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Chapter 4 Maintenance

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Figure 4-1.

Scrubber Parts List

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Summary of Contents for 1160

Page 1: ...The 220V option complies with 89 336 EEC directive for electromagnetic compatibility Model 1160 Instruction Manual Zero Air Supply Part Number 18665 11Feb2022 ...

Page 2: ...ons terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermo com aqi ...

Page 3: ...ientific has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive a...

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Page 5: ...ber Installation 2 4 CHAPTER 3 OPERATION 3 1 Front Panel Display and Controls 3 1 Pressure 3 2 Converter Temperature 3 2 Status LEDs 3 2 Converter Ready 3 2 Standby 3 2 Service Alarm 3 2 Mode Selection 3 3 Converter Temperature 3 5 Power Up Sequence 3 6 CHAPTER 4 MAINTENANCE 4 1 Spare Parts 4 1 Scrubbers 4 3 Compressor 4 4 Fan Filter 4 4 Fuse Replacement 4 4 Service Alarm Battery 4 4 Service Locat...

Page 6: ...ANCE B 1 APPENDIX C SCHEMATICS C 1 Power Supply Board C 2 Display Board C 3 Rear Connector Interface C 4 Instrument AC Power 120 VAC 50 60 Hz C 5 Instrument AC Power 220 VAC 50 Hz C 6 Instrument AC Power 240 VAC 60 Hz C 7 Instrument AC Power 100 VAC 50 60 Hz C 8 ...

Page 7: ...Flow Schematic 1 4 2 1 Model 1160 Rear Panel 2 2 2 2 Pin Out of Rear Panel Terminal Strip 2 3 2 3 Scrubber Base and Top Plates 2 5 2 4 Scrubber Assembly Components 2 6 3 1 Front Panel Display 3 1 3 2 Display Board 3 4 3 3 Power Board Component Footprint 3 5 4 1 Scrubber Parts List 4 2 ...

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Page 9: ...ix LIST OF TABLES Table Page 1 1 Pollutant Removal Method and Removal Component 1 1 3 1 Mode Selections 3 3 4 1 Recommended Spare Parts 4 1 ...

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Page 11: ... Adsorption Charcoal scrubber CO Oxidation to CO2 Catalytic Converter Hydrocarbons VOCs Oxidation Catalytic Converter Adsorption Charcoal scrubber BASIC PLATFORM Although the Model 1160 can purge all the pollutants shown in Table 1 1 many applications do not require the air system to eliminate the full range Therefore the Model 1160 is designed as a basic platform to which a number of options can ...

Page 12: ...al The following scrubbing materials are available a Charcoal Removes ozone O3 sulfur dioxide SO2 and non methane hydrocarbons b Purafil Removes NOx c Drierite Removes water vapor It should be noted that this material is not normally used without a regenerative dryer Used alone it will effectively reduce the amount of water vapor but it may quickly become saturated and increase the frequency of se...

Page 13: ...ative dryer can also be used to remove CO2 For applications using externally supplied air the regenerative dryer requires a minimum inlet pressure of 60 psi and an inlet flow rate of at least 30 LPM The maximum inlet pressure is 90 psi and the maximum flow rate is about 90 LPM An outlet dew point of 30 C or greater may be achieved with the use of Drierite desiccant The by pass consumes about 25 to...

Page 14: ...membrane dryer or heatless regenerative dryer further dries the air The dry air is then routed to the scrubbers which remove a variety of pollutants It then goes to the converter for removal of CO and VOCs before passing through a loop to cool the air to room temperature It then goes to the pressure regulator and out the rear panel to be used for instrument zero air or to provide clean diluent air...

Page 15: ...Ambient Operation temperature Range 15 35 C Storage Temperature Range 0 40 C Input Power 1300 VA Absolute maximum value Input voltage frequency dependent Input Voltages Frequency 100 VAC 60 Hz Japan 120 VAC 60 Hz North South America 240 VAC 60 Hz North America 220 VAC 50 Hz Europe Asia 240 VAC 50 Hz Asia Africa Oceania United Kingdom Ambient Environmental Conditions Indoor Use Std Atmospheric Cond...

Page 16: ...urer The test results are based on data collected using Thermo Scientific s Model 48C CO Analyzer and a Certified instrument span gas 3990 ppm CO balance Air for Carbon Monoxide Thermo Scientific s Model 51C Total Hydrocarbon Analyzer and a Certified instrument span gas 59 1 ppm Methane balance Air for Hydrocarbons ...

