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

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

Silencer

Inlet Filter

Electrical Panel

Nitrogen Tank

Air Tank

Compressor Assembly

Dryer Column Assembly

Compressor Assembly

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