CG22L - User Manual  

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PEAK Scientific Instruments Ltd
Instructions for use Manual

CG22L Calibration Gas Generator 31st March 2005

Calibration Gas Generator
CG22L

Directions For Use

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

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Instructions for use Manual

CG22L Calibration Gas Generator 31st March 2005

Document Change History
Issue No
1 3 4

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

Initials
HD FAD FAD

Date
15/04/03 17/11/04 31/03/05

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Instructions for use Manual

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Contents
Page No Warranty Statement Introduction Unpacking & Installation Electrical Connection Air Connection Principle of Operation Commissioning Parts List Routine Inspection / Trouble Shooting Technical Specifications System Diagrams 3 4 4 4 5 6 8 9 10 12 13

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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:-

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.

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

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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PEAK Scientific Instruments Ltd
Instructions for use Manual 1 Introduction

CG22L Calibration Gas Generator 31st March 2005

The Peak Scientific Instruments range of Calibration Gas Generators is designed to produce a constant flow of dry air of calibration standard with impurities reduced to better than the following levels: -

Contaminant CO CO2 SOX THC O2 H2O 2 Unpacking and Installation.

Concentration <1.0 ppm <1.0 ppm <0.1 ppm <0.1 ppm =18 - 20% <1.5 ppm

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 not the fan outlet to the rear. The generator will be warm to touch and will give off heat. The generator should be placed on a steady and level base. It is designed to fit under most workbenches alternatively it may be placed on a bench or in any convenient location.

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. A spare fuse is also provided in the drawer. Connect the generator to a single-phase supply using the power cord provided.

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Instructions for use Manual 4 Air Connection

CG22L Calibration Gas Generator 31st March 2005

The inlet and outlet connections are 1/4” female. The minimum required air conditions for the Peak CG22L Generator are as follows: Pressure: Inlet Flow: 110 / 120 PSI 37 Litres/minute (minimum)

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 Chambers 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 lower left side of the cabinet. The user's application should be connected to the outlet on the lower right side of the cabinet. To avoid leakage/impurity ingress, use PTFE tape on all fittings. Slowly, turn on the air supply until the desired pressure is attained. There is no physical method restricting the gas output from the generator. Demand in excess of the rated capacity will result in higher levels of hydrocarbons in the delivered gas.

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Principle of Operation

The Peak Scientific Instruments Calibration Gas Generator works on the basis of two fundamental processes as illustrated in the following schematic diagram. Note: - this diagram is only to illustrate the principles involved. For an actual pneumatic diagram please refer to the drawings at the end of this document.

Heater Rod

Thermocouple

Cooling Coil

Inlet Cat Chamber

Outlet

PSA Drier Cam Timer 5/2 Valve

Filter

Drain Outlet

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Instructions for use Manual Zero Air Generation

CG22L Calibration Gas Generator 31st March 2005

The first process utilizes a '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 <0.1ppm, for this process to work the catalyst requires to be heated to approximately 400 degrees celsius. After the catalytic chamber the air passes through a simple cooling coil to a filter, which removes bulk moisture and any further particulate down to a level of 5 micron. The filter incorporates an auto-drain mechanism, which will release any accumulated water from the filter bowl when the level is sufficiently high. The water passes out through a drain bulkhead at the bottom of the side of the cabinet. Because water and also carbon dioxide are created in the Catalytic Process there is a necessity to effectively remove them both.

Moisture / CO2 Removal: The second process utilizes a 'Pressure Swing Adsorption' (PSA) method to further treat the air. This is where contaminant gases and moisture can be selectively adsorbed from compressed air into a porous crystalline sieve material. The adsorption process is aided by the electrostatic interaction between the adsorbent sieve material and the gaseous adsorbate. The Peak Scientific Instruments Ltd. PSA dryer system utilizes the 'Skarstrom' process where there are two columns of adsorbent used alternatively and described as follows: The un-treated air is passed via a '5 port-2 position' (5/2) pneumatic control valve into one of the sieve columns where moisture, CO2 and other non-methane hydrocarbons are removed. Some of the purified gas is back-purged down the other column to atmosphere, which creates a regeneration effect. A simple cam timer eventually causes the 5/2 valve to change columns and the other regenerated sieve column now generates the purified gas. Again some purified gas is back purged down the other column to atmosphere to cause a regeneration effect. This process repeats itself approximately every 2 minutes indefinitely. During this process CO2 is reduced to a level of <1ppm and water moisture is removed to a level of -75o Celsius Pressure Dew Point (1.4ppm @ ATP or 0.14ppm @ 100 PSI approx.).

