Genius 3045: User Manual
Genius 3045: User Manual
User Manual
Page 2
Change History
Rev Comment Name Date
Page 3
Introduction
The Genius 3045 have been developed to provide a supply of nitrogen gas and dry air.
We have built the Genius 3045 with internal compressors to remove the reliance upon
in-house air supplies.
• Economical – More cost effective than any other gas supply method
To ensure the Generator meets our high expectations with regards to reliability and
performance, we have tested it extensively at our manufacturing plant and with end
users around the world to ensure reliability and longevity of the system.
Page 4
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 5
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
specifically 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.
Caution, risk of electric shock. Ensure power to the generator has been removed
before proceeding.
Page 6
Declaration of Conformity
Page 7
Environmental Declaration
Peak Scientific Instruments Ltd fully complies with its obligations towards the European
WEEE (Waste of Electrical and Electronic Equipment) Directive 2012/19/EU. 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
recast RoHS (Restriction of Hazardous Substances) Directive 2011/65/EU. Similar
directives in the United States and China, for example, have also been captured within
this program.
Page 8
Technical Specification
Genius 3045
Environment
Generator Outlets
Electrical Requirements
General
Page 9
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’ and ‘TIP-N-TELL’ labels for signs of rough handling prior to
unpacking
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 to
the desired location.
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 & US and also all the required fittings and warranty registration card. Be careful
not to discard these with the packaging.
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Fittings Kit Contents
Supplied in the Fittings Kit are all the fittings required to connect the generator to the
application. The contents of the Fittings Kit are as follows:
2. ¼” Teflon Tubing x 6m
3. 6mm PE Tubing x 3m
4. ¼” Compression Fitting x 3
All of the generators output ports are located on the output panel at the rear of the
unit.
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Installation
Generator Environment
The generator is designed for indoor use only. It should be installed adjacent to
the application(s) 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.
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Generator Overview
General Dimensions
1322 mm / 52"
The generator must always be placed on a flat, level surface. Failure to
do so will affect the performance of the generator.
WARNING
Page 13
Gas Outlets
Drain Outlet
Power Inlet
Page 14
Electrical Connection
Connect the generator to an appropriate 110 or 230 volt single-phase supply, refer to
the generator serial plate for input specification and ensure your supply matches the
requirements.
If the appropriate power cord is not supplied; a new plug, rated to at least 12 amps, can
be fitted by a qualified electrician.
Electrical requirements for 230V generators is 195V - 253V 50/60Hz. For 195V - 219V a
06-3210 Dual Tap Transformer is required.
Page 15
Start-Up Sequence
Before the Generator is connected to the application, the Generator
should be operated in isolation (i.e. not connected to the application)
for thirty minutes. This is to ensure any impurities present are purged
CAUTION from the system. Failure to do this may harm the application.
Before re-connecting the Generator to the mains and switching it on for the isolation
run, it is necessary to fit the silencers (supplied in the fittings kit) to the outlet ports of
the output panel as shown below.
02-1096
Once this is done, the Generator can be re-connected to the mains and switched on.
Pressure will start to build in the internal storage tanks which can be monitored by
watching the output pressure gauges on the front panel. This will climb to the factory
set pressure as noted in the specifications.
Once this pressure is reached, the compressors will continue to run until the internal
tank upper pressure limit is reached and the compressor has run for a period of at least
two and a half minutes.
The compressors will then rest until the internal tank lower pressure limits is reached.
Once this limit is reached the compressors will switch back on again. This compressor
cycling is normal and will continue throughout the operation of the Generator.
When the system has been operated for a period of 30 minutes, all the internal pipe-
work and storage tanks will have been purged with nitrogen/dry air.
Once purged, and the tubes can be connected at the rear of the unit. The generator
should be allowed to run for 1 hour to allow the gas to reach purity.
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Normal Operation
The Genius 3045 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 will produce nitrogen on demand. If the application is operating
and requires a gas flow, the system it is connected to will supply this to suit the
requirements of the application. If the application requirement for gas stops, the system
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 system will detect the demand for gas
and will automatically start again to suit the demand.
Generator Cycling
The Generator is designed for the internal compressors to cycle. This cycling reduces
the duty (run time) on the compressors. The rate at which they cycle will be dependent
on the gas required to satisfy the demand of the application. If the application demands
the maximum gas flow of the Generator, the compressor duty will be higher, (the rest
period in the compressor cycle will be shorter). If the application demand is lower than
the maximum gas flow, then the duty on the compressors will decrease, (the rest period
in the compressor cycle will be longer). If the Generator is installed in an extreme
environment or is subjected to low supply voltage or high altitude the compressors may
undergo periods where they do not cycle.
Unusual Operation
If at any time the generator begins to emit excessive noise or vibration, then it should
be switched off and you should contact Peak Scientific or the Peak Partner from which
the generator has been purchased.
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Connecting to the application
Once the initial purge run of 30 minutes has completed, and the generator has been
running for 1 hour, it is ready to be connected to the application(s).
Attach the appropriate fittings to the outlets of the generator. Using the tubing
supplied, connect the outlets of the generator to the inlets on the application.
If you require more tubing than is supplied please refer to the Tubing Lengths section.
