Altec AIR CO2-PG14 Troubleshooting guide

Page 1 P012548-14 - Rev D
CO2-PG14 CO2-FREE GAS GENERATOR
OPERATIONS & MAINTENANCE
TABLE OF CONTENTS
SECTION 1 General Information: Pg 2
Serial Numbers
Description of Operation
SECTION 2 Safety Instructions: Pg 3
Installation Safety
Operation Safety
SECTION 3 Specifications: Pg 3
Flows, Connections, Dimensions, and Weights
SECTION 4 Installation Pg 4
Parts Included
Location
Electrical Connections
Piping and Connections
Filters
SECTION 5 Start-Up Pg 4
SECTION 6 Maintenance Pg 4
SECTION 7 Replacement Parts Pg 5
SECTION 8 Troubleshooting Guide Pg 6
SECTION 9 Wiring Diagram Pg 7
SECTION 10 Warranty / Claims Pg 7
PRINTED IN THE USA

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 2 P012548-14 - Rev D
MONTH/YEAR OF MANUFACTURE SERIAL#
SECTION 1 GENERAL
INFORMATION
1.1 SERIAL NUMBER CODING
1.2 DESCRIPTION OF OPERATION
The CO2-PG14 CO2-Free Gas Generator consists of three
main components: a high-efficiency coalescing inlet filter, a
CO2adsorber/dryer, and an outlet filter/regulator.
The coalescing inlet filter removes entrained particulate and oil
contaminants prior to the adsorber/dryer.
The CO2adsorber/dryer uses the pressure swing adsorption
(PSA) method of CO2removal and drying compressed air.
This requires two identical towers containing beds of 13X
molecular sieve beaded media.
Incoming compressed air enters the adsorber/dryer through the
four-way solenoid valve, where it is directed to the bottom of
the tower containing active 13X media (T1) as shown in Fig 1
to the right. The media in this tower removes CO2to less than
1 ppm and 99.9+% of the water vapor from the air when
operated at standard catalog conditions. The dry, CO2-free air
leaving the top of the tower (T1) is directed to the outlet
through a shuttle valve. The purge orifice allows a portion of
the dry, CO2-free air to flow into the other tower (T2) being
regenerated. This cleaned purge air regenerates the desiccant
by removing the accumulated CO2and water vapor and
carrying it out the open purge port.
The 4-way solenoid valve is controlled by a solid-state timer.
After 30 seconds, the desiccant in tower T2 is regenerated, and
the timer de-energizes the solenoid valve causing the process
to reverse instantly, with tower T2 adsorbing and tower T1
regenerating. The following flow schematic demonstrates the
adsorber/dryer operation.
( Fig 1 )
CO2-PG14 4-WAY VALVE TIMING CYCLE
30 seconds energized
30 seconds de-energized
1 minute total cycle time
4-way
solenoid valve
purge port
contaminated
inlet air
tower T1
adsorbing/drying
inlet air tower T2
regenerating
purge orifice
shuttle valve shuttle ball
CO2-free/dryair outlet

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 3 P012548-14 - Rev D
SECTION 2 SAFETY
INSTRUCTIONS
2.1 INSTALLATION SAFETY
Before starting or installing the CO2-PG14 CO2-Free Gas
Generator, be sure that all power to the unit is off, valves are
shut, and the air circuit is at atmospheric pressure. DO NOT
remove, repair, or replace any component, control filter, or part,
while the unit is energized or the air circuit is under pressure.
Unplug unit and de-pressurize the unit before starting
installation or maintenance procedures.
The CO2-PG14 is rated NEMA 1.
2.2 OPERATION SAFETY
DO NOT OPERATE THE PURGE GAS GENERATOR AT
COMPRESSED AIR PRESSURES ABOVE 120 PSIG. UNIT
FAILURE, INJURY AND EQUIPMENT DAMAGE COULD
RESULT
CAUTION:
EXCEPT as otherwise specified by the manufacturer, this
product is specifically designed for compressed air service and
use with any other gas or liquid is a misapplication.
Manufacturer’s warranties are void in the event of a
misapplication and manufacturer assumes NO
RESPONSIBILITY for any resulting loss.
Before using equipment with fluids or gases other than air,
consult Altec AIR for written approval.

