TOC1500HP - User Manual  

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PEAK Scientific Instruments Ltd

TOC1500HP Generator

Instructions for use Manual

Directions For Use

Calibration Gas Generator
TOC1500HP

Peak Scientific Instruments Ltd
Fountain Crescent
Inchinnan Business Park
Inchinnan
Renfrewshire
PA4 9RE
T. (Europe) +44 (0) 141 812 8100
T. (USA) +1 866 647 1649 (sales)
T.(USA) +1 866 732 5427 (tech help)
F. (Europe) +44 (0) 141 812 8200
info@peakscientific.com
sales@peakscientific.com
support@peakscientific.com

www.peakscientific.com

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Instructions for use Manual

Document Change History
Issue No

Changed

Initials

Date

HD
FAD
FAD
LC

15/04/03
17/11/04
04/04/05
16/12/15

1
5
6
7

Document Created
USA Technical support number updated
New front cover added
Updates

8

DOC Added

LC

22/11/18

9

Declarations Update

CD

31/08/21

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Contents
Page No
Warranty Statement

4

Introduction

5

Unpacking & Installation

5

Electrical Connection

5

Air Connection

6

Principle of Operation

7

Commissioning

9

Routine Maintenance

10

Troubleshooting

13

Technical Specifications

15

System Diagrams

17

Maintenance Log

18

Notes

19

Declaration of conformity

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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:-

4.1) 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; and
4.2) 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.

SAFETY NOTICE TO USERS
These instructions must be read thoroughly and understood before installation
and operation of your Peak Nitrogen Generator. Use of the Generator in a manner
not specified by Peak Scientific Inst. 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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1

Introduction

The Peak Scientific Instruments range of Calibration Gas Generators is designed to produce a constant flow
of dry air of calibration standard with impurities reduced to better than the following levels: -

Contaminant
CO
CO2
SOX
THC
O2
H2O
2

Concentration
<1.0 ppm
<1.0 ppm
<0.1 ppm
<0.1 ppm
=18 - 20%
<1.5 ppm

Unpacking and Installation.

Although Peak Scientific take every precaution with safe transit and packaging, it is advisable to fully
inspect the unit for any sign of transit damage.

ANY DAMAGE SHOULD BE REPORTED IMMEDIATELY TO THE CARRIER AND
PEAK SCIENTIFIC OR THE DISTRIBUTOR FROM WHERE THE UNIT WAS
PURCHASED.
After unpacking and a visual inspection, the unit should be placed in a ventilated area away from direct
sunlight. Care should be taken not to obstruct the ventilation holes on the sides of the unit not the fan
outlet on the top.
The generator should be placed on a steady and level base.

3

Electrical Connection

Important Electrical Notice
This unit is classified as SAFETY CLASS 1 equipment. 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

Green
Black
White

Fuse
The generator protection fuse in the pull out drawer of the mains inlet IEC euro connector located
on the bottom right hand side of the cabinet adjacent to the off/on switch. The fuse is rated at 10
AMP.
Connect the generator to a single-phase supply using the power cord provided.

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4

Air Connection

The inlet and outlet connections are 1/4" BSP female.
The minimum required air conditions are as follows: -

Pressure
Inlet Flow

TOC1500HP
100 psig (4.8 Barg)
9.5 Litres/min

CG15L
120 psig (8.27 Barg)
28 Litres/min

The inlet air should be oil free and pre-filtered to remove bulk moisture. Although not essential, an air
drier up-stream of the generator will ensure a long and trouble free life.

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.
The air supply should be connected to the generator inlet on the left side of the cabinet. The user's
application should be connected to the outlet on the right side of the cabinet. To avoid leakage/impurity
ingress, use PTFE tape on all fittings.
Slowly, turn on the air supply until the desired pressure is attained. Output flow is factory set at 1.5 l/min
(TOC1500HP) or 15l/min (CG15L).

