Air A5, Air A20 - Masterflex
PD-0100-0073
Revision A
Air A5, Air A20
LABORATORY ZERO-AIR
GENERATORS
Installation, Operation & Maintenance
Manual
Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Zero Air 5 and Zero Air20 Laboratory Zero-Air Generators Installation,
Operation & Maintenance Manual
Covering the following laboratory zero-air generator models:
Model
Proton OnSite Part Number
Zero Air 5, 120 VAC 50/60 Hz
54-0113-0009
Zero Air 5, 230 VAC 50/60 Hz
54-0113-0010
Zero Air 20, 120 VAC 50/60 Hz
54-0113--0011
Zero Air 20, 230 VAC 50/60 Hz
54-0113-0012
Proton OnSite
10 Technology Drive
Wallingford, CT 06492
203-949-8697
203-678-2000
[email protected]
www.protononsite.com
В© 2014 Proton Energy Systems, Inc. d/b/a Proton OnSite
All rights not expressly granted herein are reserved.
Information in this document is provided in connection with Proton Energy Systems Inc. d/b/a Proton OnSite
(“Proton”) products and services. No license, express or implied, by estoppel or otherwise, to any intellectual
property rights is granted by this document. Except as provided in Proton Terms and Conditions of Sale for such
products and services, Proton assumes no liability whatsoever, and Proton disclaims any express or implied
warranty, whether written or oral, relating to sale and/or use of Proton products or services including liability or
warranties relating to fitness for a particular purpose, merchantability, or infringement of any patent, copyright or
other intellectual property right. Proton products are not intended for use in medical, life saving, or life sustaining
applications.
Proton may make changes to specifications and product descriptions at any time, without notice.
This document as well as any software, processes or procedures described in it is furnished under license and
may only be used or copied in accordance with the terms of the license. The information in this document is
furnished for informational use only, is subject to change without notice, and should not be construed as a
commitment by Proton. Proton assumes no responsibility or liability for any errors or inaccuracies that may
appear in this document or any software that may be provided in association with this document.
Except as permitted by such license, no part of this document may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means without the express written consent of Proton.
В® Proton, Proton OnSite, Proton Energy Systems, the Proton design, StableFlow, StableFlow Hydrogen Control
System and design, HOGEN, and FuelGen are trademarks of Proton Energy Systems, Inc.
Any other brands and/or names used herein are the property of their respective owners.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Disclaimer
Proton OnSite has written this manual to be an easy to use guide for the Zero Air 5 and Zero Air 20 Zero-Air
Generators. All statements, technical information, and recommendations in this manual and in any guides or
related documents are believed reliable, but the accuracy and completeness thereof are not guaranteed or
warranted. They are not intended to be, nor should they be understood to be, representations or warranties
concerning the products described.
This zero-air gas generator has been sold subject to the limited warranties set forth in the warranty statement.
Further, Proton reserves the right to make changes in the specifications of the products described in this manual at
any time without notice and without obligation to notify any person of such changes.
This laboratory zero-air generator is designed for operation only by trained personnel familiar with the use of
similar equipment and with safety requirements for the use of zero-air and other industrial gases. Before operating
this laboratory zero-air generator, make sure to read and understand this information provided herein. If you have
questions, please contact Proton OnSite Systems or your generator supplier.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
LIMITED WARRANTY
ZERO-AIR GAS GENERATOR SYSTEMS
LIMITED WARRANTY: PROTON ENERGY SYSTEMS INC. (“PROTON”) warrants that the ITEMS LISTED BELOW shall be
free from defects in material and workmanship for the stated period of time commencing from date of shipment or as stated below.
ZERO-AIR GAS GENERATOR SYSTEMS:
One (1) year from shipment
Repair or replacement parts for Zero-Gas Generator System:
Ninety (90) days from shipment
EXCLUDED FROM THIS LIMITED WARRANTY: The following shall be excluded from the Limited Warranty:
В·
Parts and items considered consumable in normal operations, including those parts and items supplied with the Zero-Air
Gas Generator System (“System”) for maintenance.
В·
Any System and its parts that are not installed, operated, and maintained in accordance with the unit’s manual supplied
with the System.
В·
Damages due to accident, abuse, acts of God, acts of terrorism, misuse or negligence, or which result, in whole or in part,
from improper or unauthorized use or repair of the System, or use of the System in a manner for which it was not
designed, or by causes external to the System such as, but not limited to, power or air conditioning failure or voltage
irregularities.
