NM20ZA - User Manual  

Extracted text

Nitrogen NM20ZA Nitrogen Generator
User Manual
NM20ZA – Rev 13

1

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Contents
Page
Contents
Document Change History
Warranty Statement
Safety Notice to Users
RoHS Compliance Statement
WEEE Compliance Statement
Technical Specification
Introduction
Unpacking and Installation
Installation
Useful Information
Electrical Connection
Generator Environment
General Dimensions
Generator Connections
Generator Operation
Principle of Operation
Routine Maintenance
Maintenance Log

2
3
4
4
5
5
6
7
8
9
10
10
11
11
12
13
14
15
16

2

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

History
Document Change History

Initials

Date

SGM

23/01/2001

Document reviewed & updated

G.L

30/01/2001

3

Document reviewed & updated

SGM

16/02/2001

4

Document reviewed & updated

G.L

08/05/2001

5
6

Document reviewed & updated

G.L

15/08/2002

Maintenance Recommeditions Altered

G.L

01/02/2003

7

Safety Statement Added & current Rating Amended

G.L

05/03/2003

8

Tech Specification -clarified,adding limits for indvidual gas streams

G.L

02/08/2004

9

Shipping Wight updated

FAD

17/03/2005

10

Generator flows updated

FAD

24/03/2005

11

New Style Front Added -General update

FAD

07/04/2005

12
13

Note added for - indoor use only & Altitude

TJG

10/09/2007

Document Created in New Format

S.K

28/01/2009

Change

Rev No.
1

Document Created

2

3

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Warranties &
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 NM20ZA generator. Use of the generator 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.

4

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Declaration of
Conformity

5

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Technical
Specification

Generator Environment
Minim um operating am bient tem perature

5°C (41°F)

Maxim um operating am bient tem perature

30°C (86°F)

Maxim um relative hum idity

70%

Maxim um Altitude

2000 Meters

Outlet Gas
Maxim um Gas Outlet Pres s ure

Curtain

60ps ig

Maxim um Gas Outlet Pres s ure

Source

100 ps i

Maxim um Gas Outlet Pres s ure

Exhaus t

Maxim um Gas Outlet Flow ( High purity Nitrogen) Curtain
Maxim um Gas Outlet Flow ( Zero Grade AIR)

Particles
Outlet 1/4" BSP
Pres s ure Gauges

60ps ig
5 Litres /m in (ATP)
30 Litres /m in (ATP)
< 0.01 µm
3
3

Pthalates

None

Sus pended Liquids

None

Electrical Requirements
230V (50/60 Hz)

5 am ps

Com pres s or Circuit Breaker

8.0 am ps

PLC / fan Circuit Breaker

2.0 am ps

Electrical connection
Nois e Level

Single phas e power cord
59DBA @ 1m

General
Dim ens ions in cm (inches ) W x D x H
Weight
Shipping weight

Annual Serviceable parts List
Com pres s or Intake Filter Elem ent
Filter Elem ent for Revers e Active Carbon
Filter Elem ent for AFD3000-02C 0.01um

60 x 67 x 94
(24 x 27 x 37)
112 kg (248 lb)
169 kg (372lb)
Service kits Part # (08-4434)
02-4187 (x4)
00-4425 (x2)
02-4335 (x2)

6

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Introduction

Welcome to the User Manual for the Peak Scientific NM20ZA Nitrogen Generator.
Enclosed in this manual you will find the information required to ensure that your
generator is operated & serviced according to our recommended guidelines which will
prepare you for long and trouble free Nitrogen 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
us at the addresses displayed on the front cover of this manual.

7

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Unpacking and
Installation

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 ‘SHOCK WATCH’ label for signs of rough handling prior to unpacking -

ANY DAMAGE SHOULD BE REPORTED IMMEDIATELY TO THE CARRIER AND
PEAK SCIENTIFIC OR THE DISTRIBUTOR FROM WHERE THE UNIT WAS
PURCHASED.
Follow the un-packing instructions posted on the side of the crate. It will require 2
people to lift the crate clear and to manoeuvre the generator onto the floor. Thereafter
the generator can be moved to its final location on the castors provided.
Note:- Included with generator is a pack containing , service filters & fittings. Be
careful not to discard these with the packing.
Please save the product packing for storage or future shipment of the
generator.

8

UM – NM20ZA – Rev 13

High Purity Nitrogen Generator
Installation

Power Cord
(04-1038-EU)
(04-1029-US)

230Vac

(04-1030-UK)

Rear View.

Exhaust Gas Outlet.

Source Gas Outlet.

Curtain Gas Outlet.

with 1/4" Tubing (00-1266)

1 off 1/8" x 1/4" Compression Fitting (02-1009)

*
#

1 off 1/4" Double Nipple (02-4399)

with 1/8" Tubing (00-1262)

2- off 1/4" x 1/8" Comp. Fitting (02-1000)

2 off 1/4" Tee (02-4307)

2 off 1/4" x 1/4" Comp. Fitting (02-4421)

APi 4000 / Q Star

2- off 1/4" x 1/8" Swagelok (02-1000)

1 off 1/4" Tee (02-4307)

3 off 1/4" x 1/4" Comp. Fitting (02-4421)

APi 3000

3 off 1/4" x 1/4" Compression Fitting (02-4421)

with 1/4" Tubing (00-1266)

*

#

*

#

9

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Installation
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 meters.
> 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), 5 Amps

Green & Yellow
Brown
Blue

or
or
or

Green
Black
White

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

10

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Generator
Environment

The Generator is designed for indoor use only.
The unit should be installed adjacent to the Mass Spectrometer 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 generator (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°C (dry bulb) 70%RH (Max)

General Dimensions

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

11

Connections and Controls
Connections and
controls

UM – NM20ZA – Rev 13

High Purity Nitrogen Generator

Curtain Gas

Exhaust Gas

API Systems

Gas Generator

Front View.

