ZA015 - ZA180 - User Manual 

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Contributed by

Liam Couttie

Updated date

-

Review date

03 May 19

Title

ZA015 - ZA180 - User Manual

Revision Number

1

Keywords

User Manual,

Product Range

Other

Company Brand

Peak Scientific

Public / Private

public

Reviewed on 3rd may 2017 - LC

Extracted text

PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Directions For Use

Zero Air Gas Generator
ZA015 - ZA180

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

ZA015 Issue 3

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Document Change History
Issue No
1 2 3

Changed
Document Created USA Technical support number updated New style front added

Initials
SGM FAD FAD

Date
01/09/98 16/11/04 30/03/05

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Contents
Page No Document 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 5 6 6 6 7 8 9 9 10 11 12 13 14

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Safety First
It is important that you thoroughly read and understand 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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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 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 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 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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PEAK Scientific Instruments Ltd
Instructions for use Manual 1 Introduction

Zero Air Gas Generator 30th March 2005

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 sides of the unit nor, on the ZA180, the fan outlet on the top. The generator should be placed on a steady and level base. Alternatively, the unit may be wall mounted using the slots on the rear of the cabinet. These are on 100mm centres.

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 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 6.3 AMP. Connect the generator to a single-phase supply using the power cord provided.

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PEAK Scientific Instruments Ltd
Instructions for use Manual 4 Air Connection

Zero Air Gas Generator 30th March 2005

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 0.69 Barg / 10 psig 8.62 Barg / 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 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 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.

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

5

Principle of Operation

The Z015-108 Zero Air generator works on the fundamental principle of Catalytic Oxidation as illustrated in the following pneumatic diagram.

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
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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

6

Commissioning
This should be undertaken by a technically competent person.

With the generator installed as described earlier remove the front cover. 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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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

8

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.
Hot

High CH4

Cat Chamber Hot/ Cold Cold

Check Flow Rate

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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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

9

Technical Specifications
General Details

Minimum Operating Ambient Temperature Maximum Operating Ambient Temperature Inlet Conditions (Free of oil and bulk moisture) Minimum Air Inlet Pressure Maximum Air Inlet Pressure Maximum Hydrocarbon Content Start up time for specified hydrocarbon concentration

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

0.69 Barg (10 psig) 8.6 Barg (125 psig) 100 ppm (CH4) 40 minutes

Physical Details Model Max Output (Litres/min) Heater Watts Fan Watts Electrical Requirements (230V 50Hz) (110V 60Hz) Dimensions (H x W x D) cm Inches Shipping Weight Kg Lbs ZA015
1.5 250 N/A 1.2A 2.3A 51x25x16 20x10x6.3 10Kg 22lb

ZA035
3.5 250 N/A 1.2A 2.3A 51x25x16 20x10x6.3 10Kg 22lb

ZA070
7.0 250 N/A 1.2A 2.3A 51x25x16 20x10x6.3 10Kg 22lb

ZA180
18.0 450 9.0 2.0A 4.5A 76x25x16 30x10x6.3 12Kg 26.4lb

Parts List Model Inlet Filter Element (110V) Catalytic chamber Heater Element Thermocouple Temperature Controller Cooling Fan (240V) Cooling Fan (110V) Transformer (230V Only) ZA015
02-1031 06-1075 04-1059 04-1051 04-1170 04-1021 04-1022 04-4356

ZA035
02-1031 06-1075 04-1059 04-1051 04-1170 04-1021 04-1022 04-4356

ZA070
02-1031 06-1075 04-1059 04-1051 04-1170 04-1021 04-1022 04-4356

ZA180
02-1031 06-1075 04-1059 04-1051 04-1170 04-1021 04-1022 04-4356

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

10

System Diagrams
Heater Rod Thermocouple

Inlet Filter / Regulator

Cooling Coil

Outlet Cat Chamber

ZAxxx Pneumatic Diagram

+

-

Temperature Controller (400 Deg C)

Switch

L NE

Fuse Out N L Transformer (230V Only)

Fan Motor (ZA180 only) Heater Rod

Thermocouple

ZAxxx Electrical Diagram

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Maintenance Log
ModelSerial number

Work Done

Remarks

Date

Name

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 30th March 2005

Notes

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