AB-3G User Manual 2015 Peak Scientific - Rev. 6A 15/09/15
Contents Change History 4 How to Use This Manual 4 Introduction 5 Warranties and Liabilities 6 Safety Notices 7 Symbols 7 Safety Notice to Users 7 Declaration of Conformity 8 Environmental declaration 9 Technical Specification 10 Environment 10 Electrical Requirements 10 General 10 Unpacking 11 Installation 12 Generator environment 12 General dimensions 12 Removal of transit brackets 13 Unit controls 14 Human Machine Interface (HMI) 14 Pressure gauges 14 Rear connections 15 Fittings Kit 15 Initial purge run 15 Drain connection 16 Electrical Connection 16 Start up sequence 18 Tubing lengths 19 Connecting to the Mass Spectrometer 20 IMPORTANT DOCUMENTS 22 Operating modes 23 Normal operation 23 Page 2 2015 Peak Scientific - Rev. 6A 15/09/15
Standby mode 23 High altitude mode 24 HMI User menus 25 User Menu 25 Run hours 25 Temperatures 25 System status 26 Event logs 26 Set time/date 26 Comp hours reset 26 High Altitude Mode 26 Event message 27 Service Engineer 27 Diagnostics 27 Service requirements 29 Service schedule 29 Service indication 29 Annual service 29 Compressor service 29 Run hour reset 30 Service plans 30 Cleaning 31 Fault warnings 32 Minor fault 32 Redundancy mode 32 System failure 32 Temperature alarms 34 Run time alarm 35 Stage 1 35 Stage 2 35 Stage 3 35 Trouble shooting 37 Page 3 2015 Peak Scientific - Rev. 6A 15/09/15
Change History Rev. Comment Name Date 1 Initial release Scott Thomson 27/07/10 2 Updated to new format, Added Voltmeter Liam Couttie 20/06/12 3 Warranty form update Liam Couttie 27/09/13 4 Content Update Liam Couttie 18/06/14 5A Technical Specification Update Liam Couttie 12/05/15 6A Transit Bracket Change Liam Couttie 15/09/15 How to Use This Manual This manual is intended for end users and has been written so that it can either be read as a step by step guide to installation and usage or as a reference document where you can skip to the relevant information. Users of a hard copy version can refer to the contents page to find the relevant information. Users of the soft copy version can use the hyperlinks from the contents page as well as the hyperlinks between sections. 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. Page 4 2015 Peak Scientific - Rev. 6A 15/09/15
Introduction Specifically designed to operate LCMS Instruments manufactured by AB Sciex, the AB-3G produces Nitrogen and Dry Air through three independent outputs in the required flow rates, purities and pressures to cater for the requirements of all available AB Sciex LCMS Models. The AB-3G essentially combines two separate gas generator systems in one unit, with the source and exhaust gases (Dry Air) being generated using one system and the curtain gas (Nitrogen) being generated by the other. The AB- 3G utilises proven membrane technology that selectively removes oxygen, moisture and other gases to leave clean, dry, phthalate free Nitrogen and Dry Air. The AB-3G has been designed with additional compressor capacity. This additional capacity allows the generator to cycle the compressors more frequently, maximising compressor life. In the unlikely event of one compressor failing, the internal control system will alert the user and manage the compressors to maintain a full output flow from the generator. This totally unique feature will allow the user to plan a service or repair visit with Peak Scientific, thus ensuring uninterrupted uptime of your LCMS. Other features include: Small in size fits under a standard lab bench Quiet in operation noise level 54 db(a) Anti- vibration maximum reduction of vibration Service indication allowing you to plan your maintenance and keep your LCMS uptime at a maximum Maximized drainage Reduction of moisture carry over and thus increased reliability Re-heat technology improves membrane performance and reliability Robust control system improves safety and reliability of units Fault diagnosis Human Machine Interface provides alarm and fault information to assist the user in obtaining help in the unlikely event of a system problem Standby mode reduces compressor run time when there is no demand for gas and thus prolongs compressor life Fail safe protection 3 internal compressors ensure continuous operation, in the unlikely event of 1 compressor failing Minimal maintenance 12 month service intervals To ensure this generator model meets our high expectations with regards to reliability and performance, we have tested this new model extensively at our manufacturing plant and with end users around the world to ensure reliability and longevity of the systems. Page 5 2015 Peak Scientific - Rev. 6A 15/09/15
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. 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 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. Page 6 2015 Peak Scientific - Rev. 6A 15/09/15
Safety Notices 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 power to the Generator has been removed before proceeding. Safety Notice to Users These instructions must be read thoroughly and understood before installation and operation of your Peak AB3G 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. Page 7 2015 Peak Scientific - Rev. 6A 15/09/15
