AirGen A*20DR - User Manual  

Extracted text

UM-NX18LA Revision 1

AirGen A*20DR Compressor

NitroGen N*18LA Nitrogen Generator User Manual
User Manual UM – A*20DR – Rev 6

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UM-NX18LA Revision 1

AirGen A*20DR Compressor
Contents

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Page
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Contents
Contents Document Change History Warranty Statement Declaration of Conformity Technical Specification Introduction Unpacking and Installation Unpacking and Installation - Removal of Transit Bracket Installation - Useful information Installation - Electrical Connection Installation - Compressor Environment Installation - General Dimensions Installation - Rear Connections & Unit Controls Operation - Principle of Operation Operation - Control Panel / Fault Diagnosis Operation - Additional Points Maintenance - Routine Maintenance Maintenance - Maintenance Log Notes - Additional Notes

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UM-NX18LA Revision 1

AirGen A*20DR Compressor
Change History

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Document Change History

Rev No.
1 2 3 4 5 6

Change
Final Review - First Commerical Release Customer Feedback Incorporated Complete Document Review NRV / Flow Control Updates Notes added for - Indoor Use Only & Altitude Changed to new format. Views updated for new mid & back panels. Maintenance schedule updated. Exploded drawings removed.

Initials
GL GL GL GL TG TG

Date
01/08/2006 09/08/2006 10/01/2007 15/03/2007 10/09/2007 03/12/2007

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AirGen A*20DR Compressor
Warranties & Liabilities

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Warranties and Liabilities

1. 2.

The Company warrants that it has title to the Goods. 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. 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.

3.

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). 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. 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.

4.

6.

7.

SAFETY NOTICE TO USERS These instructions must be read thoroughly and understood before installation and operation of your Peak A*20DR. Use of the Compressor 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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AirGen A*20DR Compressor
Declaration of Conformity

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Warranties and Liabilities RoHS Compliance Statement

Peak Scientific are fully compliant with European Directive 2002/95/EC dealing with the restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS) All materials, components, assemblies or equipment that Peak Scientific certifies to be RoHS compliant do not exceed the tolerated concentration limits of hazardous substances subject to the RoHS Directive.

WEEE Compliance Statement Peak Scientific is fully compliant with European Directive 2002/96/EC, Waste Electrical and Electronic Equipment (WEEE), with requirements that went into effect August 13, 2005. WEEE is intended to reduce the disposal of waste from electrical and electronic equipment by establishing guidelines for prevention, reuse, recycling and recovery.

Alan McBride Quality, Health & Safety Manager

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AirGen A*20DR Compressor
Technical Specification

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Technical Specification

Generator Environment
Minimum operating ambient temperature Maximum operating ambient temperature Maximum relative humidity Maximum Altitude 5° (41° C F) 25° (77° C F) 70% 2000 Meters

Air Outlet
Maximum flow Maximum pressure Particles Outlet 1/4" BSP Pressure Gauges Pthalates Suspended Liquids 80 l/min (2.8 CFM) 8.2 bar (120 psi) UM-NX18LA Revision 1

AirGen A*20DR Compressor
Introduction

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Introduction

Welcome to the User Manual for the Peak Scientific A*20DR Compressor. Enclosed in this manual you will find the information required to ensure that your compressor is operated and serviced according to our recommended guidelines which will prepare you for long and trouble free compressed air generation. Please review each of the following sections carefully and ensure that the maintenance log at the rear of this manual is updated for future reference. 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 OEM Partner / distributor from which you purchased your generator.

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AirGen A*20DR Compressor
Installation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Unpacking and Installation

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 unpacking -

ANY DAMAGE SHOULD BE REPORTED IMMEDIATELY TO THE CARRIER AND PEAK SCIENTIFIC OR THE OEM PARTNER / DISTRIBUTOR FROM WHERE THE UNIT WAS PURCHASED. Follow the un-packing instructions posted on the side of the crate. It will require two people to lift the crate clear and to manoeuvre the compressor onto the floor.

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AirGen A*20DR Compressor
Installation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Unpacking and Installation Removal of Transit Bracket

Remove Rear Panel as follows:At the rear of the unit, turn the key in the lock anti-clockwise to unlock the rear panel. Hold the rear panel by the two handles and swivel the bottom of it out and lower it until the top comes free from the chassis. Disconnect the plug at the LHS so that the rear panel can be completely removed. Disassemble Transit Bracket as follows – • Remove Screw 1 holding two pieces of transit bracket together. • Remove Screws 2,3,4,5,holding the Transit Bracket to the Compressors • Remove Screws 6,7 holding the Bracket to the internal side panels. • Remove transit bracket from unit.

