NG250A –V/F - User Manual 

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Contributed by

Liam Couttie

Updated date

-

Review date

03 May 19

Title

NG250A –V/F - User Manual

Revision Number

4

Keywords

User Manual,

Product Range

Other

Company Brand

Peak Scientific

Public / Private

public

Reviewed on 3rd may 2017 - LC

Extracted text

NG250A –V/F
User Manual – Revision 4

Directions For Use

High Purity Nitrogen Generator
With Volt-Free Alarm NG250A
Fountain Crescent Inchinnan Business Park Inchinnan Renfrew PA4 9RE Scotland 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

Peak Scientific Instruments Ltd

Email Sales: info@peakscientific.com Email Technical Support: support@peakscientific.com Or on the web @ www.peakscientific.com

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DOCUMENT CHANGE HISTORY
Issue No
1 2 3 4

Changed
First Issue USA Technical support number updated New Style Front Added New picture of filter separator

Initials
GL FAD FAD SF

Date
29/8/03 11/11/04 08/04/05 24/08/05

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CONTENTS
Page No Warranty Statement Introduction Unpacking & Installation Electrical Connection Air Connection Principle of Operation Commissioning Routine Maintenance Technical Specifications System Diagrams Maintenance Record Log Notes 4 5 5 5 6 6 7 8 11 12 13 14

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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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Introduction

The Peak Scientific Instruments High Purity Nitrogen Generator is designed specifically for use with Laboratory Analytical Instruments as a source of carrier gas. The generator has been designed to operate totally independent of external air supply and only requires an electrical supply to deliver high volume, high pressure, clean, dry, Nitrogen.

2

Unpacking & 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 or the fan outlet on the sides. The generator should be placed on a steady and level base. The NG250A has been designed to fit under most workbenches. Alternatively, the unit may be placed on a workbench or in any location convenient to the user. Performance of the generator (like all sophisticated equipment) is affected by ambient temperatures. Continuous operation in ambient temperatures exceeding 25°C will lead to a reduction in capacity and prolonged operation in temperatures exceeding 30°C will shorten the life of the unit. 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 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 10.0 amps. The drawer also holds a spare. Connect the generator to a single-phase supply using the power cord provided.
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Air Connection

The nitrogen generator has its own built-in air compressor and therefore does not require an external compressed air source. The generator has one ¼” BSPF bulkhead connection to the rear of the unit. This is the Nitrogen outlet fitting and should be coupled to the application. There is no drain on this machine. Any moisture liberated by the filter-separator is discharged through the high capacity exhaust system where the sudden reduction in pressure causes instant evaporation. The water vapour is safely removed from the unit by the ventilation system.

5

Principle of Operation

The High Purity Nitrogen Generator utilizes a ‘Pressure Swing Adsorption’ (PSA) method to extract pure Nitrogen from air. This is where un-wanted gases can be selectively adsorbed from compressed air into a porous carbon molecular sieve material (CMS). The Peak Scientific Instruments Ltd. generator utilizes a unique single column system where the column is alternately pressurised and vented under a finely tuned timing cycle. The rates of pressurisation and venting are accurately set which guarantees high purity better than can be achieved with a similarly sized traditional 2-column system.
11. 18.

10.

16.

Parts List 1. Compressor 2. Cooling Coil 3. Filter / Separator 4. Exhaust Valve 5. Exhaust Silencer 6. Internal Gauge Supply Pressure 7. Relief Valve 8. Relief Silencer 2. 12. 15. 7. 8. 9. CMS Column 10. Non-return Valve 11. Saftey Valve 12. Nitrogen Storage Tank 13. Pressure Regulator 14. Internal Gauge Tank Pressure 15. Flow Regulator 16. Front Panel Gauge Output Pressure 17. Bulkhead Connection 18. Alarm Pressure Switch

9.

13.

14.

6.

5. 6.

3.

17.

1.