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5

Principle of Operation

The TOC1500HP gas generator works on the basis of two fundamental processes as illustrated in the
following pneumatic diagram.
Heater Rod
Pressure

Temperature

Thermocouple

PEAK
Laboratory Generator

Cat
Chamber
NRV

Receiver
Gauge

Regulator

PSA
Drier

Heat
Exchanger
Inlet Filter

Receiver

Gas
Outlet

5/2 Valve
Filter

Air Inlet

Drain Outlet

3/2 Valve

CGxxL Pneumatic Diagram

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Zero Air Generation
The first process utilizes a '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 <0.1ppm for this process to work
the catalyst requires to be heated to approximately 400 degrees Celsius.
After the catalytic chamber the air passes through a simple cooling coil to a filter, which removes bulk
moisture and any further particulate down to a level of 5 micron. The filter incorporates an auto-drain
mechanism, which will release any accumulated water from the filter bowl when the level is sufficiently
high. The water passes out through a drain bulkhead at the bottom of the side of the cabinet.
Because water and also carbon dioxide are created in the Catalytic Process there is a necessity to
effectively remove them both.

Moisture / CO2 Removal: The second process utilizes a 'Pressure Swing Adsorption' (PSA) method to further treat the air. This is
where contaminant gases and moisture can be selectively adsorbed from compressed air into a porous
crystalline sieve material. The adsorption process is aided by the electrostatic interaction between the
adsorbent sieve material and the gaseous adsorbate. The Peak Scientific Instruments Ltd. PSA dryer
system utilizes the 'Skarstrom' process where there are two columns of adsorbent used alternatively and
described as follows: The un-treated air is passed via a '5 port-2 position' (5/2) pneumatic control valve into one of the sieve
columns where moisture, CO2 and other non-methane hydrocarbons are removed. Some of the purified
gas is back-purged down the other column to atmosphere, which creates a regeneration effect. A simple
timer eventually causes the 5/2 valve to change columns and the other regenerated sieve column now
generates the purified gas. Again some purified gas is back purged down the other column to
atmosphere to cause a regeneration effect. This process repeats itself approximately every 2 minutes
indefinitely.
During this process CO2 is reduced to a level of <1ppm and water moisture is removed to a level of -75o
Celsius Pressure Dew Point (1.4ppm @ ATP or 0.14ppm @ 100 PSI approx.).

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6

Commissioning
This should be undertaken by a technically competent person

With the generator installed as described earlier remove the lower front cover. Check that all internal
components are securely located and have not moved during transit.
Open the air supply and turn the unit ON.
Check that the cooling fan is operating and exhausting air out of the generator. Check that the red LED
display on the Upper Front Panel is lit.
After a maximum of 2 minutes the timer valve should operate to change over the columns on the PSA
drier unit. This is accompanied by an audible rush of exhaust air from the Exhaust Silencer.
The reading on the Digital Display should begin to increase towards its set point of 400°C. After a
maximum time of 40 minutes the Catalytic Chamber should have reached temperature. When this
happens the display will remain steady on 400°C. The heater is controlled by a PID controller which
accurately matches heater output to demand.
Do not touch any part of the Catalytic Chamber or Copper Lines, as they will be VERY hot.
Purge Setting
The PSA Purge has been set in the factory and should not require adjustment. The purge can be
checked by connecting a simple Rotameter type flow meter to the outlet of the drier purge valves in turn.
The connection is for 4mm plastic hose. The purge should be set at 100 psig input.
Specification
Output Flow
Purge Flow

TOC1500HP
1.5 l/min
8 l/min

CG15L
15 l/min
12 l/min

A reduced purge rate will result in higher levels of contaminate gases over a period of time.

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7

Routine Maintenance

WARNING: Servicing and/or repair of the generator should only be undertaken
by a TECHNICALLY COMPETENT PERSON with the generator safely isolated.
Due to the simplicity of the design and the small number of moving parts the TOC1500HP Gas
Generator will have a long and trouble free life. However as with all scientific and technical equipment it
should be regularly inspected by a competent person and the following points noted.

Filters/Separator/Silencers

Every 12 months

Service kits are available for all routine maintenance; please contact the factory for further details.

FAILURE TO FOLLOW THE PRESCRIBED
INVALIDATE THE PRODUCT WARRANTY.

MAINTENACE

PLAN

WILL

Inlet Filter / Separator Elements
These should be changed at intervals as indicated below. In addition filter bowls should be cleaned and
the operation of the auto-drains should be checked.
The Generator MUST be de-pressurised prior to attempting to remove ANY filter bowl. Failure to
do this may cause injury.

Eliminizer & Coalescing Filter Elements
These elements should be changed at 12-month intervals. Part Numbers 02-4366 & 02-4335.
Disconnect the drain fittings from the bottom of the bowls.
Turn the bowl ¼ turn counter clockwise to release. The element then un-screws. Re-assembly is the
reverse procedure.