REMEDY: BUYER’S sole and exclusive remedy in the event of defect, and the liability of PROTON hereunder is limited to
the adjustment, repair, or replacement of the defective item or part with a similar item or part free of defect.
Such adjustments, repairs, or replacements will be made at PROTON’S Wallingford, Connecticut, plant or, for Systems only, at the site of
the System, if BUYER so elects. All costs for shipping equipment or parts shall be on the account of the BUYER whether to or from the
point of manufacture. Labor costs associated with travel, expenses, and subsistence costs for field services shall be on the account of the
BUYER.
VOIDING OF THE LIMITED WARRANTY: This Limited Warranty is immediately void upon:
В·
THE OPENING OR DISASSEMBLY OF THE SYSTEM CABINET (OR ANY PART THEREIN), OR
В·
THE SALE, ASSIGNMENT OR ANY OTHER TRANSFER OF TITLE BY BUYER OF THE ITEMS OR PARTS OTHERWISE
COVERED UNDER THIS LIMITED WARRANTY
WAIVER OF ALL OTHER WARRANTIES: THE LIMITED WARRANTY PROVIDED HEREUNDER AND THE RIGHTS AND
REMEDIES OF THE BUYER HEREUNDER ARE IN LIEU OF, AND BUYER EXPRESSLY WAIVES, ALL OTHER WARRANTIES,
GUARANTEES, OBLIGATIONS, LIABILITIES, OR REMEDIES, EXPRESSED OR IMPLIED, ARISING BY LAW OR
OTHERWISE, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND NONINFRINGEMENT, IMPLIED WARRANTIES ARISING FORM THE COURSE OF DEALING OR USAGE OF TRADE AND
IMPLIED WARRANTIES OF SUITABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: THE REMEDIES PROVIDED IN THIS LIMITED WARRANTY ARE EXCLUSIVE AND PROTON
SHALL IN NO WAY BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER
INCLUDING WITHOUT LIMITATION LOSS OF USE, REVENUE OR PROFIT.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Air A5 and Air A20 Laboratory Zero-Air Generators
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Prepared by
PROTON ONSITEВ®
CONTENTS
1
Introduction ..................................................................................................................8
General Information ................................................................................................................... 9
Product Specifications............................................................................................................... 10
2
Safety .......................................................................................................................... 12
Using Zero-Air Generators ....................................................................................................... 12
Safety Devices ............................................................................................................................ 12
Technical Service Contact Information.................................................................................... 12
3
Placement ................................................................................................................... 13
Providing Suitable Location ..................................................................................................... 13
Unpacking the Generator ......................................................................................................... 13
Positioning the Generator ......................................................................................................... 14
4
Installation Procedure ................................................................................................ 15
4.1 Mechanical Setup ................................................................................................................ 15
4.2 Electrical Setup ................................................................................................................... 16
4.3 Before Using the Generator ................................................................................................ 16
4.4 Shutdown ............................................................................................................................. 17
5
Maintenance ............................................................................................................... 18
Cleaning the Generator............................................................................................................. 18
6
Troubleshooting .......................................................................................................... 19
7
APPENDIX A—FORMS ............................................................................................ 20
Customer Registration Form .................................................................................................... 20
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Air A5 and Air A20 Laboratory Zero-Air Generators
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TABLE OF FIGURES
FIGURE 1 INSTALLATION CLEARANCES .............................................................................................................. 14
FIGURE 2: ZERO AIR 5/ZERO AIR 20 INLET/OUTLET, RIGHT SIDE ........................................................................ 15
FIGURE 3: POWER SWITCH, LEFT SIDE .............................................................................................................. 17
LIST OF TABLES
TABLE 1: TECHNICAL SPECIFICATIONS FOR THE ZERO AIR 5 AND ZERO AIR 20 GENERATORS.................................. 10
TABLE 2: GENERATOR GAS INLET/OUTLET FITTINGS .......................................................................................... 11
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
This Installation, Operation & Maintenance Manual of the Air Generator uses the
following safety symbols and conventions to alert you to information intended to help
you operate your laboratory air generators correctly and safely.
Manual Conventions
—Indicates a potentially hazardous situation, which, if not avoided, could
result in death or serious injury. The reader is in a situation which could
cause bodily injury. Do not proceed beyond a Warning symbol until the
indicated conditions are fully understood and met.
—Indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury. It may also be used to alert against unsafe
practices. This could result in equipment damage or loss of data. Do not
proceed beyond a Caution symbol until the indicated conditions are fully
understood and met.
