OPERATION MANUAL MODEL 701H HIGH PERFORMANCE ZERO AIR GENERATOR © TELEDYNE ADVANCED POLLUTION INSTRUMENTATION 9480 CARROLL PARK DRIVE SAN DIEGO, CA 92121-5201 USA Toll-free Phone: Phone: Fax: Email: Website: Copyright 2010 Teledyne Advanced Pollution Instrumentation 800-324-5190 858-657-9800 858-657-9816 api-sales@teledyne.com http://www.teledyne-api.
ABOUT THIS MANUAL This M701H High Performance Zero Air Generator operation manual is comprised of multiple documents as listed below. Part No. Rev Name/Description 06712 B Operation Manual 04825 F List, Spare Parts (in Appendix A) Note: due to the dynamic nature of this document, please check our Website or with Sales for most recent version.
ii 06712B (DCN5875)
SAFETY MESSAGES Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage. Please read these messages carefully. Each safety message is associated with a safety alert symbol, and are placed throughout this manual and inside the instrument. The symbols with messages are defined as follows: WARNING: Electrical Shock Hazard HAZARD: Strong oxidizer GENERAL WARNING/CAUTION: Read the accompanying message for specific information.
CONSIGNES DE SÉCURITÉ Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments.
TABLE OF CONTENTS ABOUT THIS MANUAL ........................................................................................................... I REVISION HISTORY............................................................................................................... I SAFETY MESSAGES ............................................................................................................. III 1 INTRODUCTION ..........................................................................................
5.2.15 Charcoal Scrubber........................................................................................... 5-9 5.2.16 Final Filter ........................................................................................................ 5-9 5.2.17 Controller ......................................................................................................... 5-9 5.2.18 Dew Point Sensor ..........................................................................................
LIST OF FIGURES FIGURE 3-1: FIGURE 3-2: FIGURE 3-3: FIGURE 4-1: FIGURE 5-1: FIGURE 5-2: FIGURE 5-3: FIGURE 6-1: FIGURE 8-1: FIGURE 8-2: INSTRUMENT LAYOUT ............................................................................................. 3-2 FRONT PANEL ....................................................................................................... 3-3 REAR PANEL ......................................................................................................... 3-3 CARRYING STRAP ...
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1 INTRODUCTION 1.1 Preface Teledyne API is pleased that you have purchased the Model 701H Zero Air System. The M701H is an excellent source of clean, dry air for dilution calibrators. It also may be used as a source of purge air for permeation tube ovens or burner air for FID analyzers.
Introduction Teledyne API M701H High Performance Zero Air Generator 1.2 Using This Manual This manual has the following data structures: TABLE OF CONTENTS Outlines the contents of the manual in the order the information is presented. This is a good overview of the topics covered in the manual. There is also a list of tables, a list of figures and a list of appendices. In the electronic version of the manual, clicking on any of these table entries automatically views that section. 1.
2 SPECIFICATIONS AND WARRANTY 2.1 Specifications Table 2-1: Specifications Parameter Specification Output 30 SLPM at 30 psig Max delivery pressure 35 psig (For calibrators that have special features that include restricted output, maximum delivery pressure is 50 psig) Dewpoint < 30 SLPM < -40C Dryer Regenerative heatless dryer with lifetime of greater than 5 years SO2 <0.5 ppb NO <0.5 ppb Output Concentration NO2 <0.5 ppb O3 <0.5 ppb CO< 0.025 ppm HC< 0.
Specifications and Warranty Teledyne API M701H High Performance Zero Air Generator 2.2 Warranty WARRANTY POLICY (02024D) (DCN 4473) Prior to shipment, Teledyne API equipment is thoroughly inspected and tested. Should equipment failure occur, Teledyne API assures its customers that prompt service and support will be available.
3 GETTING STARTED This section provides instructions on the proper installation and power up of the M701H. Refer to Figure 3-1 for the instrument layout and Table 2-1 for the specifications. 3.1 Unpacking CAUTION TO AVOID PERSONAL INJURY, ALWAYS USE TWO PERSONS TO LIFT AND CARRY THE M701H. 1. Verify that there is no shipping damage. If there are signs of damage, immediately advise the shipper, then Teledyne API. 2. Remove the M701H from its shipping carton. 3. Remove the cover and check for damage inside.
