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Teledyne 701 manual

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  • Page 1

    OPERATION MANUAL MODEL 701 ZERO AIR GENERATOR TELEDYNE ADVANCED POLLUTION INSTRUMENTATION DIVISION (TAPI) 9480 CARROLL PARK DRIVE SAN DIEGO, CA 92121-5201 TOLL-FREE: 800-324-5190 FAX: 858-657-9816 TEL: 858-657-9800 E-MAIL: api-sales@teledyne.com WE B S IT E: www.te le dy n e- ap i. co m 01671H DCN6051 Copyright 2007 – 2011 Teledy ne Advanced Poll[...]

  • Page 2

    [...]

  • Page 3

    01671H (DCN6051) i ABOUT THIS MANUAL This M701 Zero Air Generator operation manual is comprised of multiple documents as listed below. Part No. Rev Name/Description 01671 H Operation Manual 02052 M List, Spare Parts (in Appendix A) with Sales for most recent version. 06172 C List, Recommended Spares Stocking Levels (RSSL), (in Appendix A) 06477 B L[...]

  • Page 4

    ii 01671H (DCN6051) REVISION HISTORY M701 Manual 01671 2011 April 8, Rev H, per DCN 6051 Document P/N Rev DCN Change Summary Operation Manual 01671 H 6051  Correct name in title: from “…Module” to “…Generator” 2010 November 5 , Rev G, per DCN 5875 Document P/N Rev DCN Change Summary Operation Manual 01671 G 5875  Replaced pressure[...]

  • Page 5

    01671H (DCN6051) iii SAFETY MESSAGES Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage. Please read these mess ages carefully. Each safety message is associated with a safety alert symbol, and are placed throughout this manual and inside the instrument. The symbols with me[...]

  • Page 6

    iv 01671H (DCN6051) CONSIGNES DE SÉCURITÉ Des consignes de sécurité import antes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instrumen ts. Veuillez lire attentivement ces consignes. Chaque cons igne de sécurité est représentée par un pictogramme d’alerte de sécu ri[...]

  • Page 7

    01671H (DCN6051) v TABLE OF CONTENTS TABLE OF CONTENTS .................................................................................. V LIST OF FIGURES ........................................................................................ VII LIST OF TABLES ......................................................................................[...]

  • Page 8

    vi 01671H (DCN6051) 5.11 P RESSURE R EGULATOR ............................................................................................ 5-8 5.12 P RESSURE G AUGE ................................................................................................... 5-9 5.13 H YDROCARBON S CRUBBER ( OPTION ) ..........................................[...]

  • Page 9

    01671H (DCN6051) vii LIST OF FIGURES F IGURE 3-1: D IMENSIONS ......................................................................................................................... 3-2 F IGURE 3-2: F RONT P ANEL ...................................................................................................................... 3-3 F IGURE 3-3:[...]

  • Page 10

    viii 01671H (DCN6051) This page intentionally left blank.[...]

  • Page 11

    01671H (DCN6051) 1-1 1 INTRODUCTION 1.1 Preface Teledyne API is pleased that you have pur chased the Model 701 (or M701) Zero Air System. The M701 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. The regenerative, heatless dryer[...]

  • Page 12

    INTRODUCTION Teledyne API Model 701 Zero Air Generator 1-2 01671H (DCN6051) 1.2 Using This Manual This manual has the following data structures: TABLE OF CONTENTS Outlines the contents of the manual in the or der 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 fig[...]

  • Page 13

    01671H (DCN6051) 2-1 2 SPECIFICATIONS AND WARRANTY 2.1 Specifications Table 2-1. Specifications PARAMETER SPECIFICATION Output STD 20 SLPM @ 30 psig Max delivery pressure 35 psig (Except in some specials that have restricted output) Dewpoint < 15 SLPM  15 SLPM < -20  C < -10  C SO 2 <0.5 ppb NO <0.5 ppb NO 2 <0.5 ppb O 3 [...]

