BREATHING AIR PURIFIER

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1 INSTRUCTION MANUAL BREATHING AIR PURIFIER Model: PBA-12 FORM NO.: REVISION: 02/2012 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

2 Contents GENERAL SAFETY INFORMATION INSTALLATION DESIGN LIMITATIONS OPERATION MAINTENANCE CARTRIDGE REPLACEMENT PROCEDURE GENERAL INFORMATION... 6 PARTS LIST... 6 WARRANTY

3 GENERAL SAFETY INFORMATION When properly installed and operated, the purifier is designed to purify ordinary compressed air to acceptable levels for supplied air breathing systems. Appropriate safety precautions must be observed to assure satisfactory service. Consult factory for assistance and recommendation if purifier performance does not meet design specifications or when its intended application is questionable. 1. LIMITATIONS ON USE OF SUPPLIED AIR RESPIRATORS This equipment is for use with supplied air respirators. Supplied air respirators should not be used in a hostile environment (highly toxic or oxygen-deficient) which is immediately dangerous to life, or where the user cannot escape without the aid of a respirator. Selfcontained breathing apparatus should be used for these applications. 2. COMPRESSOR INTAKE This equipment is for use with ordinary compressed air. The compressor intake should be located to insure that the air supply source is not oxygen-deficient or subject to unusual or gross contamination. 3. CARBON MONOXIDE DETECTION This equipment is equipped with a humidity indicator which gives advance warning of the impending expiration of the catalyst used to eliminate carbon monoxide. This indicator is not a carbon monoxide detecting device. A compressor high temperature alarm or carbon monoxide alarm (or both) should be provided. If a compressor high temperature alarm only is used, frequent testing for carbon monoxide concentration should be conducted. 4. LIMIT TO CARBON MONOXIDE REMOVAL This equipment is provided with a catalyst which can convert carbon monoxide to carbon dioxide. Its capacity to decrease the concentration of carbon monoxide is dependent on the air flow rate and inlet concentration of carbon monoxide. Although this catalyst is capable of eliminating very high concentrations of carbon monoxide (especially if of short term duration), carbon monoxide inlet concentrations higher than 400 PPM v/v exceeds the intended design specifications. Conversion of concentrations higher than 400 PPM v/v will result in the formation of excessive levels of carbon dioxide, and will also cause an undesirably high air temperature rise. 5. PRESSURIZED DEVICES This equipment is a pressure containing device. Observe normal precautions when operating and servicing. Do not exceed design limitations of pressure and temperature as noted on unit serial number tag. Always depressurize before servicing. 6. MAXIMUM WORKING PRESSURE Do not exceed maximum compressed air pressure rating as listed on dryer serial number tag. 1

4 1.0 INSTALLATION 1.1 Location See schematic drawing, Figure 1. The purifier is designed specifically to treat compressed air for supplied breathing air systems. To insure its functional operation, proper installation is vital. NOTE: Inlet and outlet isolation valves, drain and bleed valves should be kept in closed position at all times when purifier is not in operation. 1.3 Cartridge A. Purifier is shipped with convertor cartridge separately cartoned. This cartridge must be installed prior to operation. See Section 5.2 for installation instructions. 2.0 DESIGN LIMITATIONS A. Flow - nominal 10 scfm at 100 psig (7.03 kg/cm 2 ) Figure 1 in (mm) TABLE 1 Recommended maximum flow rates at various operating pressures. 51/2 (140) 61/2 (165) Inlet Pressure psig 20 kgf/cm 2 (1.4) 40 (2.8) 60 (4.2) 100 (7.0) 150 (10.6) 200 (14.0) 3 19/ 32 (91) Flow Rate scfm m 3 /hr OPEN OPEN B. Maximum working pressure psig (14.06 kg/cm 2 ) standard Air Inlet 1/2-14 NPT SHIPPING WEIGHT 34 lbs. (15.4 kg) / 8 (822) 2 13 /16 (71) 12 (305) 20 5 / 8 (524) Air Outlet 1/2-14 NPT C. Maximum operating temperature F (48.9 C) D. Chemical attack - compressed air does not normally contain contaminants which will adversely affect this purifier. However, aromatic and chlorinated hydrocarbons, acids, bases and certain other chemicals can attack parts of the filter assemblies and result in personal injury. On questionable applications, the factory should be consulted prior to installation or operation. 6 6 (152) Minimum Clearance Required for Service 1. Filter 2. Convertor 3. Indicator 4. Isolation Valves 5. Mounting Bracket 6. Drain Valve 7. Indicator Bleed & Check Valve 8. Differential Pressure Gauge NOTE: Remove plastic protectors from isolation valves, indicator bleed valve, filter and convertor drain valves, and convertor head. 1.2 Mounting A. Install so inlet and outlet connections are horizontal and so that all cartridges are in a vertical position. Tipping of cartridges from the vertical orientation can impede drainage and/or reduce their efficiency. Allow a minimum of 6" (152 mm) below the bottom edge of the convertor case for cartridge replacement. B. Bolt mounting bracket to wall or other support member by means of (4) 5/16" fasteners. 2