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Instructions for use Manual

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Commissioning
This should be undertaken by a technically competent person

With the generator installed as described earlier remove the front cover. Check that all internal components are securely located and have not moved during transit. Open the air supply and turn the unit ON. Check that the cooling fan is operating and exhausting air out of the generator. Check that the cam on the timer is rotating. The Digital Displays show the Catalyst Chamber temperatures. This is factory set at 400º C After a maximum of 2 minutes the timer should operate to change over the columns on the PSA drier unit. This is accompanied by an audible rush of exhaust air from the drain outlet.

After a maximum time of 40 minutes the Catalytic Chambers should have reached temperature. The heaters are controlled by a PID controller maintaining near constant 400ºC. The heaters will cycle as required. Do not touch any part of the Catalytic Chambers or Copper Lines, as they will be VERY hot.

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Instructions for use Manual
Purge Setting

CG22L Calibration Gas Generator 31st March 2005

The PSA Purge has been set in the factory and should not require adjustment. The purge can be checked by connecting a simple Rotameter type flow meter to the outlet of the drier purge valves in turn. The connection is for 4mm plastic hose. The correct setting is 12 l/min. This assumes a maximum generator output of 22 l/min. A reduced purge rate will result in higher levels of contaminate gases over a period of time.

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Routine Maintenance

WARNING: Servicing and/or repair of the generator should only be undertaken by a TECHNICALLY COMPETENT PERSON with the generator safely isolated.
Due to the simplicity of the design and the small number of moving parts the CG22L Gas 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.

Filters/Separator/Silencers

Every 12 months

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

FAILURE TO FOLLOW THE PRESCRIBED INVALIDATE THE PRODUCT WARRANTY. Inlet Filter / Separator Elements

MAINTENACE

PLAN

WILL

These should be changed at intervals as indicated below. In addition filter bowls should be cleaned and the operation of the auto-drains should be checked. The Generator MUST be de-pressurised prior to attempting to remove ANY filter bowl. Failure to do this may cause injury.

Eliminizer & Coalescing Filter Elements
These elements should be changed at 12-month intervals. Part Numbers 02-4366 & 02-4335. Disconnect the drain fittings from the bottom of the bowls. Turn the bowl ¼ turn counter clockwise to release. The element then un-screws. Re-assembly is the reverse procedure.

0.1 m

02-4335 02-4366 Autodrain 02-4485

Hold down and twist ¼ turn Eliminizer

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Instructions for use Manual
Dryer Filter & Silencer Elements

CG22L Calibration Gas Generator 31st March 2005

These elements should be changed at 12-month intervals. Part Numbers 02-4335 & 02-1033. The Generator MUST be de-pressurised prior to attempting to remove ANY filter bowl. Failure to do this may cause injury. Disconnect the drain fittings from the bottom of the bowl. Turn the bowl ¼ turn counter clockwise to release. The element then un-screws. Re-assembly is the reverse procedure. The Exhaust Silencers are removed by unscrewing.

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Instructions for use Manual Catalytic Chamber

CG22L Calibration Gas Generator 31st March 2005

The Catalytic Chamber is heated to 400ºC and will cause severe burns if touched. If for any reason the chamber or its associated parts need to be examined the generator must be switched off and allowed to cool. THIS COULD TAKE UP TO 10 HOURS. The Catalytic Chamber takes the form of cylindrical chamber with a heated central core. The annular space is specifically designed to allow the required contact time with the catalyst to ensure complete oxidization. The complete chamber is contained within an insulated enclosure as shown below.

Air Inlet Line

Thermocouple

Heater

Thermal Fuse

Regardless of the supply voltage the heater is rated at 110 Vac. This minimizes the volt-drop across the conductors and prolongs the life of the element. The Heater is contained within a stainless steel sleeve to facilitate removal should replacement be required.