Tubing Lengths
The diameter of the tubing which will be connected to the gas outlet is
important and is determined by the length of tubing required. Failure
to follow these recommendations could lead to pressure between
CAUTION generator and application.
< 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 Scientific with the relevant distance andwe
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 application use 6/4 tubing). Keep the connections and
bends to a minimum.
Page 18
Service Requirements
Service Schedule
Purchase Interval Component Part No. Qty.
Alternative to
compressor Compressor re-fit kit 06-8320 4
asssembly*
* Compressors can be re-fitted as an alternative to replacement up to a maximum
of 3 times, this is a more cost effective solution, however a degree of technical expertise
is required and can be time consuming. Please contact your service provider for more
information.
As an alternative to purchasing the 12 month service items individually an Annual
Service Kit is available as one part number. This contains all the filters required for this
Generator and offers a costs saving over buying the components separately.
Purchase Interval Component Part No. Qty.
Service Indication
The generator will notify the user of the service interval for the internal compressors.
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.
Page 19
Service Indication Reset
Once the service has been completed the Service Indication LED can be reset in the
main control PLC. This will be performed by the Peak Service Engineer or trained
service representative that completes the service operation.
There are a number of extreme conditions that can affect the duty cycling of the
compressors inside the generator. These extremes include very high ambient
temperatures, low supply voltages, a very high flow requirement and locations of high
altitude. Any one of these or a combination of a number of these extremes can be
evident in a customer site.
Indication of Fault
In most installations the ‘HIGH DUTY’ indicator will never be illuminated. If your Genius
3045 Generator has been operating for a significant period of time, then suddenly
develops a ‘HIGH DUTY’ indication with no apparent change in environmental
conditions or flow requirements, it may be indicative of a problem with the system such
as an external leak or imminent compressor failure.
If this is the case you should contact Peak Scientific or your service provider.
It should be noted that the Generator will continue to operate so long as it can maintain
pressure during this indication.
Page 20
Peak Protected
With Peak Scientific you invest in not only a product but peace of mind. With a network of
certified Peak engineers stationed throughout the globe, Peak’s rapid response team are
never far away and our commitment is to keep your generator running day in, day out,
protecting your laboratory workflow.
Page 21
Cleaning
Clean the outside of the generator only using warm soapy water and a clean damp
cloth. Ensure all excess fluid is thoroughly removed from the cloth prior to use.
Cleaning should only be undertaken with the power switched off and
the power cord removed from the rear of the generator.
Page 22
Troubleshooting
Problem Possible Solution
• Ensure power cord is plugged into the
Generator and that the power socket is
turned on.
The Generator will not switch on and the • Check the fuse in the power cord plug.
power switch does not illuminate.
• Contact your service provider.
The mass spec is reporting low pressure. • Contact your service provider.
Page 23
Go Online or Complete and Return
We know that registering any of your recently purchased products is not the
first thing on your mind- but it is very important to both of us. Not all warranties
are alike and Peak Scientific stand out against other gas suppliers as we offer a
comprehensive, quick response, on-site warranty. This means that in the very
unlikely case that your gas generator develops a fault we have rapid support
teams on-hand around the world who are able to come to your lab and get you
back up and running in no time.
Register for your comprehensive 12 month on-site warranty with ease online at
www.peakscientific.com/protected.
Alternatively, you can send the completed form to Peak Scientific by post or
email at [email protected].
Alternatively, you can send the completed form to Peak Scientific by post or
email at [email protected].
Contact name
Email address
Company
Address
City/town
Postcode
Country
Telephone
Generator serial #
Model type
Installation date
Product Warranty Registration
Do you still use an
alternative gas solution i.e. Yes No
cylinders or bulk liquid?
Extend your cover with
Peak Scientific offer comprehensive gas generator after sales support packages.
Peak [Protected] aftercare support can guarantee an on-site response within
72 hours*, genuine parts from our ISO9001 approved factory and a 95% first-time
fix rate. See our enclosed Peak [Protected] leaflet for further information.
Important!
You have 1 month to register your Peak Scientific product from the date of installation. Once registered
the warranty will be honoured for a period of 12 months. If you wish to defer the installation of your
generator, you must notify Peak Scientific immediately by emailing [email protected].
For generators that remain unregistered after 1 month from the shipment date, the warranty will be
considered active from the date of factory dispatch.
Important!
You have 1 month to register your Peak Scientific product from the date of
installation. Once registered the warranty will be honoured for a period of 12
months. If you wish to defer the installation of your generator, you must notify
Peak Scientific immediately by emailing [email protected]. For
generators that remain unregistered after 1 month from the shipment date, the
warranty will be considered active from the date of factory dispatch.
Page 24
Peak Scientific has highly trained, fully certified Field Service Engineers located in over 20 countries
across every continent around the world. This allows us to provide an industry-leading rapid response
service to our customers. With [Peak Protected], your laboratory’s productivity becomes our top
priority.
To discuss Peak Protected generator cover and payment options speak to your local Peak
Representative or for further information contact: [email protected]
Peak Scientific
Fountain Crescent
Inchinnan Business Park
Inchinnan
PA4 9RE
Scotland, UK
Tel: +44 141 812 8100
Fax: +44 141 812 8200
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