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 4 P012548-14 - Rev D
SECTION 3 SPECIFICATIONS
3.1 FLOWS, CONNECTIONS, DIMENSIONS, AND WEIGHT
MODEL NO. CO2-PG14
Max Flow Capacities at 100 PSIG (L/M)
Inlet Flow 25.1
Purge Flow 10.3
Outlet Flow 14.8
Connections (NPT)
Inlet 1/4”
Outlet 1/4”
Dimensions (Inches)
Height 12.5
Width 16
Depth 5
Weight (Pounds) 10.8
Note: Inlet flows and outlet flows shown above are maximum capacities and should not be exceeded for best performance.
No outlet flow metering valve or flow meter is installed on the adsorber/dryer and must be provided by the user. An integral
fixed purge orifice meters purge flow. Capacities are based on inlet conditions of 70°F, 100%RH, normal ambient CO2levels of
approx 350-375 ppm. Outlet concentration of CO2will be less than 1 ppm and outlet dew point better than -100°F. If your flow,
temperature or pressure are different from above, consult factory for performance
SECTION 4 INSTALLATION
4.1 PARTS INCLUDED
(1) CO2-PG14 CO2-Free Gas Generator Assembly
(1) Operations & Maintenance Manual
4.2 LOCATION
DO NOT INSTALL THE UNIT IN AN ENVIRONMENT OF
CORROSIVE CHEMICALS, EXPLOSIVE GASES, OR AREAS
OF HIGH AMBIENT TEMPERATURE CONDITIONS.
4.3 ELECTRICAL CONNECTIONS
Before plugging in unit, check the unit nameplate for electrical
characteristics. Standard electrical characteristics are 115 volt,
1 phase, 50/60 Hz. Models operating on 230 volts AC, 12 volts
DC, and 24 volts DC are available.
IMPORTANT!: No overload protection is provided in the
adsorber/dryer and unit should be plugged/wired into a
protected circuit.
4.4 PIPING AND CONNECTIONS
Inlet and outlet tubing should be appropriate for pressure and
temperature of operation. See specification chart for
inlet/outlet NPT thread size. Teflon tape should be used in the
makeup of joints to ensure a good, airtight fit of piping
components. Check all connections for leakage using soap
solution prior to putting unit into service.
4.5 FILTERS
A coalescing filter is provided at the inlet to the adsorber/dryer
to remove entrained particulates, liquid moisture and oil which
can cause damage to the desiccant beds. This filter must be
oriented vertically with the drain at the bottom. A particulate
afterfilter is provided after the adsorber/dryer to remove any
OUTLET FLOW
CAPACITIES AT
VARIOUS INLET
PRESSURES
PSIG lit/min
120 19.0
110 17.6
100 14.8
90 11.5
80 8.6
70 6.1
60 3.9
50 2.2