Getting Started Teledyne API M701H High Performance Zero Air Generator Figure 3-1: Instrument Layout 3-2 06712B (DCN5875)
Teledyne API M701H High Performance Zero Air Generator Getting Started 3.3 Front and Rear Panels Figure 3-2 and Figure 3-3 illustrate the Model 701H front and rear panels.
Getting Started Teledyne API M701H High Performance Zero Air Generator 3.4 Electrical And Pneumatic Connections All connections, electric and pneumatic, are made at the rear panel (Figure 3-3). NOTE To maintain compliance with EMC standards, it is required that the cable length be no greater than 3 meters for all I/O connections, which include Analog In, Analog Out, Status Out, Control In, Ethernet/LAN, USB, RS-232, and RS-485. Make the following pneumatic connections: 1.
Teledyne API M701H High Performance Zero Air Generator Getting Started 5. “COOLING FAN” The rear panel cooling fan draws air IN and requires at least 6” (150 mm) of clearance for proper operation. 3.5 Power-Up 1. Turn on the front panel POWER SWITCH (Figure 3-2). 2. The front panel POWER light should come on. 3. The cooling fan should start immediately. 4. The compressor should start after a few seconds delay. The delay is to allow the control board to measure the local line frequency. 5.
Getting Started Teledyne API M701H High Performance Zero Air Generator 2. Wait approximately 1 minute. 3. Turn on the M701H. The water drain valve will switch into the open position and vent any accumulated water through the water drain. (Standing H20 will cause corrosion) 4. Turn the M701H off. This shut down process will vent any water that has accumulated in the coalescing filter.
4 OPTIONAL HARDWARE AND SOFTWARE This section includes descriptions of the hardware and software options available for the M701H instrument. For assistance with ordering these options please contact the sales department of Teledyne API at: TOLL-FREE: TEL: FAX: E-MAIL: WEB SITE: 800-324-5190 +1 858-657-9800 +1 858-657-9816 apisales@teledyne.com http://www.teledyne-api.com/ 4.1Carrying Strap/Handle (OPT 29) The chassis allows the user to attach a strap handle for carrying the instrument.
OPTIONAL HARDWARE AND SOFTWARE Teledyne API M701H High Performance Zero Air Generator CAUTION GENERAL SAFETY HAZARD An M701H weighs about 55 lbs (25 kg). To avoid personal injury we recommend that two persons lift and carry the instrument. Ensure to disconnect all external cables and tubing connected to the rear panel before moving 4.2 Rack Mount Kits (OPT 20A, OPT 20B & OPT 21) There are several options for mounting the analyzer in standard 19” racks.
5 OPERATION 5.1 Overview Refer to Figure 5-1, and Figure 5-2. The M701H dries and scrubs ambient air to produce zero air. The compressor draws air in from the rear panel bulkhead union and inlet filter. At the compressor outlet, the air is under pressure and hot from the compression. The relative humidity is high as a result of the high pressure. The air is conducted through the cooling coil where heat is removed by transfer to the cooling fan air.
Operation Teledyne API M701H High Performance Zero Air Generator 2. The NO scrubber where NO is oxidized to NO2, then, the activated charcoal scrubber where the NO2 is absorbed. Then the CO scrubber, where CO is catalytically oxidized to CO2. 3. The clean dry air passes through a fine particulate filter and leaves the M701H through the rear panel bulkhead union (Zero Air Out). When air usage is high (approximately 25-30 LPM), the compressor may run continuously.
Teledyne API M701H High Performance Zero Air Generator Operation Figure 5-1: Pneumatic Diagram 06712B (DCN5875) 5-3
Operation Teledyne API M701H High Performance Zero Air Generator Figure 5-2: Plan View 5-4 06712B (DCN5875)
Teledyne API M701H High Performance Zero Air Generator Operation 5.2 Components This section describes the main components and their functions. 5.2.1Compressor The compressor is a dual-cylinder oscillating piston type driven by a split capacitor AC motor. The compressor is dry; that is, there are no lubricants which can contaminate the compressed air. The pistons are sealed by flexible TFE piston rings, and after a short run-in period to seat the rings, should last for years. There are no diaphragms.
