MODEL 111/111S

ZERO AIR SUPPLY

INCLUDING EXTERNAL AIR COMPRESSOR

INSTRUCTION MANUAL
P/N 7734

THERMO ENVIRONMENTAL INSTRUMENTS INC.

8 WEST FORGE PARKWAY
FRANKLIN, MASSACHUSETTS 02038

TELEPHONE: (508) 520-0430

FACSIMILE: (508) 520-1460

3-4-02
Other brands and product names mentioned in this instruction manual are trademarks of
their respective owners.

Copyright  2000-2002
Thermo Environmental Instruments, Inc.
Franklin, Massachusetts

“This manual is a work protected under Copyright law. Copying or other reproduction of
any of its contents without the prior written consent of Thermo Environmental
Instruments is expressly prohibited.”
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 TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION......................................................................... 1-1

Specifications ...................................................................................................................1-3

CHAPTER 2 INSTALLATION AND SETUP .................................................... 2-1

Unpacking ........................................................................................................................2-1
Assembly..........................................................................................................................2-2

CHAPTER 3 OPERATION............................................................................... 3-1

CHAPTER 4 THEORY OF OPERATION ......................................................... 4-1

Gas Scrubbing ..................................................................................................................4-1

Electrical...........................................................................................................................4-3

CHAPTER 5 MODEL 111S.............................................................................. 5-1

CHAPTER 6 MAINTANENCE.......................................................................... 6-1

Weekly..............................................................................................................................6-1
Monthly ............................................................................................................................6-1
Yearly ...............................................................................................................................6-1
Compressor.......................................................................................................................6-1

CHAPTER 7 SERVICING ................................................................................ 7-1

Spare Parts........................................................................................................................7-1
Servicing...........................................................................................................................7-1
Return of Merchandise .....................................................................................................7-2

APPENDIX A WARRANTY.............................................................................. A-1

v
APPENDIX B COMPRESSOR OPERATION AND MAINTANENCE...............B-1

Installation ....................................................................................................................... B-1

Disassembly..................................................................................................................... B-2
Electrical.......................................................................................................................... B-4
Assembly......................................................................................................................... B-4
Inspection ........................................................................................................................ B-5

APPENDIX C OPTIONAL HEATLESS AIR DRYER .......................................C-1

Description ...................................................................................................................... C-1

Operation......................................................................................................................... C-3
Operating Temperatures ...................................................................................... C-3
Piping .................................................................................................................. C-3
Air Connections................................................................................................... C-3
Electrical Conditions ........................................................................................... C-3
Inlet Air Preparations .......................................................................................... C-4
Solid State Timing............................................................................................... C-4
Maintenance .................................................................................................................... C-5
Parts Summary ................................................................................................................ C-7
Troubleshooting .............................................................................................................. C-8

vi
 LIST OF ILLUSTRATIONS

Figure Page

1-1 Zero Air Assembly ...............................................................................................1-1

1-2 Outline Drawing...................................................................................................1-2

2-1 Interior View ........................................................................................................2-2

2-2 Flow Schematic ....................................................................................................2-2
2-3 Option 006 for H2S Permeation ...........................................................................2-3

4-1 Model 111 Flow Schematic..................................................................................4-1

4-2 Component Layout ...............................................................................................4-2
4-3 Wiring Diagram....................................................................................................4-3
4-4 Temperature Controller Schematic ......................................................................4-4

5-1 Model 111S Flow Schematic ...............................................................................5-1

B-1 Compressor – Dimensional Data......................................................................... B-1

B-2 Standard Model 111 Compressor Motor – Exploded View................................ B-2
B-3 20 LPM Option Compressor Motor – Exploded View ....................................... B-3

C-1 Heatless Air Dryer............................................................................................... C-1

C-2 Accumulator – Outline Dimensions.................................................................... C-2
C-3 Dryer Electrical Connections .............................................................................. C-3
C-4 Cycle Timer......................................................................................................... C-4
C-5 Heatless Air Dryer – Exploded View.................................................................. C-6

vii
CHAPTER 1
INTRODUCTION
The Model 111 Zero Air Supply is a convenient system for the generation of pollutant
free zero gas for NO, -NOx, -O3, -SO2, -CO, and hydrocarbon monitoring requirements.
The Model 111 uses an external compressor; the pressure regulators, chemical scrubbers,
reactor and temperature controller are all contained in a single convenient case (see
Figure 1-1 and Figure 1-2).