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 5 P012548-14 - Rev D
adsorbent media dust that may migrate from the desiccant
beds.
SECTION 5 START UP
BEFORE UNIT START UP, FOLLOW THE INSTALLATION
INSTRUCTIONS AND PROCEDURES COMPLETELY.
DO NOT REMOVE, REPAIR OR REPLACE ANY ITEM ON
THE ADSORBER/DRYER WHILE THE ADSORBER/DRYER
IS UNDER PRESSURE.
5.1 INITIAL START UPS
1. Confirm that all piping and electrical connections are
proper.
2. Turn on the electrical power. Adsorber/dryer should start
cycling with a small purge noise heard every 30 seconds.
SECTION 6 MAINTENANCE
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON
THE ADSORBER/DRYER WHILE THE ADSORBER/DRYER
IS UNDER PRESSURE.
BEFORE BEGINNING ANY REPAIRS, MAINTENANCE, OR
INSTALLATION WORK, VERIFY THAT THE POWER IS OFF
AND THE ADSORBER/DRYER IS DEPRESSURIZED.
BEFORE WORKING ON THE ADSORBER/DRYER OR
RELATED EQUIPMENT, ENSURE THAT ALL PERSONNEL
HAVE READ AND UNDERSTAND THE SAFETY AND
OPERATION INSTRUCTIONS IN THIS MANUAL.
6.1 PREVENTIVE MAINTENANCE
Below is a suggested schedule based on average operating
conditions. As conditions such as dirty environment, humidity
conditions, ambient temperature, etc. change, the frequency of
the inspections may need to be increased.
Daily
1. Inspect the adsorber/dryer for proper cycling.
2. Inspect inlet filters for proper operation.
3. Verify proper inlet and ambient air conditions.
Semi-Annually
1. Inspect entire assembly for loose connections, screws,
etc.
Annually
1. Replace inlet filter elements, outlet filter elements, and
purge muffler [see next page for correct type]:
I
nl
et Filter
Eleme
nt
Type A: # M03-02-D00
Type B:
#
AC
-
0015XA
Type A: # PS446
Type B:
#
E00060015XA
Outlet Filter/Regulator
Element
Type A: # B03-03-G000
Type B: # AP-0015X1
Type B: # P017358 (NIPPLE-
P5000107
)
Type A: # PS403
Type B: # E00060015X1
Purge Muffler
# 10040

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 6 P012548-14 - Rev D
Type A Type B
Filter Comparison to determine correct Replacement Part #’s
SECTION 7 REPLACEMENT PARTS
Part Number Description CO2-PG14
(115V) CO2-PG14-2 (230V) CO2-PG14- 12VDC CO2-PG14- 24VDC
51460 PURGE ORIFICE, .015 WITH TUBING 1 1 1 1
51802 SHUTTLE VALVE ASSY 1 1 1 1
See Sec. 6.1 OUTLET FILTER/REGULATOR WITH GAUGE 1 1 1 1
See Sec. 6.1 - OUTLET FILTER ELEMENT ONLY 1 1 1 1
See
Sec. 6.1
-
REGULATOR
ONLY
1
1
1
1
50027
TIMER
, CYCLE, 1
15 VAC
1
50029
TIMER, CYCLE, 22
0
VAC
1
51408 TIMER, CYCLE, 12 VDC 1
P012759 TIMER, CYCLE, 24 VDC 1
10040 MUFFLER, PURGE, 1/8 NPT 1 1 1 1
51441 SOLENOID VALVE ASSY, 115 VAC 1
51441-2 SOLENOID VALVE ASSY, 220 VAC 1
51441-12VDC SOLENOID VALVE ASSY, 12 VDC 1
51441-24VDC SOLENOID VALVE ASSY, 24 VDC 1
See
Sec. 6.1
INLET FILTER WITH AUTO DRAIN
1
1
1
1
See
Sec. 6.1
-
INLET FILTER ELEMENT ONLY
1
1
1
1
Inlet
Filter
Outlet
Filter

