NM20ZA

Service Manual – Revision 13

Service Manual

High Purity Nitrogen Generator

NM20ZA 230Vac
Gas Station
(19” Rack System)
Peak Scientific Instruments Ltd
Fountain Crescent
Inchinnan Business Park
Inchinnan
Renfrew PA4 9RE
Scotland

Tel (Europe) +44 (0) 141 812 8100

Tel (USA) +1 866 647 1649 (sales)
Tel (USA) +1 866 732 5427 (tech support)

Fax (Europe) +44 (0) 141 812 8200

Email Sales: [email protected]

Email Technical Support: [email protected]
Or on the web @ www.peakscientific.com

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Document Change History

Rev. No. Change Initials Date

1 Document Created SGM 23-01-01

2 Document Reviewed & Updated GL 30-01-01

3 Maintenance Section Revised SGM 16-02-01

4 Document Reviewed & Updated GL 08-05-01

5 Electrical Drawing Updated HD 19-04-02

6 Document Reviewed & Updated GL 15-08-02

7 Maintenance Recommendations Updated GL 06-02-03

8 Safety Statement Added & Current Rating Updated. GL 05-03-03

9 Parts List Updated to include new SAP part Numbers GL 29-08-03

10 Parts List Updated to include new SAP part Numbers GL 22-06-04

11 Updated FAD 20/12/04

12 Shipping Weight updated FAD 17/03/05
13 Flow settings updated FAD 29/03/05
14 New Part No. for Relief Valve SF 24/08/05

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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 Nitrogen 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.
WARNING: Nitrogen is not a poisonous gas, but if the concentration in the
inhaled air becomes too high there will be a risk of asphyxiation.
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Contents

Page #

Document History 2

Warranty Statement 3

Safety Notice To Users 3

1) Introduction 5

2) Unpacking & Installation 5

3) Generator Environment 6

4) Technical Specification 7

5) Connection to the Instrument 8

6) Generator Controls 9

7) Electrical Connection 10

8) Operator Training 10

9) START-UP Sequence 11

10) Pressure & Flow Settings 11

11) Principal of Operation 12

12) Routine Maintenance 13

13) Electrical Diagram – WD-NM20/30 21

14) Pneumatic Diagram – PD-NM20ZA 22

15) Parts List 23

16) Maintenance Log 25

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1 Introduction
Welcome to the Service Manual for the Peak Scientific Instruments NM20ZA Laboratory Gas
Generator. Enclosed in this manual you will find the information required to ensure that your
generator is operated & serviced according to our recommended guide lines which will prepare
you for long and trouble free gas generation.

Please review each of the following sections carefully and ensure that an Operational
Validation Report is completed in full after every service task is performed and that the
maintenance log at the rear of this manual is updated for future reference (Complete IQ/OQ
procedures are available from the factory).

Thank you for selecting Peak Scientific Instruments (PSI) to meet your Gas Generation
needs, and should you require any further assistance or support please do not hesitate to
contact us at the addresses displayed on the front cover of this manual.

2 Unpacking and Installation.

Although Peak Scientific takes 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.

Follow the un-packing instructions posted on the side of the crate. It will require 2 people to lift the crate
clear and to maneuver the generator onto the floor. Thereafter the generator can be moved to its final
location on the castors provided.

Note: - Included with the generator is a pack containing keys, manuals, service filters &
fittings. Be careful not to discard these with the packing.

Please save the product packaging for storage or future shipment of the
generator.

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3 Generator Environment
The generator in designed to be installed adjacent to the Mass Spectrometer it is supplying. If this is not
convenient then the generator can be sited elsewhere, however, consideration should be made of the
lengths of pipe runs as pressure drops can result from extended runs of pipe.

Performance of the generator (like all sophisticated equipment) is affected by ambient conditions.
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. Note should also be
taken to 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. Consideration should also be given to the air flow around the unit. It is recommended that
an air gap of 75mm (3”) should be maintained down both sides and across the top of the unit. Please
refer to the drawing below for the general dimensions of the generator.

