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Air-Vac DRS24NC - User Manual

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Diffuser Heater Installation for DRS Units
Page 1
August, 2008
Diffuser Heater
Installation for DRS Units
Tools Needed: American Standard Allen Wrenches, Multi-Meter
30 Progress Avenue
Seymour, CT 06483
Tel: (203) 888-9900
Fax: (203) 888-1145
AIR-VAC ENGINEERING
COMPANY, INC.
www.air-vac-eng.com
ISO 9001:2000 Certified
Please note that a burned out heater could possibly cause other parts of the system to fail.
Perform these quick steps to ensure the new heater will not fail prematurely.
NOTE: To determine whether a heater is good or not, check with a mulit-meter:
Test across the two power leads, 26.0
Ω +/− 5.0 Ω +/− 5.0
Ω +/− 5.0 Ω +/− 5.0
Ω +/− 5.0 (coil). Across the two thermocouple
leads should have continuity.
Power Leads
Thermocouple Leads
8
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Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features

This document outlines the installation and maintenance procedures for a diffuser heater in AIR-VAC DRS units, along with relay replacement instructions for specific DRS models and warranty information.

Function Description

The primary function of the diffuser heater is to heat air within the DRS unit, which is crucial for its operation. The document emphasizes the importance of proper installation and maintenance to prevent premature failure of the heater and potential damage to other system components. The heater is equipped with both power leads and thermocouple leads, allowing for both power delivery and temperature monitoring.

Important Technical Specifications

  • Heater Resistance: When testing across the two power leads, a good heater should exhibit a resistance of 26.0 Ω +/- 5.0 (coil).
  • Thermocouple Continuity: The two thermocouple leads should show continuity when tested with a multi-meter, indicating proper sensor function.
  • Relay Voltage Check: For DRS units, a critical check involves measuring the voltage between specific terminal block points (TB18 with TB22 for the left diffuser, TB18 with TB21 for the right diffuser). If 1/2 volt or more is present, it indicates a faulty Solid State Relay (SSR) that needs immediate replacement. For CXX units, the corresponding checks are TB23 with TB24 (right diffuser) and TB21 with TB22 (left diffuser).

Usage Features

The document provides a step-by-step guide for installing a new diffuser heater:

  1. Heater Installation: The new heater is to be installed directly into the diffuser plate.
  2. Wiring: Wires from the new heater must be routed back to the terminal bar where the previous heater was connected. This ensures proper electrical connection and power supply.
  3. Air Tube Connection: The air tube needs to be securely reconnected to the pneumatics panel, specifically to the fitting labeled "diffuser air" (either right or left, depending on the diffuser being serviced). This ensures the heated air is directed correctly within the system.
  4. Initial Power-Up and Check: After installation, the machine should be powered up, and an immediate voltage check performed on the terminal bar as described in the technical specifications. This crucial step helps identify and prevent damage from a faulty Solid State Relay.

Maintenance Features

The manual details procedures for replacing Solid State Relays (SSRs) for different DRS models, which are essential for maintaining the heating function.

Relay Replacement for DRS24, 25 Models:

  1. Location: Solid State Relays are situated in the right side of the unit, within the power module.
  2. Panel Removal: Access to the relays requires removing a panel secured by four screws.
  3. Relay Identification and Replacement: Once the panel is open (from right to left), the faulty diffuser relay can be located and replaced. The document provides visual aids to identify the Nozzle Relay, Left Diffuser Relay, and Right Diffuser Relay.

Relay Replacement for DRS24NC Models:

  1. Location: Similar to other models, SSRs are in the right side of the unit's power module.
  2. Box Access: The "Right Box" needs to be opened to access the relays.
  3. Protective Cover and Relay Replacement: Inside, a protective plexiglass cover must be removed before the bad diffuser relay can be replaced. Visual labels help distinguish the Nozzle Relay, Left Diffuser Relay, and Right Diffuser Relay.

Troubleshooting:

  • Heater Failure: The document explicitly states that a burned-out heater could potentially cause other parts of the system to fail, underscoring the importance of timely replacement.
  • Pre-Installation Check: Before installing a new heater, it is recommended to test its resistance and thermocouple continuity using a multi-meter to ensure it is in good working order.

Warranty Information:

  • General Warranty: Air-Vac Engineering Company provides a one-year warranty on all parts, materials, and labor for equipment repair, excluding "wear and tear" items.
  • Heater Limited Life Warranty: Heaters, being "wear and tear" items, have a specific ninety-day warranty from the date of shipment.
  • Warranty Conditions:
    • The warranty covers defects in material and/or workmanship.
    • It does not cover products repaired or altered by unauthorized parties.
    • The warranty is void if defects are due to obvious misuse or improper maintenance.
    • Air-Vac must receive notice during the warranty period, products must be operated according to documentation, and defects must be confirmed by Air-Vac.
  • Heater Life Factors: The document highlights that heating element life is influenced by several factors, including temperature, airflow, condition of incoming air (water and oil contamination), and overall process cycle. Higher temperatures and/or lower flows can shorten the heater's lifespan, as it is considered a "consumable" item.
  • RMA Requirement: Products cannot be returned without a Return Merchandise Authorization (RMA) number. When contacting for warranty inquiries, customers should provide the order number, product model and serial number, and the reason for the warranty claim.

Air-Vac DRS24NC Specifications

General IconGeneral
BrandAir-Vac
ModelDRS24NC
CategoryMicroscope
LanguageEnglish

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