Operation Teledyne API M701H High Performance Zero Air Generator 5.2.5 Pressure Relief Valve The pressure relief valve is a safety device designed to limit the maximum pressure to which the M701H can be subjected. It is set to open at 90 psig. This can be quite loud when the valve opens and sounds like steam escaping. This is normal operation and does not mean there is a problem with the unit. CAUTION DO NOT ADJUST THE RELIEF VALVE. 5.2.
Teledyne API M701H High Performance Zero Air Generator Operation 5.2.8 Storage Tank The storage tank serves two functions. As its name implies, it stores air so that when the demand is low, the compressor can be turned off to conserve energy, allowing the storage tank to supply the air requirements. The tank also serves as “filter capacitor”, preventing pulses generated by the drier cycles or water drain valve from reaching the output port on the rear panel.
Operation Teledyne API M701H High Performance Zero Air Generator 5.2.11 Pressure Gauge The front panel-mounted pressure gauge shows approximately the regulated air pressure available to a calibrator. The gauge will usually indicate 30 psig. If the flow is very low, as in a standby condition, the gauge may read slightly higher. It will move to the correct reading when the air flow is increased. When the demand on air increases dramatically, the pressure may drop below 30 psig.
Teledyne API M701H High Performance Zero Air Generator Operation 5.2.13 CO Scrubber The CO scrubber catalytically oxidizes CO to CO2. The catalyst is proprietary and operates at room temperature; theoretically, it should never need changing. However, it may become contaminated or poisoned over time so we recommend that it be replaced once per year or sooner if the level of CO in the air is high. 5.2.14 NO Scrubber The NO scrubber uses Purafil® to oxidize NO to NO2.
Operation Teledyne API M701H High Performance Zero Air Generator Cycles the four-way valve of the Regenerative Dryer at 1 minute intervals. Cycles the water drain solenoid valve at 5 minute intervals. Starts and stops the compressor in response to the pressure sensor. This function includes cycling the Regenerative Dryer four-way valve and momentarily opening the water drain solenoid valve before starting the compressor.
Teledyne API M701H High Performance Zero Air Generator Operation Figure 5-3: Control Board Layout 06712B (DCN5875) 5-11
Operation Teledyne API M701H High Performance Zero Air Generator 5.2.18 Dew Point Sensor The dew point sensor ensures that the Regenerative Dryer maintains a dew point less than -40°C (up to 30 SLPM flow rate). This will increase the life of the chemical scrubbers. When the dew point rises above -16°C, the green LED (dew point indicator) on the front panel will light.
6 MAINTENANCE 6.1 Schedule NOTE The operations outlined in this section are to be performed by qualified maintenance personnel only. Before any maintenance cycle the power on/off and drain any water that may be present (refer to instructions for “Storage or Transportation Shut Down” in Section 3.6.2). Table 6-1 presents the maintenance schedule.
MAINTENANCE Teledyne API M701H High Performance Zero Air Generator 6.2 Cleaning 1. Occasionally, depending upon the local conditions, check the inside of the M701H for excessive dirt or dust. 2. Particularly, check the cooling fan, cooling coil and compressor fan inlet. 3. Remove any dirt or dust with a vacuum cleaner. Do not use an air jet. This will only redistribute the dirt and will not remove it. WARNING THERE ARE HIGH VOLTAGES PRESENT WHILE THE M701H IS PLUGGED IN. 6.3 Checking The Tubing 1.
Teledyne API M701H High Performance Zero Air Generator MAINTENANCE 6.4 Replacing The Charcoal Scrubber 1. Turn off the M701H and wait for the pressure to go to zero. 2. Open the front panel, or remove the top cover. 3. Remove the 1/4” tubing connected to the top of the scrubber canister. 4. Undo the Velcro strap freeing the cannister. 5. Remove the 1/4” tubing connected to the bottom of the canister. 6. Unscrew the cap of the canister. 7. Pull out the pad from the top of the canister. 8.
