OPERATION MANUAL MODEL 751H 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 2014 Teledyne Advanced Pollution Instrumentation 07773A DCN6933 800-324-5190 858-657-9800 858-657-9816 api-sales@teledyne.com http://www.teledyne-api.
ABOUT THIS MANUAL This Model 751H High Performance Zero Air Generator operation manual is comprised of multiple documents as listed below. Part No.
ii 07773A DCN6833
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.
WARRANTY WARRANTY POLICY (02024G) Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne Instruments, Inc., provides that: Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should equipment failure occur, TAPI assures its customers that prompt service and support will be available.
TABLE OF CONTENTS ABOUT THIS MANUAL ........................................................................................................... I REVISION HISTORY............................................................................................................... I SAFETY MESSAGES ............................................................................................................. III 1 INTRODUCTION .......................................................................................
4.2.10 4.2.11 4.2.12 4.2.13 4.2.14 4.2.15 4.2.16 4.2.17 4.2.18 Hydrocarbon (HC) Scrubber ......................................................................... 24 NO-NO2 Scrubber ......................................................................................... 25 Charcoal Scrubber ........................................................................................ 25 Carbon Monoxide (CO) Scrubber ................................................................. 25 Final Filter ..............
LIST OF TABLES TABLE 2-1: TABLE 4-1: TABLE 5-1: TABLE 6-1: viii SPECIFICATIONS ................................................................................................................... 11 POWER AND DEWPOINT CONDITION INDICATORS ................................................................ 27 MAINTENANCE SCHEDULE.......................................................................................... 29 TROUBLESHOOTING ..........................................................................
1 INTRODUCTION 1.1 Preface The 751H 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, zero air for ozone generators, or combustion air for FID analyzers. The 751H has an oil-free and diaphragm-free pump that pushes air through a pre-cooler and water trap that removes moisture, and passes the air through a regenerative, heatless dryer for final drying.
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2 SPECIFICATIONS AND APPROVALS 2.1 Specifications Table 2-1: Specifications Parameter Specification Output 10 SLPM at 30 psig Max delivery pressure 30 psig Dewpoint < -20 C Dryer Regenerative heatless dryer with lifetime of greater than 5 years SO2 <0.025 ppb NO <0.025 ppb Output Concentration NO2 <0.025 ppb O3 <0.3 ppb CO < 10 ppb HC < 0.25 ppb Compressor Single-cylinder, internal long-life, oil-less piston pump Dimensions 9” x 22” x 13.8” (229 x 559 x 351 mm) Weight 47 lbs (21.
Specifications and Approvals 2.2 Teledyne API M751H High Performance Zero Air Generator Approvals and Certifications The Teledyne-API Model 751H Zero Air Generator was designed, tested and certified for Safety and Electromagnetic Compatibility (EMC). This section presents the compliance statements for those requirements and directives. For additional certifications, please contract Technical Support at 1-800-324-5190 or sda_techsupport@teledyne.com. 2.2.
3 GETTING STARTED This section provides instructions on the proper installation and power up of the 751H. Refer to Figure 4-2 for the instrument layout and Table 2-1 for the specifications. NOTE Due to mounting screws through its case, the 751H is not considered waterproof. 3.1 Unpacking CAUTION TO AVOID PERSONAL INJURY, ALWAYS USE TWO PERSONS TO LIFT AND CARRY THE 751H. 1. Remove the 751H from its shipping carton. 2. Verify that there is no shipping damage.
Getting Started 3.3 Teledyne API M751H High Performance Zero Air Generator Instrument Panel Figure 3-1 shows the components in the Model 751H instrument layout that are pertinent to starting up the instrument.
Teledyne API M751H High Performance Zero Air Generator Getting Started 3.4 Electrical and Pneumatic Connections 3.4.1 ELECTRICAL NOTE To maintain compliance with EMC standards, it is required that the power cord length be no greater than 3 meters. With the power switch in the “OFF” position, connect the power cord from the AC input connection to the proper power source.
Getting Started 3.5 Teledyne API M751H High Performance Zero Air Generator Power-Up COOLING FAN Requirements The instrument panel cooling fan draws air IN and requires at least 6” (150 mm) of clearance for proper operation. NOTE: DO NOT BLOCK THE COOLING FAN; ALWAYS KEEP LID OPEN WHEN INSTRUMENT IS RUNNING. 1. Turn on the instrument panel POWER SWITCH (Figure 3-1). 2. The instrument panel POWER LED should come on. 3. The cooling fan should start immediately. 4.
Teledyne API M751H High Performance Zero Air Generator Getting Started This shut down process will vent any water that has accumulated in the coalescing filter. It will prevent this water from passing into the 751H in the event that the instrument is inverted during storage or shipment. 3.7 Expendable Kits (OPT 42A) A one-year supply of replacement particulate filters and consumable scrubber media is available from Teledyne API as Option 42A. Refer to Appendix B for a list of expendables. 3.
