Altec AIR MCA Series User manual

MCA Series CO2 Adsorber / Dryer
User’s Guide
Models covered:
MCA1 MCA2 MCA3 MCA4 MCA5 MCA6
P012554 Rev A

ALTEC AIR, LLC MCA Series User’s Guide
1. Welcome & Congratulations
Congratulations on your purchase of a new ALTEC AIR MCA SERIES CO2
ADSORBER / DRYER! We here at ALTEC AIR are very proud of our products. We are
committed to providing you with the best value and service possible.
We are sure that you will be satisfied with your new unit and would like to thank you for
choosing ALTEC AIR for your CO2 adsorber / dryer requirements. We also hope that
you will continue to choose us for your future Compressed Air Treatment and related
products purchases.
For information about this and other ALTEC AIR products, please visit us on the web at
www.AltecAIR.com
2. Introduction
PLEASE READ THIS USER’S GUIDE THOROUGHLY AND SAVE FOR
FUTURE REFERENCE.
This User’s Guide is provided for the benefit of our customers and contains information
and direction specific to the ALTEC AIR MCA SERIES CO2 ADSORBER / DRYER.
It will cover topics including: safety, specifications, installation, testing, maintenance,
and troubleshooting issues. Observation and compliance with this User’s Guide will
ensure the maximum life and efficiency of your CO2 adsorber / dryer.
This User’s Guide should be read thoroughly prior to installing, operating, or servicing
the CO2 adsorber/dryer in order to become familiar with the recommended procedures.
This will minimize the possibility of personal injury or damage to the CO2 adsorber /
dryer due to improper operation or handling.
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ALTEC AIR, LLC MCA Series User’s Guide
3. Table of Contents
1. Welcome & Congratulations .........................
3
10. Replacement Parts & Accessories..............
25
10.1 Parts .........................................................
25
2. Introduction ....................................................
3
10.2 Parts Continued........................................
26
10.3 Accessories for Your CO2 Adsorber /
3. Table of Contents............................................
4
Dryer................................................................
27
4. Safety & Warning Information.....................
5
10.4 Ordering Parts from ALTEC AIR............
28
5. Overview & Specifications.............................
6
11. Service & Repair .........................................
28
5.1 Product Description ....................................
6
11.1 Services Offered at Altec AIR’ Facility...
28
5.2 Key Features ...............................................
6
11.2 Initiating a Service Transaction ...............
29
5.3 MCA Series CO2 Adsorber / Dryer
12. Troubleshooting A CO2 Adsorber / Dryer 29
Models ..............................................................
6
12.1 Before You Call ALTEC AIR .................
29
5.4 Technical Specifications.............................
7
12.2 Safety & Warning Information ................
30
6. Installing Your CO2 Adsorber / Dryer.........
8
12.3 Low Pressure or Flow..............................
30
6.1 Safety & Warning Information ...................
8
12.4 Excessive Purge .......................................
31
6.2 Before You Begin .......................................
9
12.5 Delivers Wet Air......................................
31
6.3 Included Contents .......................................
10
12.6 Contacting ALTEC AIR Technical
6.4 Required Tools and Materials.....................
10
Support.............................................................
32
6.5 Installation Steps.........................................
11
13. Appendix ......................................................
33
6.6 Installation Checklist ..................................
14
13.1 Model Number Coding ............................
33
7. Registering Your CO2 Adsorber / Dryer ....
15
13.2 Wiring Diagram.......................................
33
8. Testing Your CO2 Adsorber / Dryer ............
16
14. Limited Warranty Agreement....................
34
8.1 Safety & Warning Information ...................
16
Registration Reminder .....................................
34
8.2 Test Consistent Cycling..............................
17
15. Contacting ALTEC AIR.............................
35
8.3 Measuring Incoming Voltage......................
18
15.1 General.....................................................
35
8.4 Measuring 4 Way Solenoid Valve Voltage 19
15.2 Sales.........................................................
35
8.5 Visually Verify Solid State Cycle Timer ..
20
15.3 Service .....................................................
35
8.6 Test for Purge Muffler Restriction..............
21
15.4 Technical Support....................................
35
8.7 Testing Air Fittings & Hoses for Leaks ....
22
16. Maintenance Log Sheet...............................
36
9. Maintaining Your CO2 Adsorber / Dryer ...
23
9.1 Safety & Warning Information ...................
23
17. Notes .............................................................
36
9.2 Maintenance Log Sheet...............................
24
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ALTEC AIR, LLC MCA Series User’s Guide
4. Safety & Warning Information
This section contains general information about safety and warning points to consider and
adhere to during installation and maintenance of your CO2 adsorber / dryer. PLEASE
READ THIS SECTION BEFORE PERFORMING ANY OPERATION OR
PROCEDURE ON YOUR CO2 ADSORBER / DRYER.