Source Gas

0

1

Curtain Gas Pressure Gauge.
Source Gas Pressure Gauge.
Exhaust Gas Pressure Gauge.

Elapsed Time Meter.

On/Off Switch.

Air Inlet Fans.

Rear View.

SUPPLY

CURTAIN

SOURCE

EXHAUST

DRAIN

Air Outlet Fans.

Curtain Gas Outlet.

Source Gas Outlet.

Exhaust Gas Outlet.

Serial Plate.

Drain Connection.

Mains Power IEC. Socket.

12

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Operation
The NM20ZA generator is designed specifically to minimize operator involvement.
Given that the system 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 generator on. The generator will automatically produce the
factory default flow and pressure.
Outlet

Output flow

Output pressure

CURTAIN

5 Litres per min (APT)

60psi

SOURCE

22 Litres per min (APT)

100psi

EXHAUST

8 Litres per min (APT)

60psi

Should the demand for gas be less than the rated flow then the generator will automatically regulate
the internal pressure and cycle of the compressors as required. This should be all the input your
generator requires from you, the only additional tasks required are,
If at any time the generator begins to emit excessive noise or vibration, then it should be switched off
and you should contact your local representative or the factory as soon as possible.
Please ensure that the drain port at the rear of the generator is led to a suitable connection or
container. It should be noted that the generator will liberate considerable amounts of water from this
port (approx. 1-2 liters weekly). If a container is used it should be emptied at regular intervals.
Ensure that the generator is serviced in accordance with the following maintenance
recommendations.

13

High Purity Nitrogen Generator

Principle of Operation

UM – NM20ZA – Rev 13

Principle of Operation

Peak Scientific Instruments NM20ZA Generators utilize two different types of air
preparation membranes to produce the required Gas outputs. The Nitrogen side of the
generator employs “Hollow Fiber Membrane” Technology to efficiently separate
Nitrogen from other gases present in ambient air. An overview of this process can be
seen below.

The Zero Air side of the generator uses the latest technology in membrane dryers to produce a clean dry supply of
Zero grade air. Both membranes are mounted in a similar fashion in the generator and utilize standard ancillary
components to maximize the interchangeability of the systems. The standard membrane diagram can be seen
below.

Membrane - Standard Diagram
Air is drawn into the system by the Compressor (1) and passed through the Cooling Coil (2) and the AFD –
3000 Micro Mist Filter (3) into the Membrane (5). After the Membrane (5) the gas is passed through a
Reverse Acting Carbon Filter (6) to remove any remaining impurities and via the Non-Return Valve (Check
Valve) (7) into the Receiver (10). The stored gas is regulated (11) to give the required output pressure and
flow. Receiver pressure is measured (9) to allow the generator to un-load (4) and shut-down should
demand cease. A Safety Relief Valve (8) is fitted to protect the system against over pressure. Gas is
delivered out of the machine via the Outlet Port (12). Any moisture collected by the AFD – 3000 Micro Mist
Filter (3) is expelled via the Drain Port (13).

14

High Purity Nitrogen Generator

UM – NM20ZA – Rev 13

Routine Maintenance

Maintenance

WARNING
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) Unplug the generator from the mains supply and remove the power cord from the rear of the unit.
c) Ensure the pressure gauges on the front panel reads zero. (If gauge does not fall to zero, loosen
outlet fittings slightly to allow trapped gas to escape.)
d) Disconnect from the application.
e) Important Note: Allow 10 minutes for unit to fully de-pressurise. After this time pull
out the
‘Quick Release Ring’ on the Pressure Relief valve situated on the tank. Ensure tank is fully
depressurised before releasing the ring.

Maintenance Schedule
Parts

Replacement Period

Compressor Inlet Filters

Every 6 months

Filter Separator Elements

Every 12- months

Compressor units (the lesser of)*

Every 6000hrs or 18-months

*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.
With the generator installed as described previously, disconnect the Curtain, Source and Exhaust gas
outputs (ENSURING THAT ANY INTERNAL PRESSURE HAS BEEN SAFELY DISSIPATED), and switch
the generator on. The on/off switch should illuminate and the cooling fans should start immediately. There
will be a 10 second delay before the first compressor starts, then after a further 3 seconds the second
compressor should also start. The three pressure gauges on the front panel will begin to climb, and after
approx 3 minutes the gauges should all have reached their rated pressure of either 60 or 100 PSI.G. The
output flows from the generator should now be measured to ensure they conform to the specification below.
Outlet

Output flow

Output pressure

CURTAIN

5 Litres per min (APT)

60psi

SOURCE

22 Litres per min (APT)

100psi

EXHAUST

8 Litres per min (APT)

60psi

The generator should now be left to run for approx. 1 hour to allow the generator to fully flush the internal
receivers etc of air and allow the membranes to stabilize. After this time the Curtain, Source and Exhaust
outputs can be re-connected and the interconnecting pipe work checked carefully for leakage.

15

High Purity Nitrogen Generator
Maintenance Log

UM – NM20ZA – Rev 13

Maintenance Log for Serial Number _____________
Work Done

Remarks

Name

Date

16