F-DBS ZERO AIR User Manual

Version 3

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

Manual updates

Version

Date

1 10/03/11

2 20/03/11

3 10/04/11

ZEROAIR User's Manual

- Fax: +33 1 69 31 23 01 - email: info@f-

dbs.com

Site web: www.f-dbs.com

1

ZEROAIR

User's Manual

Description

First draft

Update on figure dimensions and installations

Update reference to INLET and OUTLET

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

INDEX

Introduction ................................

................................

Product Description

................................

Safety instruction

................................

Engineered System

................................

Air Supply ................................

................................

Dimensions and installation

................................

Dimensions ................................

................................

Installation ................................

................................

Overview and Connections

................................

User interface ................................

................................

FID Models ................................

................................

Maintenance ................................

................................

Quick Guide ................................

................................

First start-up ................................

................................

Turning off the machine

................................

Packaging ................................

................................

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2

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Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

1 Introduction

This manual is intended to provide technical guidance on the installation, operation and maintenance of zero

air generator. Do not attempt to in

stall or operate this product without having fully read and understood the

information presented. If you have questions, please contact your local supplier.

WARNING: Any misuse of this product will avoid the manufacturer ’s warranty

2 Product

Description

This series of Zero Air Generators are systems which replace the use of inconvenient high pressure gas

cylinders as a source of hydrocarbon

managing them and reduces the ris

k of possible injury to workers

•

Zero Air Generator may be used as a source of fuel air for Flame Ionization Detectors (FID’s) or as a

zero reference for any instrument which measures hydrocarbon concentration.

•

The zero air generator will remove HC polluta

•

This system is engineered to be easy to install, need a low and requires only minimal annual

maintenance.

3 Safety instruction

Do not use the unit until the safety information and instructions in this guide have been read and

Using equipment in a manner not specified in this document may compromise the protection provided by the

generator and could lead to an unplanned release of pressure, which may cause serious personal injury or

damage.

• Read all instructions.

• C

ontact your supplier if you detect a problem that you cannot solve with this manual.

•

This equipment is for internal use only. Do not use outdoors.

•

The operator must employ safe working practices and rules when operating the Zero Air Generator.

• The owner is

responsible for maintaining the unit in a safe operating condition.

•

Always use approved parts when performing maintenance and repairs. Make sure that replacement

parts meet or exceed the pressure requirements.

•

Only authorized, trained and competent indi

•

Completely depressurize the generator prior to performing any mechanical work, including changing

the filters.

•

Do not open the generator while the machine is operating.

•

Care must be taken as burns can occur from

•

Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged

until it has been examined by a qualified serviceman.

•

Let equipment cool completely before to move or close in a box

• To reduce the risk of fir

e, do not operate equipment in the vicinity of open containers of flammable

liquids.

NOTE : It is no possible to anticipate every possible circumstance that may constitute a potential danger. The

warnings in the manual cover potential dangers best known,

SAVE THESE INSTRUCTIONS

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3

-

free air. Eliminate gas cylinders reduces annual operating costs of

nts to less than 0.05 ppm.

viduals must perform maintenance and repair.

touching hot parts.

but by definition can not be all

understood.

-inclusive.

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

4

Engineered System

Basic diagram (Figure 1)

The system consist in 3 stage of filtration :

Fisrt Stage

: high efficiency coalescing prefiltration, it removes liquids and particula

incoming air supply, to 5 micron.

These filters are equipped with float drains which automatically open to empty any liquids from inside the

filter housing. The drains are connected to 1/4" tubing which discharges to atmosphere

Second Stage

: The catalyst module is a stainless steel vessel filled with catalyst and assembled with a

cartridge heater controlled by temperature sensor and operates the catalyst bed at the required temperature

for optimal oxidation. During operation, hydrocarb

Third Stage : High-

grade filter is used to remove 99.99% of particulates with size greater than 0.5 microns.

5 Air Supply

The Zero Air Generator requires a source of clean, dry compressed air (3 to 8 Ba

air should be as close to instrument quality as possible and supplied at a flow rate and pressure above those

required at the point of use.

Air supplied to the Generator must be between 35°C (95°F) and 1°C (34°F) at dewpoint <

temperatures higher or lower or to much wet than this may cause damage not covered by warranty.

The air should be relatively free of compressor oil, hydrocarbons, and particulate matter max 100ppm.

Contamination of the catalyst bed may occ

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4

ons are oxidized into carbon dioxide and water vapor.

r) for optimal operation. The

ur if it is exposed to certain compounds.

te matter, from the

-20°C. Air at

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

6

Dimensions and installation

6.1 Dimensions

A = 34cm (13”)

B = 20cm (7.9”)

C = 43cm (16,9”)

6.2 Installation

Figure 2

A > 15cm (6”)

In order to ensure safe operation of the unit, the following steps must be taken

installation:

1.

At least 6” (150 mm) clearance at the back for proper fan operation.

2.

Adequate support for the weight (>10 kg.).

3.

Access at the rear for making the pneumatic and electrical connections.