Heater

Thermocouple Thermal Fuse

The thermocouple is “K” type spring-loaded bayonet fitting to ensure good contact with the chamber core.

The thermal fuse is provided as a safety feature to cut supply to the heater thus preventing chamber overheating in the event of a control or ventilation failure. It is a fail-safe device and if blown requires replacing. Note: - The thermal fuse will not blow under normal operation. A blown thermal fuse indicates that a fault exists which MUST be rectified before attempting to replace the thermal fuse. Refer to the trouble shooting chart on page 14 for guidance.

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Troubleshooting

Problems with the GC22L will most probably be shown up by increased levels of Hydrocarbons or CO2 being detected on the baseline. The following procedure should be followed to identify the source of the problem. Reference should be made to the following Fault Finding Charts.

1. High CH4
High CH4 Cat Chamber Hot/ Cold Cold Hot Check Flow Rate

Control Board LED On

Off

LED Off

Voltage At Heater Yes

No

Thermocouple Wiring OK

Open Circuit

Replace Heater

Voltage At Board Output Yes

No

Replace Control Board

Replace Thermocouple

Check Wiring

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Instructions for use Manual 2. High CO2
High C02 Check Drain Port Clear

CG22L Calibration Gas Generator 31st March 2005

No Flow Clear Obstruction

Check Cam Rotating Yes

No

Check Motor Operation No

Yes

Tighten Grub screw

Audible Change-over Yes

No

Check Motor Supply OK

Open Circuit

Cam Follower Operating 3/2 Valve Yes

No

Replace Cam Timer

Repair Wiring Fault

Replace Faulty 3/2 Valve

Adjust Cam Follower

Check Purge Settings OK

Wrong

Re-set Purge Settings

Purge to Atmosphere for 24 Hours

Replace Alumina Charge in Drier Columns

High

Check CO2 Levels

OK

Return to Service

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Technical Specifications

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

Minimum Operating Ambient Temperature Maximum Operating Ambient Temperature Inlet Conditions (Free of oil and bulk moisture) Minimum Air Inlet Pressure Maximum Air Inlet Pressure Minimum Air Inlet Flow Rate Outlet Gas Maximum Pressure Drop (Outlet-Inlet) δP Maximum Gas Outlet Pressure Maximum Gas Outlet Flow for specified hydrocarbons Pressure Dewpoint Start up time for dewpoint Particles Hydrocarbon concentration (as methane) Start up time for hydrocarbon concentration CO level CO2 level SOX O2 level Electrical Requirements 230V ac (50/60Hz) Electrical Connection General Dimensions W x D x H Weight Kg cm Kg cm
o

7.5 Bar (110 PSI) 8.27 Bar (120 PSI) 37 Litres/min (ATP)

0.7 Bar (10 PSI) Max Inlet-δP 22 Litres/min (ATP) -75 C (-103 F) (1.4ppm @ ATP) 8 hrs 0.01um <0.1ppm 45 minutes <1.0ppm <1.0ppm <0.1ppm 20%
o

8.7 AMPS IEC-Euro connector

43x41x88 37 100 x 57 x 67 64

Shipping Dimensions W x D x H Shipping Weight

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Heater Element Thermocouple Temperature Controller Cooling Fan Timer Eliminizer Filter Element AFD 3000 Filter Element

Item

Parts List

Part No
04-1058 04-1050 04-4459 04-1021 04-1020 02-4549 02-4366 02-4486 02-4335

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Heater Rod Thermocouple

CG22L Calibration Gas Generator 31st March 2005

Cat Chamber
NRV

Receiver Gauge Outlet Pressure Gauge

Regulator

Air Inlet Inlet Filter

PSA Drier

Receiver

Gas Outlet

5/2 Valve Filter

Drain Outlet

Cam Timer CG22L Pneumatic Diagram

12V Power Supply

12V Power Supply

Switch

L NE

Fuse

12 11 10

9

8

7

6

5

4

3

2

1

12 11 10

9

8

7

6

5

4

3

2

1

SSR Thermal Fuse Thermal Fuse

SSR

Fan Motor Heater Rod Heater Rod Cam Timer

Thermocouple

Thermocouple

CG22L Electrical Diagram

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Maintenance Log
Model- CG Serial number

Work Done

Remarks

Date

Name

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Notes

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