za 18019 - User Manual 

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237

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Contributed by

Liam Couttie

Updated date

-

Review date

03 May 19

Title

za 18019 - User Manual

Revision Number

1

Keywords

User Manual,

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Other

Company Brand

Peak Scientific

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public

Reviewed on 3rd may 2017 - LC

Extracted text

PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 20/3/2007

Installation and Directions for Use

Zero Air Gas Generator
ZA180 (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

ZA180 (19”) Issue 6

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 20/3/2007

Document Change History
Issue No
1 2 3 4 5 6

Changed
First Issue Digital PID Controller fitted USA Technical support number updated New style front added Weight of unit changed to 13kg Commissioning section updated

Initials
BC SM FAD FAD AMcB GL

Date
12/01/02 25/01/02 16/11/04 30/03/05 02/06/05 20/03/07

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Instructions for use Manual

Zero Air Gas Generator 20/3/2007

Contents
Page No Document Change History Warranty Statement Introduction Unpacking & Installation Electrical Connection Air Connection Principle of Operation Commissioning Routine Maintenance Technical Specifications System Diagram Maintenance Log Notes 2 5 6 6 6 7 8 9 9 10 11 12 13

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 20/3/2007

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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Instructions for use Manual

Zero Air Gas Generator 20/3/2007

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:-

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.

4.1) Reasonably satisfy the Company that the Goods have been properly installed, commissioned,

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

Zero Air Gas Generator 20/3/2007

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 10.0 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

Zero Air Gas Generator 20/3/2007

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 dryer 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 will result in higher levels of hydrocarbons in the delivered gas.

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PEAK Scientific Instruments Ltd
Instructions for use Manual
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Zero Air Gas Generator 20/3/2007

Principle of Operation

The ZA180-19R Zero Air generator works on the fundamental principle of Catalytic Oxidation as illustrated in the following pneumatic diagram.

Inlet air is passed into the Generator 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
Zero Air Generation

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Instructions for use Manual

Zero Air Gas Generator 20/3/2007

6

Commissioning
This should be undertaken by a technically competent person.

With the generator installed as described earlier remove the top cover. Check that all the internal components are securely located and have not become dislodged during transit. Re-fit the top cover before proceeding further. The Front Panel is shown below.

Pressure Gauge Temperature Control

Connect the generator to the electrical supply and turn the unit ON. The unit will begin to build up pressure as will be seen from the pressure gauge. The Digital Display shows the Catalyst Chamber temperature. This is factory set at 400º (normal operation may see this reading range between 390-410 º The C. C) generator should reach operating temperature within 40 minutes of switch-on.

Check that the cooling fans are operating and exhausting air out of the generator.
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.

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Instructions for use Manual

Zero Air Gas Generator 20/3/2007

8

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

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

ZA180R
18 l/min 450W 9W 4.2 A
18x48x43 7x19x17

13 28.6

Parts List Model
Catalytic chamber Heater Element Thermocouple Cooling Fan (220V)

ZA180R
06-1075 04-1059 04-1051 04-1021

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12V Power Supply Switch

L NE

Instructions for use Manual

PEAK Scientific Instruments Ltd

Fuse

12 11 10 3 2 1

9

8

7

6

5

4

Fan Motor SSR

Thermal Fuse Transformer (230V System)

Thermocouple

Heater Rod

ZA19Rack Electrical Diagram

Zero Air Gas Generator 20/3/2007

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PEAK Scientific Instruments Ltd
Instructions for use Manual

Zero Air Gas Generator 20/3/2007

Maintenance Log
ModelSerial number

Work Done

Remarks

Date

Name

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Instructions for use Manual

Zero Air Gas Generator 20/3/2007

Notes

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