AADCO 737 Series User manual

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

iii

AADCO 737-5 AND 737-10 PURE AIR GENERATORS

TABLE OF CONTENTS

Section Page

LIST OF ILLUSTRATIONS.......................................................................... iii

0.0 DAMAGED AND/OR LOSS IN SHIPMENT PROCEDURE ..........................1

1.0 INSTALLATION ............................................................................................2

2.0 REAR PANEL CONNECTIONS....................................................................4

3.0 OPERATIONAL TEST..................................................................................5

4.0 OPERATIONAL PROCEDURES..................................................................7

5.0 PRINCIPLE OF OPERATION.....................................................................10

6.0 BALLAST TANK AND BALLAST BLEED SYSTEM....................................12

7.0 COMPRESSOR UNIT.................................................................................13

8.0 COMPRESSOR CONTROL SYSTEM........................................................14

9.0 PURIFICATION REACTORS......................................................................16

10.0 METHANE REACTORS .............................................................................18

11.0 PERFORMANCE SPECIFICATIONS.........................................................20

12.0 PREVENTIVE MAINTENANCE..................................................................22

13.0 TROUBLE SHOOTING...............................................................................23

14.0 PRESSURE SWITCH ADJUSTMENT........................................................32

15.0 COMPONENT REPLACEMENT.................................................................34

16.0 737-104 AUTO PURE AIR MANIFOLD ......................................................36

17.0 737-105 AUTO SOURCE SELECTOR.......................................................37

18.0 PARTS LIST ...............................................................................................38

ILLUSTRATIONS......................................................................40 through 62

WARRANTY...............................................................................................63

AADCO 737-5 AND 737-10 PURE AIR GENERATORS

LIST OF ILLUSTRATIONS

Figure Page

1 GENERATOR & SILENCER HOUSING, REAR VIEW..........................................40

2 GENERATOR & SILENCER HOUSING, FRONT VIEW.......................................41

3 GENERATOR WITH “HOUSE” AIR ADAPTER ....................................................42

4 GENERATOR, FRONT PANEL............................................................................43

5 GENERATOR, INTERNAL VIEW, RIGHT SIDE...................................................44

6 GENERATOR, INTERNAL VIEW, LEFT SIDE......................................................45

7 GENERATOR WITH METHANE REACTOR & MIXER-RECEIVERS

OPERATING FROM EXTERNAL SOURCE, NO COMPRESSOR.....................46

7a GENERATOR, AS FIGURE 7, OPPOSITE VIEW.................................................47

8 COMPRESSOR SILENCER HOUSING, INTERNAL VIEW..................................48

9 BALLAST TANK WITH MANUAL BLEED.............................................................49

10 FREE STANDING METHANE REACTOR............................................................50

11 GENERATOR WITH AUTO SOURCE MANIFOLD...............................................51

11b GENERATOR WITH PURE AIR MANIFOLD........................................................52

11c AUTO PURE AIR MANIFOLD & AUTO SOURCE SELECTOR............................53

12 GC ANALYSIS FOR CO2, “C” PURIFICATION REACTOR ..................................54

13 CO2 OUTPUT FROM “A” VS “C” PURIFICATION REACTOR..............................55

14 MOISTURE VS TIME NOMOGRAPHS ................................................................56

15 FID RESPONSE CYLINDER AIR VS “B” PURIFICATION REACTOR..................57

16 EFFICIENCY OF THE METHANE REACTOR......................................................58

17 PNEUMATIC DIAGRAM.......................................................................................59

18 WIRING DIAGRAM ..............................................................................................60

19 737-5 ROTAMETER FLOW NOMOGRAPH.........................................................61

20 737-10 ROTAMETER FLOW NOMOGRAPH.......................................................62

0.0 DAMAGED AND/OR LOST IN SHIPMENT PROCEDURE

0.1 SHIPMENTS FOB FACTORY. This shipment was thoroughly inspected before it

was delivered to the carrier. Our responsibility for this shipment has now ended.

Therefore, a thorough inspection of the contents should be made upon its arrival.

0.2 In the event any portion of the shipment is damaged or missing, do not sign the

bill of lading or express receipt until the freight or express agent makes

appropriate notation on the receipt.

0.3 Concealed damage means damage which may not be apparent until after the

items are unpacked and tested. In case of concealed damage, a written request

for inspection should be filed with the carrier within 15 days of the delivery date.