Declaration of Conformity We Of Peak Scientific Instruments Ltd. Fountain Crescent, Inchinnan, Renfrewshire, PA4 9RE Declare that: Equipment: Model: Nitrogen Gas Generator AB-3G To which this declaration relates, is in conformity with the applicable EC directives, harmonized standards, and other normative requirements. Low Voltage Directive 2006/95/EC EN 61010-1: 2010 Electrical Equipment for measurement, control and laboratory use. CAN/CSA-C22.2 No. 61010-1-04 Safety requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part 1: General requirement. Electromagnetic Compatibility Directive 2004/108/EC EN 61326-1: 2006 Electrical Equipment for measurement, control and laboratory use. FCC 47 CFR Part 15 Class B Unintentional radiators; Conducted and Radiated emissions limits. All evaluation, testing and certification issued by: Nemko GmbH & Co. KG Nemko Canada Inc. Reetzstrasse 58 303 River Road, Ottawa D-76327 Pfinztal-Soellingen Ontario, K1V 1H2 Germany Canada Signed: Name: Chris Pugh Date: 18 th June 2014 Position: Engineering Director Page 8 2015 Peak Scientific - Rev. 6A 15/09/15
Environmental declaration We of declare that: Peak Scientific Instruments Ltd. Fountain Crescent, Inchinnan. Renfrewshire PA4 9RE Equipment Model Nitrogen Gas Generator AB-3G Is fully compliant with the following Directives: 2002/96/EC WEEE (Waste of Electrical and Electronic Equipment) 2002/95/EC RoHS (Restriction of Hazardous Substances) Peak Scientific Instruments Ltd fully complies with its obligations towards the European WEEE (Waste of Electrical and Electronic Equipment) Directive 2002/96/EC. These obligations are being met within the B2B compliance group. Peak Scientific Instruments Ltd has developed all reasonable due diligence controls to ensure that our products comply with the principles and requirements of the European RoHS (Restriction of Hazardous Substances) Directive 2002/95/EC. Similar directives in the United States and China, for example, have also been captured within this program. Where a specific certificate of compliance is required, this can be requested, on a product serial number basis, directly from Peak Scientific Instruments Ltd, by contacting us through our website on www.peakscientific.com Signed By: Name: Ken Brown Position: Quality Assurance Manager Done at: Peak Scientific Instruments Ltd, Inchinnan, Scotland. Date: 1 st November 2009 Page 9 2015 Peak Scientific - Rev. 6A 15/09/15
Technical Specification Environment AB3G AB3G Hi-Flow Min/Max Operating Ambient Temperature 5 C 30 C / 41 F 86 F Maximum relative humidity 70% Maximum operating altitude 2000 meters Min/Max Storage Temperature* -20 C 60 C / -4 F 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 Curtain Max Flow @ 80 psi 12 l/min (0.42CFM) 12 l/min (0.42 CFM) Source Max Flow @ 110 psi 24 l/min (0.85 CFM) 24 l/min (0.85 CFM) Exhaust Max Flow @ 60 psi 8 l/min (0.28CFM) 14 l/min (0.49 CFM) Dew Point -11 C / 12 F Particles <0.01µm Phthalates None Suspended Liquids None Gas Outlets 3 x ¼ BSPP Drain Outlet 1 x ¼ BSPP Pressure Gauges 3 Start-Up Time for Purity 30 minutes Electrical Requirements Voltage 230 VAC ± 10% Frequency 50/60 Hz Current 9.5 Amps Fuse 13 Amps Input Connection C20 Plug Power Cord Type C19 socket to local connection (13A minimum) Pollution Degree 2 Installation Category II General Dimensions in cm (inches) W x D x H 90 x 73 75.3 (35.4 x 28.7 x 29.6) Weight 145 kg (316 lb) Shipping weight 200 kg (441 lb) Noise level 54 dba @1m It should be noted that the gas pressures and flows are factory set. The pressures shown on the Generator front panel are in excess of the maximum inlet pressure of the Mass Spectrometer. This is to allow for known pressure drops. These settings have been approved by AB Sciex. Page 10 2015 Peak Scientific - Rev. 6A 15/09/15
Unpacking 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. Check SHOCKWATCH label for signs of rough handling prior to un-packing Any damage should be reported immediately to the carrier and Peak Scientific or the Peak Partner from where the unit was purchased. Follow the unpacking instructions posted on the side of the crate. It will require two people to remove the unit from the shipping crate and to manoeuvre the Generator onto the floor. Please save the product packaging for storage or future shipment of the Generator. Note: Included with the Generator is a Fittings Kit containing mains power leads for UK, EU and US also all the required fittings. Be careful not to discard these with the packaging. Page 11 2015 Peak Scientific - Rev. 6A 15/09/15