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2

3

1

4

5(Hidden)

7(Hidden)

Re-fit the rear panel in reverse order of removal. Important Note: The Transit Bracket must be removed prior to switching the unit on. Failure to do so will result in damage to the equipment. The compressor can now be moved to its final location on the castors provided. Note: - Included with the compressor is a pack containing hex key, manuals, fittings. Be careful not to discard these with the packing. Please save the product packaging and Transit Bracket for storage or future shipment of the compressor.

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AirGen A*20DR Compressor
Installation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Useful Information

The diameter of the tubing which will be connected to the gas outlets is important and is determined by the length of tubing required. Failure to follow these recommendations could lead to accelerated compressor wear. 10 - 40 meters. > 40 metres. Use 6/4 (6mm O/D, 4mm I/D) P.T.F.E. tubing. Use 10/8 (10mm O/D, 8mm I/D). Please contact Peak with the relevant distance and we will calculate the flow resistance and the tubing size required.

A combination of 6/4 and 10/8 tubing may be used to ensure that there is no large diameter tubing within the lab (i.e. for the first 10 meters use 6/4 tubing and the final 20 meters use 10/8). Keep the connections and bends to a minimum. The imperial equivalents are:6/4 = 1/4” O/D, 3/16” I/D. 10/8= 3/8” O/D, 5/16” I/D.

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. The Electrical requirement is:EARTH/GROUND (E):LIVE (L):Neutral (N):230V AC (50/60 Hz), 8.4 Amps or or or Green Black White

Green & Yellow Brown Blue

Connect the compressor to a single-phase supply using the power cord provided.

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AirGen A*20DR Compressor
Installation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Compressor Environment

The Compressor is designed for indoor use only. It should be installed adjacent to the Nitrogen Generator 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 “Useful Information” section for further details. Performance of the compressor (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. Maximum Ambient Conditions: 25° (dry bulb) 70%RH (Max) C

General Dimensions

Unit must always be placed on a level surface. Failure to do so will effect the performance of the Generator.

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AirGen A*20DR Compressor
Installation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Rear Connections

Serial Plate Power Cord 230V ONLY 04-1038 (EU) 04-1029 (US) 04-1030 (UK) 9 Way D-Type connector for PC Comms Water Outlets 1/4” BSPP Female

Rear Panel Lock

Blanking Grommet

Air Outlet 1/4” BSPP Female

Unit Controls

Front Panel Lock On / Off Switch Pressure Gauge Service Light Alarm Light Keypad

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AirGen A*20DR Compressor
Operation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Principle of Operation

The A*20DR compressor is designed specifically to minimize operator involvement. Given that the compressor is installed as described in earlier sections and is serviced in accordance with the following maintenance recommendations then it should simply be a matter of turning the compressor on. The compressor will automatically produce the factory default flow and pressure. Start Up Sequence When the unit is switched on the fans should power up and the display on the front panel should read –
Peak Scientific Compressor Test

The system will now run through an automatic compressor check procedure. Each of the four compressors are tested in turn to ensure that it is working. The compressor check takes a minute or so and then the system will turn on fully and “PLEASE WAIT” will be displayed while pressure builds. The pressure can be monitored on the front panel gauge. Air Generation When the system is running, the maximum number of compressors operating at any time is two. To ensure the longevity of the system, the compressors cycle in pairs, with a pair running for a few minutes while the other pair are turned off to cool, then the running pair are switched off to cool and the idle pair are switched on. The display will read Peak Scientific Mode: Dual

Note: The outlet should be vented to atmosphere for at least 30 seconds to purge the system of impurities. If only a small volume of air is being drawn from the system, it will automatically change into single compressor mode. The display will read –
Peak Scientific Mode: Single

Whilst running in this mode, if too much air is then being drawn from the system, it will automatically change into dual compressor mode to meet the increased demand. The user can manually select Single or Dual Compressor mode by pressing the relevant button on the control panel. If Single mode is selected while the system requires two compressors it will automatically return to dual mode.
SINGLE DUAL

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AirGen A*20DR Compressor
Operation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Control Panel / Fault Diagnosis

If there is a problem with the system, the user will be informed by one of the two available indicators SERVICE : Audible buzzer and light on the front panel ALARM : Audible buzzer and light on the front panel. To stop the audible buzzer press long as the unit has power.
ALARM RESET

on the Control Panel. Note the light will stay illuminated as

Interrogating the Control Panel to find fault:Diagnostic: To display the current status of each compressor, the system and the inlet filter. The compressors are numbered 1 to 4 from the right-hand side looking from the rear and are identified by holes in the panel they are sitting on.
MENU

