Model 1160 - User Manual
Contents
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3. pe roue 1 5 CHAPTER 2 INSTALLATION 2 1 dias 2 1 ILI tM RP m 2 1 ASSEMBLY 2 2 Input Output Functions ior cete teat er 2 3 Scrubber es 2 4 CHAPTER 3 OPERATION si 3 1 Front Panel Display and CONOS ans 3 1 lx s MM 3 2 Converter Temperature s ense deci 3 2 A 3 2 CA e 3 2 DEV ee 3 2 Service Alan ein 3 2 Mode Selection u a tameo pui om es gU epe FUR pu Tdi peque d 3 3 Converter Temperature sessional 3 5 Power Up Seguente a 3 6 CHAPTER 4 MAINTENANCE 2c ecce riore 4 1 Spare Pas use 4 1 Mb CM 4 3 Compressor A aa Sala 4 4 4 4 A 4 4 Service Alarm 2154 5 4 ee 4 4 Service Locations sata aan Br ira 4 5 APPENDIX A WARRANTY sionista A 1 APPENDIX PUMP COMPRESSOR B 1 APPENDIX 5 5 1 Power Supply Board Gea Pet eden o SV ne C 2 Display Board sip C 3 Rear Connector era to tese sob ct tton ede sir odis beu de oe e C 4 Instrument AC Power 120 VAC 50 60 2 22 00000 0000 C
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5. Remove the old foam filter and discard Replace with the new filter and snap filter cap back into place Figure 9 Filter Body Foam Filter Filter Cap SCHEMATICS This appendix contains the schematics for the Model 1160 Always turn off the instrument and unplug the power cord before removing any printed circuit board Schematic Diagram Drawing No Part Number Page Power Supply Board 86P901 16101 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 2 86P903 NA C 8 C 1 E 3 4
6. 5 Instrument AC Power 220 VAC 50 C 6 Instrument AC Power 240 VAC 60 C 7 Instrument AC Power 100 VAC 50 60 2 22 0 00404 00000 C 8 vi Figure LIST OF ILLUSTRATIONS Page Model 1160 Componetts sitas etre nn 1 3 Model 1160 Flow Schematic A 1 4 Mode LOU RG Ar Panel e th 2 2 Pin of Rear Panel Terminal ST 2 3 Scrubber Base and Top Plates u ara ae 2 5 Scrubber Assembly Components an ee ree eec te Ue eni 2 6 Front Panel Displays a Pec bie ae 3 1 Display Bod aa Herde 3 4 Power Board Component Footprint nennen 3 5 SeruBber Parts bist ran leeren 4 2 vii LIST OF TABLES Table Page 1 1 Pollutant Removal Method and Removal 1 1 s Mod Selections near n Ud NIS yin D dM RN 3 3 4 1 Recommended Spare uet Uo ao 4 1 1 INTRODUCTION Thermo Scientific s Model 1160 Zero Air Supply converts ambient air to pollutant free air Table 1 1 describes the pollutants that can be removed the method of removal and the removal component Table 1 1 Pollutant Removal Method and Removal Component Pollutant Contaminant Method Component Water Oxides of Nitrogen 50 Ozone CO Hydrocarbons VOCs BASIC PLATFORM Condensation Adsorbent desiccant Membrane permeation Absorpt
7. To unpack the Model 1160 Zero Air Supply follow the procedure outlined below l Remove the Model 1160 from the shipping container and set on a table or bench that allows easy access to both the front and rear of the instrument 2 Remove the Model 1160 cover from the main frame of the unit to expose the internal components of the instrument 3 Check for possible damage during shipment 4 Reinstall the cover 5 Check for possible damage during shipment Chapter 2 Installation ASSEMBLY 1 If an external compressor will be used to supply the air connect it to the inlet bulkhead with 1 4 line IMPORTANT Applications using an external air source must pressure regulate to 70 PSI or less and must pre condition the inlet air in accordance with ISO standard 8573 1 A minimum air quality level of Class 2 for hydrocarbons oils and Class 1 for particulates dust rust etc is required Failure to meet this requirement can potentially degrade the performance 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 internal scrubbers and check that the hold do
8. adequate cooling of the compressor CHECK OPERATION Hold the sleeve down against the housing with one hand and slowly ensure all components are lined up properly As the piston travels up and down it will also rock from side to side This is a feature of the WOB L Piston Figure 7 B 6 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 Accaution Make sure gasket is not twisted when seated in groove B 7 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 Ibs in a crisscross pattern Numbers indicate tightening sequence Head Assembly C caution To avoid property damage or personal injury always try rotating the fan by HAND prior to connecting the unit to the power source Check for suction atthe air inlet port by placing your finger over the port as you turn the fan You should feel a slight suction with each rotation of the fan If you don t feel suction or if you feel or hear a thump as you turn the fan DO NOT CONNECT THE UNIT TO A POWER SOURCE review the assembly procedure for possible error STEP 3 Remove the filter cap from the filter body by prying it with a flat screwdriver