Page 17: ...y grasping the bottom in the front and the other by grasping the bottom in the rear UNPACKING The Thermo Scientific Model 1160 Zero Air Supply is shipped in one container If upon receipt there is obvious damage to the shipping container notify the carrier immediately and hold for his inspection The carrier and not Thermo Fisher Scientific is responsible for any damage done during shipment To unpac...

Page 18: ...ce of certain components in the zero air supply 2 Using 1 4 Teflon or pre cleaned metal tubing connect the outlet of the Model 1160 to the device requiring zero air See Figure 2 1 3 Remove protective caps that cover the drain ports in the rear panel If desired connect a drain line to these ports using 1 8 compression fittings or soft tubing such as silicone rubber 4 Fill and re install the interna...

Page 19: ... close connecting pin 3 to pin 4 The service alarm on pins 1 and 2 is intended as reminder to change the adsorbent or scrubber canisters on a routine basis The alarm triggered on the basis total elapsed run time since last reset As described in Chapter 3 the service alarm timing may be adjusted or the alarm can be turned off by selecting a jumper on the display board located on the inside surface ...

Page 20: ...and outer cylinders of the canister to approximately of the top with the proper packing Do not over fill or the cover may not seat properly 4 Replace the top plate insuring that the O ring is properly seated Note that there are two O rings in the base plate and one in the scrubber cap as shown in Figure 2 3 The O rings can be identified by comparison with the full size or 1 1 drawing included in F...

Page 21: ...r more do not contain packing Failure to properly install the canisters will introduce leaks or ambient air into the system Note If Drierite is used as a desiccant it should be in the front canister so that it can be monitored through the view port in the front panel When this desiccant turns pink it should be changed O Rings ...

Page 22: ...Chapter 2 Installation 2 6 Figure 2 4 Scrubber Assembly Component P N 104558 00 P N 104558 00 P N 104557 00 ...

Page 23: ...pter describes the procedures necessary for operating the Model 1160 FRONT PANEL DISPLAY and CONTROLS The front panel consists of several displays for setting and monitoring the Model 1160 see Figure 3 1 Figure 3 1 Front Panel Display ...

Page 24: ...s shut down This mode minimizes wear on the compressor and conserves the scrubbing desiccants while eliminating the normal warm up period This mode can only be initiated via a grounding signal sent to the connector on the rear panel a from an external data system computer or PLC Service Alarm When the service alarm activates it indicates that a preset service interval has elapsed and that the adso...

Page 25: ...itions on the display board Table 3 1 below details the jumper position and function of that position Table 3 1 Mode Selections Jumper position Function Pump ON Pump is placed in continuous run mode AUTO Pump is activated only when the catalytic reactor temperature is above 90 of set point Pressure Units PSI Front panel displays pressure in units of Pounds per Square Inch PSI KPA Front panel displ...

Page 26: ...Chapter 3 Operation 3 4 Figure 3 2 Display Board Selectable Service Interval Jumpers Service Reset Button Service Alarm Backup Battery Mode selection jumpers ...

Page 27: ...a a jumper located on the power board which is shown in figure 3 3 The standard unit is shipped form the factory with the reactor temperature set at 450C If carbon monoxide or hydrocarbons appear to be breaking through the reactor at high flow rates the set point may be increased However the operator should be aware that increased operating temperature may result in decreased heater lifetime and i...

Page 28: ...should start and the digital meter on the front panel should display the output pressure Adjust the pressure as required most applications require between 25 to 50 psi The correct pressure setting depends upon the instrument being supplied For example to supply zero air to a Thermo Scientific Model 55 the pressure on the Model 1160 should be set at 45 psi To supply air to the Thermo Scientific Mod...

Page 29: ...Charcoal Replace on routine basis 7075 Purafil Replace on routine basis 86P714 Converter 16103 Display Board 16101 Power Board 18516 Status Control Board 86P745 Pressure Regulator Relieving type 0 100 psi output range 18638 Compressor High Output 0 20 lpm 120 VAC 60 Hz 18651 Compressor High Output 0 20 lpm 220 240 VAC 50 Hz 4300 Fan 4568 Fan Guard 4070 Fan Filter Element Clean or replace on routin...

