Peak Scientific Halo User manual

Halo Service Manual Rev 5 RSID 2629 EN 15/10/19
Halo
Service Manual

Contents
Change History 3
How to use this Manual 3
Safety Notices 4
Symbols 4
Safety Notice to Users 4
Safely Isolated Condition 5
Safe State After Repair 6
Principle of Operation 7
On Demand Gas 7
Unusual Operation 7
Technical Specification 8
Service Requirements 9
Service Schedule 9
Product Overview 10
Electircal Panel Overview 11
Compressor Inlet Filter Element Replacement 12
Filter Element Replacement 13
Compressor Replacement 14
Drain Valve Replacement 15
CMS Valve Replacement 16
Pneumatic Diagram 17
Electrical Schematics 18
Cleaning 20
Troubleshooting 21
Problem 22
Possible Solution 22
Notes 23
Page 2

Page 3
Change History
Rev Comment Name Date
1 Initial Release Liam Couttie 12/07/2018
2 Tech Spec Update Liam Couttie 20/07/2018
3 Tech Spec Update Liam Couttie 15/03/2018
4 Schematics Update Liam Couttie 15/05/2019
5 Power Cord Update Liam Couttie 15/10/2019
How to use this Manual
This manual is intended for Field Service Engineers and technically competent end
users and has been written as a reference document where you can skip to the relevant
information.
Users can refer to the contents page to find the relevant information.
Please review each of the following sections carefully.
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 Peak
Scientific or the Peak Partner from which you purchased your generator.

WARNING
Page 4
CAUTION
WARNING
WARNING
WARNING
Safety Notices
Peak Scientific Instruments cannot anticipate every possible circumstance which may
represent a potential hazard. The warnings detailed within this manual refer to the most
likely potential hazards, but by definition cannot be all inclusive. If the user employs an
operating procedure, item of equipment or a method of working which is not specifical-
ly recommended by Peak Scientific, the user must ensure that the equipment will not
be damaged or become hazardous to persons or property.
Symbols
This manual uses the following symbols to highlight specific areas important to the safe
and proper use of the generator.
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 the generator has been safely isolated before
proceeding.
Safety Notice to Users
These instructions must be read thoroughly and understood before
installation and operation of your Peak 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.
If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment may be impaired.

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 in-
structed to do so may lead to personal injuryor injury to others and
even death.
Isolating the generator:
a) Switch o the unit.
b) Unplug the unit from the mains supply and remove the power cord from the rear
of the unit.
c) Disconnect from the application.
d) Ensure the output pressure gauge reads zero.
WARNING

Page 6
Safe State After Repair
To guarantee the generator is in a safe state after a repair, please ensure the following
conditions are met;
• All panels have been correctly secured with all screws as shown.
Panels should be reconnected to the generator as shown below. This is important to
ensure all panels are safely earthed.
• The electricity cable has been correctly refitted.
The mains cable should be plugged into the IEC power inlet located on the rear
panel of the generator. This unit is classified as SAFETY CLASS 1. THIS UNIT MUST
BE EARTHED.
• The system builds pressure correctly.
Reconnect generator outlet to application and turn on the power switch. Pressure
will start to build in the internal storage tanks which can be monitored by watching
the output pressure gauge on the rear panel. This will climb to the factory set
pressure as noted in the specifications.

