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AADCO 737 Series Operating Instructions Manual

Pure air generators
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OPERATING INSTRUCTIONS
AADCO 737-SERIES
PURE AIR GENERATORS
737-5 737-10
(5-lpm)
(10-lpm)
AADCO INSTRUMENTS, INC.
145 South Miami Ave.
Village of Cleves, OH 45002
Telephone: (513) 467-1477
Fax: (513) 467-9009
ii

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  • Page 1 OPERATING INSTRUCTIONS AADCO 737-SERIES PURE AIR GENERATORS 737-5 737-10 (5-lpm) (10-lpm) AADCO INSTRUMENTS, INC. 145 South Miami Ave. Village of Cleves, OH 45002 Telephone: (513) 467-1477 Fax: (513) 467-9009...

  • Page 2: Table Of Contents

    AADCO 737-5 AND 737-10 PURE AIR GENERATORS TABLE OF CONTENTS Section Page LIST OF ILLUSTRATIONS ................iii DAMAGED AND/OR LOSS IN SHIPMENT PROCEDURE ......1 INSTALLATION .................... 2 REAR PANEL CONNECTIONS ..............4 OPERATIONAL TEST .................. 5 OPERATIONAL PROCEDURES ..............7 PRINCIPLE OF OPERATION ..............

  • Page 3: List Of Illustrations

    AADCO 737-5 AND 737-10 PURE AIR GENERATORS LIST OF ILLUSTRATIONS Figure Page GENERATOR & SILENCER HOUSING, REAR VIEW .......... 40 GENERATOR & SILENCER HOUSING, FRONT VIEW ........41 GENERATOR WITH “HOUSE” AIR ADAPTER ............ 42 GENERATOR, FRONT PANEL ................43 GENERATOR, INTERNAL VIEW, RIGHT SIDE ...........
  • Page 4 737-10 ROTAMETER FLOW NOMOGRAPH ............62...

  • Page 5: Damaged And/Or Loss In Shipment Procedure

    RETURN TO ADDCO INSTRUMENTS, INC. If your property, while being returned to AADCO Instruments, Inc., is damaged in transit, it will be your responsibility to file a claim with the carrier. To assist you we will secure an inspection report from the carrier and forward it to you.

  • Page 6: Installation

    NOT perform to specifications. AADCO Instruments, Inc. supplies pure air generators with or without air compressor, depending upon availability of compressed air at the user’s site. If “plant”...
  • Page 7 For INSTALLATION WITH COMPRESSOR, place the compressor assembly, Figures 1 and 2 (50), between two level surfaces so that the underside of the assembly is exposed. DO NOT INVERT. Remove the two red shipping bolts located on the underside and retain for future use. 1.10 Place the generator unit and compressor unit side by side as shown in Figures 1 and 2, with the compressor unit, Figures 1 and 2 (50), left of the generator unit as shown.

  • Page 8: Rear Panel Connections

    REAR PANEL CONNECTIONS. The DUMP bulkhead connection, Figure 1 (60), is the outlet for air containing those impurities removed from the unclean feed air. It is vented outside the instrument cabinet to prevent deposition of water and other materials within the instrument.

  • Page 9: Operational Test

    IF INSTALLATION HAS BEEN COMPLETED AS SHOWN IN FIGURES 1 and WHEREBY PURE GENERATOR USES AADCO COMPRESSOR, REFERENCE FIGURE FOLLOWING OPERATIONS. Depress the PUMP switch (1) on the generator unit by depressing the lamp itself.
  • Page 10 and 6 (28). Wait at least one minute to allow both sides of the purification reactor to pressure up and then adjust the output pressure to any desired pressure up to 50-psig with the OUTPUT PRESSURE REGULATOR. This output pressure will be observed on the OUTPUT PRESSURE gauge (6).
  • Page 11 3.16 Follow the procedures as outlined in Section 3.7 through Section 3.13.