—Notes contain helpful suggestions or references.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
1
Introduction
Congratulations on your purchase of a Air A5 or Air A20 zero-air generator, the most
capable family of laboratory zero-air generator products available today. Zero Air purifiers
are intended to reduce the hydrocarbon content of compressed air used for laboratory
instrumentation.
Our zero-air generators provide high purity-grade, zero-air on demand and provide the
following benefits:
· Up to 20 Lpm (liters per minute—depending on model)
В· Up to 145 psig delivery pressure
Proton OnSite has provided these instructions to guide in the installation, operation, and
maintenance of the zero-air generator. These instructions provide technical product
information, installation requirements, and detailed mechanical interface specifications.
Important safety information is also included in this manual. Please take time to familiarize
yourself with the system and the manual.
This manual attempts to answer most of the frequently asked questions with regards to the
operation of the unit. However, should you have any questions, the Proton OnSite technical
staff stands ready to answer them and support the successful deployment of this equipment.
Please call (203) 949-8697 and ask for field service technical support or email
[email protected] Please have the serial number and configuration number
of your unit available.
IT IS THE CUSTOMER’S RESPONSIBILITY TO CONSULT WITH THE
LOCAL AUTHORITY HAVING JURISDICTION (AHJ) REGARDING
LOCAL CODE REQUIREMENTS FOR INSTALLATION AND
OPERATION OF THIS EQUIPMENT.
Proton Onsite can offer a full range of installation services if you are not
comfortable with installation of the zero-air generator or purifier.
There are no user serviceable parts inside the laboratory zero-air generator. Any
interference with the internal parts voids the manufacturer’s warranty.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
General Information
The Air A5 and Air A20 are passive devices that reduce hydrocarbon content of an air-feed
to less than 1 ppmv (parts per million by volume).
The ability to meet hydrocarbon specifications diminishes as the rated flow-rate is exceeded.
This manual covers the installing, operating, and maintaining the Zero-Air Generator. The
manual assumes the user is familiar with pneumatic circuit components, and is aware of
appropriate safety precautions and use of compressed air and zero-air gases.
Detailed technical data are found in Product Specifications (Pg. 10), below. Dimensions for
the Air A5 or Air A20 cabinet, or enclosure, are found in Table 1: Technical Specifications
for the Zero Air 5 and Zero Air 20 Generators
Required fittings are displayed in Table 2 (Pg. 11).
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Product Specifications
Requirement
Zero Air 5
Zero Air 20
Product Flow Rate
5 SLPM
20 SLPM
Purity
< 1 ppm total hydrocarbons as methane
Delivery Pressure
(Output Pressure), bar (psi)
0–10 bar (0–145 psi)
Input Voltage
120 or 230 VAC 50/60Hz, 8A, factory configured
Air Input Requirements
Particulate ≤ 0.1 mg/m3 (≤ 0.01 μm)
Oil vapors ≤ 0.01 mg / m3
Moisture ≤ 3°C (37°F) dew point in pressure
0–10 bar (0–145 psi)
Enclosure Characteristics
External Dimensions
(HxDxW)
39.4 x 30.5 x 20.3 cm (15.5 x 12 x 8 inches)
Weight
24 lbs / 10.9 kg
Environmental Considerations
Location–Min/Max Ambient
Operating Temperature
5–40°C (40–104°F)
Location–Desired Ambient
Operating Temperature1
20–25°C (68–77°F)
Location–Max Ambient Humidity
≤ 80% (non-condensing or HR)
Maximum Level or Altitude
2000 m (6580 ft) above sea level
Location–Variation from Level
+/- 3Вє maximum
Location–Clearance
Recommendation
0.30 m (12 in) Minimum on Left and Right Sides
Display
Catalytic Bed Temperature Display
Environment
Indoor, non-hazardous, non-classified, non-explosive
Safety
Enclosure Protection Rating
IP20
Noise
<54 dB A
Mechanical Ports
Accept ¼” OD tubing
Expected yearly operator usage
6000 Hrs
Technologies Used
catalytic reactor
Applications
For GC FID, THC, NOX, BTX and SOX analyzers
Table 1: Technical Specifications for the Zero Air 5 and Zero Air 20 Generators
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Substance
Flow Direction
Fitting
Mating Information
Fitting
Location
Purified Air
Product
Out
¼” Push to Connect
1/4"-OD Tubing
Right Side
Air Inlet
In
¼” Push to Connect
1/4"-OD Tubing
Right Side
AC Power-In
In
Cord Set
Cord Set
Left Side
Table 2: Generator Gas Inlet/Outlet Fittings
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
2
Safety
The safety guidelines below may not cover all situations. If there are concerns or questions,
please contact Proton OnSite Technical Service or check with local authorities.