Delay in making this request may provide grounds for refusal of your claim. Be

certain to retain the carbon, packing materials, wrappings, etc., until the carrier

has made his inspection. Keep in mind that concealed damage can occur from

rough handling even though the cartons show no evidence of external damage.

0.4 The carrier may request return of the damaged item to us for inspection and

repair. In this event, we will repair or replace the item and invoice you for the

costs involved. This invoice then becomes part of your claim upon the carrier.

0.5 SHIPMENTS FOB DESTINATION. In the case of damage in transit on

shipments made FOB Destination, we will gladly handle filing of the claim,

provided an acceptable inspection report from the carrier is furnished to us. In

the event that our claim is disallowed because of your negligence in obtaining the

report, it will be necessary to bill you for the repair or replacement charges.

0.6 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.

0.7 Prior to shipment to AADCO Instruments, Inc. You should call or write notifying

us of your intent. You must include some identifying note or letter with the item.

This note should include the name of your factory contact and the nature of the

damage.

1.0 INSTALLATION.

1.1 Before attempting installation, it should be borne in mind that the performance of

the pure air generator hinges upon the availability of a large volume of

pressurized air in close proximity to the instrument. THIS IS MANDATORY. If

the air source is unable to satisfy the sudden demands for pressurized air, the

pure air generator will NOT perform to specifications.

1.2 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” air is available, follow the procedure outlined for installation WITHOUT

COMPRESSOR (Sections 1.6 through 1.8), otherwise use the WITH

COMPRESSOR procedure (Sections 1.9 through 1.12).

1.3 If initial visual inspection reveals no damage after unpacking, remove all shipping

plugs from the bulkhead fittings on the rear of the instrument. Should there be

any indications of damage, see Section 0.0 for instructions. If further information

is required, consult the factory.

1.4 Locate the unit in an area which will permit a free flow of air, avoiding confined

spaces. This is especially important if the unit houses a methane reactor system.

The heat generated during operation of the methane reactor must be dissipated

away from the instrument. If the unit does not contain a methane reactor,

location is not critical. However, it should be kept away from the wall.

1.5 It is not unusual to situate these instruments on specially constructed shelves

above head level, in out of the way places outside the area of use; e.g., in

hallways, electrical rooms, etc.

1.6 For INSTALLATION WITHOUT COMPRESSOR, using a “plant” or “house” air

source, locate the unit as in Section 1.4. Install the “house” air adapter, Figure 3

(54), being certain that the connection to the EXTERNAL SOURCE fitting,

Figure 3 (57), is tight. Connect the air supply to the inlet fitting of the “house” air

adapter, Figure 3 (56). Close the water drain valve, Figure 3 (55), finger tight.

NOTE: Inlet air pressure cannot exceed 100-psig nor be less than 70-psig.

1.7 Install the power cord into a suitable electrical outlet.

1.8 Admit the source air into the “house” air adapter. The INPUT PRESSURE

gauge, Figure 4 (3), should indicate the pressure of the air source. Leak check

all incoming air connections with soap solution and remedy as needed. The unit

is now ready for operation.

1.9 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. Place the ballast tank Figures 1 and 9 (16), on top of the compressor

unit and install the curved metal tubing which is supplied and labeled, Figure 2

(53), between the compressor outlet fitting and the check valve on the ballast

tank, Figures 1, 2 and 9 (24).

1.11 Install the ¼-inch o.d. plastic tubing, Figure 1 (51), supplied between the outlet

fitting on top of the ballast tank and the PUMP fitting, Figure 1 (58), on the rear of

the generator unit. Lastly, install the dump muffler in the DUMP fitting Figure 1

(60) and direct downward.

1.12 Connect the compressor power cord into the AUX POWER outlet on the lower

rear of the generator unit, as shown in Figure 1. Once the six-foot power cord

has been inserted into the proper electrical outlet, the unit is ready for operation.

2.0 REAR PANEL CONNECTIONS.

2.1 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. The DUMP connection also provides a suitable connection for

sample collection of the impurity concentrate which elutes from this port.

2.2 The DUMP port must NOT be closed or impeded by any restriction which would

produce back pressure at this point.

2.3 The PUMP bulkhead fitting, Figure 1 (58), is a standard ¼-inch swage

connection. Care should be taken that the air supply tubing is kink-free as in

Figure 1.

2.4 The PURE AIR bulkhead connector, Figure 1 (59), is the pure air outlet from the

pure air generator. It will accept ¼-inch swage type connectors.

NOTE: Particulate filters are neither required nor recommended.

