Altec AIR CO2-PG80 Troubleshooting guide

CO2-PG80 PURGE GAS GENERATOR
OPERATIONS & MAINTENANCE
TABLE OF CONTENTS
SECTION 1 General Information:
Model Description 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
Install Filters
Mounting
Electrical Connections
Piping and Connections
SECTION 5 Start-Up Pg 5
SECTION 6 Maintenance Pg 5
SECTION 7 Replacement Parts Pg 6
SECTION 8 Troubleshooting Guide Pg 7
SECTION 9 Wiring Diagram Pg 8
SECTION 10 Warranty / Claims Pg 8
P/N P013253 REV B

SECTION 1 GENERAL
INFORMATION
1.1 MODEL DESCRIPTION
The CO2-PG80 Purge Gas Generator is designed to remove
water and CO2 from a compressed air stream. This is done by
passing the air through beds of adsorbent media (using 13X
molecular sieve) which adsorbs both H2O and CO2.
1.2 SERIAL NUMBER CODING
1.3 DESCRIPTION OF OPERATION
The CO2-PG80 Purge Gas Generator uses the pressure swing
adsorption method of gas separation. This requires two
identical towers containing beds of adsorbent desiccant media.
Incoming wet, CO2 rich air enters the adsorber/dryer through
the inlet port, where energized SOLENOID VALVE A directs
the pressurized air stream to the bottom of DESICCANT
TOWER A containing active adsorbent. This adsorbent media
bed removes water vapor and CO2 gas from the air to better
than -100°F dew point and less than 1 PPM CO2 when
operated at catalog conditions. The dry and CO2 free air
leaving the top of DESICCANT TOWER A is directed to the
outlet through open CHECK VALVE A. PURGE ORIFICE B
and closed CHECK VALVE B allow a metered portion of the
processed air to flow into DESICCANT TOWER B being
regenerated. The open purge port on deenergized SOLENOID
VALVE B and the purge orifice reduce the pressurized dry air
down close to atmospheric pressure and regenerate the
adsorbent media by removing the accumulated water vapor
and CO2 and carrying it out the open purge port.
The two solenoid valves are controlled by a solid state timer.
After 30 seconds, the media in DESICCANT TOWER B is
regenerated, and the solid state cycle timer causes the process
to instantly reverse, with TOWER B adsorbing and TOWER A
regenerating. The following flow schematic (FIG 1)
demonstrates the adsorber/dryer operation.
FIG 1
SOLENOID VALVE TIMING CYCLE
30 seconds per side continuous
1 minute total cycle time
P/N P013253 REV B
MONTH/YEAR OF MANUFACTURE
SERIAL #

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
SECTION 2 SAFETY
INSTRUCTIONS
2.1 INSTALLATION SAFETY
Before starting or installing the CO2-PG80 Purge 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-PG80 is rated NEMA 1.
2.2 OPERATION SAFETY
DO NOT OPERATE THE CO2-PG80 PURGE GAS
GENERATOR AT COMPRESSED AIR PRESSURES ABOVE
150 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.
SECTION 3 SPECIFICATIONS
3.1 FLOWS, CONNECTIONS, DIMENSIONS, AND WEIGHT
MODEL NO. CO2-PG80
Max Flow Capacities at 125 PSIG (L/M)
Inlet Flow 114
Purge Flow 34
Outlet Flow 80
Connections (NPT)
Inlet 1/4
Outlet 1/4
Dimensions (Inches)
Height 27.7
Width 17.2
Depth 6.2
Weight (Pounds) 25
TABLE 1
OUTLET FLOW CAPACITIES AT
VARIOUS INLET PRESSURES
WITH PURGE ORIFICE REQ’D
PSIG
lit/min
orifice
no.
150
99.4
27
140
93.4
27
130
84.7
29
120
73.1
29
110
65.1
32
100
60.0
32
90
48.5
32
80
36.9
32
70
32.9
40
60
26.1
40
50
15.8
40
Note: 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. Purge flow is metered by
integral fixed purge orifices. Capacities are based on inlet conditions of 70°F, 100%RH, normal ambient CO2 levels of approx
350-375 ppm. Outlet concentration of CO2 will 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. Unless otherwise specified, a #32 orifice
set has been installed as standard.
Page 3
P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
INLET BULKHEAD
FITTING
OUTLET
BULKHEAD
FITTING
FIG 2
SECTION 4 INSTALLATION
4.1 PARTS INCLUDED
(1) CO2-PG80 Purge Gas Generator
(1) Inlet Coalescing Filter Assy.
