Section 13
SOP for Zero Air Generators
May 2016
Page 1 of 9
Revision 1
FORSYTH COUNTY OFFICE OF
ENVIRONMENTAL ASSISTANCE AND
PROTECTION
STANDARD OPERATING PROCEDURE (SOP)
Zero Air
Generators
Section 13
SOP for Zero Air Generators
May 2016
Page 2 of 9
Revision 1
Signature Page
By the signatures below, the Forsyth County Office of Environmental Assistance and Protection
(FCEAP) certifies that the information contained in the following Standard Operating Procedure
(SOP) is complete and fully implemented as the official guidance for our Office. However, due
to circumstances that may arise during the sampling year, some practices may change. If a
change occurs, a notification of change and a request for approval will be submitted to EPA
Region 4 at that time.
Name: Cary Gentry Signature: Date: 8/19/16
Title: FCEAP QA Specialist
Name: Jason Bodenhamer Signature: Date: 8/19/16
Title: FCEAP Program Manager
Name: Minor Barnette Signature: Date: 8/19/16
Title: FCEAP Director
Name: Signature: Date:
Title:
Name: Signature: Date:
Title:
Section 13
SOP for Zero Air Generators
May 2016
Page 3 of 9
Revision 1
Table of Contents
13.0 Introduction ............................................................................................................................. 4
13.1 General Overview ................................................................................................................... 4
13.2 Initial Instrument set up (Teledyne API 701H and T701H) ................................................... 4
13.3 Zero Air Generator Maintenance ............................................................................................ 5
13.4 Audit Zero Air Generator maintenance .................................................................................. 8
13.5 Verifying the Zero Air System ............................................................................................... 9
13.6 Documentation ........................................................................................................................ 9
REFERENCES ............................................................................................................................... 9
REVISION DATE CHANGES TO SOP
Section 13
SOP for Zero Air Generators
May 2016
Page 4 of 9
Revision 1
STANDARD OPERATING PROCEDURES FOR ZERO AIR GENERATORS
Forsyth County Office of Environmental Assistance and Protection
13.0 Introduction
All equipment, chemicals, field operating procedures, and laboratory operating procedures used
during the use of Teledyne 701 H series zero air supplies will comply with CFR requirements.
The following procedure manual is to be used as a supplement to the Code of Federal
Regulations (CFR). Siting and various quality assurance (QA) procedures are followed in
accordance with the Code of Federal Regulation Title 40 Part 50, Part 58 and EPA-454/B-13-
003: Quality Assurance Handbook for Air Pollution Measurement Systems: Volume II.
This “Standard Operating Procedure” (SOP) will provide guidance for the operation and
maintenance of Teledyne API 701H/T701H/T751 Zero Air Generators.
13.1 General Overview
Zero Air Generators are used to clean air from any particles, gases, and moisture while
maintaining the level of oxygen found in ambient air. This cleaned air is then used by gas
calibrators to produce contaminant/moisture free calibration gas.
A zero air system to be used in the field should be set as follows:
Ambient air entering the instrument is passed through a 5 µm Teflon filter to remove
particulates. An air compressor is connected to a drying system to extract any moisture from the
air and followed by a storage tank. The dried air is then routed through a hydrocarbon scrubber
(catalytically converting hydrocarbons to CO2 and H2O), a CO scrubber (oxidizes CO to CO2),
columns of purafil (oxidizing NO to NO2) and activated charcoal (removing NO2, O3, SO2 and
H2S), and then routed to the zero air output.
The Forsyth County Air Quality network uses Teledyne API 701H, Teledyne API T701H, and T
751 (portable) high performance zero air generators. For audit purposes a Teledyne API 751H is
used, which is the portable version of the 701H series.
13.2 Initial Instrument set up (Teledyne API 701H and T701H)
Upon receiving a new Zero Air Generator, remove the four red shipping screws on the bottom
that secure the compressor to the chassis.