Additional warnings specific to an operation or procedure will also be presented
throughout the following sections. These will include the symbol as well as a label of
“WARNING!”, “CAUTION!”, or “IMPORTANT!”. Please be sure to pay close
attention for these warnings and read them as you encounter them.
IMPORTANT!
Performing procedures not described in this User’s Guide MAY
VOID THE WARRANTY.
IMPORTANT!
Appropriate inlet filtration is MANDATORY and outlet filtration
is recommended for all application.
IMPORTANT!
Each CO2 adsorber / dryer is sized for specific operating conditions.
For OPTIMUM performance, the maximum available operating
pressure should be maintained across the unit. Any pressure
reduction or flow control should be done downstream of the unit.
Depending on the magnitude of the change, the size of the desiccant
chambers or orifice may need to be changed.
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ALTEC AIR, LLC MCA Series User’s Guide
5. Overview & Specifications
5.1 Product Description
The MCA SERIES CO2 ADSORBER / DRYER from ALTEC AIR is designed to
remove CO2 and moisture from compressed air. This CO2 adsorber / dryer uses dual
towers with media beds featuring 13X molecular sieve in a pressure swing adsorption
process. Adsorbed moisture and CO2 are purged to the atmosphere while dry CO2-
free air is provided at the outlet port.
5.2 Key Features
•Continuous, ultra-dry, CO2-free air to less than 1 PPM
•Reduces water vapor to less than 1 PPM
•Outlet flow capacities of 1.6 to 20.5 SCFM at 100 PSIG
•Operating pressures of 50 to 120 PSIG
•Miniature design sized for fractional horsepower air compressor
•Low power requirements (6 watts)
•Ideal for OEM and point-of-use applications
5.3 MCA Series CO2 Adsorber / Dryer Models
Model
Inlet Flow
Purge Flow
Outlet Flow
MCA1
2.8
1.2
1.6
MCA2
8.8
3.7
5.1
MCA3
13.2
5.5
7.7
MCA4
17.7
7.8
9.9
MCA5
25.1
10.3
14.8
MCA6
35.3
14.8
20.5
Notes:
1. Flow capacities in L/Min shown are for standard units operated at 100 PSIG.
2. Inlet and outlet flow capacities will be greater at higher pressures and lower at lower
pressures. Consult factory for other conditions.
3. Standard compressed air inlet conditions are 70°F saturated.
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ALTEC AIR, LLC MCA Series User’s Guide
5.4 Technical Specifications
Dimensions MCA1
MCA2
MCA3
MCA4
MCA5
MCA6
7.0” H x 3.5” W x 3.3” D
10.3” H x 3.5” W x 3.3” D
8.8” H x 4.0” W x 3.5” D
10.1” H x 4.0” W x 3.5” D
9.5” H x 5.0” W x 3.8” D
11.5” H x 5.0” W x 3.8” D
Voltage Requirements
(one of the following)
115 VAC, 1 Phase, 50/60 Hz
230 VAC, 1 Phase, 50/60 Hz
12 VDC
24 VDC
Power
6 Watts
Electrical Rating
NEMA 1
Operating Ambient
Temperature Range
33° to 120° F (0.5° to 49° C)
Inlet Temperature
≤ 70°F Recommended
120°F Maximum
Maximum Inlet Pressure
120 PSIG
Cycle Timer
Solid State with memory
Purge Cycle
30 seconds per side continuous
Separation Media
13X Molecular Sieve
Noise Level
<90 dBA
Inlet / Outlet Connections
MCA1-MCA4
MCA5-MCA6
1/8” NPT Female
1/4” NPT Female
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ALTEC AIR, LLC MCA Series User’s Guide
6. Installing Your CO2 Adsorber / Dryer
6.1 Safety & Warning Information
WARNING!
Extreme care should be exercised to avoid contact with live
electrical circuits. Many procedures performed during installation,
and testing of this CO2 adsorber / dryer require the equipment to
be running, creating a situation for potential electrical shock. It is
highly recommended that you remove all jewelry before
performing any procedures.
CAUTION!
Proper Installation & Maintenance as outlined in this User’s Guide
is extremely important to ensure the reliability and longevity of the
equipment as well as prevent damage or personal injury.