The Model 111 has been designed for any application where pollutant free levels of NO,
-NOx, -O3, -SO2, -CO and hydrocarbons are required, with flows up to 20 liters per
minutes at pressures of 30 PSI.

Figure 1-1. Zero Air Assembly

1-1
Chapter 1 Introduction

Figure 1-2. Outline Drawing

1-2
 Chapter 1 Introduction

SPECIFICATIONS

Power 115V 50/60 Hz

Power Consumption 120 Watts

Dimension 12 ¼” H x 19” W x 15” D

(suitable for rack mounting)

Weight 17 pounds

1-3
CHAPTER 2
INSTALLATION AND SETUP
The installation of the Model 111, Zero Air Supply (ZAS) includes unpacking the
instrument, connecting the compressor, connecting the gas flow lines, and attachment to
suitable AC power.

UNPACKING

The Model 111 Zero Air Supply is shipped in two containers. If, upon receipt of the
supply there is obvious damage to the shipping container, notify the carrier immediately
and hold for his inspection. The carrier, and not Thermo Environmental Instruments Inc.,
is responsible for any damage done during shipment.

In addition to the basic unit, an instruction manual is included in the shipping container.

Use the following procedure to unpack the instrument:

1. Remove the Model 111 from the shipping container and set on a table or bench,
which will allow easy access to both the front and rear of the instrument.

2. Remove the Model 111 cover from the main frame of the unit, thus exposing the
internal components of the instrument.

3. Check for possible damage during shipment, and then reinstall the cover.

4. Remove compressor from shipping container, unbolt from pallet, and then identify
the coalescing filter and pressure regulator.

5. Check for possible damage during shipment.

2-1
Chapter 2 Installation and Setup

ASSEMBLY

Use the following procedure to assemble the instrument:

1. Connect the coalescing filter and pressure regulator to the output of the compressor.

2. Using 1/4" Teflon tubing, connect the outlet of the pressure regulator located on the
compressor to the input of the Model 111.

3. Using 1/4" Teflon tubing, connect the outlet of the Model 111 to the device requiring
"zero air" under pressure.

• If the compressor's power cord has not been installed at the factory, remove
the controller's cover on the compressor. Connect power cord to the screw
terminals provided. Be sure to connect the ground wire, the line, and the
common. Replace the cover. For further instructions on the compressor, refer
to Appendix C, “Compressor Operation and Maintenance.”

• If an optional auto drain is being used, remove the stopcock on bottom of tank
and install the auto drain option.

4. Plug the AC line cord into an appropriate power source. Check the voltage and verify
before connecting to the power. For 220 VAC operation, a step-down transformer is
installed internally in the Model 11’s case. The compressor is operated directly off the
line voltage, 115 V or 220 V. Check the plate on the pump motor to determine the
correct voltage and frequency prior to plugging in the compressor.

2-2
CHAPTER 3
OPERATION
Once the Model 111 has been unpacked and assembled, you can use the following
procedure to power up and operate the instrument.

1. Close the manual valve on the output of the compressor and plug in the compressor.
The pressure in the tank should gradually increase to 80 to 90 psi. At that point, the
pump shuts off.

2. Open the manual valve and adjust the pressure regulator downstream of the
coalescing filter for 70 psi.

3. Adjust the pressure regulator on the Model 111 case for the desired pressure
(typically 10 to 30 psi).

4. Turn the dial on the optional CO reactor temperature controller to 350o C. Turn on the
instrument. The internal cooling fan starts blowing and the temperature controller
light is on.

