Peak Scientific Precision Zero Air Manual

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 1
Directions For Use
“Zero Air” Gas Generator
ZA300
Peak Scientific Instruments Ltd
Fountain Crescent
Inchinnan Business Park
Inchinnan
Renfrewshire
PA4 9RE
T.(Europe) [phone]
T. (USA) [phone] (sales)
T.(USA) [phone] (tech support)
F.(Europe) [phone]
[email protected]
[email protected]
[email protected]
www.peakscientific.com

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 2
Document Change History
Issue No Changed Initials Date
1 First Issue SGM 21/10/98
2 Spare Parts SGM 11/12/98
3 New style front added FAD 30/03/05

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 3
Contents
Page No
Warranty Statement 5
Introduction 6
Unpacking & Installation 6
Electrical Connection 6
Air Connection 7
Principle of Operation 8
Commissioning 10
Routine Maintenance 12
Troubleshooting 15
Technical Specifications 17
System Diagrams 19
Maintenance Log 21
Notes 22

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 4
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.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 5
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:-
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 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.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 6

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 7
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 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.
Performance of the generator (like all sophisticated equipment) is affected by ambient temperatures and
humidity. Continuous operation in ambient temperatures exceeding 25°C will lead to a reduction in
capacity and prolonged operation in temperatures exceeding 30°C will shorten the life of the unit.
Operation in relative humidity exceeding 70% may overload the filtration system and 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):- Green & Yellow or Green
LIVE (L):- Brown Black
Neutral (N):- Blue White
Fuse
The generator protection fuse is found 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.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 8
4 Air Connection
The inlet and outlet connections are 1/4" BSP female.
The Inlet air should conform to the following specifications:
Minimum Pressure 6.2 Barg / 90 psig
Maximum Pressure 8.96 Barg / 130 psig
Maximum Hydrocarbon Content 100 ppm
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 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 left side of the cabinet. 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 of will result in higher levels of hydrocarbons in the delivered gas.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 9
5 Principle of Operation
The Peak Scientific Instruments Zero Air 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.
Filter
Drier
5/2 Valve
Drain Outlet
PSA
Cam
Timer
Heater Rod
Thermocouple
Outlet
Compressed Air
Supply
Theoretical
Pneumatic Diagram
Cat
Chamber
Cooling
Coil

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 10
Moisture / Removal: -
The first process utilizes a 'Pressure Swing Adsorption' (PSA) method to further treat the air. This is
where 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 is removed. Some of the dried 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 dried gas. Again some dried
gas is back purged down the other column to atmosphere to cause a regeneration effect. This process
repeats itself approximately every 2 minutes indefinitely.
Zero Air Generation
The second 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. Any CO present in the
air supply is also converted to CO2.
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.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 11
6 Commissioning.
This should be undertaken by a technically competent person
With the generator installed as described earlier remove the front cover. Check that all the internal
components are securely located and have not moved during transit.
Open the air supply and turn the unit ON. Set the regulator on the Inlet Filter/Regulator to the desired
pressure.
Check that the cooling fans are operating and exhausting air out of the generator. Check that the cam on
the timer is rotating. Check that the red LED on the Temperature Control Boards is lit.
After a maximum of 2 minutes the cam timer valve should operate to change over the columns on the
PSA drier unit. This is accompanied by an audible rush of exhaust air from one of the exhaust ports.
Should this not happen the position of the Cam Follower will need adjusted. This is done by the adjusting
screw on the arm of the Cam Follower. (Note: - the 5/2 valve will not operate if the system pressure is
below 60 psig. If the system pressure has not reached 60 psig wait a few minutes until the next cycle.)
After a maximum time of 40 minutes the Catalytic Chambers should have reached temperature. When
this happens the relay on the Temperature Controllers will “click” and the LED's will go out. The heaters
will then cycle as required.
Do not touch any part of the Catalytic Chambers or Copper Lines, as they will be VERY hot.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 12
Purge Setting
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 30 l/min. A reduced purge rate will result in higher levels of contaminate gases over a
period of time.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 13
7 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 Peak Gas Generator will
have a long and trouble free life. However the following components should be replaced as follows:
Filter/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 MAINTENANCE PLAN
WILL INVALIDATE THE PRODUCT WARRANTY.