Air is drawn into the system by the Compressor (1) and passed via the cooling coil (2) and the Filter / Separator (4) into the CMS Column (9). Oxygen molecules in the air are trapped by the sieve however the molecules of Nitrogen pass straight through and can be collected in the Nitrogen Storage Tank (12). After a time interval the compressor is stopped and the Exhaust Valve (5) opens allowing the sieve column to vent to atmosphere. The trapped Oxygen is liberated and escapes to atmosphere via the Exhaust Valve (5) and the Silencer (6). The generated Nitrogen in the storage tank is then regulated to the correct pressure and flow rate. After another time interval the Exhaust Valve shuts and the compressor starts. This cycle runs continuously. The Volt-free contact is controlled by the Alarm Pressure Switch (18), which monitors the Nitrogen tank pressure, if this pressure drops below 80 psig, and then the switch contacts will open. Above 80 psig they will remain closed.
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Commissioning

With the Generator installed as described earlier connect power to the unit and turn it on. Disconnect the Nitrogen Outlet connection to allow the generator to vent to atmosphere until the unit is stabilised. At Switch-On the Exhaust Valve will open and the generator will commence its Venting Cycle. This is to allow venting of any residual pressure in order that the compressor does not start against pressure. The Vent Cycle may last up to 90 seconds. At the end of the vent cycle compressor should be heard to run and the normal operating cycle will begin. Pressure should begin to build on the gauge on the front panel reaching 80 psig after approximately 10 minutes. The Generator has been pre-set in the factory to give the specified output flow-rate and pressure. Once the pressure in the Nitrogen receiver exceeds that setting the Generator will stabilise and produce pure Nitrogen. Maximum purity will be achieved after around 8 hours. After this time the generator can be reconnected to the application. The design of the generator is that it will deliver up to rated output flow of Nitrogen at 80 psig. Should the demand for Nitrogen be less than the rated output flow, or indeed should the demand stop the generator will continue to operate without any problems. The generator is protected from over-pressure and its normal operating cycle ensures frequent venting. Timer Setting The Cycle Timer has been set in the factory and should not require adjustment. Adjusting the timer will affect the volume and purity of the delivered nitrogen and should NEVER be adjusted without reference to the factory. The normal settings of this generator are shown in the table below. Since each generator is individually calibrated prior to shipping these settings may vary slightly between machines. Generator NG250A Pressure Setting Output pressure is controlled by a pressure regulator located on the Gauge Rail inside the front cover. This has been factory set at 80 psig or in accordance with the customer’s instructions. Flow Setting Output flow is controlled by a Mass Flow controller. Depending on the model used this will be attached to the outlet of the Pressure Regulator on the gauge rail. This is factory set and should NOT be adjusted by the user. Altering the output flow setting will have an effect on Nitrogen Purity. Connection to the Volt-Free Contact There is a grey Hirschmann connector to the rear of the generator, the mating cable connection for this is provided in the fittings kit supplied with your generator. Take this cable connection and wire the Volt-free signal to pins 1+3. The operation of the switch is such that the switch will close as pressure builds above 80 psig and open should the pressure fall below 80 psig. Rated Output (cc/min) 250 Nominal “ON” Time 90 seconds Nominal “OFF” Time 90 seconds

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Routine Maintenance
by a TECHNICALLY COMPETENT PERSON with the Generator safely isolated.

WARNING: Servicing and/or repair of the Generator should only be undertaken

Due to the simplicity of the design and the small number of moving parts the NM Series Nitrogen Generator will have a long and trouble free life. However the following components should be replaced as follows:

Compressor Inlet Filters Filter Separator Elements Compressor Units (the lesser of)

Every 6- months Every 12- months Every 6000 hours or 18- months

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

FAILURE TO FOLLOW THE PRESCRIBED MAINTENANCE PLAN WILL INVALIDATE THE PRODUCT WARRANTY
Compressor Maintenance Every 6 Months Compressor Inlet Filter Element 1. Switch the Generator OFF and disconnect it from the Electrical supply. Disconnect the mains
supply to prevent the generator being inadvertently switched on by another person. 2. Remove the 5-off X-head screws securing the Lower Front Panel. Remove the panel to expose the compressor.

3. The filter is located on top of the compressor facing towards the left as shown below.
The cover is removed by twisting it ¼ turn and puling clear. The element simply lifts out. Part Number 02-4187. Re-assembly is the reverse procedure
Inlet Filter

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1. Switch the Generator OFF and disconnect it from the Electrical supply. Remove the fuse from the Euro-socket to prevent the generator being inadvertently switched on by another person 2. Pull the generator clear of the bench (if located under) to a place where access is possible to all 4 sides. 3. Remove the 8-off X-Head screws securing the lid. Remove the lid. 4. ENSURE THE GENERATOR IS FULLY DEPRESSURIZED 5. Remove the Coalescing Filter Bowl shown below by holding down the black slide and twisting the bowl ¼ turn. The element simply unscrews.