5. After approximately one hour, the indicating light on the temperature controller is
cycling on and off indicating that the reactor is up to temperature. The Model 111 is
now ready for use.

6. The compressor’s motor will cycle on and off, with the tank pressure is controlled
between 80 and 90 psi.

3-1
CHAPTER 4
THEORY OF OPERATION
This chapter explains the gas scrubbing and the electronics of the Model 111.

GAS SCRUBBING

The purpose of the Model 111 is to supply pollutant-free air (zero air) from the ambient
air to allow for proper zeroing, and to provide clean diluent air for spaning ambient air
analyzers. The components to be removed are SO2 NO, NO2, CO and hydrocarbons.
There is no consensus as to what extent zero air should have water vapor removed. Since
many analyzers have longer response times if super dry air (dew point less than -30o C) is
used for zero and span, and since water vapor is not a pollutant, the Model 111 does not
have a drying system. However, the dew point is reduced as a result of compression of
the ambient air.

Figure 4-1 is the gas flow schematic for the Model 111. Room air enters the compressor,
where it is raised to a pressure of approximately 80 to 90 psi (4560 mm). At 25o C the
saturation water vapor pressure is approximately 24 mm. Therefore, most of the water
condenses out, and falls to the bottom of the tank. Out of the 4560 mm of pressure in the
tank, only 24 mm is due to water vapor. When this air is later expanded to atmospheric
pressure (760 mm) the water vapor pressure is reduced to approximately 4 mm. This
corresponds to a dew point of slightly less than 0o C.

To keep any condensation from occurring in the tubing between the compressor and the
Model 111, the output of the compressor contains coalescing filter and a pressure
regulator where the pressure is reduced to 70 psig.

Figure 4-1. Model 111 Flow Schematic

4-1
Chapter 4 Theory of Operation

Inside the main case of the Model 111, the compressed air is further reduced to the final
desired pressure (10 to 30 psi). The air then passes into a column of Purafil (potassium
permanganate on alumina), which oxidizes NO to NO2. The air then passes through a
column of iodated charcoal, which removes NO2, and S02. Finally, the air goes into the
reactor where it is heated to 375 o over a catalytic surface, which oxidizes CO to CO2, and
hydrocarbons including methane, to CO2 and water. Figure 4-2 shows the layout of these
components.

Figure 4-2. Component Layout

4-2
 Chapter 4 Theory of Operation

ELECTRICAL

Figure 4-3 is an electrical schematic of the Model 111 Zero Air Supply. The transformer
is installed for 220 volt operation. If the transformer is not installed, a jumper package is
installed. Figure 4-4 is the electronic schematic of the temperature controller.

Figure 4-3. Wiring Diagram

4-3
Chapter 4 Theory of Operation

Figure 4-4. Temperature Controller Schematic

4-4
CHAPTER 5
MODEL 111S
The Model 111 is also available for continuous duty when it is supplied with a heatless
air dryer. This dryer, normally installed before the Model 111, is designed to remove
water, CO2 and some pollutants from the compressed air supply. This provides dry,
relatively pollutant free air to the Model 111 for the conversion of CO and removal of
NO, NO2, SO2 and hydrocarbons. This will significantly extend the life of the Purafil and
charcoal canisters under continuous, around the clock usage. Figure 5-1 illustrates the
flow schematic for the Model 111S.

An optional compressor can be used to supply the higher air flow rates often required in
continuous systems. Customer supplied compressed air may also be used, but caution
must be taken to ensure that liquid water and oil be completely removed prior to the
heatless air dryer or the Model 111.

The Model 111 output pressure is normally set to 60 psig under continuous operating
conditions. This pressure can be reduced in certain situations as required. It is important
to note that the supply pressure to the heatless air dryer should be 80 to 100 psig. The
heatless air dryer will not operate within specifications below 60 psig.

