Altec AIR CO2-PG80 Troubleshooting guide

CO2-PG80 PURGE GAS GENERATOR

OPERATIONS & MAINTENANCE

TABLE OF CONTENTS

SECTION 1 General Information:

Model Description Pg 2

Serial Numbers

Description of Operation

SECTION 2 Safety Instructions: Pg 3

Installation Safety

Operation Safety

SECTION 3 Specifications: Pg 3

Flows, Connections, Dimensions, and Weights

SECTION 4 Installation Pg 4

Parts Included

Location

Install Filters

Mounting

Electrical Connections

Piping and Connections

SECTION 5 Start-Up Pg 5

SECTION 6 Maintenance Pg 5

SECTION 7 Replacement Parts Pg 6

SECTION 8 Troubleshooting Guide Pg 7

SECTION 9 Wiring Diagram Pg 8

SECTION 10 Warranty / Claims Pg 8

P/N P013253 REV B

SECTION 1 GENERAL

INFORMATION

1.1 MODEL DESCRIPTION

The CO2-PG80 Purge Gas Generator is designed to remove

water and CO2 from a compressed air stream. This is done by

passing the air through beds of adsorbent media (using 13X

molecular sieve) which adsorbs both H2O and CO2.

1.2 SERIAL NUMBER CODING

1.3 DESCRIPTION OF OPERATION

The CO2-PG80 Purge Gas Generator uses the pressure swing

adsorption method of gas separation. This requires two

identical towers containing beds of adsorbent desiccant media.

Incoming wet, CO2 rich air enters the adsorber/dryer through

the inlet port, where energized SOLENOID VALVE A directs

the pressurized air stream to the bottom of DESICCANT

TOWER A containing active adsorbent. This adsorbent media

bed removes water vapor and CO2 gas from the air to better

than -100°F dew point and less than 1 PPM CO2 when

operated at catalog conditions. The dry and CO2 free air

leaving the top of DESICCANT TOWER A is directed to the

outlet through open CHECK VALVE A. PURGE ORIFICE B

and closed CHECK VALVE B allow a metered portion of the

processed air to flow into DESICCANT TOWER B being

regenerated. The open purge port on deenergized SOLENOID

VALVE B and the purge orifice reduce the pressurized dry air

down close to atmospheric pressure and regenerate the

adsorbent media by removing the accumulated water vapor

and CO2 and carrying it out the open purge port.

The two solenoid valves are controlled by a solid state timer.

After 30 seconds, the media in DESICCANT TOWER B is

regenerated, and the solid state cycle timer causes the process

to instantly reverse, with TOWER B adsorbing and TOWER A

regenerating. The following flow schematic (FIG 1)

demonstrates the adsorber/dryer operation.

FIG 1

SOLENOID VALVE TIMING CYCLE

30 seconds per side continuous

1 minute total cycle time

P/N P013253 REV B

MONTH/YEAR OF MANUFACTURE

SERIAL #

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

SECTION 2 SAFETY

INSTRUCTIONS

2.1 INSTALLATION SAFETY

Before starting or installing the CO2-PG80 Purge Gas

Generator, be sure that all power to the unit is off, valves are

shut, and the air circuit is at atmospheric pressure. DO NOT

remove, repair, or replace any component, control filter, or part,

while the unit is energized or the air circuit is under pressure.

Unplug unit and de-pressurize the unit before starting

installation or maintenance procedures.

The CO2-PG80 is rated NEMA 1.

2.2 OPERATION SAFETY

DO NOT OPERATE THE CO2-PG80 PURGE GAS

GENERATOR AT COMPRESSED AIR PRESSURES ABOVE

150 PSIG. UNIT FAILURE, INJURY AND EQUIPMENT

DAMAGE COULD RESULT

CAUTION:

EXCEPT as otherwise specified by the manufacturer, this

product is specifically designed for compressed air service and

use with any other gas or liquid is a misapplication.

Manufacturer’s warranties are void in the event of a

misapplication and manufacturer assumes NO

RESPONSIBILITY for any resulting loss.

Before using equipment with fluids or gases other than air,

consult Altec AIR for written approval.