THE AIR A5 AND AIR A20 ARE LABORATORY INSTRUMENTS DESIGNED FOR
OPERATION BY TRAINED PERSONNEL.
ALL PERSONNEL HANDLING, USING OR MAINTAINING THIS GENERATOR
MUST EMPLOY SAFE WORKING PRACTICES AND OBSERVE ALL RELEVANT
LOCAL HEALTH AND SAFETY REGULATIONS.
Using Zero-Air Generators
Unit relies on a ventilation fan to ensure adequate cooling—do not block vents. The
generator must be operated in an area with sufficient air circulation. The power switch and
electrical disconnect (removable cord set) are located on the left side of the generator.
Safety Devices
MAXIMUM TEMPERATURE: The purifier is fitted with an internal catalyzer, the
temperature of which is constantly maintained at 600В°C. A thermal switch is attached to the
catalyzer bed housing and will trip if the exterior of the catalyzer exceeds 104 В°C (220 В°F).
Technical Service Contact Information
Proton OnSite Technical Service can be contacted as follows:
Proton OnSite
10 Technology Drive
Wallingford, CT 06492
203-949-8697
203-678-2000
[email protected]
www.protononsite.com
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Air A5 and Air A20 Laboratory Zero-Air Generators
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3
Placement
Providing Suitable Location
To avoid risks of damage to its electronic components, install the purifier in an environment
consistent with the specification called out in Table 1.
The ambient temperature in the purifier installation area must be between 5В°C and 40В°C.
Unpacking the Generator
The purifier is delivered in cardboard packaging. Remove all packaging, taking care not to
damage the purifier’s panels. If possible, store the packaging to ensure adequate protection
when moved in the future.
Unpack the generator and retain the packing materials in case it is necessary to ship it in the
future.
The Air A5 and Air A20 each weigh approximately 10.9 kg (24 lbs). Please use the
following instructions to unpack your Air5/Air20 zero-air generator:
1. Remove the Air5/Air20 zero-air generator from the box carefully by lifting it straight up
while grasping underneath the generator from the front and back.
2. Keep the generator in an upright position and place the generator carefully in the
designated location for it.
В· THE PURIFIER MUST ALWAYS OPERATE WITH ITS PROTECTIVE
HOUSING INSTALLED.
В· NEVER REMOVE THE COVER WHILE THE PURIFER IS OPERATING OR
FOR 24 HOURS AFTER SHUTDOWN FOR SERVICE.
В· WHEN OPERATION HAS CEASED. THE CATALYZER BED WILL REMAIN
HOT AND PRESENTS A BURN HAZARD.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Positioning the Generator
The zero-air generator is designed for indoor, laboratory installation. AC power that meets
the specifications outlined in Product Specifications (Section 0 on Page 10) is the only utility
required. Verify that the generator is located so that it complies with local safety regulations.
Following instructions to place your zero-air generator:
1. Place the generator in a location that meets the technical specifications from Product
Specifications (Section 0 on Page 10). Some specifications are highlighted below. We
recommend that the generator be placed as close to the gas application as possible.
2. Locate the unit, keeping in mind the continuing need for access to controls, gas outlets,
and power and control wiring.
3. Install on a level site (+/- 3В° required).
4. Keep the front of unit clear with at least 30 cm (12 in) of space on either side of the
generator for adequate ventilation air flow. The power switch and electrical disconnect
(removable cord set) are located on the left side of the unit and must be accessible at all
times during operation of the generator. Position the unit so that it is possible to operate
the disconnecting device.
Figure 1 Installation Clearances
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
4
Installation Procedure
4.1 Mechanical Setup
Air Inlet and Outlet: The air inlet distribution lines must be made using tubing
rated to the operating pressure and the pipeline diameters must be sized according
to the acceptable pressure drop values.
The max acceptable inlet pressure is 10 bar (145 psi).
This section provides a detailed description of the mechanical setup requirements.
1. Locate the filters, marked “INLET” and “OUTLET” at the right of the purifier (See
Figure 2).