B50P802

Figure 5-1. Model 111S Flow Schematic

5-1
CHAPTER 6
MAINTENANCE
The Model 111 Zero Air Supply has been designed with ease of maintenance as an
important criterion. Components and sub-assemblies have been selected for high
performance, excellent stability, and long life. The exact lifetimes of the scrubbing
material is hard to predict. It is dependent upon flow, pressure, and level of contaminate.
For most applications the following recommendation should be followed:

WEEKLY

If optional automatic drain valve is not installed, open the stop cock on the bottom of the
tank and drain water.

MONTHLY

Check the condition of the Purafil. Fresh Purafil is purple. It becomes brown when it is
used up. Replace when the purple color represents less than 20% of the volume. To
replace, turn off power and unplug, wait until the reactor cools down (approximately 10
minutes with air flowing). Shut off the air supply so that the Model 111 pressure drops to
0.0 psig. Remove the cartridge holding Purafil. Slowly unscrew the cap, allowing any
remaining pressure to vent, empty out the used Purafil and discard. Replace with fresh
Purafil. Screw on cover and replace cartridge.

YEARLY

Replace the charcoal. The procedure is the same as replacing Purafil, outlined above.

COMPRESSOR

When it is observed that the pump is having difficulty keeping the pressure, rebuilding
may be necessary. For directions, refer to Appendix C, “Compressor Operation and
Maintenance.”

6-1
CHAPTER 7
SERVICING
The Model 111 has been designed with ease of maintenance as an important criterion.
Electric components have been packaged in sealed subassemblies for rapid fault isolation
and replacement. Components and subassemblies have been selected for high
performance, excellent stability and long life.

SPARE PARTS

The following list includes the recommended spare parts for the Model 111:

Part Number Description Quantity

4510 Main Fuse 1

4510 Temperature Controller Fuse 1

7075 Purafil 5 lbs.

4157 Charcoal 5 lbs.

8193 Service Kit for Standard Compressor 1

8221 Service Kit for 20 LPM Compressor 1

SERVICING

Thermo Environmental Instruments Inc. provides spare parts and servicing from the
locations listed below:

Thermo Environmental Instruments Inc.

8 West Forge Parkway
Franklin, MA 02038
Tel: (508) 520-0430
Fax: (508) 520-1460

Thermo Environmental Instruments Inc.

325 E. Arrow Hwy., suite # 506
San Dimas, California 91773
Tel: (909) 394-2373
Fax: (909) 394-2367

7-1
Chapter 7 Servicing

RETURN OF MERCHANDISE

All equipment returns require an authorization to speed response. Before shipping

material to the factory, obtain a return authorization number from the Service
Department. The number must appear on the outside of shipping container.

7-2
APPENDIX A
WARRANTY
Subject to the exceptions stated below, Thermo Environmental Instruments Inc. agrees to
correct either by repair or at our option, by replacement, any defects in materials or
workmanship which develop within one year from the date of delivery not to exceed
eighteen (18) months from date of shipment, parts and labor supplied free of charge.

The exceptions mentioned above are: (1) All defective items must be returned to Thermo
Environmental Instruments Inc., transportation charges prepaid, and will be shipped
prepaid and charged to the customer unless the item is found to be defective and covered
by the warranty in which case Thermo Environmental Instruments Inc will pay all surface
transportation charges; (2) Thermo Environmental Instruments Inc. agrees to extend to
the customer whatever warranty is given to Thermo Environmental Instruments Inc. by
suppliers of component items purchased by Thermo Environmental Instruments Inc. and
incorporated into products sold to the customer; (3) Thermo Environmental Instruments
Inc. shall be released from all obligations under this warranty in the event repairs or
modification are made by persons other than its own authorized service personnel, or
service personnel from an authorized representative, unless such repair is minor, merely
the installation of a new plug-in component; (4) if any model or sample was shown to
Purchaser, such model or sample was shown merely to illustrate the article and not to
represent that any article delivered hereunder would conform to the model or sample, and
(5) Spare parts are warranted for ninety (90) days.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER

WARRANTIES, WHETHER WRITTEN, ORAL, IMPLIED, OR STATUTORY.
SELLER DOES NOT WARRANT MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE, OR MAKE ANY OTHER WARRANTY OR
AGREEMENT EXPRESSED OR IMPLIED WITH RESPECT TO ANY ARTICLES
COVERED HEREUNDER. THERE ARE NO WARRANTIES THAT EXTEND
BEYOND THOSE EXPRESSLY STATED IN THIS CONTRACT.

