Zero-Air Generator Startup and Maintenance Instructions

Start-up Procedure

1. Place the ZAG on a level, dry surface.

2. Check to make sure the power switch is in the 'off' position.

3. Plug the unit into a standard 110 VAC electrical outlet.

4. Open the flow control knob fully (turn the knob counter-clockwise).

5. Connect the calibration gas line to the 1/4" tube compression fitting located on the top panel of the generator.

6. Turn the power switch to the 'on' position.

7. Adjust the flow control valve to the desired air output. Maximum capacity is 18 lpm.

8. High purity air will be produced within 2 minutes after start-up.

NOTE: There is a trade off between air pressure and flow. High air volumes will result in lower air pressure, and vice-versa. If low pressure, low flow applications are encountered, a pressure regulator should be connected between the instrument and the Zero-Air Generator.

Maintenance

Routine maintenance on the ZAG consists of periodic carbon replacement and outlet filter replacement. Under normal intermittent use the desiccant should last at least six months. WARNING!! Depressurize and unplug the ZAG before attempting any maintenance or removing the top or bottom panels!

Activated Carbon/Alumina Replacement

The activated carbon canister is located behind the top panel. The top half of the canister is exposed to allow visual inspection of the mixture. As the mixture is used, its color changes from purple to brown. When 3/4 of the canister has changed to brown, replace the mixture. The mixture can not be regenerated and must be discarded.

Replacing the mixture

1. Disengage the four (4) panel screws by turning 1/4 turn counterclockwise.

2. Lay the top panel down on top of the bottom panel.

3. Remove the black plug from the bottom of the canister using a 15/16" wrench.

4. Pour out the pellets while tapping the canister lightly to remove any pellets that may remain inside

5. Re-fill the canister by slowly pouring in the fresh activated carbon/impregnated alumina mixture (Approx. 0.7 lb is required per absorbent change).

6. Tap the side of the canister while filling to settle the mixture and reduce air pockets.

7. Apply Teflon tape to the plug and replace in the bottom of the canister and tighten.

8. Replace the top panel using the panel screws.

9. Place the top panel back in the lid of the case and engage the fasteners by turning 1/4 turn clockwise.

Final Filter Replacement

1. The final filter should be replaced each time the activated carbon/alumina is changed. The filter is located immediately after the outlet of the CO catalyst canister.

2. Remove the four (4) panel screws using a 1/8" allen wrench and pull the top panel out. Note the position of the filter so that you can install the replacement in the same way.

3. Loosen the 1/4" compression nuts on either end and pull the filter from the tubing.

4. install the new filter with the standoff end (visible inside the housing, supporting the filter element) connected to the catalyst canister outlet.

5. Firmly tighten the compression nuts on the inlet and outlet tubing.

Fuse Replacement

If the unit fails to run when plugged in and turned on, first check the fuse.

1. Disconnect the power cord from the power input module on the bottom panel of the unit.

2. Using a slotted tip screwdriver, pry up at the slot located about 1/4" below the surface of the power input module, inside the cord entry socket. This will pull up the fuse carrier that holds the fuse on the bottom and a spare.

3. Inspect the fuse to see if it is blown. If so, remove it and replace it with the spare fuse.

4. If the fuse is in good shape, re-install and plug in the system.

NOTE: If the unit still does not work, unplug the unit again and remove the four socket head screws located on the corners of the bottom panel. Pull the bottom panel out and inspect the wiring connections to make sure they are secure. If any loose wires are evident, tighten the connection if possible.