  • Page 14

    SPECIFICATIONS and WARRANTY Teledyne API Model 701 Zero Air Generator 2-2 01671H (DCN6051) 2.2 Warranty WARRANTY POLICY (02024D) ( DCN 4473) Prior to shipment, Teledyne API equipment is thor oughly inspected and tested. Should equipment failure occur, Teledyne API assures it s customers that prompt serv ice and support will be available. COVERAGE A[...]

  • Page 15

    01671H (DCN6051) 3-1 3 GETTING STARTED 3.1 Unpacking CAUTION To avoid personal injury, always use two persons to lift and carry the Model 701 1. Verify that there is no shipping damage. If there are signs of damage, immediately advise the shipper, then Teledyne API. 2. Remove the M701 from its shipping carton. 3. Remove the cover and check for dama[...]

  • Page 16

    GETTING STARTED Teledyne API Model 701 Zero Air Generator 3-2 01671H (DCN6051) Figure 3-1: Dimensions[...]

  • Page 17

    Teledyne API Model M701 Zero Air Generator GETTING STARTED 01671H (DCN6051) 3-3 3.3 Front and Rear Panels Figure 3-2 and Figure 3-3 illustrate the M odel 701 front and rear panels. Figure 3-2: Front Panel Figure 3-3: Rear Panel[...]

  • Page 18

    GETTING STARTED Teledyne API Model 701 Zero Air Generator 3-4 01671H (DCN6051) 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 connec tions, which in[...]

  • Page 19

    Teledyne API Model M701 Zero Air Generator GETTING STARTED 01671H (DCN6051) 3-5 3.5 Power-Up 1. Turn on the front panel POWER SWITCH. See Figure 3-2. 2. The front panel power indicator should light. 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 measu[...]

  • Page 20

    GETTING STARTED Teledyne API Model 701 Zero Air Generator 3-6 01671H (DCN6051) This page intentionally left blank.[...]

  • Page 21

    01671H (DCN6051) 4-1 4 OPTIONAL HARDWARE AND SOFTWARE This section includes descriptions of the har dware and software options available for the M701 instrument. For assistance with orderi ng these options please contact the sales department of Teledyne API at: TOLL-FREE: 800-324-5190 TEL: +1 858-657-9800 FAX: +1 858-657-9816 E-MAIL: apisales@teled[...]

  • Page 22

    OPTIONAL HARDWARE and SOFTWARE Teledyne API Model 701 Zero Air Generator 4-2 01671H (DCN6051) CAUTION THE AIR EXITING TH E SCRUBBER IS AT 300  C (575  F). THIS HOT AIR ENTERS THE COPPER TUBING WHERE IT IS COOLED BEFORE IT ENTERS THE NO SCRUBBER. THIS COPPER TUBING AND THE CASING CAN BE VERY HOT. The catalyst is proprietary. It theoretically s[...]

  • Page 23

    Teledyne API Model M701 Zero Air Generator OPTIONAL HARDWARE and SOFTWARE 01671H (DCN6051) 4-3 4.4 Rack Mount Kits (OPT 20A, OPT 20B & OPT 21) There are several options for mounting the analyzer in standard 19” racks. The slides are three-part extensions, one mounts to t he rack, one mounts to the analyzer chassis and the middle part remains [...]

  • Page 24

    OPTIONAL HARDWARE and SOFTWARE Teledyne API Model 701 Zero Air Generator 4-4 01671H (DCN6051) This page intentionally left blank.[...]

  • Page 25

    01671H (DCN6051) 5-1 5 OPERATION 5.1 Overview Refer to Figure 5-1 , Figure 5-2 , and Figure 5-3 for the following: The M701 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 [...]

