AIR SYSTEMS HP-A4K User manual

AIR SYSTEMS INTERNATIONAL, INC.
829 Juniper Crescent, Chesapeake, Va, 23320
Telephone [phone]
Toll Free 1-800-866-8100
Fax No. [phone]
http://www.airsystems.com
e-mail: [email protected]
Air Quality Test Kits
Models: LP/HP-A4K and LP/HP-A445K
OPERATING INSTRUCTIONS AND REPLACEMENT PARTS

2
Air Systems’ breathing air quality test kits are designed to test are designed to test the air produced by compressors
and compressed air in cylinders. These tests are accomplished through the use of detector tubes that provide a “go/no go”
test of the air quality. If a high reading is found, this signals the user that they have a potentially unacceptable quality of
breathing air. If this occurs, a laboratory analysis of the air components must be made to determine the exact readings of
the air quality and take corrective action. For precision laboratory analysis, contact Air Systems’ customer service depart-
ment, 1-800-866-8100.
Federal OSHA requires that Grade-D air be supplied to the respirator user. OSHA’s air quality standards are found in
Section 29CFR 1910.134(i) in the Code of Federal Regulations. OSHA’s standards are taken from the Compressed Gas
Association (CGA) Commodity Specication G-7.1 - 1989. CGA’s standard for Grade-D air is as follows:
Carbon Dioxide: 1000 ppm maximum
Carbon Monoxide: 10 ppm maximum
Oil Mist: 5.0 mg/m3(Condensed Hydrocarbons)
Water Vapor: 30-80 mg/m3(Cylinder air only)
Our test kits use the above test tubes as standard, other test tubes are available for specic tests of suspected con-
taminants. Call us for your specic aplications.
Oxygen tests are available from our oxygen test meter, Model AQT-O2. Consult factory for details.
Overview

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Low Pressure Air Tests - 125 PSI Maximum
Procedure for Model LP-A4
STEP 5)
At the end of each test period, read the tube immediately and record the results. Repeat with the other tubes until all de-
sired contaminants have been sampled.
STEP 6)
Close the regulator knob (turn counterclockwise) to shut off pressure to owmeter. Open the owmeter valve to bleed
pressure from the owmeter. Disconnect regulator from air distribution manifold and store system in case.
Model LP-A4 is supplied with a regulator/owmeter that must be con-
nected after the compressor’s Grade-D ltration system. The male plug,
1/4” industrial interchange, installed on the inlet of the pressure regulator
can be coupled directly into the air distribution manifold of the ltration
system. The test will determine acceptable air quality and whether or not
the ltration system is functioning properly.
STEP 1)
Attach regulator assembly to female coupling on air distribution manifold.
The owmeter should be in the vertical position for maximum accuracy.
NOTE: The 1/4” industrial interchange plug on the regulator will need to
be changed or an adapter used if the coupling on the manifold is some-
thing other than a 1/4” industrial interchange.
STEP 2)
Turn the regulator knob clockwise and set pressure between 20-30 PSI.
Do not adjust the owmeter at this time.
NOTE: The recommended tube testing sequence is as follows:
water vapor, carbon dioxide, carbon monoxide, and oil mist.
STEP 3)
Break the ends off a fresh test tube using the small metal breaker sleeve
in the kit. Install the test tube in the rubber tube holder with the directional
arrow found on the tube pointing down. Install tube by rst inserting the
upper end into the holder then stretching the holder over the lower
STEP 4)
The rubber tube holder is then inserted into the hose barb with the test
tube arrow pointing down. Adjust the owmeter to the ow rate per the
chart on the following page and the required time. Start the test with the
water vapor test tube and work through the chart. Test Tube Breaker Sleeve
Test Tube Holder
Flowmeter
Regulator
1/4” Male Plug
Tube Contaminant Flow Rate CC/Min Test Time In Minutes
Gastec Sensidyne Gastec Sensidyne Gastec Sensidyne
6A 603SPA Water Vapor 100 500 10 1.4
2A 601SP Carbon Dioxide 100 100 5 3.5
1A 6005P Carbon Monoxide 100 175 3 2
109AD 6025P Oil Mist 500 470 40 25
WARNING!
Do not attempt to remove regulator while system is pressurized. Always test air quality after the lter system to assure
proper function. The periodic testing of CO levels does not substitute for a CO or high temperature alarm per OSHA reg-
ulations. We recommend the installation of a CO monitor in the breathing air system to continuously monitor for CO. Call
Air Systems’ customer service department to discuss a retrot for your system.