  • Page 12: Operational Procedures

    AADCO Instruments offers in-line pressure regulators for this purpose (part no. 20033). There are two pressure conditions for operating the pure air generator.
  • Page 13 The first pressure condition is when the output is permitted to enter an ambient pressure environment; i.e., wherein the effluent enters and purges an environmental chamber; or passes into a sampling manifold which itself vents to the atmosphere, etc. In each case there will be no back pressure exerted upon the pure air generator.
  • Page 14 4.14 OUTPUT PRESSURE MULTIPLIER 2.24 2.16 2.08 2.00 1.91 1.82 1.73 1.63 1.53 1.415 1.29 1.155 4.15 The purpose of this exercise is to allow the operator to know his flow conditions but, more importantly, TO AVOID EXCEEDING THE OUTPUT CAPACITY OF THE PURE AIR GENERATOR AND JEOPARDIZING THE OUTPUT PURITY.

  • Page 15: Principle Of Operation

    PRINCIPLE OF OPERATION (REFERENCE FIGURE 17). The 737-series pure air generators produce absolutely clean air from pressurized unclean air by chromatographic techniques. Pressurized air from a compressor or other source enters the number one or number two column system, depending upon the status of the solenoid valve located at the inlet of the column.
  • Page 16 Damage to the purification reactor can occur if: (a) improperly filtered air is admitted to the columns as with oil compressors, (b) water is admitted to columns due to oversight on the operator’s part in failing to drain the ballast tank and allowing water to carry over, (c) the unit is operated above its rated capacity, or (d) the input pressure requirements are not met.

  • Page 17: Ballast Tank And Ballast Bleed System

    AADCO Instruments, Inc. supplies an internally-coated, rust-proof ballast tank with each system which is equipped with a manual toggle valve, Figures 1, 2 and 9 (12), for bleeding the coalesced water from the tank.

  • Page 18: Compressor Unit

    COMPRESSOR UNIT. A compressor, Figure 8 (43), contained is a separate sound-proofed assembly, provides compressed air to the pure air generator. Each compressor is sized for a particular generator system. When replacement is necessary, it should be replaced with the same size compressor with the same voltage requirements. The compressor is shock-isolated from the cabinet proper by four springs and a special mounting plate, Figure 8 (46).

  • Page 19: Compressor Control System

    AND FIGURE 18 FOR ELECTRICAL REFERENCE.) A combination pressure switch/pressure relief valve system is installed in all AADCO pure air generators with output volumes greater than 1-LPM but less than 50-LPM. The purpose of this system is to permit the compressor to operate intermittently rather than continuously.
  • Page 20 wear. The compressor relief valve eliminates this problem. 8.10 The AUX POWER outlet, Figure 1, is a four-conductor connector, one lead (the red lead) carries power to the cooling fan located within the compressor silencer housing. Power is applied to the cooling fan continuously, whether the compressor in on or off, thus maintaining a favorable temperature within the compressor silencer housing.
  • Page 21 PURIFICATION REACTORS AADCO Instruments, Inc. offers four basic types of purification reactors, designated “A”, “B”, “C”, and “D”. The “A” PURIFICATION REACTOR produces air of purity outlined in Section 11.0 and with an oxygen concentration of 20.8% ± 0.3%. In addition, the CO concentration will be that of the ambient environment of the user’s locale (~350-...
  • Page 22 9.11 For those instances were pure air with high humidity is required, AADCO Instruments will supply a humidifier to be located after the pure air generator. This device will operate under pressure and produce air with 50-90+% RH.
  • Page 23 See Section 9.9. 10.6 To remove the low level CO formed during the catalytic reaction, AADCO Instruments offers an in-line, see through , CO -indicating scrubber (part no. 737-120). This device is offered for those users who may be concerned with...
  • Page 24 CO free air. 10.7 AADCO Instruments offers free standing methane reactors (Models 153 and 154, Figure 10) for those individuals who wish to remove hydrocarbons and carbon monoxide from their own oxygen or air sources. It should be borne in mind that suitable halogen and sulfur scrubbers are required if these compounds are present, when using these free-standing units.