Page 7
Principle of Operation
The HALO generator utilizes Pressure Swing Adsorption (PSA) to extract pure Nitrogen
from clean filtered air. Unwanted gases are selectively adsorbed to a porous carbon
molecular sieve (CMS). Nitrogen gas continues to the storage tank to be used by
the application while unwanted gases are purged during the regeneration cycle. The
generator uses a twin column system where one column is pressurized when the other
is vented and regenerated for a short period. The gas flow is then switched to the
regenerated column for the same time interval. This process is repeated continuously
with the compressors running all the time until the demand from the customer stops
and the storage tank pressure limit is reached.
The HALO Gas 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 specified maintenance recommendations (see Service
Requirements), then it should simply be a matter of turning the Generator on when it is
required.
The Generator will automatically produce the factory set flow and pressure as detailed
in the Technical Specifications.
On Demand Gas
The Generator produces gas on demand. If the application is operating and requires a
gas flow, the Generator will supply this to suit the requirements of the application. If the
application requirement for gas stops, the Generator will also stop, once it has reached
its upper set limit in the internal storage tanks. If the demand from the application
starts again, the Generator will detect the demand for gas and will automatically start
again to suit the demand.
Unusual Operation
If at any time the Generator begins to emit excessive noise or vibration, then it should
be switched o and you should contact Peak Scientific or the Peak Partner from which
the Generator has been purchased.

Page 8
Technical Specification
Halo
Environment
Minimum Operating Ambient Temperature 5°C (41°F)
Maximum Operating Ambient Temperature 35°C (95°F)
Maximum Relative Humidity 80% Non-Condensing
Minimum Storage Temperature* -20°C (-4°F)
Maximum Storage Temperature* 60°C (140°F)
*NOTE – When taken out of storage the Generator should be allowed to acclimatize at room temperature
for a minimum of 3 hours before operation.
Generator Outlets
Plasma N2Maximum Flow 25 L/min (0.88 cfm) @ 87 psi (6 bar)
Pop Air Maximum Flow 36.5 L/min (1.28 cfm) @ 87 psi (6 bar)
Atmospheric Dew Point (Dry Air) -20°C / -4°F
Nitrogen Purity 99.5%
Particles NONE
Phthalates NONE
Suspended Liquids NONE
Gas Outlets 2 x ¼” BSPP Female
Drain Outlet 1 x ¼” BSPP Female
Pressure Gauges 2
Start-Up Time for Purity < 20 mins
Electrical Requirements
Voltage 230 VAC ± 10%
Frequency 50/60 Hz
Current 8.0 Amps
Input Connection C20 Plug
Power Cord C19 socket to local connection (10A minimum)
Pollution Degree 2
Insulation Category II
General
Dimensions mm (inches) WxDxH 570 x 870 x 765 (22.4 x 34.2 x 30.1)
Generator Weight Kg (lbs) 155 Kg (341.7 lbs)
Shipping Weight Kg (lbs) 182 Kg (401.2 lbs)

Page 9
Service Requirements
Service Schedule
Service Interval Component Visit
12 Months Halo Annual Maintenance Kit www.peakscientific.com/ordering
Service Indication
The generator has the following Service Indication Stages:-
Stage 1
Once either compressor requires a service the LED indicator (yellow) on the front of the
generator will illuminate.
This is to make the user aware that a service of the generator is due and should be
planned at the earliest convenience. The generator will continue to operate as normal
with the LED on.
Stage 2
If the service is not completed the generator will continue to run. After 2 weeks, the
service LED indicator (yellow) will start to flash.
This is to make the user aware that the service of the generator is now overdue and
must be completed immediately to ensure the continuous trouble free operation of the
generator.
Service Indication Reset
Once the service has been completed the Service Indication LED can be reset in the
main control PCB. This will be performed by the Peak Service Engineer or trained
service representative that completes the service operation.
Page 9

Page 10
Product Overview
Fan
Drain Valves
Filter Assembly
Filter Assembly
Silencer
Inlet Filter
Electrical Panel
Nitrogen Tank
Air Tank
Compressor Assembly
Dryer Column Assembly
Compressor Assembly
Compressor Assembly

Page 11
Electrical Panel Layout
Risk of electrics shock, accessing the electrical panel without safely
isolation the generator should only be carried out by trained service
personnel.
WARNING
Pressure Switches
Circuit Breakers
Temperature Controllers
PCB
Power Supply

Page 12
Compressor Inlet Filter Element Replacement
Ensure that the generator is in Safely Isolated Condition
1. Release the filter bowl by turning it anticlockwise
2. Remove the bowl by pulling it upwards.
3. Remove the paper and foam filters and clean the
inside of the filter bowl before fitting replacement
filters elements
4. Re-fit the bowl to the filter housing and turn to the
right to lock into place.
WARNING