Installation Generator environment The Generator is designed for indoor use only. It should be installed adjacent to the Mass Spectrometer it is supplying. If this is not convenient then the unit 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. Please see the Tubing lengths section for further details. Performance of the generator (like all sophisticated equipment) is affected by ambient conditions. 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 unit 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, at the rear and across the top of the unit. Please refer to the drawing below for the general dimensions of the unit. Maximum Ambient Conditions: 30 C (dry bulb) 70%RH (Max) General dimensions 900mm 730mm 753mm Figure 1: General dimensions The Generator must always be placed on a level surface. Failure to do so will affect the performance of the Generator. Page 12 2015 Peak Scientific - Rev. 6A 15/09/15
Removal of transit brackets The transit brackets must be removed prior to switching the unit on. Failure to do so will result in damage to the equipment. This will void the warranty on the generator and will result in a chargeable repair. Remove the top cover by: 1. Removing the screw along the top rear edge using a No. 2 Pozidrive screwdriver. Keep in a safe place. 2. Loosen the four captive screws on to top face of the cover. 3. Using the handle, lift the cover enough to disconnect the earth wire. 4. Remove cover and store in a safe place Remove the transit brackets by: 5. Removing the eight screws circled. 6. Remove the two transit brackets on the centre compressor first. 7. Remove the remaining for transit brackets on the left and right side compressors. The transit brackets should be refitted for future storage or transportation of the Generator. To refit the top cover repeat steps 1 to 4 in reverse order. Ensure the Earth wire is reconnected to the top cover when refitting. Page 13 2015 Peak Scientific - Rev. 6A 15/09/15
Unit controls Power Switch HMI (Human Machine Interface) Output Pressure Gauges Curtain - Source - Exhaust Left Hand Side Right Hand Side Unless otherwise stated the left and right hand side of the unit are determined from looking at the front of the unit. Human Machine Interface (HMI) The generator uses a touch screen Human Machine Interface (HMI) to inform the user of the current status of the generator as well as provide the user with information and meaningful error messages. Buttons on the screen are defined by a rectangular outline. A light tap on the screen is all that is required to activate the button. Excessive force may damage the screen. Successfully pressing of a button will be indicated by a single beep sound. Pressing the screen outside of a button area will be indicated by a double beep sound. Pressure gauges The pressure gauges are for indication only. Calibration is not required. Page 14 2015 Peak Scientific - Rev. 6A 15/09/15
Rear connections Power cord 6mm Compression fitting 6mm Push-fit fitting Fittings Kit Supplied in the Fittings Kit are all the fittings required to connect the AB-3G generator to the appliance. The contents of the Fittings Kit are as follows: 1. 8mm Hex Key x 1 2. 6mm push fit fitting x 1 (Hi-Flow x 5) 3. ¼ compression fitting x 3 (Hi-Flow x 4) 4. 6mm PE tubing x 3m 5. ¼ Teflon tubing x 12m 6. C19 power cord (UK) x 1 7. C19 power cord (EU) x 1 8. C19 power cord (US) x 1 9. Flow control silencer x 3 (Hi-Flow only) All of the Generator output ports are located on the output panel at the rear of the Generator. Initial purge run Before the Generator is connected to the Mass Spectrometer the Generator should be operated in isolation (i.e. not connected to the Mass Spectrometer) for thirty minutes after the start up diagnostics have completed. This is to ensure any impurities present are purged from the system. Failure to do this may harm the Mass Spectrometer. Page 15 2015 Peak Scientific - Rev. 6A 15/09/15
Drain connection Fit the 6mm push fit fitting (item 2 from fittings kit) to the drain port located on the output panel (see Figure 5). Tighten using a 16mm or 5/8 spanner. Use the 6mm tubing (item 4 from fittings kit) to connect this to a suitable drain connection or container. It should be noted that the generator can expel a considerable amount of water from this (dependant on ambient humidity). If a container is used it should be emptied at regular intervals. The container must NOT have an air tight seal as water and air are expelled at pressure. Electrical Connection Connect the Generator to a 230 volt single-phase supply using the power cord provided. If the appropriate power cord is not supplied; a new plug, rated to at least 12 amps, can be fitted by a qualified electrician. This unit is classified as SAFETY CLASS 1. 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 or Black Neutral (N):- Blue or White Our electrical requirements are 230VAC nominal +/- 10%. This means that the Generator can accommodate transients between 207VAC and 253VAC. However, running continuously at voltages less than 220V is not recommended and extended periods at these extremes can have a detrimental effect on the operation and life of the Generator. To ensure that the correct voltage is being supplied to the Generator, the AB3G comes equipped with an inbuilt voltmeter. This is located at the bottom of the electrical panel as shown in Figure 3 below, and will measure and display the mains voltage that is being supplied to the Generator. Page 16 2015 Peak Scientific - Rev. 6A 15/09/15