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 7 P012548-14 - Rev D
SECTION 8 TROUBLESHOOTING GUIDE
A
PROBLEM:
UNIT
DELIVERS
HIGH
CO
2
/
WET AI
R
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTIO
N
A1 No power to unit. Power supply. Correct power problem.
A2 High inlet air temperature. For standard units, inlet air temperature
should not exceed 100°F. Reduce inlet air temperature to proper level. An aftercooler may need to be
installed after compressor.
A3 Air flow through unit in
excess of rated capacity. Make sure outlet flow (total outlet flow used by applications) does not exceed
rated outlet flow.
Reduce air usage downstream.
A4 Dirty or obstructed inlet air
filter. Check inlet coalescing filter element. Replace inlet filter element.
A5 Purge orifice plugged. Check purge air flow with flowmeter. Replace purge orifice.
A6 Solenoid coil burned out. Check coil leads with ohmmeter. Open
(burned out) coil will have no reading. Replace solenoid valve.
A7 Oil contamination of
desiccant beds. Verify particle/coalescing inlet filtration is adequate and functioning properly. Towers must be replaced if contamination is suspected. Send unit to factory for
repair.
A8 Timer not operating properly. Verify correct timing cycle by listening to
purge or by using voltmeter across coil
connections on timer.
Replace timer.
A9 Purge flow restricted. Check muffler for excessive back-
pressure. Replace muffler.

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 8 P012548-14 - Rev D
B
PROBLEM: RESTRICTED FLOW THROUGH UNIT
P
OS
SIBLE CAUSE
CHEC
K
CORRECTIVE ACTION
B1 Improper operating
conditions.
See A3 above.
B2 Dirty or obstructed inlet air
filter.
See A4 above.
B3 Plugged air passages. Check inlet and outlet air passages and
piping for blockages. Clear restrictions.
C
PROBLEM: EXCES
SIVE PURGE
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTION
C1 Inlet valve or outlet shuttle
not shifting. Check for damage or contamination of inlet valve and outlet shuttle valve. Clean or replace as necessary.
C2 Timer not operating properly. Incoming power may not be "clean".
Fluctuations in voltage can occur in power
circuits shared by inductive devices such
as electric motors or welders.
Supply line voltage from another source or
install power line filter.

Altec AIR CO2-PG14 CO2-Free Gas Generator Operations and Maintenance Manual
Page 9
P012548-14 - Rev D
Tel: [phone]
226A Commerce St., Broomfield, CO. 80020 [e-mail]
SECTION 9 WIRING
CO2-PG14 WIRING DIAGRAM
SECTION 10 WARRANTY
Altec AIR warrants the CO2-PG14 to be free of defects in
materials and workmanship under proper use, installation and
application. This limited warranty shall cover parts or
replacement unit only, for a period of 18 months from date of
shipment or 12 months from date of installation, whichever
comes first.
ALL FREIGHT DAMAGE CLAIMS ARE NOT THE
RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT
COVERED UNDER WARRANTY AS ALL PRODUCTS ARE
SHIPPED F.O.B. SHIPPER. PLEASE DIRECT ALL FREIGHT
CLAIMS TO THE FREIGHT CARRIER IN QUESTION.
This warranty does not apply to any unit damaged by accident,
modification, misuse, negligence, or misapplication.
Any covered CO2-PG14 part or material found defective will be
repaired, replaced or refunded, at Altec AIR’s option, free of
charge, provided that Altec AIR is notified within the above
stated warranty period. All returns of defective parts/equipment
must have prior written Returned Material Authorization (RMA).
RMA may be obtained from our service department. All
defective parts/equipment must be returned freight prepaid to
the Altec AIR factory within 30 days of RMA issue date. Any
shipment returned to the factory collect will be refused.
If an item is found to be warrantable, the repaired item or
replacement will be shipped via standard ground freight
prepaid within the continental US and Canada.
Any replacement part or material is warranted only to the extent
of the remaining warranty period of the adsorber/dryer or to the
extent as provided by the supplier, whichever is longer.
All freight damage claims should be filed within 15 working
days and should be directed to the freight carrier.
AC POWER
CORD
AC SOLENOID VALVE
ON-OFF
SWITCH
AC
PO W ER
IN
L1
L2
GND
DC TIMER
DC
+–
LOAD
2 1
DC POWER ENTRY
RECEPTACLE
CENTER (+) POSITIVE
DC SOLENOID VALVE
ON-OFF
SWITCH
AC TIMER
AC UNITS
DC UNITS