ZA 070A-180A - User Manual  

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<p>ZA070A-180A User Manual

2015 © Peak Scientific – Rev 15A – 26/01/15

ZA070-180A User Manual

Contents
Change History How to use this Manual Introduction Warranties and Liabilities Safety Notices Symbols Safety Notice to Users Safely Isolated Condition Safe State After Repair Technical Specification Environment Generator Outlets Electrical Requirements General Unpacking Removing the generator from the crate Installation Generator Environment General Dimensions Rear Connections Electrical Connection Commissioning IMPORT ANT DOCUMENTS Normal Operation Zero Air Generation Catalytic Chamber Heater Thermocouple Thermal Fuse 4 4 5 6 7 7 7 8 9 10 12 12 12 12 13 14 15 15 15 16 16 17 18 19 19 20 20 20 20

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Service Requirements Service Schedule Service Plans Cleaning Trouble Shooting

21 21 21 22 23

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Change History
Rev. 1 2 3 4 5 6 7 8 9 10 11 12 13A 14A 15A Comment First Issue Spare Parts Moisture Carry Over Re-setting Information 2002 Revised Design Compressor Service No Longer Valid USA Technical Support Updated New Style Front Added Filter Details Updated Remove ref. to PSA Air Purifier Updated 110v Compressor Model Updated to New Format Added Removal Information Added Declarations Added ZA070A reference Name Stephen Murray Stephen Murray Stephen Murray Stephen Murray Stephen Murray Stephen Murray Fiona Dunn Fiona Dunn Gavin Logan Safder Khan Gavin Logan Liam Couttie Liam Couttie Liam Couttie Liam Couttie Date 21/10/98 11/12/98 01/04/99 11/06/99 14/11/01 07/01/03 16/11/04 30/03/05 23/06/06 04/09/06 12/10/06 25/08/14 06/10/14 09/10/14 26/01/15

How to use this Manual
This manual is intended for end users and has been written so that it can either be read as a step by step guide to installation and usage or as a reference document where you can skip to the relevant information. Users of a hard copy version can refer to the contents page to find the relevant information. Users of the soft copy version can use the hyperlinks from the contents page as well as the hyperlinks between sections. Please review each of the following sections carefully. Thank you for selecting Peak Scientific to meet your Gas Generation needs, and should you require any further assistance or support please do not hesitate to contact Peak Scientific or Peak Partner from which you purchased your Generator.

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Introduction
The Peak Scientific range of Zero Air Gas Generators is designed to produce a constant flow of Zero Grade Air with a hydrocarbon content of less than 0.1ppm. To ensure this Generator model meets our high expectations with regards to reliability and performance, we have tested this new model extensively at our manufacturing plant and with end users around the world to ensure reliability and longevity of the system.

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Warranties and Liabilities
1. The Company warrants that it has title to the Goods. 2. Subject to the provisions of this clause the Company warrants that the Goods shall comply in all material respects with any specification referred to in the Order Confirmation (as the same may be amended) and shall, subject thereto, be free from defects in material and workmanship for the lesser of a period of twelve months from the date of delivery or thirteen months from the date of dispatch from the factory. 3. Save as provided in this clause and except where the Goods are sold to a person dealing as a consumer (within the meaning of the Unfair Contract Terms Act 1977) all warranties, conditions or other terms implied by statute or common law are hereby expressly excluded save to the extent they may not be lawfully excluded. When the Goods are sold to a consumer within the meaning of the Unfair Contract Terms Act 1977 their statutory rights are not affected by the provisions of this clause. 4. In the event of the Customer making a claim in respect of any defect in terms of clause 2 hereof the Customer must. 1. Reasonably satisfy the Company that the Goods have been properly installed, commissioned, stored, serviced and used and without prejudice to the generality of the foregoing that any defect is not the direct or indirect result of lack of repair and/or servicing, incorrect repair and/or servicing, use of wrong materials and/or incorrect spare parts 2. Allow the company to inspect the Goods and/or any installation and any relevant packaging as and when reasonably required by the Company. 5. Subject to the Company being notified of any defect as is referred to in sub-clause 2 hereof within a reasonable time of it becoming apparent and subject always to the terms of sub-clause 4 hereof, the Company shall, in its option, replace or repair the defective Goods or refund a proportionate part of the Price. The Company shall have no further liability to the Customer (save as mentioned in sub-clause 6 hereof). 6. The Company shall be liable to indemnify the Customer in respect of any claim for death or personal injury to any person in so far as such is attributable to the negligence or breach of duty of the Company or any failure by the Company to comply with the provisions of sub-clause 2 hereof.