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4 OPERATION 4.1 Overview Refer to Figure 4-1 for a diagram of the 751H pneumatic flow. The 751H dries and scrubs ambient air to produce zero air. To accomplish this, first the compressor draws air in through the intake filter and compresses it. 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 M751H High Performance Zero Air Generator 751H Chassis Pressure Relief Valve Inlet Filter Condenser Coalescer “AIR IN” A 10LPM Pump B 4-Way Valve Drain Valve Relief Valve Pressure Regulator Regen Dryer “DRAIN OUT” HC Scrubber “ZERO AIR OUT” 0 Purafil Scrubber Charcoal Scrubber 30 Pressure Gauge CO Scrubber Cooling Coil DFU Filter 60 Dewpoint Sensor Figure 4-1: Pneumatic Diagram Figure 4-2 and Figure 4-3 are illustrations of the 751H plan view and a close-up o
Teledyne API M751H High Performance Zero Air Generator Operation Figure 4-2: Plan View Figure 4-3: Instrument Panel 07773A DCN6833 21
Operation Teledyne API M751H High Performance Zero Air Generator 4.2 Components This section describes the main components and their functions (not all components are visible from the plan view). 4.2.1 Intake Filter The intake filter is a serviceable assembly that houses a screen filter. Maintenance instructions are provided in Section 5 of this manual. 4.2.2 Compressor The compressor is a single-cylinder oscillating piston type driven by a split capacitor AC motor.
Teledyne API M751H High Performance Zero Air Generator 4.2.6 Operation Pressure Relief Valve The pressure relief valve is a safety device designed to limit the maximum pressure to which the 751H can be subjected. It is set to open at 75-80 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.
Operation 4.2.9 Teledyne API M751H High Performance Zero Air Generator Pressure Regulator The pressure regulator is set at 30 psig at the factory except for specially modified units. Should adjustment be desired, the regulator is accessible on the instrument panel. The adjustment knob has a push-pull locking ring which should be reengaged after making an adjustment to prevent the knob from turning under vibration.
Teledyne API M751H High Performance Zero Air Generator Operation 4.2.11 NO-NO2 Scrubber The NO scrubber uses Purafil® to oxidize NO to NO2. Purafil® has a finite life and we recommend that it be replaced annually or sooner if the level of NO in the air is high. 4.2.12 Charcoal Scrubber Activated charcoal removes NO2, O3, SO2 and H2S. The charcoal should be replaced annually or sooner if there are high atmospheric levels of these contaminants, or if the calibrator zero air shows signs of a positive drift.
Operation Teledyne API M751H High Performance Zero Air Generator Provision for voltage configuration is via a jumper plug (J5). All electrical connections are made by quick release connectors to aid in servicing. Refer to Figure 4-4 for the layout and to Appendix B for the interconnect and other drawings. The 751H Control PCB is microcontroller based and provides the following functions: Cycles the four-way valve of the Regenerative Dryer. Cycles the water drain solenoid valve.
Teledyne API M751H High Performance Zero Air Generator Operation 4.2.17 Dewpoint Sensor The dewpoint sensor ensures that the Regenerative Dryer maintains a dewpoint less than -20°C (up to the maximum flow rate). This will increase the life of the chemical scrubbers. When the dewpoint drops below -20°C, the green LED (dewpoint indicator) on the instrument panel will light green, indicating that the air is dry. 4.2.
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5 MAINTENANCE 5.1 Schedule WARNING There are high voltages present while the 751H is plugged in. CAUTION The operations outlined in this section are to be performed by qualified maintenance personnel only. Before performing any maintenance, cycle the power on/off and drain any water that may be present (refer to instructions for “Storage and Transportation” in Section 3.6). Table 5-1 presents the maintenance schedule.
MAINTENANCE Teledyne API M751H High Performance Zero Air Generator 5.2 Maintenance Mode When changing the media of the Charcoal Scrubber (Section 5.5) and the NO-NO2 Scrubber (Section 5.6), the new media will contain some moisture due to humidity in the ambient air, consequently triggering a dewpoint fault condition. Placing the 751H in Maintenance Mode will override the fault for 24 hours, allowing time to thoroughly dry the new media before resuming normal operation of the 751H.
Teledyne API M751H High Performance Zero Air Generator MAINTENANCE WARNING EVEN THOUGH THE INSTRUMENT PANEL POWER SWITCH IS OFF, THERE IS LINE VOLTAGE PRESENT AT THE POWER ENTRY TERMINALS, POWER SWITCH TERMINALS AND ON THE CONTROL BOARD. FOR ADDED SAFETY, REMOVE THE POWER CORD FROM THE INSTRUMENT PANEL RECEPTACLE. 5.
MAINTENANCE 5.6 Teledyne API M751H High Performance Zero Air Generator Replacing the NO - NO2 Scrubber Media This procedure is identical to the charcoal scrubber replacement procedure except that the canister should be refilled with Purafil . NOTE After replacing the material in these scrubbers it can take up to 48 hours for the material to dry out before the 751H is functioning optimally. 5.