13.2.1 Install the inlet air filter in the ‘Air In’ port on the back of the instrument.
13.2.2 The tubing from the ‘Drain’ port should end in a 5 gallon bucket to collect water. The
operator must check the bucket for water. Only small amounts of water should be visible (less
than 1” of water collected over a two week period). If more water starts collecting in the bucket
Section 13
SOP for Zero Air Generators
May 2016
Page 5 of 9
Revision 1
it can be a hint that the air inside the monitoring shelter is high in moisture which can lead to
instrument malfunctions or the zero air generator needs servicing.
13.2.3 Connect a line of Teflon tubing from the ‘Zero Air Out’ on the zero air generator to the
site calibrator so the zero air can be used.
13.2.4 Turn on the instrument power. A few seconds after the power light (green LED) and
cooling fan have started, the compressor should start. Observe the pressure gauge on the front
panel which should reach ~30 psi within a few minutes. If not, adjust the regulator knob to set
the pressure to 30 psi or contact the program manager.
13.2.5 The instrument is producing zero air and ready to use when the pressure is steady at 30 psi
and the dew point sensor LED is illuminated green.
Fig. 1: Front panel of the T701H Zero Air Generator.
13.3 Zero Air Generator Maintenance
Once a year the zero air generators have to be serviced. On a more frequent basis, as part of a
routine site visit, check the overall cleanliness (remove dust) of the instrument, especially the
‘Air in’ filter and fan inlet, cooling fan, cooling coil and water bucket.
Before any maintenance work, cycle the power on/off switch and drain any water that may be
present in the pressure tank. Refer to Operation Manual, Models T701, T701H, 701 and 701H
Zero Air Generators, (Oct 2014) Chapter 3.5.2.
To avoid injury, let the unit cool down! The Hydrocarbon and CO scrubbers operate at
temperatures ~300 ºC and the hot air is transported in the copper tubes.
The yearly maintenance consists of:
13.3.1 Thoroughly clean the inside of the instrument.
Section 13
SOP for Zero Air Generators
May 2016
Page 6 of 9
Revision 1
13.3.2 Check all tubing for abrasion as the compressor produces vibration. If any section of
tubing shows abrasion, or wear, it should be replaced. Check all fittings for tightness.
13.3.3 Perform a pump check. Typical life span of a freshly rebuilt pump is ~18 months, if used
continuously. The best indicator for pump wear is a vacuum check on the pump inlet. To do this,
disconnect the power cord from the Control Board. Disconnect the air out side tube line from the
pump and attach a vacuum gauge to the air in port instead of the air in filter. Connect the power
adapter cord to the pump cord and plug into a wall outlet. The gauge should now show at least -
20” Hg of vacuum.
If NOT, the pump has to be rebuilt. Refer to Compressor Service Kit Manual shipped with the
rebuild kit. (If the pump piston seal rings show a high amount of ware, check the down stream
side line for contamination. On the 4-way valve, check the inside of the two brass filters. If these
get too dirty and start clogging, a usable dew point can not be reached.)
If YES, return the instrument back to normal operating set up (procedure is the reverse of 13.3.3)
13.3.4 The charcoal and purafil columns (see Fig. 2) should be replenished. Refer to Operation
Manual, Models T701, T701H, 701 and 701H Zero Air Generators, (Oct 2014) Chapter 6.4 and
6.5.
Fig. 2: Columns filled with charcoal and purafil inside the T701H.
T701H only: After replenishing the columns, right after turning on the unit, press the
Maintenance Switch button on the Control Board (see Fig. 3) which sits on top of the storage
tank. This places the unit in maintenance mode and will override any fault warnings for 24 hours.
When in normal mode a fault warning can turn the unit off.
Section 13
SOP for Zero Air Generators
May 2016
Page 7 of 9
Revision 1
Fig. 3: T701H Control Board, maintenance mode button location
13.3.5 701 Models only! Check the pressure relief valve “cut out” pressure of 70-80 psi (cut-in
pressure at ~30 psi). Refer to Instruction Manual, Zero Air Module Model 701, (Oct 2014)
Chapter 6.8.
13.3.6 The ‘Final filter’ right before the ‘Zero Air Out’ has to be cleaned.
13.3.6.1 Detach the line from the filter housing and remove the filter from the rear panel.
13.3.6.2 Open the filter housing by unscrewing the bowl and clean the inside. If the filter is too
contaminated, it should be replaced. Cleansing with water can remove some debris.