(1) Outlet Filter Regulator Assy.
(6) Cover Screws, 6-32 x 3/8, PH, SS
(1) Operations & Maintenance Manual
4.2 LOCATION
DO NOT INSTALL THE UNIT IN AN ENVIRONMENT OF
CORROSIVE CHEMICALS, EXPLOSIVE GASES, OR AREAS
OF HIGH OR LOW AMBIENT TEMPERATURE (ABOVE 125°F
OR BELOW 33°F).
Install the unit indoors. Unit may be wall mounted or placed on
a table top.
4.3 INSTALL FILTERS
A coalescing filter is provided to be installed on the inlet to the
adsorber/dryer to remove entrained particulates, liquid moisture
and oil which can cause damage to the desiccant beds. A
particulate afterfilter is provided to be installed on the outlet of
the adsorber/dryer to remove any adsorbent media dust that
may migrate from the desiccant beds.
Using a wrench to keep inlet bulkhead fitting from turning,
install Inlet Filter Assy to left side of unit as shown in FIG 2
above. Similarly, install Outlet Filter Regulator Assy to Right
Side of unit.
4.4 MOUNTING
1. Table top
a. The unit comes with rubber feet installed on bottom
of cabinet for use on table top.
2. Wall mounting
a. Remove (6) cover screws and remove cover. While a
helper holds the unit at the mounting location, mark
the position of the (4) mounting holes at the back of
the cabinet. Mount the cabinet using these
mounting holes. Be sure to use proper wall mounting
anchors if mounting in drywall.
b. Reinstall cover.
4.5 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 are
available.
IMPORTANT!: No overload protection is provided in the
adsorber/dryer and unit should be plugged/wired into a
protected circuit.
4.6 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.
Page4
P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
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 filter for proper drain operation.
3. Verify proper inlet pressure and ambient air temperature
conditions.
Semi-Annually
1. Inspect entire assembly for loose connections, screws,
etc.
Annually
1. Replace inlet filter elements, outlet filter elements, and
purge mufflers:
Inlet Filter Element
#M18-02-CG00 #MTP-96-646
Outlet Filter/Regulator Element
#B03-02-G000 #PS403
Purge Mufflers
#ASN-6 (qty 2)
Bi-Annually
1. Order Maintenance Kit #51325. Replace solenoid valves
wearing parts and check valves parts in adsorber/dryer
manifold. See Figure 3, Item #15, in next section.
Page 5
P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
SECTION 7 REPLACEMENT PARTS
Part Number
Description (refer to FIG 3)
Call Factory
POWER ON/OFF SWITCH
B03-02-G000
OUTLET FILTER/REGULATOR WITH GAUGE
PS403
- OUTLET FILTER ELEMENT ONLY
P77413
- GAUGE ONLY
M18-02-CG00
INLET FILTER WITH AUTO DRAIN
MTP-96-646
- INLET FILTER ELEMENT ONLY
20020
POWER CORD (NOT SHOWN)
ASN-6
MUFFLER, PURGE, 1/8 NPT, (ORDER QTY 2)
51330-0XX
ADSORBER/DRYER INSERT ORIFICE NUMBER FOR
XX (SEE TABLE 1 ON PAGE 3 FOR ORIFICES/FLOWS)
OUTLETFILTER REGULATOR
WITH GAUGE
POWERON/OFFSWITCH
INLETCOALESCINGFILTER
ADSORBER/DRYER
PURGEMUFFLERS
FIG 3
Ref.
No.
Part
Number
Adsorber/Dryer Part Description
(refer to FIG 4)
Qty /
Unit
Incl. in
Kit (#15)
1
51254
TOWER, 20", 51330 CO2 ADSORBER/DRYER
2
2
-
O-RING, TOWER
2
x
3
-
O-RING, PURGE ORIFICE, INNER
2
x
4
51315-27
PURGE ORIFICE, #27 FOR 140 - 150 PSIG OPER.
2
51315-29
PURGE ORIFICE, #29 FOR 120 - 130 PSIG OPER.
51315-32
PURGE ORIFICE, #32 FOR 80 - 110 PSIG OPER.
51315-40
PURGE ORIFICE, #40 FOR 50 - 70 PSIG OPER.
