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24 

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.  Depress POWER switch, so that air will 
drain from ballast tank and compressor will start when input pressure falls 
to 60-psig or less. 

 

(1)  Input  pressure  is  less  than  60-psig  and  compressor  will  not  start.  

Fuse  is  okay  since  PUMP  switch  lights.    Problem  lies  with  the 
pressure switch, the solid state relay, or the compressor. 

 

NOTE: 

POWER  IS  ALWAYS  PRESENT  AT  TERMINAL  #1  OF  AC 
RELAY  EVEN  WHEN  PUMP  SWITCH  IS  OFF.    TO  AVOID 
SHOCK,  EXERCISE  CARE  WHEN  WORKING  IN  THE  AREA 
OR  WHEN  CHANGING  THE  RELAY.    FOR  SAFETY, 
DISCONNECT POWER TO UNIT. 

 

(2)  Check  voltage  between  terminal  #4  on  solid  state  relay  and  neutral 

on terminal strip TS-1.  Voltage not present indicates problem is with 
pressure  switch.    Confirm  by  removing  pressure  switch  cover  and 
shunting between two outside terminals.  Voltage should now appear 
at terminal #4 on solid state relay and compressor should start.  If so, 
replace or reset pressure switch as in Section 14.0. 

 

(3)  Voltage is present at terminal #4 on solid state relay but compressor 

does  not  start.    Jump  between  terminals  #1  and  #2  on  solid  state 
relay.  If compressor starts, relay is defective and must be replaced. 

 

(4)  Compressor  does  not  start  after  jumping  between  terminals  #1  and 

#2 on solid state relay.  Problem lies with compressor assembly. 

 
13.3 

THE  COMPRESSOR  HAS  BEEN  IN  OPERATION  BUT  HAS  STOPPED 
SUDDENLY.    The  unit  passes  all  tests  as  in  Section  13.2  (a)  (1)  through  (4).  
Problem must lie with cooling fan or compressor itself. 

 

(a)  Place  hand  under  silencer  housing  and  feel  for  exhaust  air  from  cooling 

fan when PUMP switch is on.  If  this exhaust air is not felt, remove cover 
from silencer housing and observe fan rotation.  If  the fan is not running, 
replace fan. 

Summary of Contents for 737 Series

Page 1: ...ii 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: ...LE 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 SELECT...

Page 3: ... 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 MOI...

Page 4: ...v 20 737 10 ROTAMETER FLOW NOMOGRAPH 62 ...

Page 5: ...ons 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 fili...

Page 6: ...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...

Page 7: ...pressor 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 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 muf...

Page 8: ...y restriction which would produce back pressure at this point 2 3 The PUMP bulkhead fitting Figure 1 58 is a standard 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 inch swage type connectors NOTE Particulate filters are neither requir...

Page 9: ...nit 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 h...

Page 10: ...bserved 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...

Page 11: ...7 3 16 Follow the procedures as outlined in Section 3 7 through Section 3 13 ...

Page 12: ...If not check for leaks at all connections with soap solution and tighten all loose connections until the rotameter ball does drop to zero It is imperative that all leaks are detected and remedied before putting the system into full operation 4 4 To determine the proper output pressure from the pure air generator ascertaining the greatest pressure required by any or all of the instruments is necess...

Page 13: ...is instance the pure air generator is operating in a back pressure mode placing the rotameter under pressure and no longer allowing the rotameter to be direct reading 4 10 The pressure under which the rotameter is operating is determined by the operator when setting the output pressure with the OUTPUT PRESSURE REGULATOR Figure 4 5 This pressure setting will greatly influence the relationship betwe...

Page 14: ...th total hydrocarbon analyzers gas chromatographs flame photometric detectors etc all require incorporation of mixer receivers Figure 7 49 in the pure air generator system for homogenization of the air mixture before use by the above mentioned detectors NDIR chemiluminescent photoionization and electrochemical sensors are unaffected by slight variations in oxygen concentration and therefore do not...

Page 15: ...olumn systems produces a steady flow of purified air 5 4 During the interval that pressurized unclean air is being separated in one column a portion of the clean air passes through the purge valve and backflushes the alternate column of impurities This purge valve Figures 5 and 6 19 has been set at the factory for optimum flow and MUST NOT BE ALTERED 5 5 The backflush flow of air with impurities e...

Page 16: ... 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 See Section 3 15 ...

Page 17: ...eed 6 3 Because the ballast tank is so critical to the operation of the system care must be taken to ensure there will be no decrease in its volume Volume loss occurs only when water from the input compressed air is permitted to collect in the tank 6 4 AADCO Instruments Inc supplies an internally coated rust proof ballast tank with each system which is equipped with a manual toggle valve Figures 1...

Page 18: ...g from the cabinet See Section 1 4 7 4 Hot air is removed from the cabinet by a high volume fan Figure 8 45 mounted on a vertical duct within the compressor cabinet Failure of the fan will cause the compressor to stop operating even though power is applied because of increased temperature within the compressor chamber A thermal switch located within the compressor motor performs this operation Thi...