MAINTENANCE Teledyne API M701H High Performance Zero Air Generator 6.6 Replacing The CO Scrubber The CO scrubber is attached to the HC scrubber housing. This is not a heated scrubber. It is secured with four screws through the body of the scrubber into the bracket. 1. Turn off power and unplug the M701H. 2. Remove the four screws to remove the scrubber. CAUTION THE SCRUBBER WILL BE HOT. 3. With a 9/16” wrench, remove the two unions from the top of the scrubber cartridge. 4.
Teledyne API M701H High Performance Zero Air Generator MAINTENANCE 6.7 Replacing The Hydrocarbon (HC) Scrubber 1. Turn off power and unplug the M701H power cord. 2. Disconnect the HC scrubber power at the Controller. 3. Unplug the thermocouple from the control board. 4. Remove the heat shield from the HC scrubber. 5. Disconnect the pneumatic connections at the CHARCOAL SCRUBBER INLET AND AT THE REAR END OF THE COPPER COOLING COIL, using 1/2 and 9/16 wrenches. CAUTION WAIT FOR THE SCRUBBER TO COOL.
MAINTENANCE Teledyne API M701H High Performance Zero Air Generator Observe that the LED starts blinking at 11.2 mV (300ºC) and that the thermocouple voltage holds steady. 14. When all traces of water have disappeared from the M701H output, the output may be reconnected to the analyzers. 6.8 Servicing The Regenerative Dryer It is unlikely that the Regenerative Dryer should ever need service.
Teledyne API M701H High Performance Zero Air Generator MAINTENANCE 16. Place the bottom of the columns with two pads in the circular grooves in the lower manifold. Ensure that they are in the grooves and not caught up on the edge. 17. Wipe the ends of the columns. These are the surfaces which seal against the o-rings. 18. Place the upper manifold on top of the two columns. Ensure that the columns are in the grooves. (Wiggle the columns sideways to ensure that the columns are trapped in the grooves.) 19.
MAINTENANCE Teledyne API M701H High Performance Zero Air Generator Figure 6-1: Regenerative Dryer 6-8 06712B (DCN5875)
Teledyne API M701H High Performance Zero Air Generator MAINTENANCE 6.9 Changing The 4-Way Valve (in the Regenerative Dryer) 1. Remove the Regenerative Dryer from the chassis as described in Section 6.8 above. 2. Disconnect the two tubing connections and the electrical connection to the 4-way valve. 3. Remove the 4-way valve bracket from the regenerative upper manifold. 4. Remove the 4-way valve from the bracket. 5. Attach a new valve, complete with tube fittings and muffler(s). 6.
MAINTENANCE Teledyne API M701H High Performance Zero Air Generator NOTE This procedure checks the majority of the components and fittings. If you believe that there is still a leak, please contact Customer Service at (858) 657-9800. 6.12 Particulate Filter Element Replacement Replace the particulate filter located at the “Air In” inlet on the rear panel (refer to Figure 5-2) as follows: 1. Remove the particulate filter (Teledyne API, P/N FL15) cap by turning it counter-clockwise. 2.
7 TROUBLESHOOTING This section presents possible problems and their causes and solutions. Table 7-1: Troubleshooting Problem Probable Cause Unplugged power cord. Power light does not come Incorrect line voltage. on. Tripped power switch/circuit breaker. Corrective Action Plug in power cord at both ends. Refer to Table 3-1 for the correct line voltage. Untrip power switch/circuit breaker. VDC power supply failed. Replace power supply. Tank pressure is above the cut-out pressure. No action.
TROUBLESHOOTING Problem Instrument vibrates excessively. (continued) Pressure does not increase to 30 psig. Teledyne API M701H High Performance Zero Air Generator Probable Cause Screws securing the compressor to the base plate are loose. Tighten the screws. The tubing attached to the compressor is vibrating against a component. Adjust the placement of the tubing. Air demand to too high. Maximum air flow is 30 SLPM. No action. Pressure will drop as air is used. Air Inlet impeded.
Teledyne API M701H High Performance Zero Air Generator A Primer on Electro-Static Discharge 8 A PRIMER ON ELECTRO-STATIC DISCHARGE Teledyne API considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time.