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 14
Catalytic Chamber
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.
Heater
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.
Thermocouple
The thermocouple is “K” type spring-loaded bayonet fitting to ensure good contact with the chamber core.
Thermal Fuse
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 15 for guidance.
Heater
Thermocouple
Thermal
Fuse
Air Inlet
Line

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 15
Inlet Filter / Separator Elements
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.
Inlet Filter
This should be changed at 6-month intervals. Part Number is 02-4187 and the filter is located as shown.
Remove the cover by rotating it anti-clockwise ¼ turn. The element can then be removed. Re-fitting is the
reverse procedure.
Inlet Filter
(02-4187)

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 16
8 Troubleshooting
Problems with the ZA300 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
Control Board
LED LED Off
Voltage
At Heater
Thermocouple
Wiring
Replace
Control Board
Replace
Thermocouple
Replace Heater
Voltage At
Board Output
Check Wiring
Off
On
Open
Circuit
OK
Yes
No
Yes
No
Check
Flow Rate
Hot
Cold

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 17
2. High Moisture Level
Wrong
Moisture
Present
Check
Drain Port
Check
Cam Rotating
Check Motor
Operation
Audible
Change-over
Check Motor
Supply
Replace
Cam Timer
Repair Wiring
Fault
Check Purge
Settings
Cam Follower
Operating
3/2 Valve
Replace
Faulty 3/2 Valve
No
Yes
Open
Circuit
OKYes
No
Yes
No
Clear Obstruction
No Flow
Clear
Tighten
Grub screw
OK
Re-set Purge
Settings
Replace Alumina
Charge in
Drier Columns
Purge to
Atmosphere
for 24 Hours
Check Moisture
Level
Return to
Service
OKHigh
Yes
No
Adjust
Cam Follower

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 18
7 Technical Specifications
General Details
Minimum Operating Ambient Temperature 5 oC (41 oF)
Maximum Operating Ambient Temperature 45 oC (113 oF)
Inlet Conditions (Free of oil and bulk moisture)
Minimum Air Inlet Pressure 90psig
Maximum Air Inlet Pressure 130psig
Minimum Air Inlet Flow Rate Gas outlet flow & Purge flow
36LPM
Outlet Gas
Maximum Pressure Drop (Outlet-Inlet) δP N/A
Maximum Gas Outlet Pressure 100 psig (6.8 Barg)
Maximum Gas Outlet Flow for specified hydrocarbons 30 Litres/min (ATP)
Pressure Dewpoint -30oC (-22oF)
Start up time for dewpoint 8 hrs
Particles 0.01um
Hydrocarbon concentration (as methane) <0.1ppm
Start up time for hydrocarbon concentration 45 minutes
O2level 20%
Electrical Requirements
@230V ac (50 Hz) 8.9 AMPS
Electrical Connection IEC-Euroconnector
General
Dimensions W x D x H cm 43 x 41x 88
Weight Kg 64
Shipping Dimensions W x D x H cm 100 x 57 x 67
Shipping Weight Kg 91

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator
Instructions for use Manual 30th March 2005
ZA300 issue 3 19
Parts List
Item Part No
Transformer 04-4356
Heater Element 04-1059
Thermocouple 04-1050
Temperature Controller 04-1170
Cooling Fan 04-1022
Cam Timer 04-1042
Coalescer 02-4366
Element 02-4335

PEAK Scientific Instruments Ltd ZA300 Zero Air Gas Generator Instructions for use Manual 30th March 2005 ZA300 issue 3 20
Cam Timer
Gas
Outlet
Drain Outlet
Front Panel
ZA300 Pneumatic Diagram
Thermocouple
Heater Rod
5/2 Valve
Flow
Regulator
NRV
PSA
Drier
Calibration Gas Pressure
Cat
Chamber
Heat
Exchanger
Filter
1110