7. Save as provided in sub-clause 2 hereof the Company shall not be liable
in respect of any claim by the Customer for costs, damages, loss or expenses (whether direct, indirect, consequential or otherwise) or indemnity in any respect howsoever arising including, but not by way of limitation, liability arising in negligence (other than pursuant to clause 6 above) that may be suffered by the Customer or any third party.

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Safety Notices
Symbols
This manual uses the following symbols to highlight specific areas important to the safe and proper use of the Generator
A WARNING notice denotes a hazard. It calls attention to an operating procedure, process or similar, which if not correctly performed or adhered to, could cause personal injury or in the worst case death. Do not proceed beyond a WARNING notice until the indicated conditions are fully understood or met. A CAUTION notice denotes a hazard. It calls attention to an operating procedure, process or similar, which if not correctly performed or adhered to, could cause damage to the Generator or the Application. Do not proceed beyond a CAUTION notice until the indicated conditions are fully understood or met.

Caution, risk of electric shock. Ensure power to the Generator has been removed before proceeding.

Hot Surface. Do NOT touch.

Safety Notice to Users
These instructions must be read thoroughly and understood before installation and operation of your Peak ZA180A Generator. Use of the Generator in a manner not specified by Peak Scientific MAY impair the SAFETY provided by the equipment. When handling, operating or carrying out any maintenance, personnel must employ safe engineering practices and observe all relevant local health and safety requirements and regulations. The attention of UK users is drawn to the Health and Safety at Work Act 1974, and the Institute of Electrical Engineers regulations.

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Safely Isolated Condition
Definition: The unit is in a Safely Isolated Condition when it is disconnected from its application, fully de-pressurised, cooled down and isolated from the Electrical Supply. Directions for isolating the Generator are shown below.

Failure to place the Generator in a safely isolated condition when instructed to do so may lead to personal injury or injury to others and even death.

Hot Surface. Do NOT touch.

Isolating the Generator: a) Switch off the unit. b) Unplug the unit from the mains supply and remove the power cord from the rear of the unit. c) Ensure the output pressure gauge read zero. (If gauge does not fall to zero, loosen the outlet fitting slightly to allow trapped gas to escape.) d) Ensure that tank pressure gauge located on electrical panel reads zero. (If gauge does not fall to zero, close pressure regulator and loosen the outlet fitting to allow trapped air to escape.) e) Ensure the temperature display on the front panel reads ZA070A-180A User Manual
Safe State After Repair
To guarantee the generator is in a safe state after a repair, please ensure the following conditions are met;

•

The electricity cable has been correctly refitted.
The mains cable should be plugged into the IEC power inlet located on the side panel of the generator. This unit is classified as SAFETY CLASS 1. THIS UNIT MUST BE EARTHED.

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Declaration of Conformity
We Of Declare that: Equipment: Model: Date: Zero Air Generator ZA180A 18 / 09 / 2014 Peak Scientific Instruments Ltd. Fountain Crescent, Inchinnan, Renfrewshire, PA4 9RE

To which this declaration relates, is in conformity with the applicable EC directives, harmonized standards, and other normative requirements. • Low Voltage Directive 2006/95/EC EN 61010-1: 2010 Electrical Equipment for measurement, control and laboratory use. Electromagnetic Compatibility Directive 2004/108/EC EN 61326-1: 2013 Electrical Equipment for measurement, control and laboratory use.

•

All evaluation, testing and certification issued by: York EMC Services Ltd Donibristle Industrial Park Dunfermline, Fife KY11 9HZ

Signed: Date: 18 September 2014
th

Name: Position:

Chris Pugh Engineering Director

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Environmental Declaration
We Of Declare that: Equipment: Model: Zero Air Generator ZA180A Peak Scientific Instruments Ltd. Fountain Crescent, Inchinnan, Renfrewshire, PA4 9RE

Is fully compliant with the following Directives • • 2002/96/EC WEEE (Waste of Electrical and Electronic Equipment) 2002/95/EC RoHS (Restriction of Hazardous Substance)

