guide Name of manufacturer or supplier domnick hunter Itd Full postal address including country of origin Dukesway TVTE Gateshead Tyne amp Wear NE11 OPZ United Kingdom Place of issue Gateshead Description of product Zero Air Generator Name type or model batch or serial number UHP 10ZA UHP 35ZA UHP 50ZA UHP 75ZA UHP 150ZA UHP 200ZA Directives used 73 23 EEC 98 37 EC 89 336 EEC 97 23 EC 98 68 EEC 9
6. e Equipment manufacturedand supplied by domnick hunter ltd domnick hunter Use of the ZERO AIR GENERATORS without the recommended inlet air quality or genuine parts will expressly invalidate the warranty Should the Equipment be defective as to materials or workmanship domnick hunter warrants that it will remedy such defect Where the Equipment is a ZERO AIR GENERATOR the warranty period will be 12 months from date of commissioning or 18 months from date of manufacture whichever is the earlier In the case of Equipment other than a ZERO AIR GENERATOR the warranty period shall commence from the date of despatch Should any defect occur during the warranty period and be notified in writing to domnick hunter or its authorised distributor within the said period domnick hunter will as its sole option remedy such defect by repair or provision of a replacement part provided that the Equipment has been used strictly in accordance with the instructions provided with each item of Equipment and has been stored installed commissioned operated and maintained in accordance with such instruction and with good practice domnick hunter shall not be under any liability whatsoever under the warranty if before giving notification in writing to domnick hunter as aforesaid the Customer or any third party meddles interferes tampers with or carries out work whatsoever apart from normal maintenance as specified in the said instructions in relation to the Equ
7. ed to ISO 8573 1 2001 class 3 2 1 A Caution If the compressed air used to supply the zero air generator contains significant amounts of particulate moisture and oil as would be expected if the compressed air is supplied straight from a compressor a small dryer should be installed upstream of the zero air generator to treat the inlet air to the required standard of cleanliness IS08573 1 2001 class 3 2 1 ISO 8573 1 2001 Class 3 2 1 equates to e 10 000 Solid Particle 0 5 1 micron m3 500 Solid Particles 1 5 micron m3 e Water Vapour Pressure Dewpoint 40 C Oil aerosol and vapour 0 01 mg m3 In such instances a MIDAS type dryer is recommended Please refer to the domnick hunter scientific product brochure for further information on the MIDAS Further information on ISO 8573 1 can be found in the domnick hunter publication A Guide to ISO 8573 1 2001 Air Quality Classes Stock Number 17 400 4765 Contact your local domnick hunter sales office or download a copy from our website www domnickhunter com 4 Check the rating plate for correct supply voltage and frequency 5 It should be noted that the catalyst could become contaminated if compounds that contain lead phosphorous sulphur silicates or halocarbons are present in the inlet air supply If in doubt use an activated carbon filter at the inlet of the generator contact domnick hunter for a suitable activated carbon filter N B Numerous dielectric test
8. ipment or any part thereof Any accessories parts and equipment supplied by domnick hunter but not manufactured by domnick hunter shall carry whatever warranty the manufacturer has given domnick hunter providing it is possible for domnick hunter to pass on such warranty to the customer To claim under the warranty the goods must have been installed and continually maintained in the manner specified in the User Guide Our product support engineers are qualified and equipped to assist you in this respect They are also available to make repairs that may become necessary in which event they will require an official order before carrying out the work If such work is to be the subject of a warranty claim the order should be endorsed for consideration under warranty Where Equipment is sold outside the UK mainland direct to the end user the warranty will cover parts only Any substitution of parts not manufactured or approved by domnick hunter will expressly invalidate the warranty 10 6 Troubleshooting No power green LED Incorrect input voltage Check mains voltage and will not illuminate rating number plate for voltage spec Fuse blown Check fuse replace if necessary On Off switch failure Consult domnick hunter service department Faulty Lamp Consult domnick hunter service department In normal operation the Faulty heater Consult domnick The unit has a safety temperature hunter service thermostat which will re
9. lyst which converts methane and oxygen in the air to carbon dioxide and water This catalytic action produces an ultra pure air stream with a residual hydrocarbon concentration as methane of less than 0 1ppm The gas exits the catalyst unit and is then cooled via a cooling coil Finally the air passes through a 0 01 micron filter to remove any particulate and water which may be generated during the hydrocarbon removal phase zero alr generator schematic Heated catalyst T N Alter Cooling coil filter Heater control 3 Technical Specification 5 1 Service Intervals 3 1 Technical Data eee oo Air 1 8 Swagelok 1 4 Swagelok nle 1 4 Swagelok 5 to 40 C 41 to 104 F Inlet Pressure 3 10barg 45 145psig 0 45 1 45Mpa Inlet Air Quality ISO 8573 1 2001 class 3 2 1 IP rating IP20 NEMA 1 indoor use only Input Voltage 115V 50 60Hz 10 230V 50 60Hz 10 Flow rate l min 1 3 5 5 0 7 5 15 20 ft h 2 12 7 42 10 59 15 9 31 8 42 3 Power W 1000 100 Relative Humidity lt 80 up to 31 C Then reduced by 3 33 C up to 40 C Installation Model No Service Kit Number Inlet Filter All UHP 35ZA 115V 60Hz 606272284 UHP 35ZA 230V 50Hz 606272286 UHP 50ZA 115V 60Hz 606272288 3 2 Dimensions UHP 50ZA 230V 50Hz 606272290 UHP 75ZA UHP 150ZA UHP 200ZA UHP 75ZA 115V 60Hz 606272292 Unit UHP 10ZA UHP 35ZA UHP 50ZA iz RE TSO TEE inches 12 8 12
10. s are not recommended 5 Connect the power supply to the mains connector Switch the generator on via the mains ON OFF switch The green and amber lights should illuminate The green LED indicates power to the unit with the amber LED indicating power to the heater Allow the catalyst to reach the operating temperature approximately 60 minutes Once the correct operating temperature of 420 C is reached the amber LED will intermittently switch on and off showing the unit is now ready for operation Start the flow of compressed air through the system and allow it to stabilise In normal operation the amber LED should illuminate intermittently
11. ures and legal requirements for safety Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures Accidents can be avoided by recognising that any machinery is potentially hazardous domnick hunter can not anticipate every possible circumstance which may represent a potential hazard The warnings in this manual cover the most known potential hazards but by definition can not be all inclusive Read manual Risk of electrical shock Pressurised components on system General Warning gt E If the generator user employs an operating procedure item of equipment or a method of working which is not specifically recommended by domnick hunter the user must ensure that the generator will not be damaged or made a potential hazard to persons or property This product should be installed in accordance with the recommendations outlined in this manual Commissioning and service should be undertaken by a domnick hunter trained qualified and approved engineer to maintain warranty Extended warranty and tailored service contracts are available for this product Please contact your local domnick hunter sales office for a tailored service agreement to meet your specific requirements Details of your nearest domnick hunter sales office can be found at www domnickhunter com 4 7 WARRANTY This warranty applies to ZERO AIR GENERATORS and associated parts th
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