  • Page 26

    OPERATION Teledyne API Model 701 Zero Air Generator 5-2 01671H (DCN6051) When air usage is high (say 5-20 LPM), the compressor may run continuously. When air usage is low, the pressure switch tu rns the compressor off until the storage tank pressure drops to 35 psig, and then turns the compressor on again. THERE IS NO NEED TO TURN OFF TH E M701 WHE[...]

  • Page 27

    Teledyne API Model M701 Zero Air Generator OPERATION 01671H (DCN6051) 5-3 Figure 5-1: M701 Pneumatic Diagram with HC/ CO and Dew Point Sensor Options[...]

  • Page 28

    OPERATION Teledyne API Model 701 Zero Air Generator 5-4 01671H (DCN6051) Figure 5-2: M701 Pneumatic Diagram with CO and Dew Point Sensor Options[...]

  • Page 29

    Teledyne API Model M701 Zero Air Generator OPERATION 01671H (DCN6051) 5-5 Figure 5-3: Internal Chassis Layout, Plan View[...]

  • Page 30

    OPERATION Teledyne API Model 701 Zero Air Generator 5-6 01671H (DCN6051) 5.2 Compressor T he compressor is a single-cylinder oscillating piston type driven by a split capacitor AC motor. The compressor is dry; that is, ther e are no lubricants which can contaminate the compressed air. The pistons are sealed by fl exible TFE piston rings, and after [...]

  • Page 31

    Teledyne API Model M701 Zero Air Generator OPERATION 01671H (DCN6051) 5-7 5.6 Pressure Relief Valve The pressure relief valve is a safety device designed to limit the maximum pressure to which the M701 can be subjected. It is set to open at 90 psig. This can be quite loud when the valve opens and sounds like steam e scaping. This is normal operatio[...]

  • Page 32

    OPERATION Teledyne API Model 701 Zero Air Generator 5-8 01671H (DCN6051) 5.9 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. T he tank also serves as “filter capacito[...]

  • Page 33

    Teledyne API Model M701 Zero Air Generator OPERATION 01671H (DCN6051) 5-9 5.12 Pressure Gauge The front panel-mounted pressure gauge s hows 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 a little higher, say 33 psig. [...]

  • Page 34

    OPERATION Teledyne API Model 701 Zero Air Generator 5-10 01671H (DCN6051) 5.14 CO Scrubber (option) The CO scrubber catalytically oxidizes CO to CO 2 . The catalyst is proprietary and operates at room temperature; howev er, it is heated to approximately 70  C to prevent water condensation. It theoretically shoul d never need changing. However, i[...]

  • Page 35

    Teledyne API Model M701 Zero Air Generator OPERATION 01671H (DCN6051) 5-11 The M701 Control PCB is microcontroller based, and all timing is derived from the AC line. It automatically senses the line fr equency (50/60 Hz) and provides the following functions: 1. Cycles the four-way valve of the Regenerative Dryer at 2 minute intervals. 2. Cycles the[...]

  • Page 36

    OPERATION Teledyne API Model 701 Zero Air Generator 5-12 01671H (DCN6051) Figure 5-4: Control Board Layout[...]

  • Page 37

    01671H (DCN6051) 6-1 6 MAINTENANCE 6.1 Schedule NOTE 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 “ Shut Down, Storage and Transportation” in Section 3.6). Table 6-1[...]

  • Page 38

    MAINTENANCE Teledyne API Model 701 Zero Air Generator 6-2 01671H (DCN6051) 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 M701 is plugged in 6.3 Checking The Tubing 1. Under the vibration of the compressor, it is [...]

  • Page 39

    Teledyne API Model 701 Zero Air Generator MAINTENANCE 01671H (DCN6051) 6-3 6.4 Replacing The Charcoal Scrubber 1. Turn off the M701 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. R[...]

  • Page 40

    MAINTENANCE Teledyne API Model 701 Zero Air Generator 6-4 01671H (DCN6051) 6.6 Replacing The CO - CO 2 Scrubber 1. Turn off power and unplug the M701. 2. Disconnect the CO-CO 2 scrubber at the Controller. 3. Lift out the scrubber by removing the two screws under the chassis and the two pneumatic fittings. CAUTION The scrubber will be hot. 4. Allow [...]