13.3.6.3 Reassemble the filter housing, place it back to the rear panel and reattach the line.
13.3.7 Perform a leak check. See below or refer to Operation Manual, Models T701, T701H, 701
and 701H Zero Air Generators (Oct 2014), Chapter 6.12.
13.3.7.1 Cap the exhaust on the rear panel and the regenerative dryer. Remove the line to the
dew point sensor and cap the fitting.
13.3.7.2 Turn on the unit and wait for the pump to turn off. Observe the pressure gauge; pressure
should not change for the next five minutes. If the pressure is steady the leak check has passed.
Section 13
SOP for Zero Air Generators
May 2016
Page 8 of 9
Revision 1
13.3.7.3 Return the unit back to operating set up.
13.3.8 Let the instrument reach normal operating condition (see 13.2.5).
13.4 Audit Zero Air Generator maintenance
The primary zero air generator used during the audits for the FCEAP monitoring network is a
Teledyne portable 751H model. The maintenance for this model is identical to the 701 series
except it uses a smaller pump, which would require a different rebuild kit. See the operation
manual for the 701 series (Oct 2014).
The secondary zero air generators used for audits contain a mobile set up of two parts: a pump
and a drier/purifier box.
Fig. 4: Two part Audit Zero Air supply set up.
13.4.1 Thoroughly clean both parts of the generator set by removing dust.
13.4.2 The silica gel, purafil, and charcoal canisters should be replaced as needed, at least once a
year.
13.4.3 Check all lines and connections for wear and tightness.
13.4.4 Perform a pump check. Disconnect the tube line from the pump and attach a vacuum
gauge to the air in port directly at the pump. Connect the pump into a wall outlet and let it run.
The vacuum gauge should now read at least - 20” Hg of vacuum.
If YES, return the system back to normal operating set up.
If NOT, the pump has to be rebuilt.
13.4.5 Leak check the system.
13.4.5.1 Cap the Air out port on the drier/purifier box.
Section 13
SOP for Zero Air Generators
May 2016
Page 9 of 9
Revision 1
13.4.5.2 Attach the pump to the drier/purifier box inlet and let it run to build up pressure. Turn
off the pump and observe the pressure gauge. The pressure should not drop more than 1 psig in
one minute.
13.4.5.3 Slowly release the pressure by slowly opening the cap on the Air out port.
13.5 Verifying the Zero Air System
13.5.1 After the annual maintenance is completed, attach the zero air system to a level 2 transfer
standard. Then connect a line between the cal gas out port of the level 2 transfer standard and the
sample port of an ozone analyzer.
13.5.2 Turn the level 2 transfer standard on to run a zero point.
13.5.3 Let the analyzer stabilize and observe the ozone value which should read <0.002 ppb O3.
13.6 Documentation
13.6 Document all problems, maintenance, test results, and verifications completed on the zero
air systems using calibrators and/or analyzers to track the quality of the zero air being produced
by each unit. All results should be logged in the S:\A&M\Repair Supplies and Logs folder under
the Ambient Equipment Repair Log ZERO AIR.xls file. Find the corresponding tab for each
unit based on serial number within the excel sheet and add documentation to track the
equipment’s history.
REFERENCES
Operation Manual, Models T701, T701H, 701 and 701H Zero Air Generators (Oct 2014),
Teledyne Advanced Pollution Instrumentation Division, 9480 Carroll Park Drive, San Diego, CA
92121-5201.
Operation Manual, Model 701H High Performance Zero Air Generator, Teledyne Advanced
Pollution Instrumentation Division, 9480 Carroll Park Drive, San Diego, CA 92121-5201.
Instruction Manual, Zero Air Module 701. Teledyne Advanced Pollution Instrumentation
Division, 9480 Carroll Park Drive, San Diego, CA 92121-5201.
Model SK2668 Compressor Service Kit Manual, Thomas, A Gardner Denver Product, 3524
Washington Avenue, Sheboygan, WI, 53081