Peak Scientific Instruments Ltd fully complies with its obligations towards the European WEEE (Waste of Electrical and Electronic Equipment) Directive 2002/96/EC. These obligations are being met within the B2B compliance group. Peak Scientific Instrument Ltd have developed all reasonable ‘due dilligence’ controls to ensure that our products comply with the principles and requirements of the European RoHS (Restriction of Hazardous Substances) Directive 2002/95/EC. Similar directives in the United States and China, for example, have also been captured within this program. Where a specific certificate of compliance is required, this can be requested, on a product serial number basis, directly from Peak Scientific Instruments Ltd, by contacting us through our website on www.peakscientific.com

Signed: Date: 18 September 2014
th

Name: Position:

Chris Pugh Engineering Director

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Technical Specification
Environment
ZA070A Minimum Operating Ambient Temperature Maximum Operating Ambient Temperature Maximum Altitude Maximum Relative Humidity Minimum Storage Temperature Maximum Storage Temperature 5°C / 41°F 30°C / 86°F 2000 meters 70% 10°C / 50°F 25°C / 75°F ZA180A

Generator Outlets
ZA070A 7L/min 80 psi 0.01μm 0.1ppm 1 1 2 40 minutes ZA180A 18 L/min 80 psi 0.01μm 0.1ppm 1 1 2 40 minutes

Maximum Flow Rate Maximum Gas Outlet Pressure Particles Hydrocarbon Concentration Gas Outlets Drain Outlets Pressure Gauges Start-Up Time For Purity

Electrical Requirements
Voltage Frequency Current Input Connection Power Cord Pollution Degree Insulation Category ZA070A & ZA0180A 230VAC 110VAC 50 Hz 60 Hz 4.9 AMPS 8.8 AMPS C14 Plug C13 Socket to Local Connection 2 II

General
Generator Dimensions cm Generator Weight Shipping Crate Dimensions cm Shipping Weight ZA070A & ZA0180A 43 x 41 x 88 64 Kg 100 x 57 x 67 91 Kg

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Unpacking
Although Peak Scientific takes every precaution with safe transit and packaging, it is advisable to fully inspect the unit for any sign of transit damage. Check ‘SHOCKWATCH’ label for signs of rough handling prior to un-packing –

Any damage should be reported immediately to the carrier and Peak Scientific or the Peak Partner from where the unit was purchased. Follow the unpacking instructions posted on the side of the crate. It will require two people to remove the unit from the shipping crate and to manoeuvre the Generator onto the floor. Please save the product packaging for storage or future shipment of the Generator. Note: Included with the Generator is a “Fittings Kit” containing mains power leads for UK, EU and US also all the required fittings. Be careful not to discard these with the packaging.

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Removing the generator from the crate
The generator weighs over 64kg and as such should be unpacked by two people using the following method. All the screws encircled in RED should first be removed from the shipping crate, there are approximately 8 screws. Now, with someone positioned at either side of the shipping crate, the top half of the crate can be lifted upwards and away from the rest of the crate. With the top of the crate removed the foam insert of top of the generator should also be taken off.

The generator can now be lifted out of the crate base and onto the floor. This should be done again with someone positioned at either side. There is a gap in the foam base for hand access; one hand should be positioned here underneath the generator and the other at the back supporting the weight. The generator should then be tilted back slightly and then up and out of the foam base and onto the floor.

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Installation
Generator Environment
The Generator is designed for indoor use only. It should be installed adjacent to the application it is supplying. If this is not convenient then the unit can be sited elsewhere, however, consideration should be made of the lengths of pipe runs as pressure drops can result from extended runs of pipe. Please see the Tubing lengths section for further details. Performance of the Generator (like all sophisticated equipment) is affected by ambient conditions. Note should also be taken to the proximity of Air Conditioning outlets. These can sometimes give rise to “pockets” of air with high relative humidity. Operation of the unit within such a pocket could adversely affect its performance. Consideration should also be given to the air flow around the unit. It is recommended that an air gap of 75mm (3”) should be maintained down both sides, at the rear and across the top of the unit. Please refer to the drawing below for the general dimensions of the unit.

General Dimensions

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Rear Connections
The outlet connections are 1/4" BSP female. Note the platinum catalyst within the Zero Air Catalytic Chamber will become poisoned if it comes into contact with any halogenated hydrocarbons, silicone sprays, silicone greases, phosphorous compounds, lead components, high sulphur vapours or other catalyst poisons.