MAXIMUM AMBIENT CONDITIONS: - 30°C (dry bulb) 70%RH (Max)

General Dimensions

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4 NM20ZA – Technical Specification

Generator Environment
Minimum Operating Ambient Temperature 5 oC (41 oF)
Maximum Operating Ambient Temperature 30 oC (86 oF)
Maximum Relative Humidity 70%

Outlet Gas
Maximum Gas Outlet Pressure Curtain 60 psig
Maximum Gas Outlet Pressure Source 100 psig
Maximum Gas Outlet Pressure Exhaust 60 psig
Maximum Gas Outlet Flow (Zero Grade Air) 30 Litres/min (ATP)
Maximum Gas Outlet Flow (High Purity Nitrogen) 5 Litres/min (ATP)
Start up time for Purity 60 minutes
Air filtration to 0.01um

Electrical Requirements
@230V±10% ac (50/60Hz) 5.0 Amps
Compressor Circuit Breaker 8.0 Amps
Control Circuit Breaker 2.0 Amps

Electrical Connection Single Phase Power Cord

General
Dimensions W x D x H cm 60 x 67 x 94
(inches)
(24 x 27 x 37)
Weight Kg 112.5
(lbs) (248)
Shipping Weight Kg 169
(lbs) (372)

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5 Connection to the Instrument

Rear View.
3 off 1/4" x 1/4" Compression Fitting (02-4421)

with 1/4" Tubing (00-1266)

Exhaust Gas Outlet.

APi 3000
3 off 1/4" x 1/4" Comp. Fitting (02-4421)
Source Gas Outlet. 1 off 1/4" Tee (02-4307)
2- off 1/4" x 1/8" Swagelok (02-1000)

Curtain Gas Outlet.

* APi 4000 / Q Star
* 2 off 1/4" x 1/4" Comp. Fitting (02-4421)
2 off 1/4" Tee (02-4307)
*
2- off 1/4" x 1/8" Comp. Fitting (02-1000) #
Power Cord with 1/8" Tubing (00-1262)
(04-1038-EU) # # 1 off 1/4" Double Nipple (02-4399)
(04-1029-US) 1 off 1/8" x 1/4" Compression Fitting (02-1009)
(04-1030-UK) with 1/4" Tubing (00-1266)
230Vac

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6 Generator Controls

Front View. Curtain Gas Pressure Gauge. Rear View.

Source Gas Pressure Gauge. Air Outlet Fans.

Exhaust Gas Pressure Gauge.

Gas Generator
API Systems

Curtain Gas Outlet.

Curtain Gas Source Gas Exhaust Gas

Source Gas Outlet.

Elapsed Time Meter. Exhaust Gas Outlet.
0

CURTAIN SOURCE EXHAUST

Serial Plate.
On/Off Switch.
Mains Power IEC. Socket.

Drain Connection.

SUPPLY DRAIN

Air Inlet Fans.

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7 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.

The Electrical requirement is 230Vac (50/60 Hz), 5.0 Amps

EARTH/GROUND (E):- Green & Yellow OR. Green

LIVE (L):- Brown Black
Neutral (N):- Blue White

Connect the generator to a single-phase supply using the power cord provided.

8 Operator Training
The NM20ZA Laboratory Gas Generator is designed specifically to minimize operator
involvement. Given that the generator is installed as described in earlier sections and is
serviced in accordance with the following maintenance recommendations then it should simply
be a matter of turning the generator on. The generator will automatically produce the factory
default flows and pressures noted below.

CURTAIN 5 litres per min (ATP) 60 PSI.G

SOURCE 22 litres per min (ATP) 100 PSI.G
EXHAUST 8 litres per min (ATP) 60 PSI.G
Should the demand for gas be less than the rated flow then the generator will automatically
regulate the internal pressure and cycle of the compressors as required. This should be all the
input your generator requires from you, the only additional tasks required are,

• If at any time the generator begins to emit excessive noise or vibration, then it should
be switched off and you should contact your local representative or the factory as soon
as possible.
• Please ensure that the drain port at the rear of the generator is led to a suitable
connection or container. It should be noted that the generator will liberate considerable
amounts of water from this port (approx. 1-2 litres weekly). If a container is used it
should be emptied at regular intervals.
• Ensure that the generator is serviced in accordance with the following maintenance
recommendations.