0.1μm

02-4335
02-4366

Hold down and
twist ¼ turn

Autodrain
02-4485

Eliminizer

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Dryer Filter & Silencer Elements
These elements should be changed at 12-month intervals. Part Numbers 02-4335 & 02-1033.
The Generator MUST be de-pressurised prior to attempting to remove ANY filter bowl. Failure to
do this may cause injury.
Disconnect the drain fittings from the bottom of the bowl.
Turn the bowl ¼ turn counter clockwise to release. The element then un-screws. Re-assembly is the
reverse procedure. The Exhaust Silencers are removed by unscrewing.

02-1033

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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.
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.

Air Inlet
Line

Thermocouple

Heater

Thermal
Fuse

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 to replace the thermal fuse. Refer to
the trouble-shooting chart on page 13 for guidance.

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8

Troubleshooting
No Gas Delivery

Check Presure
Gauges

Low

Yes

Air Escaping
From Drain

OK

Clean Autodrain

No

No flow

Check
Flow Rate

Check Aoir
supply

OK
Blocked
Chamber Contact Factory

High
Check
Flow Rate

High CH4

Reduce Demand

OK

400
Check Front Panel
Display
No
Display

No Fault - Check
Elsewhere

EEE

Replace Faulty
Thermocouple
<400

No
Check 12V @
terminals 8&9

Replace Faulty
Power Supply

Yes

Replace Faulty
Display Module

0V
Check Thermal
Fuse

Voltage
At Heater

Replace Faulty
SSR

110 V

Replace Faulty
Vent Fan

30 Ohms
Check Heater
Resistance

Replace Heater

CH4
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High CO2
Check
Drain Port

High C02

No Flow
Clear Obstruction

Clear

Check
Electronoc Timer

No

Replace
Timer

Check Timer
Operation

OK

OK

Audible
Change-over

No

Check Valve
Supply

Open
Circuit

Repair Wiring
Fault

Yes

CHeck
3/2 Valve

Replace
Faulty 3/2 Valve

Check Purge
Settings

Wrong

Purge to
Atmosphere
for 24 Hours

Re-set Purge
Settings

OK

Replace Alumina
Charge in
Drier Columns

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High

Check CO2
Levels

OK

Return to
Service

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6

Technical Specifications
General Details

Minimum Operating Ambient Temperature
Maximum Operating Ambient Temperature

5 oC (41 oF)
45 oC (113 oF)

Inlet Conditions (Free of oil and bulk moisture)
Minimum Air Inlet Pressure

6.8 Barg (100 PSI)

Maximum Air Inlet Pressure

8.6 Barg (125 PSI)

Minimum Air Inlet Flow Rate (TOC1500HP)

9.5 Litres/min (ATP)

Minimum Air Inlet Flow Rate (CG15L)

28.0 Litres/min (ATP)

Outlet Gas
Maximum Pressure Drop (Outlet-Inlet) δP
Maximum Gas Outlet Pressure

0.7 Bar (10 PSI)
Max Inlet-δP
-75oC (-103oF) (1.4ppm @ ATP)

Pressure Dewpoint
Start up time for dewpoint

8 hrs

Particles

0.01um

Hydrocarbon concentration (as methane)

<0.1ppm

Start up time for hydrocarbon concentration

45 minutes

CO level

<1.0ppm

CO2 level

<1.0ppm

SOX

<0.1ppm

Electrical Requirements
@115V ac (50/60Hz)

5.2 Amps

@230V ac (50/60Hz)

2.6 Amps

Electrical Connection

IEC-Euro connector

General
Dimensions W x D x H

cm
(inches)

Shipping Weight

Kg
(lbs)

TOC1500HP issue 8

43 x 41 x 62
(20” x 17” x 16”)
64
(136)

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Serviceable Parts List
Item

TOC1500HP
(110V 60Hz)

TOC1500HP
(230V 50HZ)

CG15L
(110V 60HZ)

CG15L
(230V 50Hz)

Fuse (10A)
Transformer
Element Eliminizer
Element AFD3000
Heater Element
Thermocouple
Temperature Controller
Thermal Fuse
Cooling Fan
Exhaust Silencer
Timer
3/2 Valve
Pressure Regulator
Flow Regulator
Safety Valve