1. Fit new element and clean and re-fit bowl. 2. Unscrew and remove the green plastic cover of the exhaust silencer. Remove the 10mm nut and lever the element free using a small flat-headed screw driver, if necessary. 3.

1. Fit new element, retaining nut and re-fit plastic cover. 2. Replace the Compressor Inlet filter as described in earlier section.
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3. Replace all covers and switch-on. Allow 4 hours to re-cover purity before re-connecting to application.

Compressor Replacement
The Intake Filter requires periodic replacement. Initial inspection should be after 500 hours operation. Most compressor related problems can be prevented by keeping the filter clean. A dirty inlet filter will decrease compressor performance and may shorten its life. The compressor head surfaces and motor casing become very HOT during operation. Do not touch these parts until the unit has been switched off and allowed to cool. Switch the Generator OFF and disconnect it from the Electrical supply. Disconnect the unit from the mains supply, to prevent the generator being inadvertently switched on by another person. This is a non-lubricated compressor and should never be oiled. Oiling this compressor will cause damage. Compressor Replacement Remove the generator to a clean dry place with sufficient room to work.

1. Remove the lower front panel. 2. Disconnect the braided hose from cone fitting where it is secured to the right hand side panel.
Take care not to disturb the fit between the cone fitting and the bracket assembly.

3. Disconnect the power connector at the front of the compressor. 4. Tip the generator onto its back and remove the 4-off nuts securing the compressor to the
base. Support the weight of the compressor with one hand while removing the last nut.

5. Lift the compressor clear of the generator. 6. Remove and clean all the fittings from the old compressor and re-assemble onto the new
machine using PTEF Tape and sealing compound. (Swagelok Teflon Free Pt No MS-TFS-50) is recommended. Re-assembly is the reverse procedure.

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Technical Specifications
General Details
Minimum Operating Ambient Temperature Maximum Operating Ambient Temperature Outlet Conditions Nominal Outlet Pressure 80 psig (5.44 barg) 5 C (41 F) 30 C (86 F)
o o o o

Physical Details
Model Max Output (cc/min) Compressor Watts Fan Watts Current load (230V ) (110V) Dims (HxWxD) cm inches Shipping Weight Kg lbs NG250A 250 250 14 2.2A 5.2A 62x43x41 25x17x16 69 152

Serviceable Parts list
Model Compressor Inlet Filter Replacement Compressor 220V Replacement Compressor 110V Filter/Separator Element (Post 2001) Cooling Fan (230V) Exhaust Valve(230V) Cooling Fan (110V) Exhaust Valve (110V) Exhaust valve Silencer Electronic Timer NG250A 02-4187 06-5513 06-5510 02-4509 04-1021 02-4289 04-1022 02-4290 02-4336 04-1019

Service Schedule
Interval 6 Months 12 Months 18 Months Action Replace Compressor Inlet Element Replace Filter/Separator Element Replace Exhaust Silencer Compressor Replacement Recommended

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11.

18.

10.

16.

Parts List 1. Compressor 2. Cooling Coil 3. Filter / Separator 4. Exhaust Valve 5. Exhaust Silencer 6. Internal Gauge Supply Pressure 7. Relief Valve 8. Relief Silencer 2. 12. 15. 7. 8. 9. CMS Column 10. Non-return Valve 11. Saftey Valve 12. Nitrogen Storage Tank 13. Pressure Regulator 14. Internal Gauge Tank Pressure 15. Flow Regulator 16. Front Panel Gauge Output Pressure 17. Bulkhead Connection 18. Alarm Pressure Switch

9.

13.

14.

6.

5. 6.

3.

17.

1.

Switch

L NE

Fuse

Terminal Rail

Timer Fan Motor(s)

Exhaust Valve

Compressor

NG Electrical Diagram

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Maintenance Record Log
Model- NG . Serial number

Work done

Remarks

Date Name

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Notes

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