  • Page 25: Purification Reactors

    11.0 PERFORMANCE SPECIFICATIONS 11.1 The AADCO 737-series pure air generators produce air with less than 0.005- ppm hydrocarbons, carbon dioxide, methane, ozone, sulfur dioxide, hydrogen sulfide, ammonia, and oxides of nitrogen. Carbon dioxide level is either at ambient level (~350-ppm) or less than 0.3-ppm, depending upon the model purification reactor selected.
  • Page 26 11.7 Factory conditions for each model are as follows: 737-5 5-LPM output flow @ 80-psig input pressure 737-10 10-LPM output flow @ 80-psig input pressure 11.8 Any output flow greater than the stated maximum output flow for any particular model pure air generator produces air with purity worse than specifications. Figures 19 and 20 are nomographs which indicate output flow versus rotameter reading at STP.

  • Page 27: Preventive Maintenance

    12.0 PREVENTIVE MAINTENANCE. 12.1 BALLAST BLEED - All accumulated water must be bled from the ballast tank at least once every three days during continuous operation. This is done by operating the manual toggle valve, Figures 1, 2 and 9 (12), located on the ballast tank.

  • Page 28: Trouble Shooting

    13.0 TROUBLE SHOOTING 13.1 COMPRESSOR (See Section 7.0). 13.2 Depress the PUMP switch. The PUMP switch lamp should light and the compressor should start. (a) PUMP SWITCH LAMP LIGHTS BUT COMPRESSOR DOES NOT START. Check INPUT PRESSURE gauge. If reading is 60-psig or greater, compressor cannot start.
  • Page 29 13.3 Continued. NOTE: There is an inaccessible thermal switch located within the body of the compressor motor which will cause the compressor to shut down should it begin to overheat. The compressor should begin operating within fifteen minutes after removing the cover from the compressor unit.
  • Page 30 there should be a sudden expulsion of air from the compressor pressure relief 13.4 (a) (1) Continued. valve, Figure 8 (23). This represents a bleeding of air from the connecting tubing by this valve so that on compressor restart this tubing will be at ambient pressure.
  • Page 31 reaches 80-psig and the pressure switch cuts off power to the compressor. This should occur within thirty seconds if the starting input pressure were at 60-psig and within two minutes if at zero. See Section 14.0 for proper adjustment of this setting if not at 80-psig and 60-psig. 13.5 Continued.
  • Page 32 (a) Check voltage between position #2 and position #4 of terminal strip TS-1, located on the front floor of generator unit (see Figure 18). When PUMP switch is off, there should be no voltage. If voltage is present, PUMP switch is defective. Replace the pump switch. (b) If no voltage is present in (a) above, check voltage between terminal #2 of AC solid state relay to neutral of terminal strip TS-1.
  • Page 33 NOTE: AADCO Instruments offers a purification reactor complete with all valves, fittings, etc., for a discounted price with trade-in of the depleted reactor.
  • Page 34 problem lies with the timer. Replace the timer. (3) If AC voltage is present at both quick-connections leading from the timer, measure the resistance of each solenoid coil at the quick- connect leading to the solenoid valve. It should be about 430-ohms if 120V and 1850-ohms if 220V.
  • Page 35 13.16 If there is purge flow although the POWER switch is off (no power to the solenoid valves or purification reactor), the problem lies with one of the purification reactor’s solenoid valves experiencing “blow by”. It is due to the weakening of the spring within the coil housing.
  • Page 36 defective check valve.
  • Page 37 13.19 Continued. NOTE: It may be necessary to remove the ¼-inch tubing joining the purge connections of the two solenoid valves to isolate that valve which is producing the improper purge flow. 13.20 Should the cooling fan, Figures 5, 6 and 11 (28), fail, the generator cabinet will feel unduly warm and the pure air that exits from the PURE AIR fitting on the rear of the unit will feel warm also, since the cooling fan passes air over the cooling coil, Figures 5, 6 and 11 (27).
  • Page 38 If zero resistance, indicating a short condition, the fuse will blow. NOTE: AADCO Instruments, Inc. offers a rebuilt methane reactor for a discounted cost with the trade-in of the depleted unit. 13.25 If the pyrometer indicates a temperature other than 290 C ± 10 C and the METHANE HEAT lamp is cycling, the methane reactor is at proper operating temperature but either the pyrometer or the thermocouple is defective.
  • Page 39 (b) If the pyrometer indicates a temperature other than 290 C ± 10 C and the thermocouple output is about 14.0-MV, replace the pyrometer.