(SEE TABLE 1 ON PAGE 3 FOR ORIFICES/FLOWS)
5
-
O-RING, PURGE ORIFICE, OUTER
2
x
6
51308
MOISTURE INDICATOR WITH O-RING (NOT SHOWN)
1
7
-
O-RING, MOISTURE INDICATOR
1
8
51316
BALL, CHECK VALVE
2
x
9
51317
SPRING, CHECK VALVE
2
x
10
P300495P
MANIFOLD
1
11
51319
PLUG, MANIFOLD
2
12
-
O-RING, SOLENOID VALVE
2
x
13
P400589DC1
SOLENOID VALVE ASSY, 53 VDC, FOR 115 VAC UNIT
2
P400589DC2
SOLENOID VALVE ASSY, 106 VDC, FOR 230 VAC UNIT
13A
-
CORE, SOLENOID VALVE
2
x
13B
-
BASE, SOLENOID VALVE
2
x
13C
-
FRAME, SOLENOID VALVE
2
x
14
-
COIL (ORDER COMPLETE SOLENOID VALVE ASSY)
2
15
51325
KIT, MAINT., ADSORBER/DRYER
1
16
P010530F1
ADSORBER TIMER, CYCLE, FOR 115 VAC UNIT (NOT SHOWN)
1
P010530F1
ADSORBER TIMER, CYCLE, FOR 230 VAC UNIT (NOT SHOWN)
17
P3005052
ADSORBER BOTTOM COVER (NOT SHOWN)
1
18
P010437
ADSORBER BRACKET, MOUNTING (NOT SHOWN)
1
FIG 4
Page 6 P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
SECTION 7 TROUBLESHOOTING GUIDE
A
PROBLEM: UNIT DELIVERS WET AIR OR HIGH CO2 LEVELS
POSSIBLE CAUSE
CHECK
CORRECTIVE ACTION
A1
High inlet air temperature.
For standard units, inlet air
temperature should be 70-80°F.
Reduce inlet air temperature to proper
level. An aftercooler may need to be
installed after compressor.
A2
Air flow through dryer in
excess of rated capacity.
Make sure outlet flow does not exceed
rated flow. See capacity chart in
Reduce air usage downstream.
SPECIFICATIONS.
A3
Low inlet pressure.
See capacity chart in SPECIFICATIONS.
Increase inlet pressure.
A4
Dirty or obstructed inlet air
filter.
Check inlet airline filter elements.
Replace elements.
A5
Purge orifice plugged.
Check purge air flow with flowmeter.
Clean or replace purge orifices.
A6
Solenoid coil burned out.
Check coil leads with ohmmeter. Open
Replace valves.
(burned out) coil will have no reading.
A7
Oil contamination of
Verify particle/coalescing inlet filtration is
Towers must be replaced if contamination
desiccant beds.
adequate and functioning properly.
is suspected.
A8
Timing cycle improper.
Verify correct timing cycle by listening
to purge or by using voltmeter across
coil connections on timer.
Replace timer if defective.
A9
Purge flow restricted.
Check mufflers for excessive back-
pressure.
Replace mufflers.
B PROBLEM: RESTRICTED FLOW THROUGH UNIT
POSSIBLE CAUSE CHECK CORRECTIVE ACTION
B1 No power to unit. On-Off switch and power supply. Correct power problem.
B2 Improper operating See A2, A3 above.
conditions.
B3 Dirty or obstructed inlet air See A4 above.
filter.
B4 Plugged air passages. Check inlet and outlet air passages and Clear
restrictions.
piping for blockages.
B5 Inlet and outlet ports Check inlet and outlet ports for proper Reconnect properly.
reversed. connections.
C PROBLEM: EXCESSIVE PURGE
POSSIBLE CAUSE CHECK CORRECTIVE ACTION
C1 Check valve not closing. Check for damage or contamination of Clean or replace as
necessary.
check valves.
C2 Purge orifice(s) incorrect. Measure purge flow with flow meter. Install correct purge orifice(s).
Page 7 P/N P013253 REV B

Altec AIR CO2-PG80 Purge Gas Generator Operations and Maintenance Manual
SECTION 9 WIRING
FIG 5
CO2-PG80 WIRING DIAGRAM
SECTION 10 WARRANTY
Altec AIR warrants the CO2-PG80 Purge Gas Generator 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-PG80 Purge Gas Generator 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.
Page 8
P/N P013253 REV B
Tel: [phone]
226A Commerce St., Broomfield, CO. 80020 [email protected]