  • Page 41

    Teledyne API Model 701 Zero Air Generator MAINTENANCE 01671H (DCN6051) 6-5 6.7 Replacing The HC Scrubber 1. Turn off power and unplug the M701 power cord. 2. Disconnect the HC scrubber pow er at the Control PCA. 3. Remove the heat shield from the HC scrubber. 4. Disconnect the pneumatic connections at the CHARCOAL SCRUBBER INLET AND AT THE REAR END[...]

  • Page 42

    MAINTENANCE Teledyne API Model 701 Zero Air Generator 6-6 01671H (DCN6051) 6.8 Servicing The Regenerative Dryer It is unlikely that the Regenerative Drye r should ever need service. Should the molecular sieve become contaminated by oil or other external contaminants, the dryer will need to be cleaned and recharged. See Figure 6-1 . 1. Turn off and [...]

  • Page 43

    Teledyne API Model 701 Zero Air Generator MAINTENANCE 01671H (DCN6051) 6-7 18. Place the upper manifold on top of the tw o columns. Be sure that the columns are really in the grooves. (Wiggle the columns sideways. You should feel that the columns are trapped in the grooves.) 19. Replace the nuts and lock-washers on t he three tie rods BUT DO NOT TI[...]

  • Page 44

    MAINTENANCE Teledyne API Model 701 Zero Air Generator 6-8 01671H (DCN6051) Figure 6-1: Regenerative Dryer[...]

  • Page 45

    Teledyne API Model 701 Zero Air Generator MAINTENANCE 01671H (DCN6051) 6-9 6.9 Changing The 4-Way Valve (in the Regenerative Dryer) 1. Remove the Regenerative Dryer from the chassis as described in 5.9 above. 2. Disconnect the two tubing connections and t he electrical connection to the 4-way valve. 3. Remove the 4-way valve bracket from the regene[...]

  • Page 46

    MAINTENANCE Teledyne API Model 701 Zero Air Generator 6-10 01671H (DCN6051) 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 t he “Air In” inle[...]

  • Page 47

    01671H (DCN6051) 7-1 7 TROUBLESHOOTING This section presents possible problems and their causes and solutions. Problem Probable Cause Corrective Action Unplugged power cord. Plug in power cord at both ends. Incorrect line voltage. Refer to Table 3-1 for the correct line voltage. Tripped power switch/circuit breaker. Untrip power switch/circuit brea[...]

  • Page 48

    TROUBLESHOOTING Teledyne API Model 701 Zero Air Generator 7-2 01671H (DCN6051) Problem Probable Cause Corrective Action Screws securing the compressor to the base plate are loose. Tighten the screws. Instrument vibrates excessively. (continued) The tubing attached to the compressor is vibrating against a component. Adjust the placement of the tubin[...]

  • Page 49

    01671H (DCN6051) 8-1 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. This section describes how static electricity occurs, why it is so dangerous[...]

  • Page 50

    A Primer on Electro-Static Discharge Teledyne API Model 701 Zero Air Generator 8-2 01671H (DCN6051) Table 8-1. Static Generation Voltages for Typi cal Activities MEA NS OF GENERATION 65-90% RH 10-25% RH Walking across nylon carpet 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 [...]

  • Page 51

    Teledyne API Model 701 Zero Air Generator A Primer on Electro-Static Discharge 01671H (DCN6051) 8-3 Potentially damaging electro-stat ic 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 [...]

  • Page 52

    A Primer on Electro-Static Discharge Teledyne API Model 701 Zero Air Generator 8-4 01671H (DCN6051) A charge can be induced onto the conductive surface and/or discharge triggered in the presence of a charged field such as a large static charge clinging to the surface of a nylon jacket of someone walking up to a workbench.  As long as my analy ze[...]