A-1
APPENDIX B
COMPRESSOR OPEARTION AND MAINTENANCE
This appendix explains proper operation and maintenance of the compressor.

! CAUTION: Never lubricate this dry oil-less piston pump. The Teflon filled rings are
self-lubricating and require no oil. The motor bearings are grease packed for the life of
the bearing.

INSTALLATION

If this compressor is being installed in a system where it will be periodically required to

start against any form of system back pressure, a positive sealing one way check valve
should be installed in the air line between the system and the compressor. Check valves
are provided as standard equipment on all Gast tank mounted compressor assemblies (see
Figure B-1 for dimensional data.

A B C D E Standard Model 111

17 1/4 16 5/8 5 5/8 4 10

A B C D E 20 LPM Option
26 20 7/8 13 1/2 11 1/2 16

Compressor CIM Free Air

Model HP @ Open @ 70 psig @100 psig

Standard 1/6 2246 1037 864

20 LPM Option 1/3 4147 2246 1901

Figure B-1. Compressor – Dimensional Data

B-1
Appendix B Compressor Operation and Maintenance

DISASSEMBLY

It is not necessary to remove the filters from the cylinder head as metal chips could be
dislodged and enter the unit. Remove the shroud, cylinder head, and valve components.
Do not rearrange the valve components. Remove the cylinder and rings. Make sure all
parts are clean before reassembling. Refer to Figure B-2 for the Standard Model 111
compressor and Figure B-3 for the 20 LPM Option.

Note: Do not use any chlorinated solvents to clean valves, or any liquids to flush
units. The stainless steel valves can be cleaned with water. All parts, except
the valves, can be cleaned with any industrial, non-flammable, non-toxic
cleaning solvent.

TEI P/N 8187 (110V)

TEI P/N 8188 (220V)

* Denotes parts included in service kit.

Figure B-2. Standard Model 111 Compressor Motor – Exploded View

B-2
 Appendix B Compressor Operation and Maintenance

TEI P/N 8216 (110V)

TEI P/N 8206 (220V)

* Denotes parts included in service kit.

Figure B-3. 20 LPM Option Compressor Motor – Exploded View

B-3
Appendix B Compressor Operation and Maintenance

ELECTRICAL

Remove the plate covering the electrical terminal for wiring instructions.

! WARNING: The motor might be thermally protected and can automatically

restart when the protector resets. Always disconnect the power source before servicing
the instrument.

ASSEMBLY

Use the following steps to assemble the compressor:

1. Install piston seals, piston rings, and rider rings on the piston.

2. Locate ring joints approximately opposite each other and attach cylinder to bracket
with the cylinder screws and lock washers.

3. Tighten screws finger tight.

4. Move pistons to top dead center position and adjust each cylinder flush with top of
piston and torque cylinder screws to 150 to 160 psi.

5. Re-torque second time.

6. Stack the valve components in order as shown in the detail. The valve leaf is pre-bent
and should not be adjusted in any way.

7. Install the cylinder head, lock washers, and head screws. The exhaust ports in the
cylinder head are marked, omitting the ends of two of the fins. Do not tighten head
screws at this time.

Note: Do not tighten head screws at this time.

8. Install manifold and nuts and seals on the manifold and assemble into the other
cylinder head and manifold. Torque all head screws to 85 to 95 psi.

9. Re-torque again.

10. Position manifold and tighten manifold nut 1/2 to 3/4 turns beyond hand tight.

B-4
 Appendix B Compressor Operation and Maintenance

INSPECTION

If the pump or motor show evidence of overheating or excessive noise, stop immediately
for repairs. Regular inspection can prevent expensive repairs. The rider thickness can be
an indication of when rings need replacing. If a rider ring measures .05511 or less in
thickness, a change of all rings should be made.