00-1208
n/a
02-4366
02-4335
04-1053
04-1051
04-4459
00-1207
04-1022
02-1033
04-1019
02-4384
02-1110
02-4437
02-4549

00-1208
04-4356
02-4366
02-4335
04-1053
04-1051
04-4459
00-1207
04-1021
02-1033
04-1019
02-4334
02-1110
02-4437
02-4549

00-1208
n/a
02-4366
02-4335
04-1059
04-1051
04-4459
00-1207
04-1022
02-1033
04-1019
02-4384
02-1110
02-4437
02-4549

00-1208
04-4356
02-4366
02-4335
04-1059
04-1051
04-4459
00-1207
04-1021
02-1033
04-1019
02-4334
02-1110
02-4437
02-4549

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Maintenance Log
Model-

Work Done

TOC1500HP issue 8

Serial number

Remarks

Date

Name

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Notes

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EU Declaration of Conformity
We

Peak Scientific Instruments Ltd.

Of

Fountain Crescent, Inchinnan, Renfrewshire, PA4 9RE

Hereby declare that, this declaration of conformity is issued under the sole
responsibility of the manufacturer.
Equipment Type:

TOC Generator

Model Designator:

TOC 1500

To which this declaration relates, is in conformity with the following applicable EU
Directives, harmonized standards, and other normative requirements.
•

Low Voltage Directive 2014/35/EU
EN 61010-1: 2010 Safety Requirements for Electrical Equipment for Measurement,
Control and Laboratory Use.

•

Electromagnetic Compatibility Directive 2014/30/EU
EN 61326-1: 2013 Electrical Equipment for Measurement, Control and Laboratory Use
– EMC Requirements. (Class A)

•

Restriction on the use of certain hazardous substances in electronic equipment
(RoHS) Directive 2011/65/EU as amended by EU 2015/863.

•

FCC 47 CFR Part 15 class A
Unintentional radiators; Conducted and Radiated emissions limits.

Signed for and on behalf of Peak Scientific by
Signed:
Name:

Fraser Dunn

Position:

Design Engineering Manager
Peak Scientific Instruments ltd,
Inchinnan, Renfrew, Scotland, PA4 9RE, UK.

Date:

31st August 2021

20

UK Declaration of Conformity
We

Peak Scientific Instruments Ltd.

Of

Fountain Crescent, Inchinnan, Renfrewshire, PA4 9RE

Hereby declare that, this declaration of conformity is issued under the sole
responsibility of the manufacturer.
Equipment Type:

TOC Generator

Model Designator:

TOC 1500

To which this declaration relates, is in conformity with the following applicable UK
Statutory Instruments, Standards and other normative requirements.
•

The Electrical Equipment (Safety) Regulations 2016 (SI 2016 / 1101) as amended.
BS61010-1:2010 Safety Requirements for Electrical Equipment for Measurement
Control and Laboratory Use.

•

The Electromagnetic Compatibility Regulations 2016 (SI 2016 / 1091) as amended.
BS61326-1:2013 Electrical Equipment for Measurement , Control and Laboratory Use
– EMC Requirements.

•

The Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment Regulations 2012 (SI 2012 / 3032) as amended.

Signed for and on behalf of Peak Scientific by
Signed:
Name:

Fraser Dunn

Position:

Design Engineering Manager
Peak Scientific Instruments ltd,
Inchinnan, Renfrew, Scotland, PA4 9RE, UK.

Date:

31st August 2021

21

WEEE Compliance Statement
The Waste Electrical and Electronic Equipment (WEEE) Regulations SI 2013 No 3113
and or the Waste Electrical and Electronic Equipment (WEEE) Directive 2012/19/EU
apply to all electrical and electronic equipment placed on the market in the UK and EU
covered by the scope of regulations which can be found in the Government Guidance
Notes (PDF) produced by the Department for Business Innovation and skills for the UK
and here for Europe.
All PEAK products that are subject to the WEEE directive are compliant with the
WEEE marking requirement. Such products are marked with the “crossed-out wheelie
bin” symbol (shown below) in accordance with European standard EN50419. All
old electrical equipment can be recycled. Please do not dispose of any electrical
equipment (including those marked with this symbol) in general rubbish bins. Please
contact your dealer or distributor for clarity.

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