ZA070 - User Manual  

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 2nd June 2005

Installation and Directions for Use

Zero Air Gas Generator
ZA070 (19” Rack System)

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 support) 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

Zero Air Gas Generator 2nd June 2005

Document Change History
Issue No
1 2 3 4 5 First Issue Digital PID Controller fitted USA Technical support number updated New style front added Weight of unit changed to 13kg

Changed

Initials
BC SM FAD FAD AMcB

Date
12/01/02 25/01/02 16/11/04 30/03/05 02/06/05

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Zero Air Gas Generator 2nd June 2005

Contents
Page No Document Change History Warranty Statement Introduction Unpacking & Installation Electrical Connection Air Connection Principle of Operation Commissioning Routine Maintenance Troubleshooting Technical Specifications System Diagrams Maintenance Log Notes 2 4 6 6 6 7 8 9 9 10 11 12 13 14

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Safety First
It is important that you thoroughly read and u nderstand this manual before operating or servicing this Peak Scientific Instruments Gas Generator. PLEASE NOTE THE FOLLOWING CAUTIONS AND WARNINGS FOR YOUR OWN SAFETY.

! Caution –
Only authorized persons should operate or service this equipment.

! Warning –
To avoid risk of electrical shock, personal injury, or death disconnect power before removing any cover of this equipment.

! Caution –
To avoid risk of personal injury NEVER disconnect any pipe, fitting, or filter bowl while the system is pressurized. Always allow pressure to dissipate before opening the system.

! Warning –
The Catalytic Process requires very high temperatures. Internal surfaces and copper lines are extremely hot and will cause burns. Always allow the generator to cool before carrying out any servicing.

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Zero Air Gas Generator 2nd June 2005

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 subclause 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 Gas 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 Zero Air Gas Generators is designed to produce a constant flow of Zero Grade Air with a Hydrocarbon content (as Methane) of less than 0.1 ppm.

2

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 bottom of the unit or the fan outlet to the rear. The generator is designed to be installed inside a standard 19” telecom cabinet. The generator requires 4U space overall. Performance of the generator (like all sophisticated equipment) is affected by ambient temperatures and humidity. Prolonged operation in temperatures exceeding 28°C will shorten the life of the unit. Operation in relative humidity exceeding 70% may result in moisture carry-over. Additional moisture traps should be installed downstream of the generator should ambient regularly exceed 70% Rh. and also if the generator is any distance from the application. Moisture traps or coalescers should be located as close to the application as possible. Note should also be taken of the proximity of Air Conditioning outlets. These can sometimes give rise to “pockets” of air with high relative humidity. Operation of the generator within such a pocket could adversely affect its performance.

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): Fuse

Green & Yellow Brown Blue

or

Green Black White

The generator protection fuse is located within the bayonet cap panel mounted fuse holder on the front panel. The fuse is rated at 6.3 AMP. Connect the generator to a single-phase 110 volt supply using the power cord provided.

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4

Air Connection

The inlet and outlet connections are 1/4" BSP female. The Inlet air should conform to the following specifications: Minimum Pressure Maximum Pressure Maximum Hydrocarbon Content 85 psig 125 psig 100 ppm

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 back panel left side of the cabinet (looking from the front). 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 required pressure is attained. There is no physical method of restricting the gas output from the generator. The user should therefore ensure that the application only receives a maximum flow not exceeding the rating for the generator. Demand in excess of the rated capacity of will result in higher levels of hydrocarbons in the delivered gas.

.5

Principle of Operation
7

The ZA070-19R Zero Air generator works on the fundamental principle of Catalytic Oxidation as illustrated
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in the following pneumatic diagram.

Zero Air Gas Generator 2nd June 2005

Heater Rod Thermocouple

Inlet Filter / Regulator

Cooling Coil

Outlet Cat Chamber

ZAxxx Pneumatic Diagram
Zero Air Generation
Inlet air is passed into the Generator via a coalescing filter, which removes bulk moisture and particles down to 0.1 micron. The air is then 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 <0.1ppm, for this process to work the catalyst requires to be heated to approximately 400 degrees Celsius. The free Carbon and Hydrogen atoms then combine with Oxygen in the air to form Carbon Dioxide and Water. After the catalytic chamber the air passes through a simple cooling coil to reduce its temperature to a safe level. This is assisted by a cooling fan.

6

Commissioning
This should be undertaken by a technically competent person. 8

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Prior to installing the generator into the Rack Cabinet, remove the lid. Check that all the internal components are securely located and have not moved during transit. Open the air supply and turn the unit ON. Set the regulator on the Inlet Filter/Regulator to the desired pressure. Check that the cooling fan (ZA180) is operating and exhausting air out of the generator. Check that the red LED on the temperature control board is lit.

After a period of time (around 40 minutes) the Catalytic Chamber should have reached the required temperature. When this happens the relay on the Temperature Controller will “click” and the red LED will go out. The heater will then cycle on & off as required. Replace the front cover, the generator is now operational.

Do not touch any part of the Catalytic Chamber or Copper Lines as they will be VERY Hot.

7

Routine Maintenance

Due to the simplicity of design and the small number of parts the Peak Zero Air 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. 1. Inlet Filter. Condensed moisture should be periodically drained from the filter. 2. Temperature Control. Check that the red LED cycles On & Off.

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Troubleshooting

Problems with the Zero Air Generator will probably be shown up by increased levels of Hydrocarbons being detected on the baseline. Reference to the following Fault Finder Chart will identify the source of the problem.
Cat Chamber Hot/ Cold Cold Hot Check Flow Rate

High CH4

Control Board LED On

Off

LED Off

Voltage At Heater Yes

No

Thermocouple Wiring OK

Open Circuit

Voltage At Board Output Replace Heater Yes

No

Replace Control Board

Replace Thermocouple

Check Wiring

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Technical Specifications
General Details
5 oC (41 oF) 28 oC (82 oF)

Minimum Operating Ambient Temperature Maximum Operating Ambient Temperature Inlet Conditions (Instrument Grade) Minimum Air Inlet Pressure Maximum Air Inlet Pressure Maximum Hydrocarbon Content Start up time for specified hydrocarbon concentration

85 psig 125 psig 100 ppm Approx. 40 minutes

Physical Details Model
Max Output (Litres/min) Heater Watts Fan Watts Electrical Requirements (110V 60Hz) Dimensions (H x W x D) cm Inches Weight Kg Lbs

ZA070R
7 l/min 450W 9W 4.2 A
18x48x43 7x19x17

13 28.6

Parts List Model
Catalytic chamber Heater Element Thermocouple Cooling Fan (110V)

ZA070R
06-1075 04-1059 04-1051 04-1022

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Switch

12V Power Supply

L NE

Instructions for use Manual

PEAK Scientific Instruments Ltd

Fuse

1 2 11 10

9

8

7 6

5

4

3 2

1

Fan Motor SSR

Thermal Fuse Transformer (230V System)

Thermocouple

Heater Rod

ZA19Rack Electrical Diagram

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Maintenance Log
ModelSerial number

Work Done

Remarks

Date

Name

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Notes

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