  • Page 53

    Teledyne API Model 701 Zero Air Generator A Primer on Electro-Static Discharge 01671H (DCN6051) 8-5  Simply touching a grounded piece of metal is insufficient . While this may temporarily bleed off static charges present at the time, once you stop touching the grounded metal new static charges will immediately begin to re- build. In some conditi[...]

  • Page 54

    A Primer on Electro-Static Discharge Teledyne API Model 701 Zero Air Generator 8-6 01671H (DCN6051)  Use a wrist strap terminated with an alligator clip and attach it to a bare metal portion of the instrument chassis. This will safely c onnect you to the same gr ound level to which the instrument and all of it s components are connected. 2. Paus[...]

  • Page 55

    Teledyne API Model 701 Zero Air Generator A Primer on Electro-Static Discharge 01671H (DCN6051) 8-7 2. Never carry the component or assembly wit hout placing it in an anti-ESD bag or bin. 3. Before using the bag or container allo w any surface charges on it to dissipate:  If you are at the instrument rack, hold the bag in one hand while your wri[...]

  • Page 56

    A Primer on Electro-Static Discharge Teledyne API Model 701 Zero Air Generator 8-8 01671H (DCN6051) 8.5.5 Packing Components for Return to Teledy ne API’s Customer Service Always pack electronic components and assemb lies to be sent to Teledyne API’s Customer Service in anti-ESD bins, tubes or bags. WARNING  DO NOT use pink-poly bags.  NE[...]

  • Page 57

    01671H (DCN6051) A-1 APPENDIX A - SPARE PARTS Note Use of replacement parts other than those supplied by TAPI may result in non- compliance w ith European standard EN 61010-1. Note Due to the dynamic nature of part numbers, please refer to the Website at ht tp :/ /www. te le d y ne -a pi . c om or call Customer Service at 800-324-5190for more recen[...]

  • Page 58

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  • Page 59

    SPARE PARTS LIST M701H Ref: 04825F (DCN5895) Part Numbe r Description 005960000 AKIT, EXPEND, 6LBS ACT CHARCOAL 005970000 AKIT, EXPENDABLE, 6LB PURAFIL 006900100 RETAINER PAD CHARCOAL, LARGE, 2-1/4" 066780000 ASSY, PUMP w/BRKT, M701H, 115V/60 066780100 ASSY, PUMP w/BRKT, M701H, 220-240V/50 073440000 AKIT, EXP KIT, M701H 016920000 AKIT, EXP KIT[...]

  • Page 60

    Reference 07346A (DCN5895) 1 2-5 6-10 11-20 21-30 017960000 ASSY, FAN M701/M701H 1 2 4 8 066180000 PCA, CONTROL BOARD, M701H 1 2 4 036260000 ASSY, 4-WAY VALVE, PARKER, M701 1 2 4 8 066780000 * ASSY, PUMP, W/BASE, 100-115V, GAST 1 2 FL0000044 FILTER, COALESCING, .03 MICRON(KB) 1 1 2 4 8 VA0000012 VALVE, RELIEF KB 1 2 4 VA0000014 REGULATOR 1 1 2 4 8 [...]

  • Page 61

    Reference 07344A (DCN5895) 005960000 AKIT, EXP, 6LBS ACT CHARCOAL 1 005970000 AKIT, EXP, 6LBS PURIFIL 1 006900100 RETAINER PAD CHARCOAL, LARGE, 2-1/4" 8 016920000 AKIT, EXP KIT, MOL SIEVE 1 057270000 GASKET SCRUBBER 4 FL0000016 FILTER ELEMENT, PAPER, FOR FL15 2 OR0000058 ORING, 2-228V, DRYER 4 Part Number Description QTY 01671H DCN6051 A-5[...]