SECTION 3 SPECIFICATIONS

3.1 FLOWS, CONNECTIONS, DIMENSIONS, AND WEIGHT

MODEL NO. CO2-PG80

Max Flow Capacities at 125 PSIG (L/M)

Inlet Flow 114

Purge Flow 34

Outlet Flow 80

Connections (NPT)

Inlet 1/4

Outlet 1/4

Dimensions (Inches)

Height 27.7

Width 17.2

Depth 6.2

Weight (Pounds) 25

TABLE 1

OUTLET FLOW CAPACITIES AT

VARIOUS INLET PRESSURES

WITH PURGE ORIFICE REQ’D

PSIG

lit/min

orifice

no.

150

99.4

140

93.4

130

84.7

120

73.1

110

65.1

100

60.0

48.5

36.9

32.9

26.1

15.8

Note: Outlet flows shown above are maximum capacities and should not be exceeded for best performance. No outlet flow

metering valve or flow meter is installed on the adsorber/dryer and must be provided by the user. Purge flow is metered by

integral fixed purge orifices. Capacities are based on inlet conditions of 70°F, 100%RH, normal ambient CO2 levels of approx

350-375 ppm. Outlet concentration of CO2 will be less than 1 ppm and outlet dew point better than -100°F. If your flow,

temperature or pressure are different from above, consult factory for performance. Unless otherwise specified, a #32 orifice

set has been installed as standard.

Page 3

P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

INLET BULKHEAD

FITTING

OUTLET

BULKHEAD

FITTING

FIG 2

SECTION 4 INSTALLATION

4.1 PARTS INCLUDED

(1) CO2-PG80 Purge Gas Generator

(1) Inlet Coalescing Filter Assy.

(1) Outlet Filter Regulator Assy.

(6) Cover Screws, 6-32 x 3/8, PH, SS

(1) Operations & Maintenance Manual

4.2 LOCATION

DO NOT INSTALL THE UNIT IN AN ENVIRONMENT OF

CORROSIVE CHEMICALS, EXPLOSIVE GASES, OR AREAS

OF HIGH OR LOW AMBIENT TEMPERATURE (ABOVE 125°F

OR BELOW 33°F).

Install the unit indoors. Unit may be wall mounted or placed on

a table top.

4.3 INSTALL FILTERS

A coalescing filter is provided to be installed on the inlet to the

adsorber/dryer to remove entrained particulates, liquid moisture

and oil which can cause damage to the desiccant beds. A

particulate afterfilter is provided to be installed on the outlet of

the adsorber/dryer to remove any adsorbent media dust that

may migrate from the desiccant beds.

Using a wrench to keep inlet bulkhead fitting from turning,

install Inlet Filter Assy to left side of unit as shown in FIG 2

above. Similarly, install Outlet Filter Regulator Assy to Right

Side of unit.

4.4 MOUNTING

1. Table top

a. The unit comes with rubber feet installed on bottom

of cabinet for use on table top.

2. Wall mounting

a. Remove (6) cover screws and remove cover. While a

helper holds the unit at the mounting location, mark

the position of the (4) mounting holes at the back of

the cabinet. Mount the cabinet using these

mounting holes. Be sure to use proper wall mounting

anchors if mounting in drywall.

b. Reinstall cover.

4.5 ELECTRICAL CONNECTIONS

Before plugging in unit, check the unit nameplate for electrical

characteristics. Standard electrical characteristics are 115

volt, 1 phase, 50/60 Hz. Models operating on 230 volts are

available.

IMPORTANT!: No overload protection is provided in the

adsorber/dryer and unit should be plugged/wired into a

protected circuit.

4.6 PIPING AND CONNECTIONS

Inlet and outlet tubing should be appropriate for pressure and

temperature of operation. See specification chart for

inlet/outlet NPT thread size. Teflon tape should be used in the

makeup of joints to ensure a good, airtight fit of piping

components. Check all connections for leakage using soap

solution prior to putting unit into service.

Page4

P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

SECTION 5 START UP

BEFORE UNIT START UP, FOLLOW THE INSTALLATION

INSTRUCTIONS AND PROCEDURES COMPLETELY.

DO NOT REMOVE, REPAIR OR REPLACE ANY ITEM ON

THE ADSORBER/DRYER WHILE THE ADSORBER/DRYER

IS UNDER PRESSURE.

5.1 INITIAL START UPS

1. Confirm that all piping and electrical connections are

proper.

2. Turn on the electrical power. Adsorber/dryer should start

cycling with a small purge noise heard every 30 seconds.

SECTION 6 MAINTENANCE

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON

THE ADSORBER/DRYER WHILE THE ADSORBER/DRYER IS

UNDER PRESSURE.

