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MAINTENANCE MANUAL
P.O. Box 2105, 8 Executive Drive, Toms River, N.J. 08754
OPERATION AND
Phone: (732) 244-0010 / (800) 337-3762
Fax: (732) 244-8140
Form #240
Rev 11/98
Table of Contents Page #
1. Introduction………………………………………………………………………….. 2
2. Description of Components………………………………………………………. 3
2.1 Perma Pure Dryer
2.2 Ultraviolet Lamp
2.3 Activated Carbon/Alumina Mixture
2.4 Carbon Monoxide Catalyst
2.5 1µ Particulate Filter
3. Start-Up Procedure…………………………………………………………………. 4
4. Maintenance
4.1 Activated Carbon/Alumina Replacement …………………………….………5
4.2 Final Filter Replacement ……………………………………………………… 6
4.3 Fuse Replacement ………………………………………………………….…. 6
5. Spare Parts…………………………………………………...……………………… 8
6. Specifications…………………………...……………………………………………8
Table of Figures Page #
Figure 1 – ZAG Flow Schematic ……………………………………………………… 2
Figure 2 – Perma Pure Nafion Membrane Dryer Schematic ……………………… 3
Figure 3 – Control Panel ………………………………………………………………. 4
Figure 4 – ZAG Performance Curve …………………………………………………. 4
Figure 5 – Wiring Schematic……………………………………………………………7
1 Form #240
Zero-Air Generator Manual Rev 11/98
Introduction
1
The Zero-Air Generator (ZAG) is a simple, light-weight, self-contained system capable of producing
high purity, particle free, dr y air at up t o 18 liters per minute. It is designed to r eplace gas cylinders as a
source of calibration standard. T he ZAG can be used with stationar y analyzers, but its portability
makes it especially well suited for use with remote m onit o r ing sites and mobile testing facilities.
Operation is very simple. Ambient air is brought into the Zero-Air Generator where it is com pr essed
and then purified using a combination of membranes, adsorbents, and f ilters. The only outside item
that needs to be supplied is AC power.
Figure 1 – ZAG Flow Schematic
Maintenance requirements are minimal and easy to perfor m. There are two desiccant canisters, one of
which needs to be replenished periodically; under normal use, it will last up to six months. T he ot her
desiccant canister contains a catalyst that is not consumable. The only other regular maintenance is to
replace the particulate filter per iodically. All ot her com ponents in the system are designed to provide
years of trouble-free service.
The Perma Pure ZAG is ideal for use with the following monitors:
! Nitrogen oxides (NO
! Carbon monoxide ! Ozone
) ! Sulfur oxides (SO x)
! VOC’s (except methane)
x
Consult Perma Pure for other m onit o r ing applicat ions.
The rugged design of the ZAG makes it ideal for field use. The components are protected inside a
hard plastic enclosure, which is roughly the size and weight of a fishing tackle box. The ZAG takes up
a minimal amount of space and is very easy to start up.
In addition to its convenience, the ZAG is also a safe and cost- effective source of high pur it y air. G as
cylinders are heavy, bulky, and under high pressure. Extreme caution must be exercised when
working with them. In addition, these cylinders are very expensive and can cause storage problems.
The only operating costs associated with the ZAG are electricit y (about $75/ year if run continuously)
and replacement desiccant. Depending on zero air consumpt ion, it will normally pay for itself within 12
months.
2 Form #240
Zero-Air Generator Manual Rev 11/98
Description of Components
2
2.1 Perma Pure Dryer
Water vapor and certain polar organic compounds (i.e. alcohols, ketones) are removed
here. A bundle of Nafion tubes is housed inside the dryer shell. As the wet compressed
air flows through the tubes, the water vapor is absorbed through the membrane and
carried off by a counter-current purge air flow at a reduced pressure. The driving force for
this process, known as permeation distillation, is the difference in partial vapor pressure of
water between the product and purge gas flows. In this system, a portion of the dried air
is expanded and used as the purge gas.
Figure 2 – Perma Pure Nafion Membrane Dryer Schematic
2.2 Ultraviolet Lamp
Used for the destruction of bacteria into carbonaceous by-products. The lamp produces
approximately 1-3 PPM of ozone (O3), which then breaks down microorganisms into
carbon compounds that are removed further downstream. The lamp also oxidizes NO to
NO2, which is readily removed by system adsorbents.