9. Model 1160 Instruction Manual Zero Air Supply Part Number 18665 2Jun2010 The 220V option complies with 89 336 EEC directive for electromagnetic compatibility 2007 Thermo Fisher Scientific Inc rights reserved Specifications 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 Thermo Fisher Scientific WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific 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 are available www thermo com WEEEROHS WEEE Compliance TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1 1 Basic tt 1 1 O 1 2 Performance
10. Scientific Appendix A Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller s published specifications and be free from defects in material and workmanship when subjected to normal proper and intended usage by properly trained personnel for the period of time set forth in the product documentation published specifications or package inserts If a period of time is not specified in Seller s product documentation published specifications or package inserts the warranty period shall be one 1 year from the date of shipment to Buyer for equipment and ninety 90 days for all other products the Warranty Period Seller agrees during the Warranty Period to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with said published specifications provided that a Buyer shall promptly notify Seller in writing upon the discovery of any defect which notice shall include the product model and serial number if applicable and details of the warranty claim b after Seller s review Seller will provide Buyer with service data and or a Return Material Authorization 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 refurbi
11. TEP 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 side B 3 STEP 5 Remove the intake valve flapper 1 keeper 2 restraint 3 if assembled and screw from the bottom of the valve plate and discard Clean the bottom of the plate with a clean soft cloth Install the new intake valve flapper and restraint if one was removed The valve keeper should be placed on top of the flapper so that the word UP is visible See Fig 2 NOTE Pay close attention to valve assembly Some parts in kit may not be for your model NOTE Torque new flapper screw to 18 inch pounds STEP 6 Install the new O ring seating it firmly into the groove with your finger or blunt object See Fig 2 Figure 3 O Ring Groove STEP 9 Remove the fan by using two flat blade screwdrivers to pry off making sure screwdriver contact is made with hub back and not the fan blades Note fan orientation for reassembly Figure 2 O Ring Groove STEP 7 Remove the exhaust valve flapper 1 restraint 2 and valve keeper 3 from the top of the valve plate and discard them Clean th
12. canisters being sure that the O rings are properly seated and then swing the handle back up into position Tighten the hold down screw finger tight Then use a 3 8 open end wrench to turn the screw approximately 34 turn more Do not over tighten Chapter 2 Installation Figure 2 3 Scrubber Base and Top Plates Be sure to properly seat all of the canisters even if one or 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 Chapter 2 Installation P N 14558 00 P N 104558 00 P N 104557 00 7 Figure 2 4 Scrubber Assembly Component 2 6 CHAPTER 3 OPERATION This chapter 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 AAAA U 7 7 7 7 4 Figure 3 1 Front Panel Display 3 1 Chapter 3 Operation Pressure The digital display shows the current output pressure in PSIG or kPa The output pressure is adjusted by pulling the regulator knob out and turning it Push the knob in to lock the pressure setting Converter Tempe