  • Page 40: Pressure Switch Adjustment

    14.0 PRESSURE SWITCH ADJUSTMENT 14.1 The pressure switch, Figures 5, 6 and 11 (17), controls the pressure range for compressor operation. This range is usually between 60 and 80-psig. 14.2 The two opposing but adjacent white, knurled knobs (one considerably larger than the other) are accessible without removing the dark plastic cover.
  • Page 41 also be adjusted to maintain the 80-psig cut off because of the interaction of the two knobs. 14.8 Continued NOTE: ONCE THE SWITCH HAS RESPONDED TO THE PRESSURE CHANGES BY TURNING THE COMPRESSOR ON OR OFF, IT IS NECESSARY THAT THE SWITCH PERFORM ITS OPPOSITE FUNCTION BEFORE THE EFFECT OF ANY SETTING CHANGE CAN BE PERCEIVED.

  • Page 42: Component Replacement

    15.0 COMPONENT REPLACEMENT 15.1 TO REPLACE THE PURIFICATION REACTOR: (a) REMOVE THE POWER CORD FROM THE WALL OUTLET and disconnect the two electrical disconnects leading to the solenoid valves of the purification reactor. (b) Disconnect the ¼-inch stainless steel tubing at the inlet of the purification reactor, allowing the stainless steel tubing and all of its connecting tubing to remain suspended.
  • Page 43 the inlet of the methane reactor. 15.2 Continued. (d) Remove the three 8-32 kep-nuts from the underside of the generator cabinet which hold the methane reactor in place. (e) Remove the methane reactor from the cabinet and install the replacement, reversing steps (a) through (d).

  • Page 44: 737-104 Auto Pure Air Manifold

    16.0 737-104 AUTO PURE AIR MANIFOLD. 16.1 Auto Pure Air Manifolding only occurs outside of the pure air generator. See Figures 11b and 11c. All of the manifolding connections are made outside of the pure air generator and are visible to the operator. 16.2 The purpose of this manifold is to be certain that pure air is available to the analytical instruments at all times, whether source air to the pure air generator...

  • Page 45: 737-105 Auto Source Selector

    17.0 737-105 AUTO SOURCE SELECTOR 17.1 Auto Source Manifolding occurs within the pure air generator. See Figures 11 and 11c. None of this manifolding is visible to the operator because all of the pneumatic connections are inside the pure air generator. 17.2 The purpose of this manifold is to be certain that an air source is admitted to the pure air generator at all times to assure a continuous flow of pure air from...

  • Page 46: Parts List

    18.1 Before attempting to replace any part or component, be certain to read the blue AADCO Instruments, Inc. label on the outside rear wall of your pure air generator to determine the model number and operating voltage requirements for proper parts selection.
  • Page 47 18.0 Continued. Reference Catalog Number Number Description 20169-1 Relay, solid state, AC, 40-AMP, specify voltage 20060 Rotameter, specify output 20162 Shroud for Compressor Fan 20180 Spring, Compressor Support, Set/4 20150 Switch, Power & Pump, Pre-wired 20149-2 Thermocouple, Pre-wired 20153 Timer, Specify generator output 20047 Valve, Compressor Pressure Relief 20048...

  • Page 71: Warranty

    The expense of warranty shipping charges to the customer will be borne by AADCO Instruments, Inc. Service performed to rectify an instrument malfunction caused by abuse or neglect and service...

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737-5737-10

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