TOC 1000 - User Manual  

Extracted text

TOC 1000
User Manual

Copyright © Peak Scientific Instruments Ltd 2024 — TOC 1000 User Manual Rev 7 RSID 3471 EN —12/11/2024

Contents
Change History

3

How to use this Manual

3

Warranties and Liabilities

4

Safety Notices

5

Symbols

5

Safety Notice to Users

5

EU Declaration of Conformity

6

UK Declaration of Conformity

7

WEEE Compliance Statement

8

Technical Specification

9

TOC 1000

9

Unpacking

10

Fittings Kit Contents

11

Installation

12

Generator Environment

12

Generator Overview

13

General Dimensions

13

Rear Connections

14

Electrical Connection

15

Air Purity

16

Start-Up Sequence

17

Connecting to the application

18

Tubing Lengths

18

Service Requirements

19

Service Schedule

19

Peak Protected

20

Cleaning

21

Troubleshooting

22

Page 2

Change History
Rev
1
2

Comment
Initial Release
Declarations Update

Name
Liam Couttie
Cleo Denholm

Date
18/02/2020
31/08/2021

3

Compressed Air Supply Update

L. Couttie

28/07/2023

4

Spec. Update

L. Couttie

22/03/2024

5

Sticker added on

Cleo Denholm

07/06/2024

6

Compressed Air Note Added

L. Couttie

09/08/2024

7

Spec. Update

L. Couttie

12/11/2024

How to use this Manual
This manual is intended for end users and has been written as a reference document
where you can skip to the relevant information.
Users can refer to the contents page to find the relevant information.
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 the Peak Partner from which you purchased your generator.

Page 3

Warranties and Liabilities
Visit: www.peakscientific.com/warranty-statement/

Page 4

Safety Notices
Peak Scientific Instruments cannot anticipate every possible circumstance which may
represent a potential hazard. The warnings detailed within this manual refer to the most
likely potential hazards, but by definition cannot be all inclusive. If the user employs an
operating procedure, item of equipment or a method of working which is not specifically
recommended by Peak Scientific, the user must ensure that the equipment will not be
damaged or become hazardous to persons or property.

Symbols
This manual uses the following symbols to highlight specific areas important to the safe
and proper use of the generator.

WARNING

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.

CAUTION

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.

Safety Notice to Users

WARNING

WARNING

These instructions must be read thoroughly and understood before
installation and operation of your Peak 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.
If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment maybe impaired.

WARNING

Page 5

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 Air Generator

Model Designator:

TOC 1000

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

Page 6

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 Air Generator

Model Designator:

TOC 1000

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

Page 7

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.

Page 8

Technical Specification
TOC 1000
Environment
Minimum Operating Ambient Temperature
Maximum Operating Ambient Temperature
Maximum Altitude
Maximum Relative Humidity
Minimum Storage Temperature*
Maximum Storage Temperature*
Maximum Storage Temperature*
Inlet Conditions
Min/Max Inlet Air Pressure
Minimum Air Inlet Flow
Minimum Air Inlet Quality
Maximum Inlet CH4 Concentration

5°C (41°F)
35°C (95°F)
2000m
70% @ 35°C
5°C ( 41°F)
35°C (95°F)
90% non-condensing
100psi / 6.9bar - 120psi / 8.3bar
6 LPM
ISO 8573 - 1:2010 Class 1.4.1†
100ppm CH4

Generator Outlets
Maximum Gas Output Pressure
Maximum Outlet Flow Rate**
Gas Purity
Dewpoint (°C)
Particles
Phthalates
Suspended Liquids
Gas Outlets
Start-Up Time
Electrical Requirements
Voltage
Frequency
Current
Power Cord (Supplied)
Circuit Breakers
Pollution Degree
Insulation Category
Transient Over Voltages
General

120V±5% / 230V ±10%
120V/ 60Hz / 230V 50/60Hz
120V 4A / 230V 1A
C13 Plug
10A
2
Class 1
Over Voltage Category II

Dimensions mm (inches) HxWxD
Shipping Dimensions mm (inches) WxDxH
Generator Weight Kg (lbs)
Shipping Weight Kg (lbs)
Noise Level
* Note: Please ensure generator is situated in a well ventilated environment.