2.5 The AUXILIARY POWER outlet, Figure 1, provides power to the compressor

through the PUMP switch, Figure 4 (1).

2.6 Those units supplied for connection to “house” air, as in Figure 3, are shipped

without PUMP switch, fuseholder, and AUXILIARY POWER outlet.

3.0 OPERATIONAL TEST.

3.1 DO NOT CONNECT ANY EQUIPMENT TO THE PURE AIR GENERATOR

SYSTEM AT THIS TIME.

3.2 After making all electrical and pneumatic connections to both generator and

compressor units according to instructions attached to each unit and as

shown in the appropriate figures, the system is ready for operation.

3.3 IF INSTALLATION HAS BEEN COMPLETED AS SHOWN IN FIGURES 1 and

2 WHEREBY THE PURE AIR GENERATOR USES AN AADCO

COMPRESSOR, REFERENCE FIGURE 4 FOR THE FOLLOWING

OPERATIONS.

3.4 Depress the PUMP switch (1) on the generator unit by depressing the lamp

itself. The compressor should start and the indicator lamp within the PUMP

switch should light. Within a short time there should be indication of increasing

input pressure as noted on the INPUT PRESSURE gauge (3).

NOTE: The compressor will not start at this time if any pressure greater than

60-psig appears on the INPUT PRESSURE gauge.

3.5 At this time, the tubing leading from the compressor unit to the ballast tank and

to the generator unit should be checked for leaks by applying a soap solution to

all of the connections and tightening as required.

3.6 When the input pressure reaches 80-psig as evidenced on the INPUT

PRESSURE gauge, the compressor will cease to operate. The input pressure

at this time will remain constant at 80-psig.

NOTE: Checking for leaks when the compressor is not operating will be

pointless since the connecting hoses between the compressor and

generator will not be pressurized. This check can be made only

when the compressor is running.

3.7 Depress the power switch (2) by depressing the lamp itself. The indicator lamp

within the switch will light. The METHANE HEAT lamp (4) will light if there is a

methane reactor within the unit. There should be an audible “click” of the

solenoid valve on the purification reactor followed immediately by a momentary

decrease of the input pressure. This is the initial pressurization of one side of

the purification reactor. There may also be a rise in the output pressure, as

evidenced on the OUTPUT PRESSURE gauge (6), if the OUTPUT PRESSURE

REGULATOR (5) had been set previously to some pressure. In addition, the

cooling fan on the inside rear wall of the generator should operate, Figures 5

and 6 (28).

3.8 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).

3.9 Output flow should be adjusted via the OUTPUT FLOW ADJUST valve (13) to

some value between zero and 10.0 on the rotameter (10).

3.10 After about one-half hour of operation the METHANE HEAT lamp (4), if

present, should cycle, indicating that a maximum temperature has been

reached and is being maintained. During this half-hour “burn-in”, copious

amounts of water will exit from the PURE AIR FITTING, Figure 1 (59), on the

rear of the generator unit. It is advantageous to attach temporarily a short (six

to twelve-inch by ¼-inch o.d.) length of plastic tubing to that fitting to permit the

exiting water to clear the hoses and power cords of the unit.

3.11 The METHANE HEAT pyrometer (7) should indicate 290C ± 10C. If a

temperature other than this is observed, refer to Section 13.22, Methane

Reactor, for remedial action.

3.12 During the entire interval, from start up to full maximum temperature of the

methane reactor, the input pressure should be cycling between 60 and 80-psig

indicating that the pressure switch is operating properly. If not, consult Section

14.0, Pressure Switch Adjustment.

3.13 If all operations have been followed according to Sections 3.4 through 3.11,

allow the system to operate for several hours to permit maximum elimination of

the “burn-in” water. See Figure 14 for moisture versus time for both purification

and methane reactors.

3.14 IF INSTALLATION HAS BEEN COMPLETED AS SHOWN IN FIGURE 3

WHEREBY THE PURE AIR GENERATOR USES “HOUSE” AIR FOR ITS AIR

SOURCE, OBSERVE THE FOLLOWING OPERATIONS.

3.15 Admit the source air into the pure air generator. The INPUT PRESSURE

gauge, Figure 4 (3), should indicate the pressure of the source air.

NOTE: This pressure must not be less than 60-psig nor greater than 100-

psig. If the input pressure is less than 60-psig the quality of the air

produced by the pure air generator will be jeopardized. If the

pressure is greater than 100-psig the unit may malfunction since the

components are not rated greater than 100-psig.

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