Electrical Connection
Connect the Generator to a 230 volt 50Hz single-phase supply using the power cord provided. If the appropriate power cord is not supplied; a new plug, rated to at least 13 amps, can be fitted by a qualified electrician. This unit is classified as SAFETY CLASS 1. THIS UNIT MUST BE EARTHED. Before connecting the unit to the mains supply, please check the information on the serial plate. The mains supply must be of the stated AC voltage and frequency. EARTH/GROUND (E):LIVE (L):Neutral (N):Green & Yellow Brown Blue or or or Green Black White

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Commissioning
With the generator installed as described earlier remove the front cover. Check that all the internal components are securely located and have not moved during transit. Connect the generator to the electrical supply and turn the unit ON. The unit will begin to build up pressure as will be seen from the two pressure gauges. The lower gauge indicates the Output Pressure which is factory-set at 80 psig. The upper gauge indicates the internal receiver pressure which will fluctuate between 120 and 90 psig. The Digital Display shows the Catalyst Chamber temperature. This is factory set at 400ºC. There are two Status LEDs on the front panel. Once the Catalyst reaches operating temperature the RED will switch off and the GREEN will illuminate indicating that the generator is ready for use. The generator should reach operating temperature within 40 minutes of switch-on. Check that the cooling fans are operating and exhausting air out of the generator. Do not touch any part of the Catalytic Chambers or Copper Lines, as they will be VERY hot.

Hot Surface. Do NOT touch.

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IMPORTANT DOCUMENTS Warranty Entitlement
To register your generator for your warranty entitlement, send the completed form to Peak Scientific by: • • • • Email Online Phone Fax
warranty@peakscientific.com http:/ /www.peakscientific.com/service-and-support/warranty_registration

+44 (0)141 530 4185 +44 (0)141 812 8200

PRODUCT WARRANTY REGISTRATION
COMPANY: ADDRESS: EMAIL ADDRESS: CONTACT NAME:

CITY/TOWN: POSTCODE: COUNTRY: TELEPHONE:

GENERATOR SERIAL NUMBER:

MODEL TYPE: INSTALLATION DATE (DD/MM/YYYY):

Important Please Note:
You have 1 month to register your Peak Scientific product from the date of shipment. If you wish to defer installation of your generator you must notify Peak Scientific within 1 month of the shipment date. This can be done by emailing warranty@peakscientific.com Once registered the warranty will be honoured for a period of 12 months after the installation date. For any generators that remain unregistered the warranty will begin from date of shipment. Thank you on behalf of Peak Scientific.

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Normal Operation
Zero Air Generation
Ambient air is compressed and after cooling is passed through the Filter Separator which removes liquid moisture to and particles down to 0.1 micron. The air is then passed through a Membrane Dryer to remove any remaining moisture and on into and internal Receiver. The receiver is designed to provide volume within the system to cope with different flow rates and to allow the compressor to operate a duty cycle. When the Receiver reached its maximum pressure the Pressure Switch will operate stopping the compressor and opening the unloading valve. Air from the Receiver is regulated for pressure and flow and passed to the 'Zero Air' catalytic combustion chamber. This works on the principle of catalytic oxidation where hydrocarbons from the incoming compressed air supply are cracked to carbon dioxide and water. The hydrocarbon level in the form of methane is reduced to ZA070A-180A User Manual
Catalytic Chamber
The Catalytic Chamber is heated to 400ºC and will cause severe burns if touched. If for any reason the chamber or its associated parts need to be examined the generator must be switched off and allowed to cool. THIS COULD TAKE UP TO 10 HOURS.

Hot Surface. Do NOT touch.

The Catalytic Chamber takes the form of cylindrical chamber with a heated central core. The annular space is specifically designed to allow the required contact time with the catalyst to ensure complete oxidization. The complete chamber is contained within an insulated enclosure as shown below.

Heater
Regardless of the supply voltage the heater is rated at 110 Vac. This minimizes the volt drop across the conductors and prolongs the life of the element. The Heater is contained within a stainless steel sleeve to facilitate removal should replacement be required.

Thermocouple
The thermocouple is “K” type spring-loaded bayonet fitting to ensure good contact with the chamber core.