5 3.0 OPERATION A. The purifier, when installed properly and operated within its design limitations, will effectively purify compressed air at system pressure so that it can be utilized, after appropriate pressure reduction, with respirators, hoods and similar breathing apparatus. It will remove liquid and solid contaminants, odors and many toxic gases including carbon monoxide. (Traces of hydrogen sulfide, sulfur dioxide, nitrogen dioxide, and miscellaneous organic gases [not methane]) Treated air purity either meets or exceeds OSHA standard for breathing air (See Table 2.) Although the purifier will eliminate the impurities commonly found in compressed air, care should be exercised in the location of the air compressor intake to avoid very high concentrations of impurities or unusual toxic contaminants from being introduced into the system. Occupational Safety and Health Regulations ( d) These regulations correspond to the Commodity Specification for Air, Compressed Gas Association Inc. - (CGA Specifications G-7.1 Type 1, Grade D). TABLE 2 Contaminant Maximum Allowable Concentrations OSHA (1) CSA (2) Catalite Air Purifier Outlet Concentrations at Rated Operating Conditions 4. Check Indicator - DO NOT OPEN PURIFIER OUTLET ISOLATION VALVE IF UPPER INDICATOR BAND IS YELLOW. a. With outlet isolation valve closed and purifier pressurized, open indicator bleed valve until upper indicator band turns green (approximately 5 minutes). b. After upper indicator band has turned green, close indicator bleed valve. (Note: A fixed orifice will allow a small and continuous bleed of air to flow through the indicator.) c. Open outlet isolation valve to place purifier in operation. d. Low indicator band should gradually turn green during operation. e. Periodically (about every 30 minutes), check to see that upper indicator band is green. During this check, establish that indicator has slight bleed flow. f. When upper indicator band turns yellow, convertor cartridge should be replaced. g. Lower indicator band will begin to turn yellow if cartridge is not replaced. Cartridge must be replaced before lower indicator band turns completely yellow to avoid toxic levels of carbon monoxide from passing through the purifier. Carbon Monoxide (CO) PPM v/v 10 5 Carbon Dioxide (CO 2 ) PPM v/v Normally below 10* Normally below 1000** Condensed Hydrocarbons mg/m to 0.2 Odor Not Noticeable Not Detectable None*** Moisture Content dew point temperature 10 F (5.6 C) below ambient temperature (at 1 atm. pressure) 9 F (5 C) below the min. temperature breathing air is exposed to (at lime pressure) -40 F (-40 C) at line pressure, -71 F (-57 C) when 100 psig and reduced to 1 atm. pressure acceptable for life of cartridge (1) The OSHA standard also states that compressed breathing air shall meet at leat the requirements for Type-1 Grade 2 breathing aire described in ANSI/Compressed Gas Association Commodity Specification for Air ANSI/CGA G (2) The CSA standard lists levels for a number of additional contaminants (methane. nonmethane hydrocarbons, nitrogen dioxide, nitrous oxide, halodenated hydrocarbons) and includes by reference contaminants documented by the ACGIH for chemical substances and physical agents in the workroom environment. The purifier will remove only those gaseous contaminants normally adsorbable by activated carbon. * At rated conditions, the purifier will reduce CO concentrations up to 400 PPM v/v to below allowable limits. ** Since CO is converted to CO 2 by the purifier, high concentrations of CO in the system and/or high concentrations of CO 2 at the compressor intake could result in exceeding allowable Co 2 limits. ***Will remove gaseous hydrocarbons normally adsorbable by activated carbon. B. Before and during operation, it is necessary to make certain checks to insure satisfactory performance. 1. Check to see that lines downstream of the purifier are clean and free of materials which could show up at the point of use of the air. 2. Check to see that the filter and convertor are installed level. This is necessary to insure adequate drainage. 3. Check the flow, pressure, and temperature to insure that the purifier is being operated within design limitations. 3