CAUTION!
Incoming power to dryer must be one of the following:
•115 VAC, 1 Phase, 50/60 Hz
•230 VAC, 1 Phase, 50/60 Hz
•12VDC
•24VDC
CAUTION!
Do NOT exceed the SCFM outlet flow capacity of the CO2
adsorber / dryer. Be aware of what your unit is rated for before
installation.
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ALTEC AIR, LLC MCA Series User’s Guide
6.2 Before You Begin
6.2.1 Carefully inspect the unit, including the shipping box as well as the air
dryer, for ANY DAMAGE CAUSED BY SHIPPING. If any shipping
damage is detected, it is important to file a claim with the shipping
company prior to continuing the installation procedures.
6.2.2 Read the entire Installing Your CO2 Adsorber / Dryer section to familiarize
yourself with the components and procedures before performing the
installation.
6.2.3 Verify the installation location of the CO2 adsorber / dryer:
6.2.3.1 Ambient temperature is between 33° and 100°F
NOTE: Temperatures above 120°F will decrease component lifespan.
6.2.3.2 Meets one of the following power requirements:
•115 VAC, 1 Phase, 50/60 Hz
•230 VAC, 1 Phase, 50/60 Hz
•12 VDC
•24 VDC
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ALTEC AIR, LLC MCA Series User’s Guide
6.3 Included Contents
(1) MCA Series CO2 Adsorber /
Dryer
(1) User’s Guide (not shown)
6.4 Required Tools and Materials
•Power Cord (varies on voltage of unit)
•Needle nose pliers
•Mounting hardware
•Drill
•Drill bit (varies on mounting hardware)
•Small flathead screwdriver
•Medium adjustable wrench (used only when installing a Complete System)
•Cup of soapy water
•1-inch paint brush (recommended)
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6.5.4 With needle nose pliers,
remove and discard plugs.
ALTEC AIR, LLC MCA Series User’s Guide
6.5 Installation Steps
IMPORTANT!
To properly operate the CO2 adsorber / dryer, ALTEC AIR
recommends that all air filtration and options be installed.
SEE SECTION 10.3
6.5.1 Remove the CO2 adsorber / dryer from packaging.
6.5.2 Check for loose parts or
wiring.
NOTE: If ANY SHIPPING
DAMAGE is detected, file a
claim with the shipping
company prior to continuing
the installation procedures.
6.5.3 Place the CO2 adsorber / dryer in the operating location.
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ALTEC AIR, LLC MCA Series User’s Guide
6.5.5 Install inlet and outlet
fittings, filters and
assemblies to the CO2
adsorber / dryer.
6.5.6 Pre-drill holes in wall, and
install wall mount hardware.
(See chart below)
Model
Width (A) x Height (B)
MCA1
3 1/8" x 6 5/8"
MCA2
3 1/8" x 9 7/8"
MCA3
3 5/8" x 8 3/8"
MCA4
3 5/8" x 9 5/8"
MCA5
4 1/2" x 9"
MCA6
4
1/2" x 10 15/16"
NOTE: Wall mounting
hardware installation
instructions may vary. The
model will determine the layout
for your mounting.
6.5.7 Mount unit to wall using
secure wall mounting
hardware.
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6.5.9 Connect the air line to the
inlet and outlet port.
ALTEC AIR, LLC MCA Series User’s Guide
6.5.8 With a small flathead
screwdriver, wire power
cord to timer.
NOTE: Customer must
supply a power cord and
plug to match their
receptacle.
CAUTION: Do not exceed SCFM outlet flow capacity of the CO2 Adsorber /
Dryer.
6.5.10 Plug in the Power Cord to
an outlet:
•115 VAC power
outlet, 1 Phase.
•230 VAC power
outlet, 1 Phase.
•12 VDC power outlet
(Not shown)
•24 VDC power outlet
(Not shown)
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ALTEC AIR, LLC MCA Series User’s Guide
6.5.11 Check for air leaks:
NOTE: This is a general procedure that can be applied to any fitting or hose
that has air pressure in it.
6.5.11.1 Listen for any ‘hissing’ sounds which may indicate a fitting or hose
air leak.
6.5.11.2 Use a 1-inch paint
brush to dab soapy water
on the air fitting or hose
connection to be tested.
If air bubbles appear at
the connection, this
indicates that air is
leaking from the connection.
If any leaks are detected, take steps to seal them off (as necessary):
•Tighten the fitting
•Re-connect the hose end
•Replace the fitting/hose/component
6.5.12 REGISTER YOUR CO2 ADSORBER / DRYER.
See section 7. for details.