Voltmeter Figure 2: Voltmeter Location The voltmeter should be checked prior to the initial purge of the system. To do this, with the doors remaining off and with the Generator still connected to the 230 volt single-phase supply, the unit should be powered ON using the power switch (identified by I ). Do not touch anything inside the Generator whilst the side panels are removed and the mains power is connected to the unit When the Generator is switched on, the input voltage will be displayed on the voltmeter. If this reading is 219V or less, then we would highly recommend fitting a transformer. This can be ordered directly from Peak Scientific with the order number being as below. Product Description Part Number Dual Tap Transformer 200V 230V 06-3200 Table 1: Additional Transformer On completing the voltage check, the Generator should be powered OFF using the switch on the front panel, the power cord removed from the rear of the generator and the door panels refitted. Ensure the Earth wires are reconnected to the side covers when refitting. Page 17 2015 Peak Scientific - Rev. 6A 15/09/15
Start up sequence Once connected to the mains supply the generator can now be switched on. Flick the power switch on the front panel (see Figure 4) of the generator to the on position (identified by I ). The first time the unit is switched on it will ask you to confirm that the transit brackets have been removed (see page 11). The unit will not start until the user has pressed the confirm button (Figure 6). This message will not appear on subsequent start ups. Figure 3: Transit bracket removal confirmation screen The unit will then start an installation diagnostics sequence. The diagnostics will take approximately twenty minutes to complete. A progress bar is shown to indicate the progress of the diagnostics sequence (Figure 7). It should be noted that the bar indicates tests completed and is not an indication of time. Figure 4: Diagnostics running screen During the diagnostics the user will be asked to confirm that the tubing connected to the drain outlet is secure and that if it is connected to a drain container that it is empty. The diagnostics will be paused until the user presses confirm. Figure 5: Drain test warning screen During diagnostics air is expelled through the drain outlet at pressure. Please ensure that the tubing is secure. If a drain bottle is used please ensure that it is empty before carrying out a diagnostics check as water may be sprayed from the container. The drain bottle should NOT have an air tight seal. Page 18 2015 Peak Scientific - Rev. 6A 15/09/15
It should be noted that the gas pressures and flows are factory set. The pressures shown on the Generator front panel are in excess of the maximum inlet pressure of the Mass Spectrometer. This is to allow for known pressure drops. These settings have been approved by AB Sciex. Once the tubing is connected to the Mass Spectrometer, please ensure that they are thoroughly checked for being leak-tight. Even the slightest leak in the gas supply between the Generator and the Mass Spectrometer can lead to a reduction in efficiency, or possible alarm of the Generator. The diagnostics sequence will only run on subsequent start ups if there was a problem detected before it was shut down. If no fault had previously been detected and the installation diagnostics has been completed, a start up screen will appear for 30 seconds to allow the user to initiate a diagnostics check. This is recommended if the unit has been turned off for a long period or the generator has been moved. Tubing lengths The diameter of the tubing which will be connected to the gas outlets are important and is determined by the length of tubing required. < 10 meters. Use 6/4 (6mm O/D, 4mm I/D) P.T.F.E. tubing. > 10-40 meters. Use 10/8 (10mm O/D, 8mm I/D). Tubing and fittings not supplied in the fittings kit. > 40 metres. Please contact Peak with the relevant distance and we will calculate the flow resistance and the tubing size required. A combination of 6/4 and 10/8 tubing may be used to ensure that there is no large diameter tubing within the lab (i.e. for the first 20 meters from the Generator use 10/8 and the final 10 meters to the Mass Spectrometer use 6/4 tubing). Keep the connections and bends to a minimum. The imperial equivalents are: 6/4 = 1/4 O/D, 3/16 I/D. 10/8 = 3/8 O/D, 5/16 I/D. Page 19 2015 Peak Scientific - Rev. 6A 15/09/15