13. d For example to supply zero air to a Thermo Scientific Model 55C the pressure on the Model 1160 should be set at 45 psi To supply air to the Thermo Scientific Model 146 calibrator the 1160 regulator could be set to any pressure between 35 and 50 psi If the requirements for the instrument being supplied are not specified it is recommended that the output pressure be set at 45 psi To be certain of maximum converter efficiency wait until the Converter Ready light on the front panel turns green before using zero air from the instrument 3 6 4 MAINTENANCE This chapter describes the routine maintenance procedures that the Model 1160 may require It assumes that a subassembly has been identified as defective and needs to be replaced or is an expendable item needing periodic maintenance not covered under warranty Expendable items are indicated in the Spare Parts list with an asterisk SPARE PARTS Table 4 1 lists recommended spare parts in the Model 1160 Table 4 1 Recommended Spare Parts Part Number Description 6998 4158 7075 86P714 16103 16101 18516 86P745 18638 18651 4300 4568 4070 18639 18640 86P731 106422 01 18642 18571 11526 106422 02 106422 03 109981 00 Drierite Replace on routine basis Charcoal Replace on routine basis Purafil Replace on routine basis Converter Display Board Power Board Status Control Board Pressure Regulator Relieving type 0 100
14. e 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 is visible See Fig 3 NOTE Torque flapper screw to 18 inch pounds STEP 8 Install the new head gasket seating it firmly into the groove with your finger or blunt object See Fig 3 Set aside Repeat steps 5 thru 8 to service other end of compressor View of Fan with spring clip facing in Figure 4 STEP 10 Insert the 5 32 Allen wrench Eccentric into the access hole in the compres Set Screw sor housing Loosen the set screw 1 4 Access turn Rotate connecting rod to top dead Hole center 180 and slide the connecting rod eccentric assembly off the shaft and N through the opening in the housing 2 Figure 5 Set Screw STEP 11 Secure the rod assembly in a fixture Remove the sleeve 1 discard from the connecting rod Remove the screw 2 compare to screws from kit from the cup retainer 3 retain for reassembly Remove the piston cup 4 compare to cups from kit and wipe debris from the top of the connecting rod and retainer with a clean damp cloth 2 This retainer screw may be one of two different sizes depending on when it was manufactured Both of the different screw
15. f the basic instrument and the options are shown in Figure 1 1 Figure 1 1 Model 1160 Components 1 3 Chapter 1 Introduction The flow through a fully equipped Model 1160 is shown in Figure 1 2 Ambient air is drawn into the instrument by the internal compressor It enters a loop where air from the fan cools the air stream and condenses out water The water condensate is removed by the water coalescing filters and ejected via drains in the rear panel The 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 for span gas systems Figure 1 2 Model 1160 Flow Schematic Note PN7075 Purafil PN4157 Charcoal PN6988 Drierite System Check valve opens at approximately 80 psi Parameter Maximum Capacity Maximum Delivery Pressure CO Oxidizing Efficiency CO Breakthrough HC Oxidizing Efficiency HC Breakthrough SO Breakthrough Breakthrough Dew Point Temperature option Ambient Operation temperature Range Storage Temperature Range Input Power Input Voltages Frequency Ambient Environmental Conditions Mounting Dimensions Weight User In
16. for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty Buyer shall pay Seller therefor at 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 THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMENT TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY STATEMENT SELLER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT A 2 Warranty Thermo Fisher Scientific APPENDIX PUMP COMPRESSOR MAINTENANCE The information in this appendix wa
17. generative dryer provides a lower dew point than the membrane dryer it is more costly and requires higher airflow to operate The membrane dryer is suitable for many applications that do not require a dew point below 5 C The operation of the dryers is as follows a Membrane The membrane dryer uses non porous hollow fiber membranes Compressed air is conducted inside the membranes Water vapor molecules permeate the wall of the membrane leaving the oxygen and nitrogen molecules to exit the outlet as dry air A small amount of dry air is routed to the outside of the membrane fibers to sweep away the permeated water vapor through a purge valve 1 2 Chapter 1 Introduction b Regenerative The regenerative or heatless air dryer consists of two chambers filled with an adsorbent desiccant One chamber dries the gas stream while the other is regenerated using a small amount of the dried air flowing as a countercurrent The wet air is released as a vapor through an exhaust port The regenerative dryer can also be used to remove CO 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 30 of the total available flow The components o