  • Page 62

    LEVEL 1 SPARES KIT M701H Ref: 07345A (DCN5895) Part Numbe r Description 03626000A Valve, 4-way, regenerative scrubber 066180000 PCA, CONTROL BOARD, M701H CB0000004 Fuse, 3A, SB (HC temp control) FA0000006 Fan, cooling FL0000011 Filter, final FL0000044 Filter, water coalescing HE0000017 Heater, CO scrubber OR0000058 O-ring, 2-228V PU0000090 Kit, Pum[...]

  • Page 63

    01671H (DCN6051) B-1 APPENDIX B - Schematics[...]

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    B-2 01671H (DCN6051) This page intentionally left blank.[...]

  • Page 65

    1 1 2 2 3 3 4 4 D D C C B B A A Tit le Num ber Revi sion Si ze A Da te: 10 /1 1/2010 Sh eet of Fil e: N:P CBM GR.. 06619 -1B .Sch Doc Dr awn By: 701/701H Controller Boa rd (AC POWER) 06619 B 1 5 1 2 3 4 J6 PU MP 1 2 3 4 5 6 J1 A C IN P UT IN - 4 IN + 3 A C 2 A C 1 K1 PF24 0D25 IN - 4 IN + 3 A C 2 A C 1 K2 GA8-6B02 PT C1 +V OP TIO NAL +5V +5V +5V[...]

  • Page 66

    1 1 2 2 3 3 4 4 D D C C B B A A Tit le Num ber Revi sion Si ze A Da te: 10 /1 1/2010 Sh eet of Fil e: N:P CBM GR. . 06619 -2B .Sch Doc Dr awn By: 701/701H Controller Boa rd (DC POWER) 06619 B 2 5 T P1 + C1 6800uF 16V S ta tu sPU RE C-O UT A UX -IN 1 1 15 2 15 3 4 4 5 5 8 8 7 7 6 6 T VS1 SM DA15L CC +V +5V KBI NT K BINT A UX -IN RE C-O UT S ta tu[...]

  • Page 67

    1 1 2 2 3 3 4 4 D D C C B B A A Tit le Num ber Revi sion Si ze A Da te: 10 /1 1/2010 Sh eet of Fil e: N:P CBM GR.. 06619 -3B .Sch Doc Dr awn By: 701/701H Controller Boa rd (CPU) 06619 B 3 5 1 3 2 X1 4. 00 M Hz + C6 10 /35 1 2 3 4 5 6 Progr am Po rt J10 KBI NT S CL SDA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 JP1 HEA DE R 7X2 S CL SDA TX RX RX TX R2 2.2K[...]

  • Page 68

    1 1 2 2 3 3 4 4 D D C C B B A A Tit le Num ber Revi sion Si ze A Da te: 10 /1 1/2010 Sh eet of Fil e: N:P CBM GR. . 06619 -4B .Sch Doc Dr awn By: 701/701H Controller Boa rd (I/O) 06619 B 4 5 A0 1 A1 2 A2 3 P0 4 P1 5 P2 6 P3 7 VSS 8 P4 9 P5 10 P6 11 P7 12 I NT 13 S CL 14 SDA 15 VDD 16 U3 P CF85 74T /3 ,512 1 2 JP2 I DC-H EADER - 20-SC -20-SE LE D[...]

  • Page 69

    1 1 2 2 3 3 4 4 D D C C B B A A Tit le Num ber Revi sion Si ze A Da te: 10 /1 1/2010 Sh eet of Fil e: N:P CBM GR.. 06619 -5B .Sch Doc Dr awn By: 701/701H Controller Boa rd (SENSORS) 06619 B 5 5 R32 6.81K R31 20K 3 2 6 1 8 7 4 U6 OPA 340 UA R30 10 0K 3 2 1 4 Q1 I RLL014N BAS E A DD R: 0x90 H UMI DI TY P RESS URE HEA TE R- ON I N+ 1 H YS 2 GND 3 V[...]