6.6 Installation Checklist
No shipping damage was detected.
Wall mounted properly.
No air leaks are present.
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ALTEC AIR, LLC MCA Series User’s Guide
7. Registering Your CO2 Adsorber / Dryer
Please take a moment to register your ALTEC AIR MCA SERIES CO2 ADSORBER
/ DRYER. Registering is necessary to activate the Limited Warranty on your product.
Once you register, you are eligible to receive free technical support, as well as
updates concerning your ALTEC AIR products.
Register Online at www.AltecAIR.com/registration
Or by Phone [phone] (option 2)
Have the following information available:
Model #: _______________________________Serial #: ______________________
Company Name: ________________________Location Name:________________
Shipping Address: _____________________________________________________
City: ______________________State: ___________ Zip Code: _________
Contact Name: Phone #: ( ) - ext.
Email:
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ALTEC AIR, LLC MCA Series User’s Guide
8. Testing Your CO2 Adsorber / Dryer
8.1 Safety & Warning Information
WARNING!
Extreme care should be exercised to avoid contact with live
electrical circuits. Many procedures performed during
installation, testing, and maintenance of this CO2 adsorber / dryer
requires the equipment to be running, creating a situation for
potential electrical shock. It is highly recommended that you
remove all jewelry before performing any procedures.
CAUTION!
Observe precautions for handling Electrostatic Sensitive Devices.
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8.2.4 MCA5-6:
With a small flathead
screwdriver, remove the
Purge Mufflers.
ALTEC AIR, LLC MCA Series User’s Guide
8.2 Test Consistent Cycling
NOTE: For MCA1-4 proceed to the next step, for MCA5-6 skip to step 8.2.4.
8.2.1 MCA1-4:
Push the tube in and hold
the ferrule. While holding
the ferrule, pull the tube
out.
8.2.2 Place your hand beneath the disconnected tube and feel for air.
•Tower 1 will purge for 30
seconds
•Tower 2 will purge for 30
seconds
•Tower 1 will purge for 30
seconds
•. . . and so on.
8.2.3 Reinstall tubes after each cycle has been verified.
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ALTEC AIR, LLC MCA Series User’s Guide
8.2.5 Place your hand beneath the 4 Way Solenoid Valve and feel for purging
air.
•Tower 1 will purge for 30
seconds
•Tower 2 will purge for 30
seconds
•Tower 1 will purge for 30
seconds
•. . . and so on.
8.2.6 With a small flathead screwdriver, reinstall Purge Mufflers.
8.3 Measuring Incoming Voltage
8.3.1 Locate the Solid State Cycle
Timer.
The timer has two (2) sets of
terminals (from left-to-right):
The first set will be labeled
one of the following:
•115V (AC voltage)
•230V (AC voltage)
•12VDC
•24VDC
The second set is the 4 Way Solenoid Valve and is labeled “Valve”.
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ALTEC AIR, LLC MCA Series User’s Guide
8.3.2 Use a Voltmeter to measure
the voltage across the
incoming terminals.
The voltage should measure ±
10%:
•115 VAC
•230 VAC
•12 VDC
•24 VDC
If the incoming voltage measures less than indicated above, it is recommended
that steps be taken at your facility to increase the incoming power to the
recommended levels.
8.4 Measuring 4 Way
Solenoid Valve Voltage
8.4.1 Locate the Solid State
Cycle Timer.
The timer has two (2) sets of
terminals (from left-to-right):
The first set will be one of
the following:
•115V (AC voltage)
•230V (AC voltage)
•12VDC
•24VDC
The second set is the 4 Way Solenoid Valve and is labeled “Valve”.
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ALTEC AIR, LLC MCA Series User’s Guide
8.4.2 Use a Voltmeter to measure
the voltage across the set of
“Valve” terminals.
The voltage should measure ±
10%:
•115VAC
•230VAC
•12 VDC
•24 VDC
Continue to measure for up to 60 seconds if no voltage is initially measured.
If the voltage does not measure as indicated above replace 4 Way Solenoid Valve.
See sections 10.1 for part detail and 10.4 for ordering information.
8.5 Visually Verify Solid State Cycle Timer
8.5.1 Locate the Solid State
Cycle timer.
8.5.2 The timer has two LEDs.
Green for the incoming
power and Amber for the 4
Way Solenoid Valve. These
lights should always be on.
If either light is off see sections 8.3 and 8.4 to verify the Solid State Cycle
Timer has the correct voltages.
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