For a unit operating at sea level, in fairly clean air, at an ambient of 65º to 75º F, relative
humidity of approximately 35 percent, and at maximum advertised duties, it is suggested
that 4,000 hours of operation be used as an initial inspection point. As operating
conditions on your particular application improve or worsen, your own experience can be
used to determine whether this 4,000-hour figure can be lengthened or should be
shortened.

Note: If your pump is equipped with plastic plugs in the exhaust or intake ports,
remove them before starting the unit.

! WARNING: To prevent explosive hazard, do not pump combustible liquids or

vapors with these units.

It is usually quickest and least expensive to send the motor in for repair. Authorized
service facilities are located at:

Gast Manufacturing Co., Ltd. Gast Manufacturing Corp.

Halifax Road, Cressex Estate 2550 Meadowbrook Road
High Wycombe, Bucks HP123SN Benton Harbor, MI 49022
England (616) 926-6171
High Wycombe 23571

Wainbee, Ltd. Gast Manufacturing Corp.

121 City view Drive 505 Washington Ave.
Rex dale, Ontario Carlstadt, NJ 07072
Canada M9W 5A9 (201) 933-8484

Wainbee, Ltd. Brenner-Fielder & Assoc.

215 Brunswick Blvd. 16210 Gundry Ave.
Ponte Clair, Montreal Paramount, CA 90723
Canada H9R 4R7 (213) 636-3206
(514) 697-8810

B-5
APPENDIX C
OPTIONAL HEATLESS AIR DRYER
This appendix provides the following details for Heatless Air Dryer:

• Description
• Operation
• Maintenance
• Parts
• Troubleshooting

DESCRIPTION

The heatless air dryer provides clean dry air with minimal carbon dioxide to provide zero
air for ultra sensitive analyzers. The function of the dryer is to first remove moisture
from compressed air, and second, to remove the desiccant chambers due largely to the
multiple layering of special adsorbent materials (see Figure C-1 and Figure C-2).

Note: All units are equipped with a power cord.

Chamber
Weight
Model Lengths A B C D
(pounds)
(inches)

Standard Option 12” 17” 11.5” 5” 10

Optional 20” 25” 11.5” 5” 19 ¼”

Figure C-1. Heatless Air Dryer

C-1
Appendix C Optional Heatless Air Dryer

Figure C-2. Accumulator – Outline Dimensions

C-2
 Appendix C Optional Heatless Air Dryer

OPERATION

Operating Temperatures

The heatless air dryer can operate at maximum ambient temperatures of +100o F. (38 o C)
and a maximum inlet air temperature of +125 o F (52o F). However, the recommended
operating temperature is +70 o F (21 o C) ambient and inlet air conditions.

Piping

The heatless air dryer is designed for wall mounting, with the desiccant chambers always
up.

Air Connections

The inlet and outlet connections are 1/4" female NPT. When connections are made
directly into unit, a pipe compound should be used to prevent galling of the threads. 3/8"
tubing with 1/4" pipe connections should be installed at the input and output for
maximum flow. Larger lines are recommended to avoid pressure drop where long piping
runs are encountered. After connecting the piping or tubing to the unit, use a soap
solution to check the connections for air leaks.

An upstream inlet filter is recommended to remove particulate matter 20 microns and

larger and liquid water. If oil in liquid form or mist form is present in the air stream, an
oil coalescing filter must be used. The dryer should not be operated in a corrosive
atmosphere.

Electrical Conditions

Before wiring, check the nameplate for electrical requirements. Standard electrical
characteristics are CDAl-115VAC, 50/60 Hz, 36 watts. 230 VAC units are available (see
Figure C-3).

Note: No overload protection is provided in the dryer. The attached 8-foot wire
power cord must be plugged into a properly protected outlet.

Figure C-3. Dryer Electrical Connections

C-3
Appendix C Optional Heatless Air Dryer

Inlet Air Preparations

Air entering the dryer must be free of dirt, rust, oil vapors, condensation, and scale that
might accumulate in the piping or compressor.