Once diagnostics have completed the generator will take a couple of minutes to become ready for use. Figure 6: Diagnostics complete screen Once pressure is within the normal operating limits the buzzer will sound two short beeps to signify the generator is ready for use. A reminder to register the Generator with Peak Scientific will be displayed. Figure 7: Warranty registration reminder Once you have registered the generator pressing [Acknowledge] will prevent this message appearing again. Pressing [Remind me later] will display the message again in one and a half hours. You can register online at http://www.peakscientific.com/service-and-support/warranty-registration Figure 8: Main screen Before the Generator is connected to the Mass Spectrometer the Generator should be operated in isolation (i.e. not connected to the Mass Spectrometer) for thirty minutes after the start up diagnostics have completed. This is to ensure any impurities present are purged from the system. Failure to do this may harm the Mass Spectrometer. Connecting to the Mass Spectrometer Once the initial purge run of 30 minutes has completed the generator is now ready to be connected to the Mass Spectrometer. Attach the three 1/4 compression fittings supplied in the fitting kit to the Curtain, Source and Exhaust outlets on the output panel (see Figure 5) PTFE thread tape should be used. Using the Teflon tubing supplied connect each outlet of the generator to the corresponding inlet on the Mass Spectrometer. If you require more tubing than is supplied please refer to the Tubing Lengths section. Page 20 2015 Peak Scientific - Rev. 6A 15/09/15
It should be noted that the gas pressures and flows are factory set. The pressures shown on the Generator front panel are in excess of the maximum inlet pressure of the Mass Spectrometer. This is to allow for known pressure drops. These settings have been approved by AB Sciex. Once the tubing is connected to the Mass Spectrometer, please ensure that they are thoroughly checked for being leak-tight. Even the slightest leak in the gas supply between the Generator and the Mass Spectrometer can lead to a reduction in efficiency, or possible alarm of the Generator. The diagnostics sequence will only run on subsequent start ups if there was a problem detected before it was shut down. If no fault had previously been detected and the installation diagnostics has been completed, a start up screen will appear for 30 seconds to allow the user to initiate a diagnostics check. This is recommended if the unit has been turned off for a long period or the generator has been moved. Page 21 2015 Peak Scientific - Rev. 6A 15/09/15
IMPORTANT DOCUMENTS Warranty Entitlement To register your generator for your warranty entitlement, send the completed form to Peak Scientific by: Email warranty@peakscientific.com Online http://www.peakscientific.com/service-and-support/warranty_registration Phone Fax +44 (0)141 530 4185 +44 (0)141 812 8200 COMPANY: ADDRESS: PRODUCT WARRANTY REGISTRATION CONTACT NAME: EMAIL ADDRESS: CITY/TOWN: POSTCODE: COUNTRY: TELEPHONE: GENERATOR SERIAL NUMBER: MODEL TYPE: INSTALLATION DATE (DD/MM/YYYY): Important Please Note: You have 1 month to register your Peak Scientific product from the date of shipment. If you wish to defer installation of your generator you must notify Peak Scientific within 1 month of the shipment date. This can be done by emailing warranty@peakscientific.com Once registered the warranty will be honoured for a period of 12 months after the installation date. For any generators that remain unregistered the warranty will begin from date of shipment. Thank you on behalf of Peak Scientific. Page 22 2015 Peak Scientific - Rev. 6A 15/09/15
Operating modes The generator can operate in a number of modes depending on the gas demand from the Mass Spectrometer and the health of the generator. The operating mode is displayed on the main screen of the HMI (see Figure 13). The operating mode will change automatically, no user intervention is required. Operating Normal operation Figure 9: Operating mode Whilst the Mass Spectrometer is running a sample the Generator will be in Normal Operation mode. In this mode compressor one supplies compressed air to the Nitrogen system. The Dry Air system is supplied by compressors two and three alternately (i.e. only one compressor runs at a time and they change over on each pressure cycle) Standby mode The generator will detect when the Mass Spectrometer enters standby mode. Due to the reduced gas demand the Generator controls the compressors differently to help extend compressor life. It should be noted that even in standby the Mass Spectrometer still consumes a small amount of Nitrogen and Dry Air. This in turn reduces the receiver pressure within the Generator causing the compressors to start up. This is normal in Standby Mode. The operating mode on the main screen will change to Standby Mode. Figure 10: Standby mode screen Page 23 2015 Peak Scientific - Rev. 6A 15/09/15
High altitude mode High altitude mode allows the Generator to operate easier at high altitude. In this mode both air compressors run together during Normal Operation. Consult with your local Peak Representative before enabling this function. It should be noted that this will increase the duty on the compressors and reduce time between services. This mode should only be used where required. The main screen will now display High Altitude Mode instead of Normal Operation Page 24 2015 Peak Scientific - Rev. 6A 15/09/15