18. he inside surface of the front panel The timer reset button is also located on the display board In addition to the alarm outputs the rear panel connector also has one input and a ground By connecting pin 7 to instrument ground at pin 8 a data logger or other control device can switch the 1160 to stand by mode In stand by mode the internal pump is switched off Stand by is used to reduce pump wear and prolong adsorbent media life by turning the pump off when zero air is not needed 7 Figure 2 2 Pin Out of Rear Terminal Strip Chapter 2 Installation SCRUBBER INSTALLATION The 1160 are shipped with the adsorbent scrubber systems empty Before turning the instrument on make sure that the canisters contain fresh packing Please refer to Figures 2 3 2 4 and 4 1 while reviewing the following procedure l 2 Loosen the hold down screw swing the handle aside and remove the top plate Insure that both felt pad filters are flat against the bottom of the plastic canister Fill both the inner 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 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 Figure 2 4 Re seat the
19. hown 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 increased operating costs 005 _ 0000000 Sa Wess gos m im y y 1000000 m la e L ja 55 oc nun STE 5 oe SH in i Figure 3 3 Power Board Component Footprint 3 5 Chapter 3 Operation POWER UP SEQUENCE Turn the instrument on with the rocker switch on the front panel The compressor if installed will not start immediately and the digital gauge on the front panel should display zero output pressure This is normal start up operation since the compressor remains inactive until the catalytic reactor reaches 90 percent of its set point temperature Depress the converter temperature button and verify that the reactor temperature is increasing Once the catalytic reactor is within 10 percent of the set point temperature the compressor 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 supplie
20. iencies are derived from empirical data established by the Manufacturer 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 e Thermo Scientific s Model 51C Total Hydrocarbon Analyzer and a Certified instrument span gas 59 1 ppm Methane balance Air for Hydrocarbons 1 6 2 INSTALLATION Installation of the Model 1160 zero air supply includes lifting and unpacking the instrument connecting the compressor connecting the gas flow lines and attachment to suitable AC power LIFTING A procedure appropriate to lifting a heavy object should be used when lifting the zero air supply This procedure consists of bending at the knees while keeping your back straight and upright The case should be grasped at the bottom in the front and at the rear of the unit Do not attempt to lift by the cover or other external fittings While one person may lift the unit it is desirable to have two persons lifting one by 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
21. ing to stand by mode when zero air is not needed To refill the scrubbers follow the procedures presented in Chapter 3 For maximum effectiveness remember to fill both the inner and outer cylinders of the scrubber with packing material to approximately 1 4 of the top Do not fill the outer cylinder completely to the top since the recessed cover requires proper seating against the O ring Press the Reset button on Display Board to reset the service alarm when the desiccants are changed see Chapter 3 Operation The reset will adjust the service alarm timer to zero and will also deactivate the service alarm LED and relay Again it should be noted that the service alarm is based on the instrument s operation time not calendar time When changing desiccants the operator should also visually inspect the coalescing filters that are located just down stream of the pump If they appear dirty clean both the bowls and clean or replace the filter elements 4 3 Chapter 4 Maintenance COMPRESSOR Compressor maintenance procedures are described in Appendix B FAN FILTER The fan filter is located on the outside of the rear panel When the filter shows sings of dust buildup snap off the protective cover Remove the filter and wash in cold water Ring it out replace it in the protective cover and snap the cover in place FUSE REPLACEMENT Two 5x20mm 250V SLO BLO fuses are located in a drawer above the power cord socket The curre