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9 START-UP Sequence.
With the generator installed as described previously, disconnect the Curtain, Source and
Exhaust gas outputs (ENSURING THAT ANY INTERNAL PRESSURE HAS BEEN SAFELY
DISSIPATED), and switch the generator on. The on/off switch should illuminate and the
cooling fans should start immediately. There will be a 10 second delay before the first
compressor starts, then after a further 3 seconds the second compressor should also start.
The three pressure gauges on the front panel will begin to climb, and after approx 3 minutes
the gauges should all have reached their rated pressure of either 60 or 100 PSI.G. The output
flows from the generator should now be measured to ensure they conform to the specification
below.

CURTAIN 5 litres per min (ATP) 60 PSI.G

SOURCE 22 litres per min (ATP) 100 PSI.G
EXHAUST 8 litres per min (ATP) 60 PSI.G
The generator should now be left to run for approx. 1 hour to allow the generator to fully flush
the internal receivers etc. of air and allow the membranes to stabilize. After this time the
Curtain, Source and Exhaust outputs can be re-connected and the interconnecting pipe work
checked carefully for leakage.

10 Pressure & Flow Settings.

Output pressures and flow rates are controlled by pressure regulators located behind the left side panel
as shown below. The Factory settings for the 3 outputs are shown above:-

Flow Controllers

Pressure Regulators

The above settings should allow the PSI Gas Station to be operated with all standard configurations for
the Api range of LC/MS/MS instruments. Should the above settings not provide sufficient flow or pressure
for your application please contact the factory for assistance.

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11 Principal of Operation.
Peak Scientific Instruments NM20ZA Generators utilize two different types of air preparation membranes
to produce the required Gas outputs. The Nitrogen side of the generator employs “Hollow Fibre
Membrane” Technology to efficiently separate Nitrogen from other gases present in ambient air. An
overview of this process can be seen below.

The Zero Air side of the generator uses the latest technology in membrane dryers to produce a clean dry
supply of Zero grade air. Both membranes are mounted in a similar fashion in the generator and utilize
standard ancillary components to maximize the interchangeability of the systems. The standard
membrane diagram can be seen below.

9.

7. 8.

2.

6.
4.

5.
10.
3.

11.

1.

Membrane - Standard Diagram

Air is drawn into the system by the Compressor (1) and passed through the Cooling Coil (2) and the
AFD – 3000 Micro Mist Filter (3) into the Membrane (5). After the Membrane (5) the gas is passed
through a Reverse Acting Carbon Filter (6) to remove any remaining impurities and via the Non-Return
Valve (Check Valve) (7) into the Receiver (10). The stored gas is regulated (11) to give the required
output pressure and flow. Receiver pressure is measured (9) to allow the generator to un-load (4) and
shut-down should demand cease. A Safety Relief Valve (8) is fitted to protect the system against over
pressure. Gas is delivered out of the machine via the Outlet Port (12). Any moisture collected by the
AFD – 3000 Micro Mist Filter (3) is expelled via the Drain Port (13).

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12 Routine Maintenance.

WARNING:
Servicing and/or repair of the Generator should only be undertaken by a
TECHNICALLY COMPETENT PERSON, with the Generator in its safely isolated
condition.

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 can be seen below.

Isolating the Generator:

a) Switch off the unit & disconnect it from the application.

b) Unplug the generator from the mains supply and remove the power cord from
the rear of the unit.

c) Remove the Left hand (when viewed from the front) side panel and ensure the 2
pressure gauges on the electrical panel read zero.

Maintenance Schedule

Due to the simplicity of the design and the small number of moving parts the NM Series Nitrogen
Generator will have a long and trouble free life. However the following components should be replaced as
follows:

Compressor Inlet Filters Every 6-months

Filter Separator Elements Every 12-months

Compressor Units (the lesser of) Every 6000 hours

or 18- 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

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Compressor Inlet Filters.