Teledyne API M751H High Performance Zero Air Generator 5.8 MAINTENANCE Replacing the Hydrocarbon (HC) Scrubber 1. Turn off power and unplug the 751H power cord. CAUTION WAIT FOR THE SCRUBBER TO COOL. THE SCRUBBER CASING AND THE COPPER COOLING COIL WILL BE VERY HOT. 2. Remove the six screws which secure the chassis to the case. 3. Remove the chassis assembly from the case. 4. Remove the cover, exposing the pump and HC scrubber. 5. Disconnect the HC scrubber power at the Controller. 6.
MAINTENANCE 5.9 Teledyne API M751H High Performance Zero Air Generator Servicing The Regenerative Dryer It is unlikely that the Regenerative Dryer should ever need service. Should the molecular sieve become contaminated by oil or other external contaminants, the scrubber will need to be cleaned and recharged. Refer to Figure 5-1. NOTE Wearing a dust mask could be helpful as a preventive measure since the molecular sieve may be dusty. 1. Turn off the 751H and turn on again and remove any water in bowl. 2.
Teledyne API M751H High Performance Zero Air Generator MAINTENANCE 19. Wipe the ends of the columns. These are the surfaces which seal against the o-rings. 20. Set the bottom of the columns into the lower manifold. Ensure that they are in the grooves and not caught up on the edge. 21. 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.) 22.
MAINTENANCE Teledyne API M751H High Performance Zero Air Generator Figure 5-1: Regenerative Dryer 36 07773A DCN6833
Teledyne API M751H High Performance Zero Air Generator MAINTENANCE 5.10 Changing the Regenerative Dryer’s 4-Way Valve 1. Remove the Regenerative Dryer from the chassis as described in Section 5.9 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 M751H High Performance Zero Air Generator 5.12 Filter Element Replacement 5.12.1 Intake Filter To service the intake filter (Figure 4-2): 1. Turn the filter cap counter-clockwise and remove from the filter housing. 2. Remove the filter screen and use compressed air to blow out any debris. 3. Reseat the filter screen inside the filter housing. 4. Return the cap to the filter housing and secure in place with a clockwise turn.
Teledyne API M751H High Performance Zero Air Generator 6 TROUBLESHOOTING TROUBLESHOOTING This section presents possible problems and their causes and solutions. CAUTION – Avoid Warranty Invalidation Failure to comply with proper anti-Electro-Static Discharge (ESD) handling may void your warranty. For anti-ESD handling instructions please refer to the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.
TROUBLESHOOTING Teledyne API M751H High Performance Zero Air Generator Problem Probable Cause Output pressure surges. Output air is not “Zero”. Output air is not dry. Pressure regulator is set too high and pegged. Scrubbers may be contaminated. 4-way valve is jammed; only one column is being used. Reflux flow controller is plugged. Molecular sieve is contaminated. Corrective Action Adjust pressure regulator down. Replace the scrubbers. Check to ensure the valve is plugged in; replace the valve.
APPENDIX A - SPARE PARTS Note Use of replacement parts other than those supplied by TAPI may result in noncompliance 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 Technical Support at 800-324-5190 for more recent updates to part numbers.
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078390000 751H SPARE PARTS LIST PART NUMBER 005960000 005970000 006900000 006900100 016920000 018490000 040370000 057270000 077830100 077990000 077990100 078580000 078600000 078610000 FL0000007 FL0000050 FL0000051 HW0000439 OR0000035 PU0000099 DESCRIPTION MEDIA, ACTIVATED CHARCOAL KIT MEDIA, PURAFIL KIT FELT PADS FOR REGEN DRIER FELT PADS FOR SCRUBBER CANISTERS MEDIA, MOLECULAR SIEVE KIT PRESSURE GAGE CO SCRUBBER ASSEMBLY GASKET FOR SCRUBBER CANISTERS PCA, CONTROL BOARD, 751H PUMP ASSY, 115V/60HZ, 751H P
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APPENDIX B - SCHEMATICS 07773A DCN6833 B-1
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Interconnect List 751H Revision A Cable Part # Description Production Release Signal Checked RH Assembly CONNECTION FROM PN 077940100 Cbl Assy, Front Panel LED Indicator, 751X PWR RED LED Front Panel LED Board PWR GREEN LED Front Panel LED Board RH RED LED Front Panel LED Board GND Front Panel LED Board GND Front Panel LED Board RH GREEN LED Front Panel LED Board 077990000 Assy, Pump. 115V~, 751H AC Line Assy, Pump. 115V~ AC Neutral Assy, Pump. 115V~ Power Gnd Assy, Pump. 115V~ 077990100 Assy, Pump.
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AC POWER ENTRANCE DRIER RELIEF VALVE WATER DROP VALVE SCRUBBER HEATER J1 J1 J1 AC PS48 J15 4-WAY SHUTTLE VALVE AC POWER SWITCH J3 J2 DC J17 J16 J2 J1 J13 FRONT PANEL LED J1 CONTROL BOARD 077830000 T751H J19 THERMISTOR TEMP 751H FAN FA10 J7 J11 J8 J5 PUMP CONFIG PLUG 078670000 (115V) 078670100 (230V) Printed Documents are Uncontrolled The information hereon is the property of API and is submitted in strictest confidence for reference only.