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prior to

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

6.3

Overview and Connections

All connections,

electric and pneumatic, are made at the back panel. Refer to follow Figure 3

Front view (Figure 3)

Description

1 Status leds

2 START/STOP Button

3 AIR outlet

4 Compress AIR inlet

5 WATER DRAIN purge

6 Cooling fan air (intake)

7 RS485 (optional)

8

Power Switch and power socket

Make the following pneumatic connections:

•

AIR INLET (1/8” female pipe thread)

•

AIR OUTLET (1/8” female pipe thread)

Keep this line as short as possible to minimize pressure drops

• WATER

DRAIN Connect a 6mm(1/4”) diameter tubing to the water out fitting to avoid the occasional

spurts of water on the instrument under. Connect the other end of the tubing to a drain or, alternatively, the

water can be collected in a tray or bucket and disper

Make the following pneumatic connections

•

POWER. Connect the power cord to the proper power source.

•

COMMUNICATION : connect the communication cable to the control unit (if need)

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Back view (Figure 4)

sed by normal evaporation.

-4.

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

7 User interface

Figure 6

The front panel has th

ree LEDs : GREEN (1), YELLOW (2), RED(3) and a one button (4). Pressing

START/STOP button (1) you can turn on or off / warming oven catalyst. The following table show the link

between led's state and unit's state.

Status

Green Led(1)

STOP

COOLING DOWN

FLASHING

WARMING UP

READY

ALARM

CATALYST EXAUSTED

8

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Yellow Led(2)

ON OFF

OFF

ON FLASHING

ON ON

X X

Red Led

(3)

OFF

FLASHING

ON

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

9 FID Models

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The FID Models are without the top cover and it can

be put under the H2 generator of the same

line. Once the special cable is connected between

both the units the control of ZEROAIR module is

transferred to the generator H2. The operator can

control ZEROAIR unit by the H2 user interface.

product

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

10 Maintenance

All maintenance procedures should be p

Prior to servicing Zero Air Generator, turn off the compressed air and power supplies to the generator, and

ensure that the system is depressurized.

To ensure consistent product performance and reliabi

filter cartridges.

The primary maintenance tasks required are :

Operation

Changing the high efficiency coalescing

prefilter cartridges

Changing the High-grade filter

cartridges

Replacing the catalyst oven

11 Quick Guide

11.1 First start-up

Figure 7

List of the

operations to be performed for first start



Connect the hose to the AIR inlet fitting (3).



Connect the hose to the AIR outlet fitting (2)



Connect the voltage wire to the power socket (4).



Turn on the power switch (5).



Start the internal oven heating pre



Wait until the yellow LED will be solid(8)

11.2

Turning off the machine

List of the operations to be performed before turning off the back power switch



Stop the internal oven heating pressing START/STOP button(6).

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9

erformed by suitable personnel using reasonable care.

lity use only genuine Balston replacement parts and

Interval

KIT parts ordering code

Every year

SP.ZA.FILTER

Every year

SP.H2.WFILT.M

When the Red Led is solid on

SP.ZA.SKIT1 for 1,5 L/in

SP.ZA.SKIT3 for 3,5 L/in

SP.ZA.SKIT6 for 6,0 L/in

-up

ssing START/STOP button(1).

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

 Turn off the

power switch (5).

11.3 Packaging

List of the operations to be performed before packing the machine to return it for maintenance service:



Stop the internal oven heating pressing START/STOP button(1).



Wait until Green led will be solid(7)

 Turn off the power switc

h (5).



Disconnect the power cable from the voltage socket (4)



Disconnect the AIR's hose from the feed fitting (2).



Place the generator in its special packaging.

The generator contains Hot elements. Ensure that it is fully cooled prior to shipment or

servicing.

Models

Z.

-

1500

Air outlet

Flow rate (max)

OUTLET pressure (min)

OUTLET pressure (max)

Total hydrocarbon content

Startup time

Air inlet

Max inlet hydrocarbon content

Min Supply Pressure

Max Supply Pressure

Dewpoint

Min Temperature

Max Temperature

Communication

RS485

Option

General data

Connection type

IC320

Supply voltage 90-

240Vac

50/60Hz

Installation Power (max)

Fuse Rating (230V)

(110V)

2A(5x20mm)

Dimensions

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Z.

-

1500

ZA.FID.1500

ZA.3000

ZA.FID.3000

1,5 l/min 3,0 l/min

Pressure INLET –

0.5 Bar (8 psi) at maximum flow

6.5 Bar(94 psi)

< 0.05ppm

40 min 45 min 45 min

100ppm

3 Bar (43psi)

10 Bar (145 psi)

< -20°C

1°C (34°F)

35°C(95°F)

X Option X

-C13 4 pole connector

IC320-C13 4 pole

connector

24VDC

± 5%

90-240Vac

50/60Hz

24VDC

± 5%

240W (280VA)

Internal 2A

(5x20mm)

Internal

43x34x20(H) cm

ZA.6000

ZA.FID.6000

6,0 l/min

50 min 50 min

Option X

IC320-C13 4 pole

connector

90-240Vac

50/60Hz

24VDC

± 5%

2A

(5x20mm)

internal

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

Net weight(water tank empty)

Connections

Outlet port

Inlet port

Water purge

Ambient data

Temperature

Humidity (max, non condensing)

Noise

IP rating

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8Kg

1/8" Female

6mm(1/4) push fitting

5-35°C (41-95°F)

80% at 25°C (77°F)

<25dB(A)

IP20

9Kg

Version 2

ZEROAIR User's Manual

F-DBS SAS

, La Maison des Services, Av des 2 Lacs, Courtabœuf 7, 91971 VILLEJUST

Tél: +33 1 64 86 25 40

NOTE :

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dbs.com

Site web: www.f-dbs.com

12