High Pressure Air Cylinder Tests
Procedure for Models: HP-A4 and HP-A445
Select the proper test module based on the pressure of the cylinder to be tested (HP-A4 up to 3000 PSI and HP-A445
up to 5000 PSI. A dual stage high pressure regulator is provided to reduce cylinder pressure before it is delivered to the
owmeter. The CGA-346 or 347 wrench tight nut/stem is attached to the cylinder valve. The output pressure to the ow-
meter is set between 20-30 PSI. Attach the test module, Model LP-A4 to the female coupling on the regulator and follow
steps 1 thru 6 on the previous page.
Detector Tube Reading and Interpretaon
The following information will be helpful when reading and interpreting the detector tubes.
A. Always read the tubes and record the results immediately after testing. In some cases stains may fade or crawl within
a few hours.
B. A tube may not be reused; even after a zero reading.
C. The oil mist is normally used at 500 cc/min for 2 hours, however, reliable results are obtained using shorter sampling
periods and correcting the reading with a multiplication factor as indicated below.
Test Duration Multiply Reading By
30 Minutes 4
60 Minutes 2
D. If at the end of a test it is noted that the stain has overshot the scale, the actual concentration may be determined as
follows; repeat the test with a new tube and observe the time required to reach the highest calibration mark (full scale).
Multiply the full scale concentration by the ratio of recommended test time to actual test time.
Example: The H2O tube reaches full scale (80 mg/m3) in six minutes.
80 x 106 = 133 mg/m3(actual concentration).
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High moisture content, usually above 250 mg/m3, will result in unreliable readings in the oil mist tube. To remove ex-
cessive moisture from the breathing air line, prior to running the moisture test tube, order Air System’s prelter assembly
P/N FLTR020. Attach the lter to the male inlet plug located on the LP-A4 test module before performing the air test. An
approximate 10% correction factor should be added to the oil tube reading to achieve a more accurate reading.
Enclosed in the kit is a data sheet to allow you to send your lter sample to Trace Analytics if you would like an inde-
pendent laboratory to provide the weighing service for your lter. To obtain more information, contact Trace Analytics at
1-800-247-1024.
The module has been designed for quick, accurate tests of total particulates and oil mist found in breathing air. One
cubic meter of air is passed over a pre-weighted lter with the resulting difference in weight equaling the total particulate
and oil found in the tested breathing air.
The LP-47PF test module is plugged directly into the output air coupling after the Grade-D lter system or into the
pressure reducing regulator used for bottled air testing. Maximum pressure should not exceed 20 PSI coming into the
test module. The polycarbonate test module holds the pre-weighted lter. The other end has a 1/4” plug attached which is
plugged into the air outlet coupling of the breathing air system. After testing, the lter is weighed to check lter weight and
a calculation is made in mg/m3.
Using the steel forceps supplied in the kit, install a 47mm pre-weighted lter in the polycarbonate lter holder. With the
lters installed, plug the test module into the air outlet tting, not exceeding 20 PSI. Adjust the ow to 50 LPM and allow
the air to ow for 20 minutes. This results in 1 cubic meter of air being passed over the lters. If a different time is used
it should be noted. After 20 minutes, the air is turned off at the regulator, the lter is removed from the housing using the
forceps and placed in the supplied petri dish. The tested lter sample should be sent to a laboratory for weighing on a
microbalance scale.
Detector Tube Reading and Interpretaon
Special Applicaon For High Moisture Environment
Total Parculate/Oil Mist Test Procedure For Model LP-47PF
Laboratory Services Available
First H2O (Water)
Second CO2 (Carbon Dioxide)
Third CO (Carbon Monoxide)
Fourth Oil Mist
E. Excessive water vapor (i.e. greater than 250 mg/m3 H2O) may cause the oil mist tube (#109-AD) to become unrelia-
ble. Run the water vapor test before running the oil mist test to determine the water vapor level. The recommended
testing sequence is shown below:
F. Always use the enclosed quick connect valve to ush the system before putting the lter holder in-line for analysis.
Flushing or purging should continue at 2-3 minutes until no visible water is discharged from the line.
G. Never exceed 20 PSI into the lter holder otherwise damage to the assembly may occur.
H. Always record the ow rate and run time on the petri dish lter holder when returning the unit for weighing.
I. Never touch the lter membranes as the results could be contaminated.
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LP47PF Specicaons
LP47PF Assembly
Filter Handling Tips
Holder Material Polycarbonate
O-Ring Ethylene Propylene Rubber
Maximum Operating
Temperature/Pressure
100° Fahrenheit @ 50 PSI
38° Celsius @ 3.4 Atmospheric
Sterilization 250° Fahrenheit (121°Celsius)
For 15 Minutes
Filter Diameter 47mm
Pre-Filter Diameter 42mm
Filtration Area 11.3 cubic cm
Connections 1/4” MPT or 1/4” Barb
Assembly Ring
Cap/Support Grid
Flat Gasket (Orange)
47 mm Filter
O-Ring (Black)
Support Grid
Base
Flowmeter
NOTE: Place the support grids in the assembly with the smooth sides facing
the 47mm lter.
1. Never handle lter with ngers. Use blunt, curve tipped forceps (wet or dry lters) or vacuum tweezers (dry membrane).
2. Filter identication can be made by marking the bottom side of the petri dish with an indelible black or blue pen.
6