6 4.0 MAINTENANCE THE PURIFIER IS A PRESSURE CONTAINING DEVICE. DEPRESSURIZE BEFORE SERVICING. A. Periodically drain the two (2) vessels. 1. Filter - Before liquid level reaches cartridge bottom cap. 2. Convertor - Each time cartridge is replaced or when purifier is taken out of operation. 4.1 Procedure for Filter Element Replacement (See Section 5 for cartridge replacement procedure.) A. Filter - When pressure drop across the filter exceeds 10 psi, or when pressure drop across the purifier exceeds 15 psi. 1. The filter is supplied with a differential pressure gauge. Pressure differential in excess of 10 psi (0.7 kgf/cm 2 ) - pressure indicator in red area - indicates that the element should be replaced. B. Convertor - When upper indicator band changes from green to yellow. C. Determine Cartridge life 1. Determine cartridge life at actual operating conditions. At 80 F saturated inlet compressed air temperature and 100 psig inlet pressure, a cartridge will purify 5400 standard cubic feet of air. 2. Determine cartridge life at other conditions as follows: Step 1 - From Table 3, find Maximum Theoretical Life (MTL) in standard cubic feet (scf) that model 1901 can handle at the pressure and dew point temperature at the inlet to the purifier. Step 2 - If the inlet air is less than 100% saturated (dew point temperature is less than sensible temperature), adjust MTL for level of saturation. Refer to Table 4 and find the Saturated Air Correction Factor (SACF) at the intersection of the dew point and sensible temperatures corresponding to your operating conditions. Step 3 - Multiply MTL from step 1 by SACF to get adjusted MTL. Step 4 - To find actual life in minutes, divide adjusted life found in Step 3 by flow requirements of breathing apparatus. EXAMPLE - Determine cartridge life at the following conditions: Flow requirement: 5 scfm Inlet pressure: 100 psig Inlet sensible temperature: 80 F Inlet dew point temperature: 40 F Step 1 - Find MTL from Table 3 at 40 F and 100 psig. MTL = 22,470 scf. Step 2 - Find SACF from Table 4 for 40 F dew point and 80 F sensible temperatures. SACF = 0.28 Step 3 - Find adjusted MTL by multiplying MTL by SACF. 22,470 x 0.28 = 6292 Step 4 - Find cartridge life in minutes by dividing adjusted MTL from Step 3 by flow requirement, 5 scfm =1258 minutes (21 hours) TABLE 3 Maximum Theoretical Life (MTL) in scf at various inlet pressure dew points and pressures. Inlet dew point (saturated air) temperature F ( C) 40 (4) 50 (10) 60 (16) 70 (21) 80 (27) 90 (32) 100 (38) 20 (1.4) 6,798 4,644 3,230 2,281 1,634 1, (2.8) 10,716 7,321 5,091 3,596 2,575 1,869 1,375 Inlet Pressure psig (kgf/cm 2 ) 60 (4.2) 14,634 9,998 6,953 4,911 3,517 2,552 1, (5.6) 18,552 12,675 8,814 6,226 4,458 3,236 2,380 TABLE 4 Saturated Air Correction Factor (SACF) Dew point (saturated air) temperature 100 (7.0) 22,470 15,352 10,676 7,541 5,400 3,919 2, (10.5) 32,265 22,044 15,330 10,828 7,754 5,627 4, (14.1) 42,060 28,736 19,984 14,116 10,108 7,336 5, F (49 C) F (43 C) F (38 C) F (32 C) F (27 C) F (21 C) F (16 C) F (10 C) F (4 C) F (4 C) 50 F (10 C) 60 F (16 C) 70 F (21 C) 80 F (27 C) 90 F (32 C) Sensible temperature 100 F (38 C) 110 F (43 C) 120 F (49 C) 4