BEFORE BEGINNING ANY REPAIRS, MAINTENANCE, OR

INSTALLATION WORK, VERIFY THAT THE POWER IS OFF

AND THE ADSORBER/DRYER IS DEPRESSURIZED.

BEFORE WORKING ON THE ADSORBER/DRYER OR

RELATED EQUIPMENT, ENSURE THAT ALL PERSONNEL

HAVE READ AND UNDERSTAND THE SAFETY AND

OPERATION INSTRUCTIONS IN THIS MANUAL.

6.1 PREVENTIVE MAINTENANCE

Below is a suggested schedule based on average operating

conditions. As conditions such as dirty environment, humidity

conditions, ambient temperature, etc. change, the frequency of

the inspections may need to be increased.

Daily

1. Inspect the adsorber/dryer for proper cycling.

2. Inspect inlet filter for proper drain operation.

3. Verify proper inlet pressure and ambient air temperature

conditions.

Semi-Annually

1. Inspect entire assembly for loose connections, screws,

etc.

Annually

1. Replace inlet filter elements, outlet filter elements, and

purge mufflers:

Inlet Filter Element

#M18-02-CG00 #MTP-96-646

Outlet Filter/Regulator Element

#B03-02-G000 #PS403

Purge Mufflers

#ASN-6 (qty 2)

Bi-Annually

1. Order Maintenance Kit #51325. Replace solenoid valves

wearing parts and check valves parts in adsorber/dryer

manifold. See Figure 3, Item #15, in next section.

Page 5

P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

SECTION 7 REPLACEMENT PARTS

Part Number

Description (refer to FIG 3)

Call Factory

POWER ON/OFF SWITCH

B03-02-G000

OUTLET FILTER/REGULATOR WITH GAUGE

PS403

- OUTLET FILTER ELEMENT ONLY

P77413

- GAUGE ONLY

M18-02-CG00

INLET FILTER WITH AUTO DRAIN

MTP-96-646

- INLET FILTER ELEMENT ONLY

20020

POWER CORD (NOT SHOWN)

ASN-6

MUFFLER, PURGE, 1/8 NPT, (ORDER QTY 2)

51330-0XX

ADSORBER/DRYER INSERT ORIFICE NUMBER FOR

XX (SEE TABLE 1 ON PAGE 3 FOR ORIFICES/FLOWS)

OUTLETFILTER REGULATOR

WITH GAUGE

POWERON/OFFSWITCH

INLETCOALESCINGFILTER

ADSORBER/DRYER

PURGEMUFFLERS

FIG 3

Ref.

No.

Part

Number

Adsorber/Dryer Part Description

(refer to FIG 4)

Qty /

Unit

Incl. in

Kit (#15)

51254

TOWER, 20", 51330 CO2 ADSORBER/DRYER

O-RING, TOWER

O-RING, PURGE ORIFICE, INNER

51315-27

PURGE ORIFICE, #27 FOR 140 - 150 PSIG OPER.

51315-29

PURGE ORIFICE, #29 FOR 120 - 130 PSIG OPER.

51315-32

PURGE ORIFICE, #32 FOR 80 - 110 PSIG OPER.

51315-40

PURGE ORIFICE, #40 FOR 50 - 70 PSIG OPER.

(SEE TABLE 1 ON PAGE 3 FOR ORIFICES/FLOWS)

O-RING, PURGE ORIFICE, OUTER

51308

MOISTURE INDICATOR WITH O-RING (NOT SHOWN)

O-RING, MOISTURE INDICATOR

51316

BALL, CHECK VALVE

51317

SPRING, CHECK VALVE

P300495P

MANIFOLD

51319

PLUG, MANIFOLD

O-RING, SOLENOID VALVE

P400589DC1

SOLENOID VALVE ASSY, 53 VDC, FOR 115 VAC UNIT

P400589DC2

SOLENOID VALVE ASSY, 106 VDC, FOR 230 VAC UNIT

13A

CORE, SOLENOID VALVE

13B

BASE, SOLENOID VALVE

13C

FRAME, SOLENOID VALVE

COIL (ORDER COMPLETE SOLENOID VALVE ASSY)

51325

KIT, MAINT., ADSORBER/DRYER

P010530F1

ADSORBER TIMER, CYCLE, FOR 115 VAC UNIT (NOT SHOWN)

P010530F1

ADSORBER TIMER, CYCLE, FOR 230 VAC UNIT (NOT SHOWN)

P3005052

ADSORBER BOTTOM COVER (NOT SHOWN)

P010437

ADSORBER BRACKET, MOUNTING (NOT SHOWN)

FIG 4

Page 6 P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

SECTION 7 TROUBLESHOOTING GUIDE

PROBLEM: UNIT DELIVERS WET AIR OR HIGH CO2 LEVELS

POSSIBLE CAUSE

CHECK

CORRECTIVE ACTION

High inlet air temperature.