Mode Diagnostic

ENTER

Compressor 1: OK Compressor 2: OK

Compressor 3: OK Compressor 4: OK

System: OK Inlet filter: OK

To exit.
MENU ENTER

Operating hours: To display the current operating hours of each compressor in hours and minutes.
MENU

Diagnostic Operating Hours

ENTER

Comp 1: 29Hr 24Min Comp 2: 27Hr 30Min

Comp 3: 29Hr 24Min Comp 4: 27Hr 30Min

To exit.
MENU ENTER

System hours: To display the time since the last service and the total system operating time in days.
MENU

Operating Hours System Hours

ENTER

Time since last service: 21 days

Total system run time: 30 days

To exit.
MENU ENTER

To display the software revision.
MENU

System Hours N#00/A#20DR V3.20

To exit.
MENU ENTER

Mode: To display the current operating mode.
MENU

Mode Diagnostic

ENTER

Peak Scientific Mode: Dual

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AirGen A*20DR Compressor
Operation

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Additional Points

Pressure / Flow Adjustment The system is configured in the factory to give standard Outlet Pressure. The Flow controller is set to fully open after factory testing and it is assumed the generator connected to the compressor will control the flow. (See ‘Technical Specification’ page 6). These settings should NEVER require adjustment during normal operation. During service / fault diagnosis the settings can be changed by adjusting the pressure regulator and flow controller situated on the Electrical Panel. Both will be in the locked position on receipt of the unit. To unlock and reset the following steps should be completed – Pressure Regulator •Pull adjustment knob upwards away from the bracket to release the lock. •Rotate to increase/decrease pressure. •Push adjustment knob downwards towards the bracket to lock. Flow Controller •Rotate knurled locking nut at base of adjustment knob to release lock. •Rotate to increase/decrease flow. •Rotate knurled locking nut at base of adjustment knob to lock. Unusual Operation If at any time the generator begins to emit excessive noise or vibration, then it should be switched off and you should contact your authorised service provider or Peak Scientific as soon as possible. System Drain Please ensure that the drain ports at the rear of the unit are led to a suitable connection or container. It should be noted that the generator will expel considerable amounts of water from this port. If a container is used it should be emptied at regular intervals. NOTE: The container must NOT have an airtight seal. Service Ensure that the generator is serviced in accordance with the maintenance recommendations (refer to maintenance schedule for details).

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AirGen A*20DR Compressor
Maintenance

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Routine Maintenance

Servicing and/or repair of the Generator should only be undertaken by a TECHNICALLY COMPETENT PERSON, with the generator in its safely isolated condition. SAFELY ISOLATED CONDITION Definition: The unit is in a Safely Isolated Condition when it is disconnected from its application, fully de-pressurised and isolated from the Electrical Supply. Directions for isolating the generator are shown below. Isolating the Generator: a) Switch off the unit. b) Disconnect the unit from the mains supply. c) Ensure the internal pressure gauges (page 12) reads zero. (If gauge does not fall to zero, loosen outlet fitting slightly to allow trapped gas to escape). d) Disconnect from the application. Maintenance Schedule
SERVICE INTERVAL COMPONENT ELIMINISER FILTER x 1 1 YEAR 1 YEAR OR ON ALARM SYSTEM ANNUAL PM KIT COALESCER FILTER x 1 FLOAT ASSY VALVE x 2 INLET FILTER (x1) ALL PARTS LISTED ABOVE MAC 3/2 240V SOLENOID VALVE x 2 2 YEARS BEKO ELEMENT BEKO FLOAT DRAIN COMPRESSOR ASSEMBLY (x4) COMPRESSOR RE-FIT (X4) PART NO. 02-4366 02-4364 02-5458 02-1054 08-8137 02-5440 02-5437 02-5438 08-8136 06-5529

ALTERNATIVE TO COMPRESSOR ASSY.

Note: Compressors can be re-fitted as an alternative to replacement up to a maximum of 3 times, this is a more cost effective solution, however a degree of technical expertise is required and can be time consuming. Service kits are available for all routine maintenance. Please contact Peak Scientific for further details.

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AirGen A*20DR Compressor
Maintenance

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Maintenance Log

Maintenance Log for Serial Number _____________
Work Done Remarks Name Date

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UM-NX18LA Revision 1

AirGen A*20DR Compressor
Notes

NitroGen N*18LA Nitrogen Generator – Rev 6 UM – A*20DR User Manual
Additional Notes

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