Page 13
Filter Element Replacement
Ensure that the generator is in Safely Isolated Condition
1. Remove tubing from push-fit fitting situated on
under-side of the filter bowl, then using the filter
tool supplied loosen the filter bowl by turning as
shown.
2. Remove the filter bowl to reveal the filter
element inside.
3. Remove the filter element by unscrewing it as
shown and then pulling down.
4. Fit a new 02-4339 filter element for stage 1 &
3301822 filter element for stage 2 to the Filter
assembly.
5. Re-fit the filter bowl, and reconnect the tubing
to complete.
WARNING

Page 14
Compressor Replacement
Ensure that the generator is in Safely Isolated Condition
1. Remove the Fan Panel
2. Disconnect the compression fittings on the
compressor hose
3. Disconnect both the compressor power plug
4. Disconnect 12mm tubing from the compressor
intake
5. Pull compressor out half way until it stops
6. Tilt the compressor slightly downwards and
support its whole weight
7. Slide the compressor completely out of the
generator, ensuring you support the weight of
the compressor
Re-fitting the compressor
Follow steps 1-6 in reverse to refit the compressor.
WARNING

Page 15
Drain Valve Replacement
Ensure that the generator is in Safely Isolated Condition
1. Remove Right hand side cover
2. Remove 6mm tubing from each end of drain
valve.
3. Disconnect Molex connector associated with
valve.
4. Remove M3 screws
5. Replace new drain valve in reverse order.
WARNING

Page 16
CMS Valve Replacement
Ensure that the generator is in Safely Isolated Condition
1. Remove Top cover.
2. Remove Front Facia.
3. Disconnect appropriate molex connector
from PCB that connects with the valve being
replaced.
4. Remove tubing from the valve being replaced.
5. Remove the M5 or M6 screws fixing the valves
to the mounting plate.
6. Replace new valve in reverse order
WARNING

Page 17
Compressor Run Hours Reset
Risk of electrics shock, accessing the electrical panel without safely
isolation the generator should only be carried out by trained service
personnel.
1. Press NEXT button on PCB touchscreen.
2. Enter Service Access Password using keypad on
touchscreen.
3. Press NEXT This will show output test buttons
up to OUT 7.
4. Press NEXT This will show output test buttons
up to COMP 3.
5. Press NEXT then PRESS to perform Factory
Reset.
6. Press CONFIRM.
7. Power cycle unit to complete Factory Reset.
WARNING