A Primer on Electro-Static Discharge Teledyne API M701H High Performance Zero Air Generator Table 8-1 : Static Generation Voltages for Typical Activities MEANS OF GENERATION 65-90% RH 10-25% RH 1,500V 35,000V Walking across vinyl tile 250V 12,000V Worker at bench 100V 6,000V Poly bag picked up from bench 1,200V 20,000V Moving around in a chair padded with urethane foam 1,500V 18,000V Walking across nylon carpet 8.
Teledyne API M701H High Performance Zero Air Generator A Primer on Electro-Static Discharge Potentially damaging electro-static discharges can occur: Any time a charged surface (including the human body) discharges to a device. Even simple contact of a finger to the leads of a sensitive device or assembly can allow enough discharge to cause damage. A similar discharge can occur from a charged conductive object, such as a metallic tool or fixture.
A Primer on Electro-Static Discharge Teledyne API M701H High Performance Zero Air Generator As long as my analyzer is properly installed, it is safe from damage caused by static discharges: It is true that when properly installed the chassis ground of your analyzer is tied to earth ground and its electronic components are prevented from building static electric charges themselves.
Teledyne API M701H High Performance Zero Air Generator A Primer on Electro-Static Discharge Always store sensitive components and assemblies in anti-ESD storage bags or bins: Even when you are not working on them, store all devices and assemblies in a closed anti-Static bag or bin. This will prevent induced charges from building up on the device or assembly and nearby static fields from discharging through it.
A Primer on Electro-Static Discharge Teledyne API M701H High Performance Zero Air Generator 3. Open the casing of the analyzer and begin work. Up to this point, the closed metal casing of your analyzer has isolated the components and assemblies inside from any conducted or induced static charges. 4. If you must remove a component from the instrument, do not lay it down on a non-ESD preventative surface where static charges may lie in wait. 5.
Teledyne API M701H High Performance Zero Air Generator A Primer on Electro-Static Discharge If you are at an anti-ESD workbench, lay the container down on the conductive work surface. In either case wait several seconds. 4. Place the item in the container. 5. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape. Folding the open end over isolates the component(s) inside from the effects of static fields.
A Primer on Electro-Static Discharge Teledyne API M701H High Performance Zero Air Generator WARNING DO NOT use pink-poly bags. NEVER allow any standard plastic packaging materials to touch the electronic component/assembly directly. This includes, but is not limited to, plastic bubble-pack, Styrofoam peanuts, open cell foam, closed cell foam, and adhesive tape. DO NOT use standard adhesive tape as a sealer. Use ONLY anti-ESD tape. 1.
APPENDIX A - SPARE PARTS Note Use of replacement parts other than those supplied by T-API may result in non-compliance with European standard EN 61010-1. Note Due to the dynamic nature of part numbers, please refer to the Website at http://www.teledyne-api.com or call Customer Service at 800-324-5190for more recent updates to part numbers.
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SPARE PARTS LIST M701H Ref: 04825F (DCN5895) Part Number 005960000 005970000 006900100 066780000 066780100 073440000 016920000 073380000 017710000 017960000 018490000 036260000 040370200 066180000 066780000 066780100 057270000 FL0000044 FL0000015 FL0000016 HW0000190 HW0000396 HW0000395 HW0000396 OR0000058 PU0000090 VA0000012 VA0000014 VA0000016 VA0000017 06712B (DCN5875) Description AKIT, EXPEND, 6LBS ACT CHARCOAL AKIT, EXPENDABLE, 6LB PURAFIL RETAINER PAD CHARCOAL, LARGE, 2-1/4" ASSY, PUMP w/BRKT, M701H
Recommended Spare Parts Stocking Levels M701H Reference 07346A (DCN5895) Recommended Spare Parts Stocking Level: Standard Part Number 017960000 066180000 036260000 066780000 * Description ASSY, FAN M701/M701H PCA, CONTROL BOARD, M701H ASSY, 4-WAY VALVE, PARKER, M701 ASSY, PUMP, W/BASE, 100-115V, GAST FILTER, COALESCING, .