Page 19: ...n turn supplies power to the compressor through the AUX POWER outlet Figure 1 8 5 Any low pressure condition 60 psig or less within the ballast tank produces a closed switch condition at the pressure switch This in turn causes power to be supplied to the compressor via the solid state relay Figures 5 6 and 11 21 and the AUX POWER outlet 8 6 At 80 psig the pressure switch opens removing power from ...

Page 20: ...T PRESSURE gauge Figure 4 3 8 12 At 80 psig the pressure within the ballast tank causes the pressure switch to open removing power from the coil of the solid state relay which in turn removes power from the compressor and the compressor relief valve 8 13 When power is removed from the compressor the compressor pressure relief valve vents the connecting tubing to atmospheric pressure and causes the...

Page 21: ...as become the purification reactor of choice when high sensitivity FID is required It has also been found to decrease the noise level of the flame photometric detector when used in conjunction in a gas chromatography mode Use of this purification reactor will eliminate both the oxygen and air cylinders when operating this detector for that application 9 4 It should be noted that output flows less ...

Page 22: ...12 and 13 This reactor is mandatory in those situations where carbon dioxide is actually being measured e g nondispersive infrared where all hydrocarbons and carbon monoxide are oxidized to carbon dioxide before measurement the moving wire liquid chromatograph whereby all carbon dioxide is converted to methane and measured with flame ionization detection and those TOC systems employing the techniq...

Page 23: ...rotameter reading of about 1 4 scale set with the OUTPUT FLOW ADJUST Figure 4 13 and about 20 psig output pressure set with the OUTPUT PRESSURE REGULATOR Figure 4 5 should be adequate 10 4 The methane reactor will accommodate hydrocarbons methane and carbon monoxide concentrations in air to 500 ppm Most ambient levels are below 5 ppm The life span of the catalyst is almost indefinite though rapidl...

Page 24: ...these free standing units The Models 153 and 154 are also ideal for destroying the ethylene used as excitation gas for chemiluminescent ozone analyzers rather than venting the ethylene within the monitoring vehicle 10 8 The temperature of the methane reactor is monitored by the panel mounted pyrometer Figure 4 7 Confirmation that the unit is operating at a controlled temperature is made by observi...

Page 25: ...n 0 2 ppm methane methane reactors are required These accessory units mount within the cabinets of all models and completely remove all hydrocarbons carbon monoxide and methane by converting these compounds to carbon dioxide and water They are low temperature catalytic oxidizers that when properly installed have effluent temperatures no greater than 40 C See Section 10 0 for details 11 5 Output pr...

Page 26: ...ar 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 11 9 The operator must realize that once other equipment is connected to the pure air generator and output flow is controlled at the other equipment the rotameter will then be pressurized and will indicate less flow than is actua...

Page 27: ... compressor operates continuously The filters in question are the two inlet filters on the compressor Figure 8 44 12 4 METHANE REACTOR A one or two minute observation of the METHANE HEAT lamp Figure 4 4 should reveal cycling of the lamp This gives positive indication of heat control to the methane reactor A glance at the pyrometer will also reveal that the unit is at temperature 290 C 10 C If eith...

Page 28: ... and neutral on terminal strip TS 1 Voltage not present indicates problem is with pressure switch Confirm by removing pressure switch cover and shunting between two outside terminals Voltage should now appear at terminal 4 on solid state relay and compressor should start If so replace or reset pressure switch as in Section 14 0 3 Voltage is present at terminal 4 on solid state relay but compressor...

Page 29: ... AS IN SECTION 13 2 THE PUMP SWITCH LAMP DOES NOT LIGHT Depress POWER switch confirming that power is present because if power is present POWER switch lamp should light as well as the METHANE HEAT lamp and the cooling fan should operate If not circuit breaker is out and there is no power to unit Restore breaker If breaker okay check power cord connections a Check PUMP fuse PUMP fuse blown REMOVE P...

Page 30: ...switch off and disconnect the metal tubing Figure 2 53 at the check valve Figures 1 2 and 9 24 connect a short piece of plastic tubing to the check valve and immerse the free end in a cup of water If air bubbles are present replace the check valve No air should be released from the tank 2 To determine if there is a short in the compressor REMOVE THE POWER CORD FROM THE WALL OUTLET and disconnect t...

Page 31: ...ressure is below 100 psig If there is the valve should be adjusted to eliminate the leakage Use a _ inch wrench to loosen the locknut at the end of the pop off valve and a inch wrench to turn the adjustment nut clockwise to increase the pop off pressure setting Once the air leakage has been stopped tighten the _ inch locknut while holding the inch adjustment nut securely to avoid changing its sett...

Page 32: ...m permissible output pressure as set with the OUTPUT PRESSURE REGULATOR is 50 psig in order to maintain the 10 psig differential If either of the above pressure settings do not conform to this restriction make the necessary pressure adjustments beginning with the low pressure setting of the pressure switch See Section 14 0 13 11 It should be noted that during some portion of each one minute cycle ...

Page 33: ...ly operational or not operational a Listen for the click of the solenoid valves during one full one minute cycle of the timer Each should be energized for alternate halves of each cycle If both solenoids click the problem is an obstruction in one or the other solenoid valves on the purification reactor If the purification reactor is older than one year replacing both of the solenoid valves is best...