Page 18
Pneumatic Diagram
1.
2.
3.
1. Compressor Inlet Filter
2. Compressor
3. Heat Exchanger
4. Filter - Water /Mist
5. N/C Solenoid Drain Valve
6. Shuttle Valve
7. Dryer Column
8. Fixed orifice 0.18mm
9. Non-Return Valve
10. 7L Storage Tank 11. Pressure Switch 12. Pressure Regulator
13. Pressure Gauge (Tank) 14. Flow Contoller 15. 4-Port Manifold 16. Drain Silencer 17. 22Solenoid Valve
18. CMS Tank 19. Equalisation Valve
20. 7L Storage Tank 21. 5L Storage Tank 22. Outlet Port - Drain 23. Outlet Port - Air 24. Outlet Port - N2 25. Oxygen sensor on PCB 26. Fixed orifice. 0.1mm 27. Inline Filter
4.
5.
P
A
4.
5.
P
A
2.
3.
4.
5.
P
4.
AIR
N2
9.
22.
2. 5.
A
5.
P
A
15.
2
1A
1B
5.
P
A
5.
P
A
17.
0.18mm
2
1A
1B
12. 14.
10.
13.
11.
8.
7.
3
2
1
3
2
1
0.18mm
18.
18.
8. 19.
9.
20.
12. 14.
13.
11.
9.
24.
23.
16.
6.
A
P
17.
7.
9.
6.
21.
9.
9.
O2
25.
26.
27.
27.
H G F E D C B A
Sheet No:
IF IN
DOUBT ASK
PEAK SCIENTIFIC INSTRUMENTS Ltd 2013
PEAK SCIENTIFIC OWN THE COPYRIGHT FOR THIS DRAWING. NO INFORMATION
CONTAINED IN THIS DRAWING MAY BE CONVEYED TO A THIRD PARTY WITHOUT
THE WRITTEN CONSENT OF THE COPYRIGHT HOLDER.
DESCRIPTION OF CHANGE:REV/DCL:ECN: SIG: APP: DATE:
UNLESS OTHERWISE STATED: DIMENSIONS IN mm. LINEAR TOLERENCES: ±0.25mm.
ANGULAR TOLERENCES: ±0.1°.
ALL MATERIALS SHALL BE COMPLIANT WITH THE RoHS DIRECTIVE
FOUNTAIN CRESCENT
INCHINNAN BUSINESS PARK
RENFREWSHIRE, PA4-9RE
TEL: [phone]
FAX: [phone]
www.peakscientific.com APPROVED BY:
DETAILED BY: DATE:
DATE: DRAWING TITLE:
PROJECT/LEAD ENGINEER: DRAWING No: DCL:
THIRD ANGLE
PROJECTION
C
REV:
PD-HALO PD-HALO
J.McDermott S.Currie
02/10/2017
3A
SHEET 1 OF 2
15/03/2018
n/a 1N2 5L tank added SC IK 15/03/18
n/a 2Oxygen sensor and fixed orififce added. SC IW 03/07/18
03338 3 Shuttle valve ports now matching added 2 inline Filters 27; 8mm tubing added; tubing re-numbered SC IK 14/03/2019

Page 19
Electrical Schematics
L N E L N E
EARTH STUD
PCB - 230v - SH2
MCB - 10A - SH1
10A
- 0V
+ 24V
N
L
PSU 24v, 2.5A
PCB - 2-PIN CONNECTOR (BLUE) - SH2
LED - O2 PURITY SIGNAL - SH2
LIVE (L)
NEUTRAL (N)
EARTH
0V DC
24V DC
SH - SHEET SV - SOLENOID VALVE
C - COMPRESSOR
R - RELAY
Component / ID / Sheet #
TD +24v SH2
ID EXAMPLE:
24VDC FANS - 6-OFF - SH2
H G F E D C B A
Sheet No:
IF IN
DOUBT ASK
PEAK SCIENTIFIC INSTRUMENTS Ltd 2013
PEAK SCIENTIFIC OWN THE COPYRIGHT FOR THIS DRAWING. NO INFORMATION
CONTAINED IN THIS DRAWING MAY BE CONVEYED TO A THIRD PARTY WITHOUT
THE WRITTEN CONSENT OF THE COPYRIGHT HOLDER.
DESCRIPTION OF CHANGE:REV/DCL:ECN: SIG: APP: DATE:
UNLESS OTHERWISE STATED: DIMENSIONS IN mm. LINEAR TOLERENCES: ±0.25mm. ANGULAR TOLERENCES: ±0.1°.
ALL MATERIALS SHALL BE COMPLIANT WITH THE RoHS DIRECTIVE
FOUNTAIN CRESCENT
INCHINNAN BUSINESS PARK
RENFREWSHIRE, PA4-9RE
TEL: [phone]
FAX: [phone]
www.peakscientific.com APPROVED BY:
DETAILED BY: DATE:
DATE: DRAWING TITLE:
PROJECT/LEAD ENGINEER: DRAWING No: DCL:
THIRD ANGLE
PROJECTION
C
REV:
WD-HALO HALO ELECTRICAL DIAGRAM
J.McDermott I Kean
28/09/2017
3A
SHEET 1 OF 2
14/03/2018
N/A 2PURITY LED CONNECTION CHANGED TO SINGLE LED SC DM 03/07/18
03338 3 PRESSURE SWITCH INPUTS SWAPPED & COMP LABELS 1 & 3 SWAPPED - TITLE CHANGED WAS MP-AES SC IK 14/03/2019