HMI User menus The AB-3G s advanced control system employs an easy to navigate menu system to give the user additional information about the Generator. The menu is accessed by pressing the [Menu] button on the main screen. User menu Event message Service Engineer Figure 11: User menu tree User Menu The user menu gives access to the following functions Run hours Displays: Unit on time The total time the unit has been turned on. The date the next annual service is due. Compressor run times The time that each compressor has actually been running. Temperatures The AB-3G monitors ambient (room) temperature and the temperature within the compressor cabinet inside the generator as part of the temperature alarm Page 25 2015 Peak Scientific - Rev. 6A 15/09/15
system. The information on this screen is a live reading of these two temperature inputs. The alarm set points can be accessed via this screen also. System status The status of each component within the Generator is displayed. This includes the three compressors and all of the solenoid valves used within the system. This can be used should a fault be detected to show which components have failed. Event logs The event logs record the date and time of all system events. These are split into two logs System Faults Temperature alarms System faults log the error code along with the date and time. Recent error codes should be noted and passed to your service provider if you are reporting a fault. The last twenty faults are logged. Temperature alarms will record every time a temperature warning or over temperature shutdown occurs. The last ten faults are logged. Set time/date The date and time, as displayed on the main screen, is set here. Setting the date and time ensures that any events a correctly logged. Comp hours reset When a compressor is serviced or replaced the run hours of the compressor need to be reset here. This screen is password protected. A password will be included in the instruction manual provided with your replacement compressor or compressor service kit. High Altitude Mode This allows High Altitude Mode to be enabled or disabled Page 26 2015 Peak Scientific - Rev. 6A 15/09/15
Event message This displays details of the current error if either of the fault icons are displayed on the main screen. Service Engineer This is a password protected area of the controls. A caution screen is displayed to allow the user to go back to the main menu. Access is only granted to qualified service personnel. Please contact Peak Scientific if you require training. Diagnostics The AB-3G has an advanced diagnostics feature that can check the function of every compressor and valve in the system. Diagnostics will start automatically when the generator is turned on for the first time or if a fault was detected prior to the generator being switched off. If no fault was previously detected then the user is given the option for thirty seconds after turning the unit to start a diagnostics check. Figure 12: Initial start up screen (shows for 30 seconds) The diagnostics run starts by venting the internal storage tanks for four minutes (this is bypassed on the initial diagnostics run). This progress is shown of the following screen. Figure 13: Tank venting progress Once the tanks have vented the diagnostics progress bar is shown. It should be noted that the progress bar indicates tests completed and not time. Figure 14: Diagnostics progress screen During the diagnostics the user will be asked to confirm that the tubing connected to the drain outlet is secure and that if it is connected to a drain Page 27 2015 Peak Scientific - Rev. 6A 15/09/15
container that it is empty. The diagnostics will be paused until the user presses confirm. Figure 15: Drain test warning screen During diagnostics air is expelled through the drain outlet at pressure. Please ensure that the tubing is secure. If a drain bottle is used please ensure that it is empty before carrying out a diagnostics check as water may be sprayed from the container. Once diagnostics has completed the generator will take a couple of minutes to become ready for use. Figure 16: Diagnostics complete screen Once pressure has built within the unit the buzzer will sound two short beeps and the screen will change to the main screen The Generator is now ready for use. Figure 17: Main screen Page 28 2015 Peak Scientific - Rev. 6A 15/09/15
Service requirements Service schedule Your AB-3G generator requires a service annually. The generator will indicate when a service is due (12 months after the initial installation date). A service kit is available from your service representative which includes all the consumables required to maintain your generator. The kit also offers a 10% discount over purchasing the components individually. Service Interval Component Part No. Qty. AB-3GGenerator Annual Service Kit 12 months Kit includes: 3 x First stage filter element 3 x Second stage filter element 1 x Inlet filter element 2 x RAC filter element 08-4726 1 3750 hours Compressor assembly 08-8141 3 Alternative to compressor assembly * Compressor re-fit kit 06-5529 3 Table 2: Service schedule * Compressors can be re-fitted as an alternative to replacement up to a maximum of 3 times. This is a more cost effective solution, although a degree of technical expertise is required and can be time consuming. Please contact your service provider for more information. Service indication Annual service The AB-3G will remind the user twelve months after installation that the annual service is due. Figure 18: Annual service reminder screen Once the users acknowledges this message the due date for the next service is moved forward a year. Compressor service To minimise the risk of unplanned compressor downtime Peak Scientific recommends that the compressors are serviced every three thousand run hours. Once a compressor reaches three thousand run hours the alarm will sound and the HMI screen will display the following screen. Page 29 2015 Peak Scientific - Rev. 6A 15/09/15