Page 30: ...Chapter 4 Maintenance 4 2 Figure 4 1 Scrubber Parts List ...

Page 31: ...t is suggested that charcoal should be changed whenever one of the other scrubbers is changed or at least once every six months As noted above the recommended service times are only approximate More frequent replacement of one or more of the desiccant materials is necessary if a downstream instrument shows signs of contaminant breakthrough In all cases scrubber lifetime is dependent on the instrum...

Page 32: ...ngs for your Model 1160 SERVICE ALARM BATTERY The backup battery shown in Figure 3 2 provides an alternative power source to the service alarm timer and prevents a reset from occurring when the AC power is cycled In normal operation the battery should last between two and three years To remove the battery gently lift the retaining clip outward until the battery can be removed from its holder Repla...

Page 33: ...nal assistance service is available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information or visit us on the web at www thermo com aqi 1 866 282 0430 Toll Free 1 508 520 0430 International ...

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Page 35: ...ial Authorization RMA which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replaceme...

Page 36: ... Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS ...

Page 37: ...B 1 APPENDIX B PUMP COMPRESSOR MAINTENANCE The information in this appendix was obtained from Gardner Denver Thomas ...

Page 38: ...rx T 27 attachment for torque wrench for retainer screws Torx T 25 attachment for torque wrench for head screws 5 32 Allen wrench for torque wrench eccentric screw Flat Screwdriver Clean Cloths WARNING Unplug the compressor before beginning disassembly This kit includes the following parts 625175 Head Screw 4 625180 OR 625776 Screw Piston Cup 1 each 670031 Cylinder Sleeve 1 625591 Flapper Screw 2 ...

Page 39: ...aution Place capacitor off to side leaving it connected to lead wires STEP 3 Carefully remove the valve plate 4 from the bottom of the head or cylinder sleeve Note orientation with respect to the tab on valve plate for reassembly STEP 4 Remove the head gasket O ring 3 and discard Turn the valve plate over Remove the valve plate O ring 5 and discard Figure 1 Tab on valve plate indicates exhaust sid...

Page 40: ...he exhaust valve flapper 1 restraint 2 and valve keeper 3 from the top of the valve plate and discard them Clean the top of the plate with a clean soft cloth Install the new exhaust valve flapper restraint and keeper The valve keeper should be placed on top of the flapper so that the word UP is visible See Fig 3 NOTE Torque flapper screw to 18 inch pounds STEP 8 Install the new head gasket seating...

Page 41: ...oth 2 This retainer screw may be one of two different sizes depending on when it was manufactured Both of the different screw sizes are supplied in this kit Compare the screw and piston cup you removed with the 2 screws and piston cups from the kit to determine which one to use in this repair Discard unneed parts STEP 12 Carefully place new sleeve 1 over connecting rod top Place new cup 4 in cente...

Page 42: ...ccess hole in the housing and tighten set screw to 125 in lbs STEP 15 Align the flat on the fan with the flat on the motor shaft and slide the fan back onto the motor shaft making sure you position the fan clip in the same orientation as it was before you removed it Incorrect orientation of the fan will not provide adequate cooling of the compressor Hold the sleeve down against the housing with on...

Page 43: ...ed in groove REASSEMBLY STEP 1 With the sleeves firmly seated on the housing replace the valve plates in same manner as they were See Fig 8 Make sure the top edge of the sleeve locates in the O ring groove in the bottom of the valve plate Figure 8 B 7 ...

Page 44: ...e fan DO NOT CONNECT THE UNIT TO A POWER SOURCE review theassembly procedurefor possible error Numbers indicate tightening sequence Head Assembly 3 1 4 2 STEP 2 Place head on the valve plates making sure that the same letter orientation is as was before disassembly Torque the head screws to 55 inch lbs in a crisscross pattern STEP 3 Remove the filter cap from the filter body by prying it with a fl...

Page 45: ...d circuit board Schematic Diagram Drawing No Part Number Page Power Supply Board 86P901 16101 C 2 Display Board 86P902 16104 C 3 Rear Connector Interface 86P907 18516 C 4 Instrument AC Power 120 VAC 50 60 Hz 86P903 NA C 5 Instrument AC Power 220 VAC 50 Hz 86P903 NA C 6 Instrument AC Power 240 VAC 60 Hz 86P903 NA C 7 Instrument AC Power 100 VAC 50 60 Hz 86P903 NA C 8 ...

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