2. Make the appropriate pneumatic connection between the purifier and the lines.
Air Inlet
Filter
Air Outlet
Filter
(Coalescing)
(Particulate)
Figure 2: Zero Air 5/Zero Air 20 Inlet/Outlet, Right Side
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
4.2 Electrical Setup
This section provides a detailed description of the mechanical setup requirements.
1. Determine the electrical supply outlet that serves the generator.
2. Ensure that the electrical supply is properly grounded and the voltage corresponds with
the generator rating plate.
Do not bypass ground pin.
3. Ensure that there is a good fuse in the power switch fuse drawer (located under the cord
set female fitting). The proper fuse is rated for 8 amps.
4. Connect the supplied cord set to the side of the unit.
5. Plug the generator into the electric outlet.
4.3 Before Using the Generator
1. Switch the power on using the power switch on the left side of the unit (Figure 3: Power
Switch).
2. The temperature controller power on and begins heating the catalyzer bed. The
temperature of the bed is displayed in degrees Celsius.
3. Allow the unit to reach the operating temperature of 600В° C before flowing air through
the system.
4. When the set point is reached, allow air to flow through the unit. Adjust the air flow to
ensure the flow rate does not exceed the rating of the unit.
5. The catalyzer should take less than 60 minutes to reach operating temperature.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
Power Inlet
Module
Figure 3: Power Switch, Left Side
Hydrocarbon content may not be within specs until the catalyzer has established operating
temperature.
4.4 Shutdown
Under normal circumstances, no special procedures are required for shutdown of the zero-air
generator. Simply use the electronic controls as follow:
1. Shut off the power using the power switch on the side of the generator.
2. Turn off the flow of feed-air to the zero-air generator.
This procedure ceases generation and zero-air flow and removes all power from all system
components. To restart, plug in the unit and follow the instructions found on page 16.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
5
Maintenance
The Zero Air generator uses an inlet coalescing filter and a particulate filter on the outlet of
the generator. These filters should be replaced at a minimum of 6 month intervals. The Zero
Air generator does not include consumable parts inside the enclosure. Scheduled
maintenance is limited to the external filters every 6 months and a periodic inspection
(general overhaul) recommended every 6,000 hours of operation. During this inspection, the
unit is checked for leaks. The cooling fan is also checked to make sure that it's running
properly.
The lifetime of the catalyzer depends under what conditions it is used, in particular, the
quality of inlet air. Refer to Table 1on page 10.
The Inlet filter kits can be ordered by contacting Proton OnSite Customer Service. The part
number for the annual filter kit for the Air A5 and Air A20 is KT-0201-0019
Cleaning the Generator
1. Clean only the outside of the generator.
2. Disconnect the generator power cord before cleaning the generator.
3. Use a damp sponge or soft cloth and a mild soap solution to clean the outside of the
generator.
TO AVOID MARRING THE PLASTIC AND POWDER COATED METAL
SURFACES, DO NOT USE ABRASIVE CLEANERS ON THE GENERATOR.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
6
Troubleshooting
These purifier models do not have alarms.
In case of malfunction, make sure that the gas flow through the purifier does not exceed the
maximum value given in its technical specifications (Section 0, Page 10); and/or check the
displayed operating temperature. If the temperature on the display does not increase, please
call the factory. Phone and contact info is found on page 2.
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Air A5 and Air A20 Laboratory Zero-Air Generators
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7
APPENDIX A—FORMS
Customer Registration Form
Please fill out the form on the following page, tear it out of the manual, and fax it to Proton
OnSite (Fax Number: 1-203-949-8016) to ensure that your Zero Air 5/Zero Air 20 Generator
is properly registered. The form may also be sent by mail to the following address:
Customer Service
Proton OnSite, Inc.
10 Technology Drive
Wallingford, CT 06492
Proper registration is important for product support and automatic notification regarding
routine maintenance.
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Air A5 and Air A20 Laboratory Zero-Air Generators
Installation, Operation & Maintenance Manual
CUSTOMER REGISTRATION FORM
LCMS Laboratory Zero Air 5 / Zero Air 20 Generator
Generator Model Name?
Generator Serial Number?
From what supplier did you purchase the
generator?
Name of your company?
Company website address?
The application for your zero-air generator?
Your name?
Your title?
Your phone number with country code?
Your fax number with country code?
Your e-mail address?
The place where the generator is located (city,
state, country)
Are you the person responsible for the operation
of the zero-air generator?
Do you have any questions at this time that you
need Proton OnSite to answer?
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