Problems with the aerosol output of the thermal generators seem to occur frequently. Since DOP and PAO are hydrocarbon products, carbon builds up in the heater block.
To correct this problem, it is assumed that the heater block and heaters are working properly. That is, the unit is maintaining a 765 ± 15º F or 407 ± 10º C operating temperature, and there is no carbon build up restricting the heater block nozzle.
To check for nozzle restriction, insert a piece of wire (such as a paper clip) into the nozzle tip, while it is at operating temperature and NOT producing aerosol, to remove any residue which may have accumulated. Caution: The nozzle tip is very hot. Use a pair of long nose pliers to hold the wire.
If the heater block and heaters are working properly and the outlet nozzle is clear, the problem should be the setting of the internal inert gas flow regulator. The problem might be solved by restricting oil flow through closing the liquid metering valve between 50 and 75%. This will reduce the flow of liquid to the block and should minimize droplet formation at the nozzle tip. Droplet formation is the typical cause of aerosol pulsation.
For a TDA-5B, 5C, or 5D if the problem persists, please follow the steps below:
- Disconnect power cord from electrical outlet and allow unit to cool down to ambient temperature.
- Completely close (fully clockwise) the metering valve located on the front of the unit.
- Turn AEROSOL switch OFF.
- Remove liquid fill cap and completely drain any liquid remaining in the generator reservoir.
- Remove the screws which secure top of unit to panels exposing interior of unit.
- Reinstall the liquid fill gauge.
- Connect a compressed air or gas source to the inert gas fitting located on the front of the unit.
- Adjust the pressure regulator for the inert gas supply to 50 psig and maintain this pressure.
- Connect a flow meter capable of accurately measuring 10 lpm to the aerosol outlet nozzle on the front panel.
- Turn ON the AEROSOL switch.
- Adjust the internal regulator located behind the front panel that connects to the compressed air or inert gas source to obtain a reading of approximately 6 lpm on the flow meter.
- Turn AEROSOL switch to the OFF position.
The unit should now function normally, especially if a large adjustment was needed to obtain the 6 lpm gas flow. The unit can be reassembled, energized, brought to operating temperature, and tested for operation.
If pulsing or wet aerosol still occurs, please contact ATI Customer Service for further options.