Figure 19: Compressor service due alarm screen Once the user has acknowledged the message the alarm will stop and the service icon will be displayed on the main screen. Figure 20: Service icon displayed on main screen Once an hour the Generator will sound the buzzer for three seconds and flash the service icon for 30 seconds to serve as a reminder. It is highly recommended that the compressor is serviced or replaced after 3750 run hours to prevent any unplanned downtime. Please contact your service provider for more information Should the compressor reach four thousand hours the compressor service overdue message is displayed and the alarm is escalated to two seconds on and five seconds off. Figure 21: Compressor service overdue alarm screen Once acknowledged the alarm will continue to sound and the service icon will flash constantly. After 4000 hours it is highly likely that the compressor will fail in the near future. Please contact your service provider as soon as possible to arrange a service or replacement of your compressor. Run hour reset Once a compressor has been serviced or replaced it is important that this is properly logged through the compressor run hour reset function in the user menu. Access to this menu is password protected. The password will be issued to the user upon purchasing the service items. Service plans Peak Scientific offer two service plans. The Complete Service Plan, specifically designed for generators operated in critical environments, also includes full Page 30 2015 Peak Scientific - Rev. 6A 15/09/15
breakdown cover, guaranteed response times and generator upgrades if available. Our Standard Service Plan, covering the basic needs of our generators, features special deals on spare parts and breakdowns. If you want to know more about our Service Plan options and how we ensure that your instrument can run uninterrupted with maximum uptime and performance, please contact us at maintenance@peakscientific.com Cleaning Clean the outside of the generator only using warm soapy water and a clean damp cloth. Ensure the cloth is thoroughly rung out to remove excess fluid prior to use. Cleaning should only be undertaken with the power switched off and the power cord removed from the rear of the Generator. Under no circumstances should any solvents or abrasive cleaning solutions be used as these can contain fumes that could be harmful to the generator. Page 31 2015 Peak Scientific - Rev. 6A 15/09/15
Fault warnings Minor fault A minor fault will be flagged after diagnostics. This indicates that one of the valves used during diagnostics has failed. These are set to fail in their normal operating state therefore the system can function as normal. You should contact your service provider to rectify the problem at your convenience. Figure 22: Main screen showing minor fault icon Redundancy mode The Generator has a fail safe mode should any one compressor fail. Should a compressor be found to be faulty the program takes this compressor out of operation and another compressor takes over. The generator will supply full output pressure and flow without interruption ensuring that the sample being analysed is not lost. If compressor one fails then compressor two switches to supplying the Nitrogen system and compressor three supplies the air system. If compressor two or three fails it is taken out of operation and the air system is supplied by the other compressor. When the Generator detects a fault that forces it into Redundancy Mode an error message will be displayed on the HMI and an intermittent alarm will sound (see Figure 16). There are three buttons on this screen. [More] will display further details of the fault. [Mute] will mute the alarm but keep the alarm screen active. [Acknowledge] will mute the alarm and return the HMI to the main screen. The main screen will now display the redundancy mode icon and the operation mode will have changed to Redundancy Mode. It is worth noting the error code in the top right hand corner of the alarm screen although this code can also be recalled through the event logs. Figure 23: Redundancy mode alarm screens Page 32 2015 Peak Scientific - Rev. 6A 15/09/15