Thermal Fuse
The thermal fuse is provided as a safety feature to cut supply to the heater thus preventing chamber overheating in the event of a control or ventilation failure. It is a fail-safe device and if blown requires replacing. Note: - The thermal fuse will not blow under normal operation. A blown thermal fuse indicates that a fault exists which MUST be rectified before attempting

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Service Requirements
Service Schedule
Service Interval Component ZA Annual Service Kit 12 months Kit Includes; 2 x Inlet Filter Element* 1 x Ultra-Fine Element 08-4708 1 Part No. Qty.

Table 1: Service schedule

*Note: There are 2 Inlet Filter Elements supplied, one for each six months of usage.

Service Plans
Peak Scientific offer two service plans. The Complete Service Plan, specifically designed for Generators operated in critical environments, also includes full breakdown cover, guaranteed response times and Generator upgrades if available. Our Standard Service Plan, covering the basic needs of our Generators, features special deals on spare parts and breakdowns. If you want to know more about our Service Plan options and how we ensure that your instrument can run with the maximum uptime and performance, please contact us at maintenance@peakscientific.com

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Cleaning
Clean the outside of the Generator only using warm soapy water and a clean damp cloth. Ensure the cloth is thoroughly rung out to remove excess fluid prior to use. Cleaning should only be undertaken with the power switched off and the power cord removed from the rear of the Generator. Under no circumstances should any solvents or abrasive cleaning solutions be used as these can contain fumes that could be harmful to the Generator.

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Trouble Shooting
Problem
The Generator will not switch on and the power switch does not illuminate. • • • • The Generator will not switch on but the power switch is illuminated. • Temperature is not rising Temperature controller is not lit Pressure not building Excessive noise • • • • •

Possible Solution
Ensure power cord is plugged into the Generator and that the power socket is turned on. Check the fuse in the power cord plug. Contact your service provider. Disconnect power cord from the rear of the Generator. Open the left hand panel are check that both circuit breakers are turned on (switch in the up position). Reconnect power cord. Contact your service provider. Contact your service provider. Check the fuse in the power cord plug. Contact your service provider. Contact your service provider. Contact your service provider.

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Peak Scientific UK Fountain Crescent Inchinnan Business Park Inchinnan PA4 9RE Scotland, UK Tel: +44 (0)141 812 8100 Fax: +44 (0)141 812 8200 Peak Scientific Germany Herriotstrasse 1 60528 Frankfurt

Peak Scientific North America 19 Sterling Road Suite #1 Billerica, MA 01862 USA Tel: +1 866 647 1649 Fax: +1 978 608 9503 Peak Scientific China Room 606 Building 1 Lane 2277 Zuchongzhi Road Pudong New Area Shanghai 201203, China Tel: +86 21 5079 1190 Fax: +86 21 5079 1191 Peak Scientific Brazil Peak Scientific Brasil Av. Quieroz Filho 1700 – torre Sunny-Conj. 602 São Paulo SP Brasil Tel: +1 866 647 1649

Peak Scientific India 202, Amsri Shamira Old Lancer Line Opp. St. Mary’s Degree College S.D. Road Secunderabad 500 025, India Tel: +91 40 2780 0663 Fax: +91 40 2780 0663 Peak Scientific Mexico Solon 352 Col. Los Morales Polanco 11530 Mexico, D.F. Mexico Tel: Fax: +1 866 647 1649 +1 978 608 9503

Peak Scientific Africa PO Box 478 Somerset Mall 7137 South Africa Tel: +27 (0)2185 16542 Fax: +27 (0)8654 64473 Peak Scientific Australia PO Box 65 Belmont Victoria 3216 Australia Tel: +61 1300 965 352

Germany Tel: +49 (0)69 677 33 490 Fax: +49 (0)69 677 33 200 Peak Scientific Taiwan 4F.-6, No.736 Zhongzheng Rd. Zhonghe Dist. New Taipei City Tel: +886 2 8226 2383 Fax: +886 2 8226 9499

Peak Scientific Japan K.K. 2-7-56, 2F Fuji Building 28 Kita Aoyama, Minato-Ku Tokyo, Japan 107-0061 Tel: +81 3-6864-0468

Peak Scientific Singapore 3 Science Park Drive #03-14 The Franklin Science Park Drive 1 Singapore, 118223 Tel: +65-6777 1966 Fax: +65-6777 1978

2015 © Peak Scientific – Rev 15A – 26/01/15

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