22. ion Adsorption absorption chemical reaction Adsorption Adsorption Oxidation to CO Chemical reaction Reversible adsorption Oxidation Adsorption Cooling loop coalescing filters Regenerative dryer Membrane dryer Drierite scrubber Purafil scrubber Charcoal scrubber Charcoal scrubber Catalytic Converter Ascarite scrubber Regenerative dryer Catalytic Converter Charcoal scrubber 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 be added The exact configuration of each system depends upon the application and the pollutant s to be eliminated The basic Model 1160 platform consists of the following e Electronics Control instrument power front panel display and I O e Cooling loop coalescing filters Remove water e Regulator Controls output pressure e Single Scrubber Choice of removing NOx Oxides of Nitrogen or CO or SO and O3 1 1 Chapter 1 Introduction ADD ONS Depending upon the application the following items may be added to the basic platform Internal Compressor Depending on the model the internal compressor provides up to 20 LPM of flow at pressures up to 50 psi If the internal compressor is not purchased an external compressor or a house air supply can be connected to the inlet bulkhead o
23. n the rear panel The inlet bulkhead connects the air supply to the coalescing filters If the Model 1160 utilizes an external pump or air supply and has a regenerative dryer installed the air supply should be able to produce at least 30 LPM of flow at a pressure of at least 60 psi At lower pressures the drying efficiency will be compromised Inlet pressure must be limited to 90 PSI when using an external air supply Scrubbers The Model 1160 can contain up to three scrubbing modules When multiple scrubbers are installed they may be used in any combination to simultaneously remove more than one pollutant or multiple modules may be filled with the same material to extend the time between service The following scrubbing materials are available a Charcoal Removes ozone sulfur dioxide SO and non methane hydrocarbons b Purafil Removes NO C Ascarite Removes carbon dioxide CO d 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 service Dryers If dry air is required the Model 1160 may include either a membrane or a regenerative dryer For most applications it is recommended that one of these be used since the efficiency of adsorbents such as charcoal and Purafil may decrease at high humidity levels Although the re
24. nge color routine replacement is not required It should be noted that the desiccant is extremely efficient and will produce a very low dew point air stream However the scrubber capacity is relatively limited If you find that the color change is occurring rapidly and that the unit requires frequent service it may suggest that the upstream drying system is not operating properly Contact the Thermo Fisher Scientific service center or your local agent if this becomes a problem Purafil Purafil also exhibits a slight color change from purple to brown as it becomes expended However the color change can be subtle and we recommend that the materials should be changed at least once every 12 months even if the color appears stable Activated Charcoal Replacement frequency of charcoal depends entirely on usage and required performance Since there is no color change to indicate when the material 15 saturated it 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 instrument duty cycle and on the amount of air moving through the system The time between service can be extended by turning the system off or switch
25. nt rating of the individual fuses depends on the mains supply voltage that your Model 1160 has been configured Refer to the instrument data label located on the rear panel near the input power module for the fuse ratings 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 Replace with a new battery Be sure to note the battery polarity when installing the new battery The positive plate of the battery should be facing the installer during installation The battery backup circuit is diode protected In the event that the battery is installed improperly reversed polarity the diodes prevent a short circuit current flow from the battery However the backup voltage will not be applied to the service alarm circuit resulting in loss of service alarm timing functions Chapter 4 Maintenance SERVICE LOCATIONS For additional assistance service 15 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 Thermo Fisher