System failure System failure shuts down the generator if it detects that it is no longer able to supply all three output gases. This may be caused by multiple compressor failures or a combination of failures detected during diagnostics. An alarm screen will be displayed on the HMI (see Figure 17) coupled with a constant alarm. There are three buttons on this screen: [More] will display additional information and the error code for the fault. This should be noted and passed to your service provider (the error code is also displayed in the top right hand corner of the error screen). The [Mute] button will mute the alarm but keep the alarm screen active. The [Menu] button opens the menu screen to allow further information on the fault to be found through the user menu. Exiting the menu will take you to the main screen which will now show System Failure as the operating mode and display both the Minor Fault and Redundancy Mode icons. Page 33 2015 Peak Scientific - Rev. 6A 15/09/15
Temperature alarms The AB-3G monitors ambient temperature to ensure that it is not being operated over the specified maximum temperature (30 C). The temperature within the internal compressor cabinet is also monitored to ensure that they are properly cooled. If the Generator is operated above the maximum temperatures then damage can be caused to the internal compressors and the membrane separators. Warning limit Shutdown limit Ambient 33 C 36 C Compressor Cabinet Ambient temp + 20 C Ambient temp + 25 C Table 3: Temperature alarm settings The alarm works in two stages, the first stage is a warning that the Generator is operating out with the temperature specification, the generator will continue to operate during a warning. The second stage alarm will shut down the generator until normal conditions have resumed. The following error message will display upon a temperature warning. Figure 24: Over temperature warning screens The [More] button will detail whether or not it is the ambient or compressor cabinet temperature that is too high. If the ambient temperature is too high please ensure that the Generator is in a suitable environment and that there is ample ventilation space around the generator. If the compressor cabinet temperature is too high please ensure that there is nothing being stored below the generator and that the exhaust fans at the rear of the generator are not covered. Should the problem persist please contact your service provider. The following message will be displayed to ensure the user is aware that the maximum operating conditions where exceeded. Figure 25: Over temperature occurred screen Page 34 2015 Peak Scientific - Rev. 6A 15/09/15
Run time alarm The AB-3G monitors the length of time that the compressors have been running. If everything is working properly the compressors should cycle regularly. If a compressor has not cycled but is still maintaining pressure the Generator will continue to operate. A run time alarm will generally mean there is a problem with the system which may lead to system failure. Your service provider should be contacted immediately. The run time alarm operates in three stages: Stage 1 If either compressor has been running for eight hours continuously the following screens will be displayed Figure 26: Run time stage 1 alarm screens Stage 2 If the compressor has still not cycled within twelve hours a stage two alarm is sounded as a reminder. A similar alarm screen is displayed as above. Your service provider should be contacted immediately. Stage 3 If the compressor has still not cycled after 72 hours then the generator enters a stage 3 alarm. The alarm can now only be silenced by a qualified Service Engineer. The Generator will continue to operate as long as it can maintain pressure. Page 35 2015 Peak Scientific - Rev. 6A 15/09/15
Figure 27: Run time stage 3 alarm screens IT SHOULD BE NOTED THAT THE GENERATOR WILL CONTINUE TO OPERATE SO LONG AS IT CAN MAINTAIN PRESSURE DURING THESE ALARMS. Page 36 2015 Peak Scientific - Rev. 6A 15/09/15
Trouble shooting Problem The Generator will not switch on and the power switch does not illuminate. Possible solution Ensure power cord is plugged into the generator and that the power socket is turned on. Check the fuse in the power cord plug. Contact your service provider. The Generator will not switch on but the power switch is illuminated. Disconnect power cord from the rear of the generator. Open the right hand panel are check that both circuit breakers are turned on (switch in the up position). Reconnect power cord. Contact your service provider. Compressors are running but pressure is not building. The HMI screen says Standby Mode but the compressors are still running. The mass spec is reporting low pressure. Check the HMI screen to ensure that diagnostics are not running. The pressure gauges on the front panel will read zero for the majority of the diagnostics run. Run diagnostics. Contact your service provider This is normal. When the Mass Spectrometer is in standby it still requires a gas supply, the Generator changes its operation to best cope with this reduced demand. Check pressure gauges are showing normal pressure. Contact your service provider Page 37 2015 Peak Scientific - Rev. 6A 15/09/15
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