Introduction:

The Compressor Inlet Filters are located next to the Air Compressors and are accessed through the
lower front panel, which is attached to the compressor tray.

Procedure:

ENSURE THE GENERATOR IS IN THE SAFELY ISOLATED CONDITION AS

DESCRIBED ABOVE BEFORE CARRYING OUT ANY MAINTENANCE.

NOTE: - Compressed gas systems are dangerous and attempting to remove or

open any component whilst under pressure could result in injury or death.

Remove the 8-off fixing screws securing the Lower Front Panel and push forward the sliding tray as
shown.

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1. Small Compressor: - The filter is located on top of the compressor facing towards the rear
as shown below.

The cover is removed by twisting it ¼ turn

and puling clear. The element simply lifts out.

Part Number 02-4187.

Re-assembly is the reverse procedure

Inlet Filter
Small Compressor

2. Large Compressor: - The filter is located on the tray at the left hand side towards the front.

The cover is removed by twisting it ¼ turn

and puling clear. The element simply lifts out.

Part Number 02-4187.

Re-assembly is the reverse procedure

Inlet Filter
Large Compressor

Once the filters are replaced, carefully slide the tray back into place ensuring that the power cables and
silver braided hoses are clear of all obstructions. Re-fit the 8-off screws ensuring they are properly
tightened to prevent vibration.

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Filter Separator Elements.

Introduction:

The In-Line Coalescing and RAC Filters are located on the side rails and accessed through the Right
Side Panel and are arranged as shown.

RAC Filters

Coalescing Filters

Procedure:

ENSURE THE GENERATOR IS IN THE SAFELY ISOLATED CONDITION AS

DESCRIBED ABOVE BEFORE CARRYING OUT ANY MAINTENANCE.

NOTE: - Compressed gas systems are dangerous and attempting to remove or

open any component whilst under pressure could result in injury or death.

Un-lock and remove the right side panel.

Continued > Next Page

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Filter Replacement

RAC Filter :-

Remove Filter Bowl by un-screwing in a

counter-clockwise direction. The element
(Part No 00-4425) is removed by pulling
downwards. Re-assembly is the reverse
procedure.
Filter Element
(00-4425)

RAC
Filter

Coalescing Filter :-

Remove Filter Bowl by pulling down the

black slide with your thumb and rotating the
bowl ¼ turn. The element (Part No 02-4335)
is removed by unscrewing in a counter-
clockwise direction. Clean the bowl with a
Filter Element damp cloth prior to re-assembly. Re-
(02-4335) assembly is the reverse procedure. Ensure
the drain pipe is secure in the fitting at the
Coalescing
Filter bottom of the bowl

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Compressor Maintenance
It is not envisaged that the compressors would be serviced on site, but that the complete tray assembly
would be exchanged as required. Earlier models of the generator may have an older style gold
compressor tray as shown below, if this is the case then please refer to the COMPRESSOR TRAY
UPGRADE document available from our factory.

The Elapsed Time Meter on the front panel indicates the Compressor Running Hours.

Procedure for Exchanging the Compressor Tray.

ENSURE THE GENERATOR IS IN THE SAFELY ISOLATED CONDITION AS

DESCRIBED ABOVE BEFORE CARRYING OUT ANY MAINTENANCE.

NOTE: - Compressed gas systems are dangerous and attempting to remove or

open any component whilst under pressure could result in injury or death.

Remove the 8-off fixing screws securing the Lower Front Panel and pull out the sliding tray as shown.

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Disconnect the two braided hoses to the

compressors

Disconnect the two grey compressor plugs

(ensuring the metal clip has been loosened)
and the white fan plug.

Disconnect the two black plugs from the front

panel fans.

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Remove the 2-off nuts securing the front panel

to the underside of the compressor tray & lift
the panel clear.

Remove the four fixing screws from the sides

of the compressor tray.

The tray assembly can now be lifted clear.

Re-assembly is the reverse procedure. After re-fitting switch the generator on and
check for leaks.