26. peration The jumper settings are as follows e J 30days e J2 60days e J3 90days e 120 days e 5 150 days None alarm disabled Mode Selection Pump operation mode and pressure units displayed can be selected by changing jumper positions 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 is placed in continuous run mode AUTO Pump is activated only when the catalytic reactor temperature is above 90 of set point PSI Front panel displays pressure in units of En Pounds per Square Inch PSI go Front panel displays pressure in units of gt KER Kilopascals kPa 3 3 Chapter 3 Operation Mode selection jumpers Selectable Service Interval Jumpers uy quc ae ese pores reet Service Reset Button Service Alarm Backup Battery e T z 2 mo 0905000 sS vay 2 COCO 00000000 TES Hoo00000 iss Vis oo e 2000000 e 2 Display Board Figure 3 3 4 Chapter 3 Operation Converter Temperature When the converter temperature button is pushed the digital display shows the temperature of the converter The temperature is displayed only as long as this button is pressed The converter temperature can be adjusted via a jumper located on the power board which is s
27. psi output range Compressor High Output 0 20 Ipm 120 VAC 60 Hz Compressor High Output 0 20 Ipm 220 240 VAC 50 Hz Fan Fan Guard Fan Filter Element Clean or replace on routine basis Regenerative Dryer Membrane Dryer Water Trap Purge Single Scrubber assembly see Figure 4 1 Fuses 115V T 10 A 250 V Slo Blo Fuses 240V 6 3 A 250 V Slo Blo Service Alarm Backup Battery Dual Scrubber Assy Triple Scrubber Assy Compressor Rebuild Kit 4 1 Chapter 4 Maintenance ae de SCRUBBER MEDIA PART NUMBERS CAN BE FOUND ON THE SPARE PARTS LIST Figure 4 1 Scrubber Parts List 4 2 86P703 ITEM DESCRIPTION QTY 1 104535 00 BASE SINGLE 1 2 N A HANDLE 1 3 s6P401 CANNISTER ASSEMBLY 1 104536 00 1 104557 00 O RING 1 8 104558 00 O RING 2 8 18617 FILTER INNER 1 9 18618 FILTER PAD OUTER 1 10 4407 ELBOW MALE 1 11 4400 CONNECTOR MALE 1 OTE Chapter 4 Maintenance SCRUBBERS Replacement frequency of scrubber materials depends on usage and on composition of input air The following guidelines are suggested but may not be appropriate for all applications Desiccant The Drierite desiccant should be replaced when the color changes from blue to pink As long as the material is not exposed to humidity and does not cha
28. rature The current converter temperature can be shown on the digital display by pressing and holding the Converter Temperature button The set point is adjusted at the factory using jumpers located on the power supply board Status LEDs Converter Ready The converter ready light on the front panel remains red while the instrument warms up This light turns green when the instrument is warmed up within 90 percent of set point temperature Standby The standby light indicates that the pump is 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 adsorbent scrubbers may need to be changed The preset service interval is set for 90 days at the factory and can be changed using jumpers located on the Display Board The Display Board is attached to the inside of the front panel see Figure 3 2 The Service Reset button which 1 also located on the Display Board sets the elapsed time back to zero It should be noted that the elapsed time is retained in battery backed memory when the unit s main power is turned off but the service clock only increments when the unit is actually in use 3 2 Chapter 3 O
29. s obtained from Gardner Denver Thomas B 1 MODEL SK668 COMPRESSOR SERVICE KIT For use on 668 Model Compressors A WARNING Unplug the compressor before beginning disassembly A CAUTION Improper assembly or use of damaged parts may lead to premature failure To avoid frequent repairs follow the recommended assembly procedures This kit includes the following parts 623143 Head Gasket 1 I 625175 Head Screw 4 Cy 625591 Flapper Screw 2 623071 O Ring 1 617562 CX Valve 2 A lt gt 621647 Valve Backer 1 624396 Piston Cup 1 Post 04 01 Production 621485 Valve e lapper 2 624684 Piston Cup 1 Pre 04 01 Production 670031 Cylinder Sleeve 1 625180 OR 625776 Screw Piston Cup 1 each NOTE Before you begin read these instructions thoroughly and assemble the necessary tools You will need 1 4 Hex Socket attachment for torque wrench Torx 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 Part No 642751A 11 08 DISASSEMBLY STEP 1 Clean loose dirt from the outside of the compressor STEP 2 Loosen the 4 head screws 1 and remove the compressor head 2 Note orientation of head for reassembly very important Discard head screws Caution Place capacitor off to side leaving it connected to lead wires S