2.3 Activated Carbon/Alumina Mixture
This is a blend of high performance activated carbon and impregnated alumina pellets.
This mixture will remove trace quantities of chlorine (Cl2), hydrogen fluoride (HF),
hydrogen sulfide (H
S), nitrogen oxides (NOx), ozone (O3), sulfur dioxide (SO2), sulfur
2
trioxide (SO3), and general hydrocarbons (HC). In addition to removing these substances,
the mixture changes from purple to brown, indicating the need for replacement.
2.4 Carbon Monoxide Catalyst
Palladium impregnated alumina pellets are used to convert low levels of CO to CO2. This
catalyst is not consumable, and should last for the lifetime of the unit.
2.5 1µµµµ Particulate Filter
The last stage of purification is the particulate filter. This filter has an absolute retention
rating of 1 micron, and a 93% rating for particles down to 0.1 micron. The disposable
filter is housed in a transparent plastic housing, allowing easy visual determination of the
filter’s condition.
3 Form #240
Zero-Air Generator Manual Rev 11/98
3
Start-Up Procedure
1. Place the ZAG on a level,
dry surface.
2. Check to make sure the
power switch is in the ‘off’ position.
3. Plug the unit into a
standard 110V electrical outlet.
4. Open the flow control knob
fully (turn the knob counter-clockwise).
5. Connect the calibration gas line to the 1/4”
tube compression fitting located on the top
panel of the generator.
6. Turn the power switch to the ‘on’ position.
7. Adjust the flow control valve to the desired air
output. Maximum capacity is 18 lpm.
8. High purity air will be produced within 2
minutes after start-up.
Note: There is a
trade off between
air pressure and
flow. High air
volumes will result
in lower air
pressure, and vice
versa. If low
pressure, low flow
applications are
encountered, a
pressure regulator
should be
connected between
the instrument and
the Zero-Air
Generator.
35
30
25
20
15
10
Pressure (psig)
5
0
0 2 4 6 8 101214161820
Figure 4 – Zero-Air Generator Performance Curve
REPLACE ABSORBEN T WHEN COLOR
CHANGE REACHES THIS POINT
Figure 3A – ZAG Top Panel
CAUTION : READ INSTR UCTIO N
MANUAL BEFORE OPERATING
ZERO−AIR
GENERATOR
SYSTEM POWER 110VAC 50/60HZ
FUSE 3A FAST ACTING 5x 20mm
Figure 3B – ZAG Bottom Panel
Flow Ra te (L/min)
15
10
20
psi
25
5
0
30
SYSTEM
PRESSURE
ZERO−AIR
OUTLET
PERMA PURE INC.
8 EXECUTIVE DRIVE P.O. BOX 2105
TOMS RIVER, NEW JERSEY 08754
30
25
20
15
10
5
OUTLET FLO W
(LPM)
4 Form #240
Zero-Air Generator Manual Rev 11/98
Maintenance
4
Routine maintenance on the ZAG consists of periodic
carbon replacement and outlet filter replacement.
Under normal, intermittent use, the desiccant should
last at least six months.
4.1 Activated Carbon/Alumina Replacement
WARNING!! De-pressurize
and unplug the ZAG before
attempting any
maintenance or removing
the top or bottom panels!
The activated carbon canister is located behind the top panel. The top half of the
canister is exposed to allow visual inspection of the mixture. As the mixture is
used, its color changes from purple to brown. When ¾ of the canister has
changed to brown, replace the mixture. The mixture can not be regenerated and
must be discarded.
Replacing the mixture
1. Disconnect the three (3) air lines by loosening the ¼”
compression nuts with a 9/16” wrench. Hold the bulkhead
nut with a 5/8” wrench to prevent turning.
2. Remove the four (4) panel screws using a 1/8” Allen
wrench and pull the top panel out.
3. Remove the black plug from the bottom of the canister
using a 15/16” wrench.
4. Pour the pellets out, tapping the canister lightly to
remove any that may remain inside.
5. Re-fill the canister by slowly pouring in the fresh
activated carbon/impregnated alumina mixture. Tap the
side of the canister while filling to settle the mixture and
reduce air pockets.