AKIT, EXPENDABLES KIT, M701H Reference 07344A (DCN5895) Part Number 005960000 005970000 006900100 016920000 057270000 FL0000016 OR0000058 06712B (DCN5875) Description AKIT, EXP, 6LBS ACT CHARCOAL AKIT, EXP, 6LBS PURIFIL RETAINER PAD CHARCOAL, LARGE, 2-1/4" AKIT, EXP KIT, MOL SIEVE GASKET SCRUBBER FILTER ELEMENT, PAPER, FOR FL15 ORING, 2-228V, DRYER QTY 1 1 8 1 4 2 4 A-5
LEVEL 1 SPARES KIT M701H Ref: 07345A (DCN5895) Part Number 03626000A 066180000 CB0000004 FA0000006 FL0000011 FL0000044 HE0000017 OR0000058 PU0000090 VA0000017 A-6 Description Valve, 4-way, regenerative scrubber PCA, CONTROL BOARD, M701H Fuse, 3A, SB (HC temp control) Fan, cooling Filter, final Filter, water coalescing Heater, CO scrubber O-ring, 2-228V Kit, Pump Rebuild, for M701H Valve, water drain 06712B (DCN5875)
APPENDIX B - Schematics 06712B (DCN5875) B-1
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1 2 3 4 COD1 D1 A PID101 PF240D25 IN- fuse1 PIPTC101 PIPTC102 A 9 PIT109 3PIT103 4PIT104 +5V COPTC1 PTC1 10 PIT1010 6PIT106 COT1 T1 12 PO0V +V PID202 1N4007 fuse2PIPTC201 PIT1012 +V COD2 D2 diode1 PID201 4 3 7 PIT107 1PIT101 PIK103 PIK104 2 1 PIK10 PIK102 PID102 1N4007 IN+ AC AC COK1 K1 PIPTC202 diode2 COPTC2 PTC2 COK2 K2 PIK203 PIK204 +5V IN- PIK20 B 4 3 IN+ 4-WAY 2 PIK201 1 B AC GA8-6B02 AC PUMP PUMP-ON POUM0ON PO40WAY0VALVE 4-WAY-VALVE AC-HOT
1 2 3 4 A A COTP7 TP7 COTP8 TP8 PITP701 +V +5V PITP801 1 PIVR101 PIC101 + PIC102 PIC301 PIC302 COC1 C1 6800uF 16V VI VO PIVR102 COC3 C3 +5V 3 PIVR103 COVR1 VR1 2 PO0V +V GND 7805 PIC401 PIC402 0.1uF PIC201 + COC4 C4 0.
2 +5V 3 PIR201 A PIR301 POSCL SCL POSDA SDA COR2 R2 COR3 R3 2.2K 2.2K PIR20 A PIC702 B I/O-SPARE PIR10 1 PIC701 SCL PIJP101 1 SDA PIJP103 3 PIJP105 5 PIJP107 7 PIJP109 9 PIJP1011 11 PIJP1013 13 PIR701 PIR801 PIR901 COR7 R8 COR9 R7 COR8 R9 1K PIR10 2 +5V-REF 2 4 6 8 10 12 14 RX TX PIJP102 PIJP104 PIJP106 PIR402 PIJP108 PIJP1010 COR4 R4 4.7K PIJP1012 PIJP1014 PIR401 HEADER 7X2 PIDS10 PIR502 COR5 R5 4.7K PIR501 1K PIR1 0 PIR702 PIR802 PIR902 2M 0.
1 2 3 4 +5V PIR1501 PIR1601 COR14 R14 COR15 R15 2.2K 4.
1 2 3 4 K-Type Thermocouple CODS8 DS8 + _ +5V PIDS801 PIDS802 PIR2601 PIR2602 A POSCL SCL 2.2K RED 1 2 COR26 R26 COJ12 J12 PIJ1201 PIJ120 POSDA SDA A +V COC16 C16 S3 PIH10S3 BASE ADDR: 0x90 V+ S1 PIH10R1 SDA +V 8 PIH108 2 PIH102 SCL A0 7 PIH107 A1 6 PIH106 GND INT 5 PIH105 3 PIH103 V- Out S2 PIH10S2 1 PIH101 4 PIH104 TCR 10 PIH1010 COC15 C15 0.1uF PIR102 +5V-REF 7 PIU603 2 COR30 R30 100K 4 1 1.0uFPIC1801 PIR30 1 PIR320 COR32 R32 6.