30. shed at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replacement Products shall be made in accordance with the Delivery provisions of the Seller s Terms and Conditions of Sale Consumables including but not limited to lamps fuses batteries bulbs and other such expendable items are expressly excluded from the warranty under this warranty Notwithstanding the foregoing Products supplied by Seller that are obtained by Seller from an original manufacturer or third party supplier are not warranted by Seller but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier to the extent such assignment is allowed by such original manufacturer or third party supplier In no event shall Seller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear and tear ii accident disaster or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which Warranty 1 they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage and handling of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products
31. 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 center of connecting rod top Do not damage the cup Place retainer 3 on top of cup counterbore up making sure that the cup inside diameter is seated properly over retaining boss Note that the retainer has a locating boss that must insert into rod top pilot Drive new retainer screw to 100 in Ibs Carefully push sleeve up forming the cup Stop pushing the cylinder sleeve up when the piston cup is positioned midway inside Figure 6 the sleeve B 5 STEP 13 Rotate the rotor shaft so that flat faces up 12 00 Position piston cup at bottom dead center of cylinder sleeve STEP 14 Slide the connecting rod assembly onto the shaft until the eccentric face positively stops against the bearing Align the eccentric setscrew with the flat of the shaft Rotate the eccentric and shaft 90 degrees so the set screw is visible through the access hole in the housing and tighten set screw to 125 in Ibs 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
32. terface Control Alarm Contact Rating PERFORMANCE SPECIFICATIONS Specification 0 71 CFM 20 SLPM 0 53 CFM 15 SLPM 50 PSIG 345 KPa 40 PSIG 275 KPa 99 998 undetectable 99 798 lt 5 ppb output lt 0 5 PPB lt 0 5 PPB lt 5 0 lt 30 C 15 35 C 0 40 C 1300 VA 100 VAC 60 Hz 120 VAC 60 Hz 240 VAC 60 Hz 220 VAC 50 Hz 240 VAC 50 Hz Chapter 1 Introduction Comments 120 VAC 60 Hz input permeation dryer 120 VAC 60 Hz input regenerative dryer 120 VAC 60 Hz input permeation dryer 120 VAC 60 Hz input regenerative dryer Based on typical ambient air as input Specified as methane Based on typical ambient air as input Permeation method Regenerative method Absolute maximum value Input voltage frequency dependent Japan North South America North America Europe Asia Asia Africa Oceania United Kingdom Indoor Use Std Atmospheric Conditions Bench Top Standard Rack mount option 206 16 90 W x 24 0 D x 9 20 H 42 93 cm x 55 88 cm x 23 37 cm 85 Ibs 38 6 Kg Output Pressure Reactor Temperature Compressor Stand by Pressure Alarm Temperature Alarm 0 24 Volts 0 5 Amps 1 5 Fully Equipped Front Panel LED Display Default Front Panel LED Display Pushbutton J2 Header Rear Panel Pin 7 to Ground J2 Header Rear Panel Passive Contacts J2 Header Rear Panel Passive Contacts Chapter 1 Introduction Note Oxidizing effic
33. wn screws are securely fastened Detailed instructions are presented at the end of this chapter 5 Check the voltage label to verify that it matches the local power and plug the AC line cord into an appropriate power source STATUS CONTROL AC NE RE Her B 2 TED Ln 2 86P702 Figure 2 1 Model 1160 Rear Panel Chapter 2 Installation INPUT OUTPUT FUNCTIONS The 1160 rear panel includes one set of eight I O pins that can be used to monitor and control the unit s operation The pin assignments for the connector are shown in Figure 2 2 As indicated pins 1 and 2 are used for a general service alarm pins 3 and 4 are used by the low temperature alarm and pins 5 and 6 are used by the low pressure alarm The pressure alarm is triggered in the event of a pump failure and the temperature alarm is triggered in the event of heater failure In each case an alarm condition is indicated by continuity between the two pins For example if the heater circuit fails it will create a low temperature condition and a relay will 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 t
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