Solid State Timing

The cycle timers are of solid state design and are equipped with a one hour minimum
memory circuit that restarts the timers at the same point in the timing cycle, as when the
power was interrupted (see Figure C-4). The timers feature DC electrical outlets for the
DC solenoid valves. The dryer will automatically begin re-pressurizing the purging
desiccant chamber before switching chambers. The re-pressurization period is 3.75
seconds and the purging-period is 26.25 seconds. Re-pressurization helps to minimize
outlet pressure fluctuation as the flow switches from one desiccant chamber to the other.

Further reduction in outlet pressure swings can be obtained by installing a surge reduction
tank between the dryer outlet and the outlet pressure regulator. This tank is provided in
systems, supplied by Thermo Environmental Instruments Inc. when necessary.

Figure C-4. Cycle Timer

C-4
 Appendix C Optional Heatless Air Dryer

MAINTENANCE

If the unit is installed in accordance with these instructions, field adjustments are
unnecessary. No lubrication is required on this instrument. It is recommended that at six-
month intervals the unit be thoroughly inspected. Inspection should include audible
inspection for proper solenoid valve operation, purge and visual inspection for excessive
dirt or oil fouling, and for desiccant attrition. This involves removal of the air manifold
covers and the desiccant chambers. Annual inspections should be more thorough and
need to include removal of the solenoid valves, and the purge orifice glands to inspect for
excessive wear or deterioration of valve parts or the check valve balls, and possible
plugging of the purge orifices (see Figure C-5).

Note: Orifices are critical parts in determining the performance of a dryer. Therefore
do not, in any way, increase the size of the orifice. Orifices of the appropriate
size can be obtained from the factory.

Purge orifice glands are screwed into the manifold beneath the desiccant chambers. To
change orifices, unscrew the chambers and remove the orifices with a standard 7/8"
socket wrench. The cycle timer can be replaced in the field.

Note: Improper packing of the desiccant chambers can cause channeling of the gas
stream and unsuitable purification. For this reason, do not attempt to repack
desiccant chambers in the field. Replacement chambers must be obtained from
your local authorized distributor.

C-5
Appendix C Optional Heatless Air Dryer

Figure C-5. Heatless Air Dryer – Exploded View

C-6
 Appendix C Optional Heatless Air Dryer

PARTS SUMMARY

The following list includes a summary of parts for the Heatless Air Dryer:

Item No. Description Quantity

1 Desiccant Chamber 12" Inc. Item 2 Consult Factory N/A
Desiccant Chamber 20" Inc. Item 2 Consult Factory
2 O-Ring- 1.720 I.D. X 0.118W 2
3 O-Ring- 0.362 I.D. X 0.103W 2
4 Purge Orifice Assembly (includes No. 3 and No. 5) 2
5 O-Ring -0.644 I.D. X 0.0878W 2
6 Ball, Check Valve 1
7 Plug, Hex 1
7A Moisture Indicator 1
_
8 O-Ring 351 I.D. X 0.072W 1
9 Name Plate 1
10 Drive Screw, #4 X 3/6" Type Urnd. hd. st. st. 2
11 Screw #10-24 X 5/8", Pan hd. 6
12 Pipe Plug, 1/4" - 8" Socket hd. 2
13 Mounting Bracket 2
_
14 O-Ring 0.731 I.D. X 0.0103W 4
15 Air Manifold 1
_
16 O-Ring 0.850 I.D. X 0.0115W 2
17 Solenoid Valve 53 VDC (for 120 V, 50/60 Hz units) 2
Solenoid Valve 106 VDC 2 (for 240 V, 50/60 Hz units)
18 Core Assembly 2
19 Base Assembly 2
20 Coil, 53 VDC, Coil, 106 VDC 2
25 Screw, #6 - 32 X 1/8" Pan hd. 4
26 Air Manifold Cover 1
27 Timer S.S 1 min cycle 120 VAC Re-pressurization 1
Timer S.S 1 min cycle 240 VAC Re-pressurization
28 Nut Keps -8-32 2
29 Screw, 8-32 X 1" BH 2
30 Screw, 6-32 X 1/4" BH 2
31 Screw, 6-32 X 1/2" BH 2
32 Plate, Adapter - S.S. Timer Bracket 1
33 Bracket - S.S. Timer 1
34 Cover -Terminal 1
35 Decal -Terminal Cover 1
42 Spring - Check Ball 2

