PEAK Scientific Instruments Ltd

Calibration Gas Generator

Instructions for use Manual

Directions For Use

Calibration Gas Generator
CG15L
TOC1500HP

Peak Scientific Instruments Ltd
Fountain Crescent
Inchinnan Business Park
Inchinnan
Renfrewshire
PA4 9RET.(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

CG15L Rev 81

PEAK Scientific Instruments Ltd

Calibration Gas Generator

Instructions for use ManualDocument Change History
Issue No

ChangedInitials

Date1
567

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

HDFADFAD
LC

15/04/03
17/11/04
31/03/05
16/12/15

8Declarations Added

LC

11/04/19

CG15L Rev 82

Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use ManualContents
Page No
Warranty Statement

4

Introduction

5

Unpacking & Installation

5

Electrical Connection

5

Air Connection

6

Principle of Operation

7Commissioning

9

Routine Maintenance10

Troubleshooting

13

Technical Specifications

15

Maintenance Log

17Notes

18

CG15L Rev 83PEAK Scientific Instruments Ltd

Calibration Gas Generator

Instructions for use Manual

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 aconsumer (within the meaning of the Unfair Contract Terms Act 1977) all warranties, conditions or otherterms 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 theCustomer 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 theforegoing 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; and4.2) 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 areasonable time of it becoming apparent and subject always to the terms of sub-clause 4 hereof, theCompany shall, in its option, replace or repair the defective Goods or refund a proportionate part of thePrice. The Company shall have no further liability to the Customer (save as mentioned in sub-clause 6hereof).

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 Companyor 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 theCustomer for costs, damages, loss or expenses (whether direct, indirect, consequential or otherwise) orindemnity in any respect howsoever arising including, but not by way of limitation, liability arising innegligence (other than pursuant to clause 6 above) that may be suffered by the Customer or any thirdparty.

SAFETY NOTICE TO USERS
These instructions must be read thoroughly and understood before installationand 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 theequipment.
When handling, operating or carrying out any maintenance, personnel must
employ safe engineering practices and observe all relevant local health andsafety requirements and regulations. The attention of UK users is drawn to theHealth and Safety at Work Act 1974, and the Institute of Electrical Engineers
regulations.
CG15L Rev 84

Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual
1Introduction

The Peak Scientific Instruments range of Calibration Gas Generators is designed to produce a constant flowof dry air of calibration standard with impurities reduced to better than the following levels:-Contaminant
CO
CO2SOXTHC
O2
H2O
2Concentration<1.0 ppm<1.0 ppm<0.1 ppm<0.1 ppm=18 - 20%
<1.5 ppm

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 fanoutlet on the top.
The generator should be placed on a steady and level base.

3Electrical Connection

Important Electrical NoticeThis 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. Themains supply must be of the stated AC voltage and frequency.

EARTH/GROUND (E):LIVE (L):Neutral (N):-Green & YellowBrown
BlueorGreenBlackWhite

FuseThe generator protection fuse in the pull out drawer of the mains inlet IEC euroconnector locatedon the bottom right hand side of the cabinet adjacent to the off/on switch. The fuse is rated at 10AMP. A spare fuse is also provided in the drawer.
Connect the generator to a single phase supply using the power cord provided.

CG15L Rev 85

Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual4

Air Connection

The inlet and outlet connections are 1/4" BSP female.
The minimum required air conditions are as follows:-Pressure
Inlet Flow

TOC1500HP
100 psig (6.8 Barg)
9.5 Litres/min

CG15L
120 psig (8.27 Barg)
28 Litres/min

The inlet air should be oil free and pre-filtered to remove bulk moisture. Although not essential, an airdrier 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, highsulphur 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 desired pressure is attained. Output pressure and flows are factory
set at 80 psi and 1.5 l/min (TOC1500HP) or 15l/min (CG15L).

