Peak Scientific Corona CA User manual

Corona
Compressed Air
Service Manual
2019 © Peak Scientific – Rev 6 – 07/11/2019

Corona CA Service Manual
Page 2
Contents
Change History 3
How to use this Manual 3
Related Documents 3
Safety Notices 4
Symbols
4
Safety Notice to Users 4
Safely Isolated Condition 5
Technical Specifications 6
Environment 6
Generator Outlets 6
Electrical Requirements 6
General 6
Principle of Operation 7
System Description 7
Normal Operation 7
Service Requirements 8
Service Schedule 8
Product Overview 9
Electrical Panel Layout 10
Pressure switch overview 11
Air pressure switch settings 11
Compressor Contactor 12
Valve Relay 12
Compressor Inlet Filter Replacement 13
Duplex Filter Element Replacement 14
Compressor Replacement 15
Corona Compressed Air Pneumatic
Schematic 16
Corona Compressed Air Electrical Schematic
110V 17
Corona Compressed Air Electrical Schematic
230V 20
Trouble Shooting 23

Corona CA Service Manual
Page 3
Change History
Rev.
Comment
Name
Date
1
Update Pressure Switch Settings
Liam Couttie
25/04/2014
2
Content Update
Liam Couttie
27/01/2015
3
Electrical Panel Upgrade
Liam Couttie
12/02/2015
4
Component Upgrade
Liam Couttie
20/03/2018
5
Electrical Diagram Update
Liam Couttie
18/06/2019
6
Updates to Incorporate CSA Feedback
Liam Couttie
07/11/2019
How to use this Manual
This manual is intended for Field Service Engineers and technically competent
end users. It has been written as a reference document where you can skip to
the relevant information.
This manual does not cover all information that is included in other manuals.
Please see the Related Manuals section if you require further information.
Users of a hard copy version can refer to the contents page to find the relevant
information. Users of the soft copy version can you the hyperlinks from the
contents page as well as the hyperlinks between sections.
Related Documents
Document number
Manual name
Description
UM-CoronaCompressedAir
Corona Compressed Air
User Manual
Describes:
• Installation
• User menu structure
• Service requirements

Corona CA Service Manual
Page 4
Safety Notices
Symbols
This manual uses the following symbols to highlight specific areas important to
the safe and proper use of the Generator
Safety Notice to Users
These instructions must be read thoroughly and understood
before installation and operation of your Peak Corona
Compressed Air 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.
A WARNING notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
personal injury or in the worst case death. Do not proceed beyond a WARNING notice
until the indicated conditions are fully understood or met.
A CAUTION notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause damage
to the Generator or the Application. Do not proceed beyond a CAUTION notice until
the indicated conditions are fully understood or met.
Caution, risk of electric shock. Ensure power to the Generator has been removed
before proceeding.

Corona CA Service Manual
Page 5
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.
Failure to place the Generator in a safely isolated condition
when instructed to do so may lead to personal injury or injury
to others and even death.
Isolating the Generator:
a) Switch off the unit.
b) Unplug the unit from the mains supply and remove the power cord from
the rear of the unit.
c) Ensure the output pressure gauge read zero. (If gauge does not fall to
zero, loosen the outlet fitting slightly to allow trapped gas to escape.)
d) Ensure that tank pressure gauge located on electrical panel reads zero.
(If gauge does not fall to zero, close pressure regulator and loosen the
outlet fitting to allow trapped air to escape.)
e) Disconnect from the application.

Corona CA Service Manual
Page 6
Technical Specifications
Environment
Min/Max Operating Ambient Temperature
5°C - 35°C / 41°F - 95°F
Maximum Altitude
2000 metres
Maximum Relative Humidity
70% Non-condensing
Min/Max Storage Temperature
-20°C - 60°C / -4°F - 140°F
Generator Outlets
Max Flow Rate
30 l/min
Max Pressure
110 psi / 7.58 bar
Particles
<0.01µm
Phthalates
None
Suspended Liquids
None
Gas Outlets
1
Drain Outlets
1
Pressure Gauges
1
Electrical Requirements
Voltage
~100 / 100-115VAC
~220-240 / 208-
230VAC
230 VAC ±10%
Frequency
50/60 Hz
12x10x29
12x10x29
50/60 Hz
Current
5.0 / 5.2A
TBC
TBC
2.3-2.7 / 3.2A
0.17A
Input Connection Type
C14 Plug
Power Cord Type
C13 Socket to Local Connection
Pollution Degree
2
Insulation Category
II
General
Generator Dimensions HxWxD
406 x 417 x 540 mm / 16 x 16.4 x 21.3”
Generator Weight Kg (lbs)
41.5 (91.5)
21 (46.2)
26(57.3)
Shipping crate dimensions HxWxD WxDxH
60.5 x 79.0 x 58.2 / 17.1 x 31.1 x 22.9”
Shipping Weight Kg (lbs)
64 (141)
24 (53)
29(64)
!