Page
9


50 psi / 3.4 bar
1000 cc/min
<1ppm CO2 <1ppm CO <1ppm SOx
<1ppm NOx<0.05ppm CH4
-60°C / -76°F
<0.01 μm
Phthalate & BHT Free
None
1 x 1/4” BSPP x 6mm push-fit connection
120 minutes

343 x 270 x 530 mm (13.5 x 10.7 x 20.9'')
435 x 650 x 400mm (17.1 x 25.5 x 15.7")
27kg (59.6lbs)
38kg (83.8lbs)
Virtually Silent
** Note: Flows in LPM are expressed as normalised volumes at 101.3kPa, 20°C.

† This unit should be connected to an air supply that, as a minimum, meets ISO 8573-1:2010 Class 1.4.1 or connected to the relevant Peak air compressor model.

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’ and ‘TIP-N-TELL’ labels for signs of rough handling prior to
unpacking.

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 to
the desired location.
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 & US and also all the required fittings and warranty registration card. Be careful
not to discard these with the packaging.

Page 10

Fittings Kit Contents
Supplied in the Fittings Kit are all the fittings required to connect the generator to the
application. The contents of the Fittings Kit are as follows:
1. Tube PE 6mmOD 4mmID

x3m

2. Cable C13 BS 1363 UK 230V 10A 2m

x1

3. Cable C13 Nema 6 15 US 220V 2m

x1

4. Cable C13 Schuko H05VV-F EU 230v 2.5m

x1

5. Cable C13 Nema 5 15 US 110V 2m

x1

6. Elbow ¼”M BSPPx6mm Push Fit

x2

7. TOC 1000 Installation guide

x1

All of the generators output ports are located on the output panel at the rear of the unit.

Page 11

Installation
Generator Environment
The generator should, if possible, be installed next to the application,. If, however, this is
not possible, please consider the distance between the generator and your application,
since pressure drops can result from extended lengths of tubing and may affect gas
delivery.
Performance of the generator is affected by ambient conditions. Note should also
be taken to the proximity of Air Conditioning outlets. Air conditioning systems 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 and at the rear of the unit. Please refer to the
drawing below for the general dimensions of the unit.
Please ensure Generator is situated in a well ventilated environment and is positioned to
allow easy disconnection from the mains supply if required.
Minimum Operating Ambient Temperature:

5 °C (41 °F)

Maximum Operating Ambient Temperature:

35 °C (95 °F)

Compressed air supplied to the TOC 1000 generator should meet ISO 8573-1:2010
Class 1.4.1 standard and should be supplied at 100psi (6.9bar) - 145psi (10 bar)
pressure. Supply of compressed air at a pressure of below 100psi may result in poor
quality air that may not meet instrument requirements. Supply of compressed air at a
pressure greater than 145psi may cause damage to the generator and could result in
damage to any instrument supplied.
Compressed air supplied at <100psi could result in poor performance of the TOC
1000 gas generator and may affect instrument performance.
Compressed air supplied at >145psi may result in damage to the TOC 1000 gas
generator and may result in damage to instrumentation connected to the gas
generator.

Page 12

Generator Overview
General Dimensions

343 mm

270 mm

530 mm

The generator must always be placed on a flat, level surface. Failure to
do so will affect the performance of the generator.
WARNING

Page 13

Rear Connections

Product Gas Outlet

Power Inlet

Air Inlet

Ensure all inlets and outlets are connected to correct sources and
applications.
WARNING

WARNING

Page 14

All Connections should only be carried out by trained personnel.
Generator must be switched off and unplugged prior to any cleaning or
maintenance operations.

Electrical Connection
Connect the generator to an appropriate 120 or 230 volt single-phase supply, refer to
the generator serial plate for input specification and ensure your supply matches the
requirements.
If the appropriate power cord is not supplied, a new plug with correct rating can be
fitted by a qualified electrician, ensuring that it has adequate ratings and appropriate
approvals for the country of operation. Failure to do so could cause damage to the
generator or risk of overloading of the power cord.