CG15L Rev 86

Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use Manual
5Principle of Operation

The CG15L calibration gas generator works on the basis of two fundamental processes as illustrated in
the following pneumatic diagram.
Note: - This diagram is only to illustrate the principles involved. For an actual pneumatic diagram pleaserefer to the drawings at the end of this document.
Heater RodPressure

Temperature

Thermocouple

PEAK
Laboratory Generator

CatChamber
NRVReceiver
GaugeRegulator

PSADrierHeat
Exchanger
Inlet Filter

ReceiverGasOutlet

5/2 Valve
FilterAir Inlet

Drain Outlet

3/2 Valve

CGxxL Pneumatic Diagram

Zero Air GenerationCG15L Rev 87

PEAK Scientific Instruments Ltd

Calibration Gas Generator

Instructions for use Manual

The first process utilizes a 'Zero Air' catalytic combustion chamber. This works on the principle of catalyticoxidation 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-drainmechanism 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 toeffectively remove them both.

Moisture / CO2 Removal:The second process utilizes a 'Pressure Swing Adsorption' (PSA) method to further treat the air. This iswhere 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 theadsorbent 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 anddescribed as follows:The un-treated air is passed via a '5 port-2 position' (5/2) pneumatic control valve into one of the sievecolumns 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
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 toatmosphere 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.).

CG15L Rev 88

Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual6Commissioning
This should be undertaken by a technically competent person

With the generator installed as described earlier remove the lower 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 red LED
display on the Upper Front Panel is lit.
After a maximum of 2 minutes the 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 the Exhaust Silencer.
The reading on the Digital Display should begin to increase towards its set point of 400°C. After amaximum time of 40 minutes the Catalytic Chamber should have reached temperature. When thishappens the display will remain steady on 400°C. The heater is controlled by a PID controller which
accurately matches heater output to demand.
Do not touch any part of the Catalytic Chamber or Copper Lines as they will be VERY hot.
Purge Setting
The PSA Purge has been set in the factory and should not require adjustment. The purge can bechecked 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 purge should be set at 100 psig input.
Specification
Output Flow
Purge Flow

TOC1500HP
1.5 l/min
8 l/min

CG15L
15.0 l/min
12.0 l/min

A reduced purge rate will result in higher levels of contaminate gases over a period of time.

CG15L Rev 89Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual
7Routine 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 CG15L 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 PRESCRIBEDINVALIDATE THE PRODUCT WARRANTY.

MAINTENACE

PLAN

WILL

Inlet Filter / Separator Elements
These should be changed at intervals as indicated below. In addition filter bowls should be cleaned andthe 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 02-4339 & 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 thereverse procedure.

0.1μm
Filter02-4335
02-4339

Hold down andtwist ¼ turnAutodrain
02-4485

Eliminizer

CG15L Rev 810PEAK Scientific Instruments LtdCalibration Gas Generator

Instructions for use ManualDryer Filter & Silencer Elements
These elements should be changed at 12-month intervals. Part Numbers 02-4335, 02-4339 & 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 thereverse procedure. The Exhaust Silencers are removed by unscrewing.

CG15L Rev 811Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual
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 annularspace is specifically designed to allow the required contact time with the catalyst to ensure completeoxidization. The complete chamber is contained within an insulated enclosure as shown below.

Air Inlet
LineThermocouple

Heater

Thermal
FuseHeater
Regardless of the supply voltage the heater is rated at 110 Vac. This minimizes the volt-drop across theconductors and prolongs the life of the element. The Heater is contained within a stainless steel sleeve tofacilitate 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 indicatesthat a fault exists which MUST be rectified before attempting to replace the thermal fuse. Refer tothe trouble shooting chart on page 13 for guidance.

CG15L Rev 812

Calibration Gas Generator

PEAK Scientific Instruments LtdInstructions for use Manual

8

Troubleshooting

1.