Corona CA Service Manual
Page 7
Principle of Operation
System Description
Normal Operation
The Corona Compressed Air Generator is designed specifically to minimize
operator involvement. Given that the system is installed correctly and is
serviced in accordance with the specified maintenance recommendations (see
Service Requirements), it should simply be a matter of turning the generator on
when required.
The generator has been factory set to produce the required outlet pressure.
Flow from the generator is unrestricted internally but is instead controlled by
the consuming nitrogen generator. This ensures minimal pressure drops
between generators. It is therefore important to note that normal operation of
the air compressor system can only be achieved when it is connected to the
nitrogen generator. Unconnected it will not reach pressure.
Connected as required, the compressor will periodically stop to eject moisture
from its drain bowls. Other than during this time, the compressor will run
continuously when powered on.
Figure 1: System Outline

Corona CA Service Manual
Page 8
Service Requirements
Service Schedule
Service Interval
Component
Visit
Qty.
12 months
Corona Compressed Air Generator
Annual Service Kit
www.peakscientific.com/ordering
1
Table 1: Service schedule
** 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 this can be time consuming. Please contact
your service provider for more information.

Corona CA Service Manual
Page 9
Product Overview
Tank
Electrical Panel
BPRV
Re-Heat Coil
Compressor
Pressure Regulator
Drain Valves
Silencer
IEC Power Inlet
Air Output and Drain
Inlet Filter
Dryer Membrane
Duplex Filter
Assembly
Fin Tube Cooler
Power Switch
Cooling Fan
Compressor NRV

Corona CA Service Manual
Page 10
Electrical Panel Layout

Corona CA Service Manual
Page 11
Pressure switch overview
NOTE:
The pressure switch is for indication only. Calibration is not required.
Air pressure switch settings
Output
Mode
Set point (SP)
Hysteresis (HY)
Switching
A
(default)
8.3
1.6
NO (default)
B
(default)
9.5
0.7
NO (default)
Table 2: Air pressure switch settings
Output A indicator
Pressure display
Edit button
Button “A”
Button “B”
Output B indicator
Bar graph display

Corona CA Service Manual
Page 12
Compressor Contactor
Accessing the electrical panel without safely isolating the
Generator should only be carried out by trained service
personnel
The compressor contactors can be manually
activated by sliding the switch on the front of the
contactor to the left.
Valve Relay
Accessing the electrical panel without safely isolating the
Generator should only be carried out by trained service
personnel
Manual Activation of Relays
As a means of checking the valve operation, the relays can be manually
activated in the following manor:

Corona CA Service Manual
Page 13
Compressor Inlet Filter Replacement
Ensure that Generator is in Safely Isolated Condition
1. Remove the filter lid by turning it clockwise
and pulling upwards
2. The filter element is fitted into the filter
lid. Pull it out and clean the inside of the
lid before fitting a replacement filter
element into the lid.
3. Clean the filter bowl (situated inside of
the unit) and then re-fit the lid (including
attached filter element) to the filter
housing, turning it anti-clockwise to lock
it in position.

Corona CA Service Manual
Page 14
Duplex Filter Element Replacement
Ensure that Generator is in Safely Isolated Condition
1. Remove 6mm drain tubing
from push-fit stud situated
on under-side of both of the
bowls.
2. Remove the filter bowls by
turning the bowl anti-
clockwise
3. Remove the filter elements
by pulling downwards.
4. Fit replacement elements.
5. Re-fit the filter bowls.

Corona CA Service Manual
Page 15
Compressor Replacement
Ensure that Generator is in Safely Isolated Condition
Removing the Compressor
1. Disconnect the quick release coupling on the compressor hose, located
behind the compressor. Un-clip safety latch on electrical plug and
disconnect electrical power supply plug.
2. Disconnect 10mm tubing from compressor intake 10mm push-fit fitting.
3. Remove 10mm compressor mount nut from all four corners of the
compressor footplate.
4. The compressor can now be lifted out.
Re-fitting the Compressor
1. Lift the compressor into position and locate the compressor mounts
through their corresponding holes in the footplate.
2. Replace the 10mm compressor mount nuts, and tighten, ensuring
mounts are not twisted.
3. Reconnect the 10mm tubing from compressor intake to the push-fit
fitting.
4. Reconnect the compressor hose quick release coupling
5. Reconnect the electrical plug ensuring that the safety latch is clipped
securely back into position.

Corona CA Service Manual
Page 16
Corona Compressed Air Pneumatic Schematic

Corona CA Service Manual
Page 17
Corona Compressed Air Electrical Schematic 110V

Corona CA Service Manual
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Corona CA Service Manual
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Corona CA Service Manual
Page 20
Corona Compressed Air Electrical Schematic 230V