C-7
Appendix C Optional Heatless Air Dryer

TROUBLESHOOTING

In the event of an instrument malfunction, the following troubleshooting guide enables

you to determine the problem. Contact your local authorized distributor for replacement
parts.

MALFUNCTION POSSIBLE CAUSE ACTION

Instrument delivers Improper operating Adjust operating conditions.
wet air or a high conditions.
concentration of
carbon dioxide.
Solenoid core spring is Remove solenoid valve and inspect core
broken. assembly. Spring should be seated on
core and broken. Replace if necessary.

Purge orifice plugged. Remove, inspect, and clean orifice. Do

not force wires through critically drilled
holes. Use air to clean.

Solenoid coil burned out. Remove cover, place iron or steel

material (screwdriver or nail) on
exposed end of solenoid base to feel the
magnetic effect indicating proper
operation. Note: Each adsorber coil
should be energized for 33.75 seconds.
Check the improper operation of cycle
timer before replacing coil.

C-8
 Appendix C Optional Heatless Air Dryer

MALFUNCTION POSSIBLE CAUSE ACTION

Improper operation of 1. Check the power supply. If the
cycle timer. correct voltage is not present
between L1 and both of the L2
terminals, check the wiring and
protective devices supplying power
to the dryer.

2. Dryers with DC solenoid valves

between L2 and DC1 and between
L2 and DC2. Replace the timer if
voltage is present at either DC
terminal continuously or not at all.
Timer input 120 VAC/Timer Output
53 VDC. Timer Input 240
VAC/Timer Output 106 VDC.

3. Refer to Solid State Timers section

for timing cycle information.

Desiccant contamination 1. Check inlet and outlet filters and

or attrition. outlet air line for indication of oil.

2. Remove the desiccant chambers

from the air manifold. If the
perforated disc at open end of the
chambers can be depressed more
than 1/4" from the retaining ring,
replace chamber, or have it
repacked.

Excess drop in outlet Improper operating Adjust operating conditions.

pressure. conditions.

Solenoid coil burned out. Remove cover, place iron or steel

material (screwdriver or nail) on
exposed end of solenoid base to feel the
magnetic effect indicating proper
operation. Note: Each adsorber coil
should be energized for 33.75 seconds.
Check for plugged air passages before
replacing coil.

C-9
Appendix C Optional Heatless Air Dryer

MALFUNCTION POSSIBLE CAUSE ACTION

Improper operation of 1. Check the power supply. If the
cycle timer. correct voltage is not present
between L1 and both of the L2
terminals, check the wiring and
protective devices supplying power
to the dryer.

2. Dryers with DC solenoid valves

between L2 and DC1 and between
L2 and DC2. Replace the timer if
voltage is present at either DC
terminal continuously or not at all.
Timer input 120 VAC/Timer Output
53 VDC. Timer Input 240
VAC/Timer Output 106 VDC.

3. Refer to Solid State Timers section

for timing cycle information.

Check valve balls seated Remove check balls and springs and
improperly. inspect for excessive wear or damage.
Replace if necessary.

Plugged air passages. Check inlet and outlet air passages and
piping for blockage.

Desiccant contamination 1. Check inlet and outlet filters and

or attrition. outlet air line for indication of oil.

2. Remove the desiccant chambers

from the air manifold. If the
perforated disc at open end of the
chambers can be depressed more
than 1/4" from the retaining ring,
replace chamber, or have it
repacked.

Solenoid valve Solenoid valve defective. 1. Solenoid valve connected to AC

chatter. terminal on solid-state timer.

2. Voltage too low.

C-10