For standard units, inlet air

temperature should be 70-80°F.

Reduce inlet air temperature to proper

level. An aftercooler may need to be

installed after compressor.

Air flow through dryer in

excess of rated capacity.

Make sure outlet flow does not exceed

rated flow. See capacity chart in

Reduce air usage downstream.

SPECIFICATIONS.

Low inlet pressure.

See capacity chart in SPECIFICATIONS.

Increase inlet pressure.

Dirty or obstructed inlet air

filter.

Check inlet airline filter elements.

Replace elements.

Purge orifice plugged.

Check purge air flow with flowmeter.

Clean or replace purge orifices.

Solenoid coil burned out.

Check coil leads with ohmmeter. Open

Replace valves.

(burned out) coil will have no reading.

Oil contamination of

Verify particle/coalescing inlet filtration is

Towers must be replaced if contamination

desiccant beds.

adequate and functioning properly.

is suspected.

Timing cycle improper.

Verify correct timing cycle by listening

to purge or by using voltmeter across

coil connections on timer.

Replace timer if defective.

Purge flow restricted.

Check mufflers for excessive back-

pressure.

Replace mufflers.

B PROBLEM: RESTRICTED FLOW THROUGH UNIT

POSSIBLE CAUSE CHECK CORRECTIVE ACTION

B1 No power to unit. On-Off switch and power supply. Correct power problem.

B2 Improper operating See A2, A3 above.

conditions.

B3 Dirty or obstructed inlet air See A4 above.

filter.

B4 Plugged air passages. Check inlet and outlet air passages and Clear

restrictions.

piping for blockages.

B5 Inlet and outlet ports Check inlet and outlet ports for proper Reconnect properly.

reversed. connections.

C PROBLEM: EXCESSIVE PURGE

POSSIBLE CAUSE CHECK CORRECTIVE ACTION

C1 Check valve not closing. Check for damage or contamination of Clean or replace as

necessary.

check valves.

C2 Purge orifice(s) incorrect. Measure purge flow with flow meter. Install correct purge orifice(s).

Page 7 P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual

SECTION 9 WIRING

FIG 5

CO2-PG80 WIRING DIAGRAM

SECTION 10 WARRANTY

Altec AIR warrants the CO2-PG80 Purge Gas Generator to be

free of defects in materials and workmanship under proper use,

installation and application. This limited warranty shall cover

parts or replacement unit only, for a period of 18 months from

date of shipment or 12 months from date of installation,

whichever comes first.

ALL FREIGHT DAMAGE CLAIMS ARE NOT THE

RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT

COVERED UNDER WARRANTY AS ALL PRODUCTS ARE

SHIPPED F.O.B. SHIPPER. PLEASE DIRECT ALL FREIGHT

CLAIMS TO THE FREIGHT CARRIER IN QUESTION.

This warranty does not apply to any unit damaged by accident,

modification, misuse, negligence, or misapplication.

Any covered CO2-PG80 Purge Gas Generator part or material

found defective will be repaired, replaced or refunded, at Altec

AIR’s option, free of charge, provided that Altec AIR is notified

within the above stated warranty period. All returns of defective

parts/equipment must have prior written Returned Material

Authorization (RMA). RMA may be obtained from our service

department. All defective parts/equipment must be returned

freight prepaid to the Altec AIR factory within 30 days of RMA

issue date. Any shipment returned to the factory collect will be

refused.

If an item is found to be warrantable, the repaired item or

replacement will be shipped via standard ground freight prepaid

within the continental US and Canada.

Any replacement part or material is warranted only to the extent

of the remaining warranty period of the adsorber/dryer or to the

extent as provided by the supplier, whichever is longer.

All freight damage claims should be filed within 15 working

days and should be directed to the freight carrier.

Page 8

P/N P013253 REV B

Tel: 800-521-5351

226A Commerce St., Broomfield, CO. 80020 [email protected]

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