High CH4

No Gas Delivery

Check Presure
GaugesLowYes

Air Escaping
From Drain

OKClean Autodrain

NoNo flow

CheckFlow Rate

Check Aoir
supplyOK
BlockedChamber Contact Factory

HighCheckFlow Rate

High CH4

Reduce Demand

OK400
Check Front Panel
Display
NoDisplay

No Fault - Check
Elsewhere

EEE

Replace Faulty
Thermocouple<400

No
Check 12V @terminals 8&9

Replace Faulty
Power Supply

Yes

Replace Faulty
Display Module

0V
Voltage
At Heater

Check Thermal
Fuse

Replace Faulty
SSR

110 V

Replace Faulty
Vent Fan30 Ohms
Check Heater
Resistance

CG15L Rev 8

Replace Heater13Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use Manual

2.

High CO2
CheckDrain PortHigh C02

No Flow
Clear Obstruction

Clear

CheckElectronoc Timer

No

Check TimerOperation

OKReplace
Timer

OK

AudibleChange-overNo

Check Valve
SupplyOpen
Circuit

Repair Wiring
Fault

Yes

CHeck
3/2 Valve

Replace
Faulty 3/2 Valve

Check Purge
Settings

Wrong

Purge toAtmospherefor 24 Hours

Re-set Purge
Settings

OK

Replace Alumina
Charge inDrier Columns

CG15L Rev 8High

Check CO2
Levels

OKReturn toService14Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use Manual
9Technical 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

6.8 Barg (100 PSI)

Maximum Air Inlet Pressure

8.6 Barg (125 PSI)

Minimum Air Inlet Flow Rate (TOC1500HP)

9.5 Litres/min (ATP)Minimum Air Inlet Flow Rate (CG15L)

28.0 Litres/min (ATP)Outlet Gas
Maximum Pressure Drop (Outlet-Inlet) P
Maximum Gas Outlet Pressure

0.7 Bar (10 PSI)
Max Inlet-P-75oC (-103oF) (1.4ppm @ ATP)Pressure Dewpoint
Start up time for dewpoint

8 hrsParticles

0.01umHydrocarbon concentration (as methane)<0.1ppm

Start up time for hydrocarbon concentration

45 minutes

CO level<1.0ppm

CO2 level<1.0ppm

SOX<0.1ppm
Electrical Requirements@115V ac (50/60Hz)

5.2 Amps@230V ac (50/60Hz)

2.6 Amps

Electrical Connection

IEC-Euroconnector
GeneralDimensions W x D x H

cm(inches)

Shipping WeightKg(lbs)

CG15L Rev 8

43 x 41 x 62(20” x 17” x 16”)
64
(136)

15

Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use ManualServiceable Parts List
Item

TOC1500HP(110V 60Hz)

TOC1500HP(230V 50HZ)

CG15L(110V 60HZ)

CG15L(230V 50Hz)

Fuse (10A)
Transformer
Element Eliminizer
Element AFD3000
Heater Element
Thermocouple
Temperature Controller
Thermal Fuse
Cooling Fan
Exhaust Silencer
Timer
3/2 Valve
Pressure Regulator
Flow Regulator
Safety Valve00-1208
n/a02-4339
02-4335
04-1053
04-1051
04-445900-1207
04-102202-1033
04-101902-4384
02-111002-4437
02-454900-1208
04-4356
02-4339
02-4335
04-1053
04-1051
04-445900-1207
04-102102-1033
04-101902-4334
02-111002-4437
02-454900-1208
n/a02-4339
02-4335
04-1059
04-1051
04-445900-1207
04-102202-1033
04-101902-4384
02-111002-4437
02-454900-1208
04-4356
02-4339
02-4335
04-1059
04-1051
04-445900-1207
04-102102-1033
04-101902-4334
02-111002-4437
02-4549

CG15L Rev 816

Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use Manual

Maintenance Record Log
Model- CGWork
done

CG15L Rev 8

Serial numberRemarks

Date Name17

Calibration Gas Generator

PEAK Scientific Instruments Ltd
Instructions for use Manual

Notes

CG15L Rev 818••••

Signed:Date:

1st February 2015

Name:

Chris Pugh

Position:

Chief Technology Officer