WARNING

If a substitute main supply cord is used, ensure that it has adequate
ratings and appropriate approvals for the country of operation. Failure
to do so could cause damage to the generator or risk of overloading of
the power cord.

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):-

Green & Yellow

or

Green

LIVE (L):-

Brown

or

Black

Neutral (N):-

Blue

or

White



Electrical requirements are 120VAC nominal +/- 5% or 230VAC nominal +/- 10%
depending on chosen model. Extended periods at extremes can have a detrimental
effect on the operation and life of the generator.
If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment maybe impaired.
WARNING

Page 15

Air Purity
The Precision Zero Air Series generator should be connected to an air supply that, as a
minimum, meets ISO8753-1:2010 Class 1.4.1

Class 1 Particulate
In each cubic metre of compressed air, the particulate count should not exceed 20,000
particles in the 0.1 - 0.5 micron size range, 400 particles in the 0.5 - 1 micron range and
10 particles in the 1 - 5 micron size range.

Class 4 Water
A pressure dew point (PDP) of +3°C or better is required and no liquid water is allowed.

Class 1 Oil
In each cubic metre of compressed air, not more than 0.01mg of oil is allowed. This is a
total level for liquid oil, oil aerosol and oil vapour.

Page 16

Start-Up Sequence

CAUTION

Page 17

Before the generator is first connected to the application, the generator
should be operated in isolation (i.e. not connected to the application)
for 120 minutes. This is to ensure that any impurities are purged from
the system. Failure to do this may harm the application.

Connecting to the application
Using the tubing provided, connect the outlet of the unit to the inlet on the application.
If you require more tubing than is supplied please refer to the Tubing Lengths section below.

CAUTION

Once the tubing is connected to the application, please ensure that it is
thoroughly checked for leaks. Even the slightest leak in the gas supply
between the generator and the application can lead to a reduction in
efficiency and gas purity.

Compressed air supplied to the TOC 1000 generator should meet ISO 8573-1:2010
Class 1.4.1 standard and should be supplied air at a pressure of 100psi (6.9bar) 145psi (10bar). Supply of compressed air at a pressure of below 100psi may result in
poor quality air that may not meet instrument requirements. Supply of compressed
air at a pressure greater than 145psi may cause damage to the generator and could
result in damage to any instrument supplied.
Compressed air supplied at <100psi could result in poor performance of the TOC
1000 gas generator and may affect instrument performance.
Compressed air supplied at >145psi may result in damage to the TOC 1000 gas
generator and may result in damage to instrumentation connected to the gas
generator.

Tubing Lengths

CAUTION

The diameter of the tubing which will be connected to the gas outlet is
important and is determined by the length of tubing required. Failure to
follow these recommendations could lead to pressure drops between
generator and application.

< 3 meters: Use 6mm OD / 4mm ID or 1/4” OD / 3/16” ID tubing.
> 3-10 meters: Use 8mm OD / 6mm ID or 5/16” OD / 1/4” ID tubing.
Some tubing and fittings not supplied in the fittings kit.
> 10 - 40 meters: Use 10mm OD / 8mm ID or 3/8” OD / 5/16” ID tubing.
> 40 metres: Please contact Peak Scientific with the relevant distance and we will
calculate the flow resistance and the tubing size required.

Page 18

Service Requirements
Service Schedule
Purchase Interval

Component

12 Months

TOC 1000 Annual Maintenance Kit

Qty.

Visit

1

Note: Only Peak approved components should be used.

Page 19

www.peakscientific.com/ordering

Peak Protected
With Peak Scientific you invest in not only a product but peace of mind. With a network of
certified Peak engineers stationed throughout the globe, Peak’s rapid response team are
never far away and our commitment is to keep your generator running day in, day out,
protecting your laboratory workflow.