6. Apply Teflon
®
tape to the plug and replace in the bottom
of the canister tightening fully.
7. Replace the top panel using the panel screws.
8. Re-connect the three (3) air lines to the bulkead fittings,
making sure to re-connect to the proper ports. Once
again, hold the bulkhead nuts in place using a 5/8”
wrench.
5 Form #240
Zero-Air Generator Manual Rev 11/98
4.2 Final Filter Replacement
The final filter should be replaced each time the activated carbon/alumina is changed. The
filter is located immediately after the outlet of the CO catalyst canister.
1. Remove the four (4) panel screws using a 1/8” Allen wrench
and pull the top panel out. Note the position of the filter so
that you can install the replacement in the same way.
2. Loosen the 1/4” compression nuts on either end and pull the
filter from the tubing.
3. Remove the nuts from the old filter and place them on the
new filter.
4. Install the new filter with the standoff end (visible inside the
housing, supporting the filter element) connected to the
catalyst canister outlet.
5. Firmly tighten the compression nuts on the inlet and outlet
tubing.
4.3 Fuse Replacement
If the unit fails to run when plugged in and turned on, first check the fuse.
1. Disconnect the power cord from the power input module
on the bottom panel of the unit.
2. Using a slotted tip screwdriver, pry up at the slot located
about ¼” below the surface of the power input module,
inside the cord entry socket. This will pull up the fuse
carrier that holds the fuse on the bottom and a spare.
3. Inspect the fuse to see if it is blown. If so, remove it and
replace it with the spare fuse.
4. If the fuse is in good shape, re-install and plug the system
back in.
" If the unit still does not work, unplug the unit again and remove the four socket head
screws located on the corners of the bottom panel. Pull the bottom panel out and inspect
6 Form #240
Zero-Air Generator Manual Rev 11/98
the wiring connections to make sure they are secure. If any loose wires are evident,
tighten the connection if possible. Refer to the wiring schematic for details if necessary.
Figure 5 – ZAG Wiring Schematic
" If the unit still does not run after re-installing the panel and connecting power, it may be
necessary to return it to Perma Pure for maintenance. Please contact Perma Pure to
arrange any returns for maintenance.
The following items do not require any routine maintenance:
#
The Pump
#
UV Lamp
#
Perma Pure Dryer
If performance of any of the non-maintenance components begins to degrade, contact Perma
Pure for assistance.
Spare and Replacement Parts
5
7 Form #240
Zero-Air Generator Manual Rev 11/98
The following spare parts are recommended for each maintenance period. All maintenance
should be performed each time the activated carbon/alumina canister changes color from
purple to brown along 3/4 or more of its length.
1) Activated Carbon/Impregnated Alumina Blend - Purafil
CP Blend
Purafil, Inc.
P.O. Box 1188
Norcross, Georgia 30091
Approximately 0.7 lb. required per adsorbent change.
2) Outlet Filter - 1µ absolute particulate filter available from:
Headline Filters Inc.
27610 College Park Drive
Warren, MI 48093
Phone: (810) 773-9111
Fax: (810) 773-9357
One (1) filter is required per maintenance period.
Please note that all maintenance items are also available from Perma Pure directly.
Specifications
6
PUMP
INLET FILTER
DRYER
STERILIZER
NOx, SOx, HC SCRUBBER
CO CATALYST
FINAL FILTER
OVERALL DIMENSIONS
WEIGHT
POWER REQUIREMENT
FUSE REPLACEMENT
OPERATING ENVIRONMENT
Dual Head Diaphragm, up to 30 PSIG, 18 SLPM
Sintered SST,10 Micron Porosity
PD-750-12PR Nafion Gas Dryer
Ultraviolet Light Chamber,
254 nm peak wavelength
Activated Carbon, Indicating Catalyst Blend
Palladium Impregnated Alumina
0.1µ Glass Fiber Particulate Filter
8.5”W x 10”H x 16.5”L
(216 x 254 x 419 mm)
27 Pounds
(12.3 kg)
2.5A @ 110 VAC, 1.25A @ 220 VAC, 50/60 Hz
2.5A/110 VAC, 1.25A/220 VAC
Fast Acting, 5x20mm
-20°C To +40°C
0 to 95% RH
8 Form #240
Zero-Air Generator Manual Rev 11/98
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