Page 20
LIVE (L)
NEUTRAL (N)
EARTH
0V DC
24V DC
SH - SHEET SV - SOLENOID VALVE
C - COMPRESSOR
R - RELAY
Component / ID / Sheet #
TD +24v SH2
ID EXAMPLE:
L N
MCB - 10A - SH1
SV/8 - CMS VENT 2 - (N2 Column/2)
SV/9 - CMS VENT 1 - (N2 Column/1)
SV/2 - AIR DRAIN 2
SV/1 - AIR DRAIN 1
SV/6 - AIR VENT 1 (AIR Dryer Column/1)
SV/5 - AIR VENT 2 (AIR Dryer Column/2)
SV/3 - N2 DRAIN 1
SV/4 - N2 DRAIN 2
SV/7 - CMS EQUALISATION
LED - ANNUAL SERVICE
HEAT EXCHANGER - FAN ASSEMBLY
+240v -0v L N
Wh Blk
MFAN 14W
- +
+240v -0v L N
Wh Blk
MFAN 14W
P
PRESSURE SWITCH AIR
+24V +24V
- 0V
P
PRESSURE SWITCH N2
+24V +24V
- 0V
1
2
8W
1
2
8W
1
2
8W
1
2
8W
1
2
8W
1
2
8W
1
2
8W
1
2
8W
1
2
8W
- +
M
M
M
- 0V
+ 24V
NL
PSU 24v, 2.5A - SH1
PSU - 24v, 2.5A - SH1
- 0V
+240V
- 0V
+240V
HEAT EXCHANGER
THERMO-COUPLE
HEAT EXCHANGER
THERMO-COUPLE
- +
FAN TEMP.
CONTROL - 1
FAN TEMP.
CONTROL - 2
+24V
- 0V
MFAN 14W
PSU - 24v, 2.5A - SH1
MFAN 14W
MFAN 14W
MFAN 14W
MFAN 14W
MFAN 14W
LED - PURITY
- +
C3 - Comp 3 (AIR) 2.7A, 50Hz
3.0A, 60Hz
C2 - Comp 2 (N2/1) 2.7A, 50Hz
3.0A, 60Hz
C1 - Comp 1 (N2/2) 2.7A, 50Hz
3.0A, 60Hz
H G F E D C B A
Sheet No:
IF IN
DOUBT ASK
PEAK SCIENTIFIC INSTRUMENTS Ltd 2013
PEAK SCIENTIFIC OWN THE COPYRIGHT FOR THIS DRAWING. NO INFORMATION
CONTAINED IN THIS DRAWING MAY BE CONVEYED TO A THIRD PARTY WITHOUT
THE WRITTEN CONSENT OF THE COPYRIGHT HOLDER.
DESCRIPTION OF CHANGE:REV/DCL:ECN: SIG: APP: DATE:
UNLESS OTHERWISE STATED: DIMENSIONS IN mm. LINEAR TOLERENCES: ± 0.25mm.
ANGULAR TOLERENCES: ±0.1°.
ALL MATERIALS SHALL BE COMPLIANT WITH THE RoHS DIRECTIVE
FOUNTAIN CRESCENT
INCHINNAN BUSINESS PARK
RENFREWSHIRE, PA4-9RE
TEL: [phone]
FAX: [phone]
www.peakscientific.com APPROVED BY:
DETAILED BY: DATE:
DATE: DRAWING TITLE:
PROJECT/LEAD ENGINEER: DRAWING No: DCL:
THIRD ANGLE
PROJECTION
C
REV:
WD-HALO HALO ELECTRICAL DIAGRAM
J.McDermott I Kean
28/09/2017
3A
SHEET 2 OF 2
14/03/2018
N/A 2PURITY LED CONNECTION CHANGED TO SINGLE LED SC DM 03/07/18