[Peak Protected] can provide…

Installation

A dedicated Peak engineer will visit
your lab to install and setup your
generator

IQ/OQ

Certified assurance for applications
requiring documented qualification

Complete plan

Swift response by a Peak Service
Engineer within 72 hours & planned
preventative maintenance

Spares

Genuine Peak parts with express
delivery, ensuring optimal
performance and lifetime

Premium Protected

Guaranteed rapid on-site response
within 24 hours & planned
preventative maintenance

Technical Support Hotline

Around the clock support by phone
or online with our global technical
helpdesk

To find out more about protecting your investment visit: www.peakscientific.com/protected

Page 20

Cleaning
Clean the outside of the generator only using warm soapy water and a clean damp
cloth. Ensure all excess fluid is thoroughly removed from the cloth prior to use.
Cleaning should only be undertaken with the power switched off and
the power cord removed from the rear of the generator.

CAUTION

Under no circumstances should any solvents or abrasive cleaning
solutions be used as these can contain fumes that could be harmful to
the generator.
Care should be taken with Leak Detection Liquids.

CAUTION

Page 21

Troubleshooting
Problem

Possible Solution
•

Check for leaks between the TOC 1000 and
the application.

•

Contact your service provider.

•

Check inlet air pressure is set to 100psi

•

Check inlet air flow is 6LPM

•

Check outlet air flow is 1LPM

•

Contact your service provider

The application is reporting low pressure.

Unstable baseline

Page 22

Go Online or Complete and Return
We know that registering any of your recently purchased products is not the
first thing on your mind- but it is very important to both of us. Not all warranties
are alike and Peak Scientific stand out against other gas suppliers as we offer a
comprehensive, quick response, on-site warranty. This means that in the very
unlikely case that your gas generator develops a fault we have rapid support
teams on-hand around the world who are able to come to your lab and get you
back up and running in no time.
Register for your comprehensive 12 month on-site warranty with ease online at
www.peakscientific.com/protected.
Alternatively, you can send the completed form to Peak Scientific by post or
email at warranty@peakscientific.com.

Go Online or Complete and Return
You can register for your FREE 12 month Warranty with ease online at
www.peakscientific/protected.
Alternatively, you can send the completed form to Peak Scientific by post or
email at warranty@peakscientific.com.



Product Warranty Registration
Contact name
Email address
Company
Address
City/town
Postcode
Country
Telephone
Generator serial #
Model type
Installation date
Do you still use an
alternative gas solution i.e.
cylinders or bulk liquid?

Yes

What gas requirements do
you have in your lab?

Hydrogen

No

Nitrogen

Zero Air

Extend your cover with
Peak Scientific offer comprehensive gas generator after sales support packages.
Peak [Protected] aftercare support can guarantee an on-site response within 72
hours*, genuine parts from our ISO9001 approved factory and a 95% first-time fix
rate. See our enclosed Peak [Protected] leaflet for further information.
Important!
You have 1 month to register your Peak Scientific product from the date of installation. Once registered
the warranty will be honoured for a period of 12 months. If you wish to defer the installation of your
generator, you must notify Peak Scientific immediately by emailing warranty@peakscientific.com.
For generators that remain unregistered after 1 month from the shipment date, the warranty will be
considered active from the date of factory dispatch.
* Complete Plan only






Important!
You have 1 month to register your Peak Scientific product from the date of
installation. Once registered the warranty will be honoured for a period of 12
months. If you wish to defer the installation of your generator, you must notify
Peak Scientific immediately by emailing warranty@peakscientific.com. For
generators that remain unregistered after 1 month from the shipment date, the
warranty will be considered active from the date of factory dispatch.
Page 23

Peak Scientific has highly trained, fully certified Field Service Engineers located in over 20 countries
across every continent around the world. This allows us to provide an industry-leading rapid response
service to our customers. With [Peak Protected], your laboratory’s productivity becomes our top
priority.
To discuss Peak Protected generator cover and payment options speak to your local Peak
Representative or for further information contact: protected@peakscientific.com

Peak Scientific
Fountain Crescent
Inchinnan Business Park
Inchinnan
PA4 9RE
Scotland, UK
Tel: +44 141 812 8100
Fax: +44 141 812 8200
For further information on any of our
generator products please contact
discover@peakscientific.com

Copyright © Peak Scientific Instruments Ltd 2024 — TOC 1000 User Manual Rev 7 RSID 3471 EN —12/11/2024