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Hour
Meter

L1 N I1 I2 I3 I4 I5 I6

LIVE NEUT.

LOGO! 230RC

On/Off
Q1 Q2 Q3 Q4 Switch

LN

ENLNL

Pressure
Switch

Pressure
Switch
LNE

LN
Compressor
LNLNE
Un-Loading
Mains Socket Pin
Valves
Supply Configuration

Small Compressor (Q2)

Large Compressor (Q1)
Connector Plug Connector
Connector Plug Connector Plug Plug

Rear Cooling Fans Front Cooling Fans

Beko Autodrain
(If Fitted)

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1. Large Compressor 11. Nitrogen Membrane

2. Small Compressor 12. Reverse Acting Carbon Filter
3. Compressor Braided Hose 13. Non Return Valve (Check Valve)
4. Cooling Coils 14. Safety Relief Valve
5. AFD - 3000 Micro Mist Filter 15. Nitrogen Receiver
6. AP-100 Back Pressure Regulator 16. Zero Air Receiver ELECTRICAL PANEL ASSEMBY
7. Solenoid Valves 17. Pressure Flow Controller
8. Exhaust Silencer FRONT PANEL
18. Output Ports 8.
9. Pressure Switches 19. Drain Port Curtain Source Exhaust
10. DryPoint Membrane
7. 9.

4. 4.
6. 12. 13.
14.

5. 5.
12.

13.
14.
3. 3.
17. 17. 17.
10. 11.

16.
15.
1. 2.

19.

18.

NM20ZA Pneumatic Diagram

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15 Parts List
Peak App.Bio
Part # Part#
Preventative Maintenance

Annual Service Kit 08-4434 WP084434

Reverse Acting Carbon Filter Element 00-4425
AFD-3000 Micro Mist Filter Element 02-4335 WP024335 (Avail Sep)
Compressor Inlet Filter Element 02-4187

Pneumatic Parts

Tubing, Nylon 4MM Yellow 00-1305 WP001305

Tubing, Nylon 6MM Yellow 00-1306 WP001306
Safety Relief Valve 02-4544
Non Return Valve (Check Valve) 02-4546
Panel Mounted Gauge 02-1020 WP021020
DryPoint Membrane 06-4441 WP064441
Nitrogen Membrane 08-5075 WP085075
AFD-3000 Micro Mist Filter Assy 02-4486 WP024486
Exhaust Silencer Element 02-4336 WP024336 (Avail Sep)
Reverse Acting Carbon Filter 02-4552 WP024552

Electrical Parts

On/Off Switch 04-1005

Elapsed Time Meter 04-4414
Rear Cooling Fan 08-5068
Front Cooling Fan 04-1021 WP041021
Inlet Electrical Filter 04-4434

Sub Assemblies

Electrical Panel 08-4479 WP084479

Solenoid Valve 08-4482 WP084482
Pressure Switch 08-4481 WP084481
Motor Contactor 04-4439 WP044439
2 amp Circuit Breaker 04-4436
8 amp Circuit Breaker 04-4437
Programmable Logic Controller (PLC) 08-1104 WP081104
Compressor Tray Assembly 08-4649 WP084649
Compressor Braided Hose 02-1100
Large Compressor Assy 08-4643 WP084643
Anti-vib Mount 06-1022
Capacitor 04-4472
Service Kit 06-5529
Small Compressor Assy 08-4644 WP084644
Anit-vib Mount 06-1020
Capacitor 04-4470
Service Kit 06-5530
Air Preparation Assembly 08-4513
Valve – 130PSI Relief St/Steel ¼” BSP M+F 02-1215
Output Regulator Assembly 08-4484
Pressure / Flow Controller 08-4486

Preventative Maintenance

Kit, Svc Flow Meters peak Gas Gen 08-5100 WP085100

Gauge Pressure 100mm 0-11 BAR for Service Engineers 02-4593 WP024593
CD, NM20ZA SERVICE INFO PEAK NM20ZAV11 WPNM20ZAV11

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Notes:

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16 Maintenance Log

Model- NM20ZA. Serial number :

Work Done Remarks Date Name

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