7 5.0 CARTRIDGE REPLACEMENT PROCEDURE THE PURIFIER IS A PRESSURE CONTAINING DE- VICE. DEPRESSURIZE BEFORE REPLACING ANY CARTRIDGE. 5.1 Filter Cartridge No Close inlet and outlet isolation ball valves. Depressurize the filter by slowly opening manual drain as shown. 2. Unscrew the metal collar holding the filter bowl to the head and remove the filter bowl and collar. Clean the filter bowl. 5.2 Convertor Cartridge P/N Head O-ring 1-3/4 X 1-7/8 Sleeve Seal Assembly Hex Nut 5/16-18 O-ring 1-7/8 x 2 Cartridge No KNURLED FITTING Converter Case Spring OPEN ( TO RIGHT ) 3. Unscrew the old filter cartridge and discard. Also discard the small o-ring that seals the filter cartridge top cap to the filter assembly head. 4. Insert small replacement o-ring on top of new replacement filter cartridge and screw replacement filter cartridge into filter assembly head. It is only necessary to finger tighten the filter cartridge into position to insure the seal. DO NOT WRENCH TIGHTEN. THE FILTER CARTRIDGE SHOULD NEVER BE HANDLED BY ITS OUTSIDE FOAM COVER. DAMAGE CAN RE- SULT. WHEN INSTALLING A REPLACEMENT FILTER CARTRIDGE, IT SHOULD BE HELD BY THE BOTTOM END CAP ONLY. (See Drawing) 5. Replace filter bowl and screw collar onto filter assembly head. 1. Disconnect spring which holds convertor case to bracket. 2. Using hands or strap wrench, unscrew case collar and lower case assembly vertically downward to clear used cartridge. If insufficient space is available to clear cartridge, allow case to rest on floor and proceed to next step. 3. Unscrew used cartridge and remove cartridge and bowl assembly. 4. Remove 5/16" nut and sleeve seal assembly from top of used cartridge. 5. Open new cartridge bag. Replacement cartridges are furnished in a dated vapor barrier bag. (NOTE: DO NOT OPEN VAPOR BARRIER BAG UNTIL READY TO INSTALL NEW CARTRIDGE.) 6. Insert new 1-7/8" I.D. x 2" O.D. o-ring in o-ring groove on top cap of new cartridge. 7. Fasten sleeve seal assembly to top of new cartridge. Check to see that o-ring is properly seated in top cap o- ring groove. 8. Insert new 1-3/4" I.D. x 1-7/8" O.D. o-ring in sleeve seal. 9. Check convertor case to see that cartridge support spring is positioned in the bottom of the case. 10. Screw cartridge into head and hand tighten. Install case and hand tighten collar. (If bottom edge of mounting bracket is less than 45 inches above floor, place cartridge in case and position both below head before installing cartridge.) Hand tightening of cartridge and case is adequate to insure seals. DO NOT USE WRENCH TO TIGHTEN CARTRIDGE. 11. Reconnect convertor case retaining spring. 12. Prior to placing air purifier into service, observe purifier warning labels. Do not open purifier outlet isolation valve if upper indicator band is yellow. See Section 3.0. NOTE: DO NOT USE A WRENCH TO TIGHTEN THIS EQUIPMENT. 5

8 5.3 Indicator Kit P/N INLET ORIFICE Inlet Orifice Indicator INDICATOR Housing HOUSING UPPER GASKET Upper Gasket INDICATOR Indicator TUBE Tube LOWER Lower Gasket GASKET COMBINATION Combination BLEED & CHECK Bleed & Check VALVE ASSEMBLY Assembly 6.0 GENERAL INFORMATION 1. When the purifier is not in operation, all valves should be closed, including the vessel drain cocks and the indicator bleed valve. The convertor cartridge and indicator vessel contain moisture sensitive materials. NOTE: When indicator bleed valve is closed and system is not in operation, an integral check valve will prevent atmospheric air from entering and contaminating cartridges. 2. Replacement convertor cartridge should not be exposed to moisture or high humidity. Do not unseal vapor bag until immediately before installation and operation. 3. Replacement of the convertor cartridge, which is consumable, is much more frequent (hours of use) than the filter cartridge (months of use). 4. Consult factory for questionable applications or when in doubt about intended usage. PARTS LIST 1. Depressurize the purifier. 2. With indicator still installed, unscrew combination bleed and check valve assembly from indicator housing. 3. Remove lower gasket and old indicator cartridge. 4. Replace upper gasket and check to insure that it is properly seated in housing. 5. Install new indicator cartridge in housing so that thinner band of colored granules (indicator gel) is at the top. 6. Insert new lower gasket. 7. Screw the combination bleed and check valve assembly back into indicator housing. Description Filter Convertor Case Moisture Indicator Isolating Valve (2) Drain Cock (Manual) (2) Bleed & Check Valve Assembly Spring Bracket O-ring 1-3/4 ID x 1-7/8 OD Nut Hex 5/16-18 Sleeve Seal Assembly O-ring 1-7/8 ID x 2 OD Part Number Cartridge Replacement No

9

10

11 WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with procedures and recommendations outlined in manufacturer s instruction manuals, to be free from defects in material or workmanship for a period as specified below, provided such defect is discovered and brought to the manufacturer s attention within the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident. Normal maintenance items requiring routine replacement are not warranted. The warranty covers parts and labor for the warranty period unless otherwise specified. Repair or replacement shall be made at the factory or the installation site, at the sole option of the manufacturer. Any service performed on the product by anyone other than the manufacturer must first be authorized by the manufacturer. Unauthorized service voids the warranty and any resulting charge or subsequent claim will not be paid. Products repaired or replaced under warranty shall be warranted for the unexpired portion of the warranty applying to the original product. The foregoing is the exclusive remedy of any buyer of the manufacturer s product. The maximum damages liability of the manufacturer is the original purchase price of the product or part. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR STATUTORY, AND IS EXPRESSLY IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE OR INSPECTION OF THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT. The manufacturer does not warrant any product, part, material, component, or accessory manufactured by others and sold or supplied in connection with the sale of manufacturer s products. AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.

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