Sterilizaon
Holders*; loaded or unloaded with membranes can be repeatedly autoclaved at 250° F (121° C) for 15 minutes @ 15 PSI
or sterilized purging with standard serilizing gas mixtures (not >20% ethylene oxide).
* Loosen assembly ring 1/8 of a turn. Retighten after autoclaving. Inlet and outlet should be covered with appropriate
autoclave wrap during autoclaving.
Disassembly
Cleaning
Operang Tips
STEP 1)
Unscrew assembly ring. Remove cap and at gasket.
STEP 2)
Carefully unload membrane.
STEP 3)
Remove o-ring.
STEP 4)
The support grids should be removed for cleaning as needed.
STEP 1)
Disassemble holder completely.
STEP 2)
Wash all parts with a suitable solvent (i.e. isopropyl alcohol). Do not use acetone.
STEP 3)
Rinse in clean water.
1) Check to see that the assembly ring is tightened after making inlet and outlet connections.
2) Never operate holders above 50 PSI @ 100°F (3.4 atmospheric @ 38° C)
3) Periodically inspect seals for signs of deterioration (cracks, discoloration, etc.) and replace as needed.
7

8
LP/HPA4 and LP/HPA445 System Components
LP-47PF System Components
ITEM # DESCRIPTION PART #
1 47MM FILTER HOLDER MWH-44
2 INLET FITTING QDH3PL4F
3 FLOWMETER SAM024
HP-A4 (3000 PSI)
HP-A445 (5000 PSI)
LP-A4
Forceps
Test Tubes
Laboratory Return Box
With MW-47 Filter
LP-47PF

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HP-A4/HP-A445
LP-A4
ITEM # DESCRIPTION PART #
1 125 PSI RELIEF VALVE VR4125BR
2 HANSEN COUPLING QDH3SL4M
3 HANSEN DUST CAP QDH3DCAP
4 REGULATOR (HP-A4)(NO GAUGES) REG-3000NG
4A REGULATOR (HP-A445)(NO GAUGES) REG-5000NG
5 0-200 PSI PRESSURE GAUGE GA25200SRG
6 0-4000 PSI PRESSURE GAUGE (HP-A4) GA254KSREG
6A 0-6000 PSI PRESSURE GAUGE (HP-A445) GA256KSREG
7 CGA-346 WRENCH TIGHT NUT (HP-A4) HPBR025
7A CGA-346 WRENCH TIGHT STEM (HP-A4) HPBR026
8 CGA-347 WRENCH TIGHT NUT (HP-A445) HPBR049
8A CGA-347 WRENCH TIGHT STEM (HP-A445) HPBR050
ITEM # DESCRIPTION PART #
1 TEST TUBE HOLDER/BREAKER SLEEVE CAL007
2 INLET FITTING QDH3PL4M
3 PRESSURE REGULATOR WL013A
4 0-60 PSI PRESSURE GAUGE GA1560S
5 FLOWMETER WL033NS

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Notes:

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Air Systems’ manufactured equipment is warranted to the original user against defects in workmanship or materials under
normal use for one year from the date of purchase. Any part which is determined by Air Systems to be defective in mate-
rial or workmanship will be, as the exclusive remedy, repaired or replaced at Air Systems’ option. This warranty does not
apply to electrical systems or electronic components. Electrical parts are warranted, to the original user, for 90 days from
the date of sale. During the warranty period, electrical components will be repaired or replaced at Air Systems’ option.
NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, FIT-
NESS FOR A PARTICULAR PURPOSE, OR ANY OTHER MATTER IS GIVEN BY AIR SYSTEMS IN CONNECTION
HEREWITH. UNDER NO CIRCUMSTANCES SHALL THE SELLER BE LIABLE FOR LOSS OF PROFITS, ANY OTHER
DIRECT OR INDIRECT COSTS, EXPENSES, LOSSES, OR DAMAGES ARISING OUT OF DEFECTS IN, OR FAILURE
OF THE PRODUCT OR ANY PART THEREOF.
The purchaser shall be solely responsible for compliance with all applicable Federal, State and Local OSHA and/or MSHA
requirements. Although Air Systems International believes that its products, if operated and maintained as shipped from
the factory and in accordance with our “operations manual”, conform to OSHA and/or MSHA requirements, there are no
implied or expressed warranties of such compliance extending beyond the limited warranty described herein. Product
designs and speci cations are subject to change without notice. Rev. 2, 12/98
Air leaks are not covered under warranty except when they result from a defective system component, i.e. an on/off valve
or regulator or upon initial delivery due to poor workmanship. Air leaks due to poor delivery or damage will be covered un-
der delivery claims. Minor air leaks are part of routine service and maintenance and are the responsibility of the customer
just as are  lters and oil changes.
Warranty

Printed in the U.S.A. ©Copyright Air Systems International, Inc. 2018 All Rights Reserved
Manual No. AIRTST01
Rev. 9 May 2018