Page 34: ...onnect leading to the solenoid valve It should be about 430 ohms if 120V and 1850 ohms if 220V If other than this the coil is either open or shorted and the solenoid valve should be replaced c Check the AC voltage going to and from the RFI filter If voltage is going in but not coming out replace the RFI filter If both voltages are present then the timer is defective Replace the timer ...

Page 35: ... solenoid valve is that valve which does not evidence purge flow since its opposite number is leaking when non energized Replace solenoid valves 13 18 If the purge flow is constant never having no flow conditions as described in Section 13 10 or appears to be extremely unequal from one side of the purification reactor to the other during normal operation with the POWER switch on the cause is a def...

Page 36: ...32 defective check valve ...

Page 37: ...of a proper rotameter and instructions for resetting Improper purge flows will cause the production of air which will not meet specifications 13 22 THE METHANE REACTOR 13 23 When the POWER switch is depressed power is applied to the methane reactor Figure 5 7 and 7a 20 The METHANE HEAT lamp Figures 4 4 should light and within a few minutes there should be an upscale deflection of the pyrometer Fig...

Page 38: ...howing continuity through the temperature controller If resistance if infinite replace the controller c Measure resistance between red and white leads Resistance should be about 50 ohms for 120V or 190 ohms for 220V operation If resistance is zero or infinite replace heater If infinite resistance the heater is open and will not heat nor blow the fuse In addition the METHANE HEAT lamp will remain o...

Page 39: ...35 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: ...ts off This should be about 80 psig If not at 80 psig but at some lower pressure rotate the larger knob clockwise so that the black ring on the knob moves to a higher pressure setting as observed on the pressure scale of the switch calibration marks 0 260 psig and vice versa if too high 14 6 Depress the POWER on switch so that air is bled from the ballast tank by the system and the input pressure ...

Page 41: ...ESSARY THAT THE PRESSURE IN THE BALLAST TANK DECREASE AND THE COMPRESSOR CUT ON AGAIN BEFORE THE NEXT OFF PRESSURE READING WILL BE RELEVANT SIMPLY ALTERING THE HIGH PRESSURE SETTING AT ONE END OF THE PRESSURE RANGE OR THE OTHER WHILE AT THAT PRESSURE IS IMPRACTICABLE 14 9 It is possible to make fairly close pressure settings for both the 60 psig and 80 psig settings by following the directions abo...

Page 42: ...erator cabinet which hold opposite corners of the purification reactor e Disconnect the inch tubing leading to the DUMP connection on the rear wall of the generator unit f It may be necessary to remove the mixer receivers if present to gain access to the connection on the purification reactor g Lift the defective purification reactor from the generator unit h To install new purification reactor re...

Page 43: ...OWER or PUMP fuse back and remove the black lead quick connect from the fuseholder c Use a 9 16 inch wrench to loosen the nut behind the front panel which holds the switch in place d Unscrew the black switch bezel which encircles the red cap while holding the switch with other hand The switch is now free to be removed e Before installing the new switch be certain to transfer the nut and washer in ...

Page 44: ...he air cylinder will supply air to the instrument until the generator is once again producing pure air 16 4 In operation the Auto Pure Air Manifold is connected to the PURE AIR outlet fitting on the rear of the pure air generator by means of the swage type tube end reducing fitting Cylinder air is connected to the manifold inlet fitting isolated by and at the inlet to the check valve Final pure ai...

Page 45: ...e 11 57 and the compressor with its ballast tank is connected to the PUMP fitting Figure 11 58 The house air is admitted to the pure air generator and its pressure appears on the INPUT PRESSURE gauge Figure 4 3 17 4 Depress the POWER switch Figure 4 2 and permit the generator to operate for several minutes During the interval the operator should note that the input pressure does NOT fall below 80 ...

Page 46: ...pare for above 2 set 50 20166 Filter Generator In Line 20166 1 Filter Element spare for above 40 20034 Filter RFI 9 20010 Fuse Kit Power and Pump 4 20156 Lamp Methane Heat Indicator 1 2 20150 1 Lamp Power Pump Switch 20150 2 Lens Cap Power Pump Swtich 20 737 40 Methane Reactor complete 20155 5 Methane Reactor Cartridge Heater 300W specify voltage 20155 Methane Reactor Heater Harness specify voltag...

Page 47: ...mpressor Support Set 4 1 2 20150 Switch Power Pump Pre wired 20149 2 Thermocouple Pre wired 41 20153 Timer Specify generator output 23 20047 Valve Compressor Pressure Relief 48 20048 Valve Compressor Pop off 24 20046 Valve Check Ballast Tank Mount Elbow 13 20064 Valve Output Flow Control 20031 Valve Solenoid purification reactor inlet 20184 Valve Check 1 8 inch female pipe end purification reactor...

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Page 71: ...onsidered warranty service and is performed free of charge The expense of warranty shipping charges to our factory will be the customer s responsibility 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 performed after the one year warranty period will be char...

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