Parker NitroFlow HP User manual

K3.1.141e Manual NitroFlow HP_EN.doc - 1 -

USER MANUAL

NitroFlow

®

HP

NITROGEN GENERATOR

Parker Filtration & Separation B.V.

PO Box 258

4870 AG - Etten-Leur

The Netherlands

Tel: +31 (0)76-508 53 00

Fax: +31 (0)76-508 53 33

E-mail: [email protected]

www.parker.com/pfs

K3.1.141e Manual NitroFlow HP_EN.doc - 2 -

No part of this publication may be reproduced and/or publicized by being printed,

photocopied, placed on microfilm or in any other manner without the prior written

permission of Parker Filtration & Separation B.V.

Parker Filtration & Separation B.V. retains the right to make changes in parts at any

point without first or directly notifying the customer. The contents of this manual can

also be changed without prior warning.

This manual is valid for the NitroFlow® HP in its standard version. Parker Filtration &

Separation B.V. can therefore not be held liable for specifications of the delivered

system that may deviate from the standard version.

For information concerning adjustments, maintenance or repairs not contained in

this manual, please contact Parker Filtration & Separation B.V.

This manual has been prepared with all possible care, but Parker Filtration &

Separation B.V. cannot accept responsibility for possible errors in this document or

for the consequences thereof.

K3.1.141e Manual NitroFlow HP_EN.doc - 3 -

USER MANUAL..........................................................................................................1

1 INTRODUCTION ...................................................................................................5

1.1 G

ENERAL...........................................................................................................5

1.2 P

ICTOGRAMS ..................................................................................................... 6

1.3 I

DENTIFICATION AND SERVICE .............................................................................7

1.4 C

ERTIFICATES....................................................................................................7

1.5 U

SE IN ACCORDANCE WITH PURPOSE ..................................................................8

1.6 U

SER INSTRUCTIONS ..........................................................................................8

1.7 L

IABILITY............................................................................................................ 8

2 HEALTH, SAFETY AND ENVIRONMENTAL ASPECTS..................................... 9

2.1 G

ENERAL...........................................................................................................9

2.2 N

ITROGEN AND OXYGEN .....................................................................................9

2.3 E

LECTRICITY.................................................................................................... 10

2.4 S

AFETY PRECAUTIONS......................................................................................10

2.5 E

NVIRONMENTAL ASPECTS ...............................................................................11

3 DESCRIPTION OF THE APPLIANCE ................................................................12

3.1 G

ENERAL.........................................................................................................12

3.2 S

EPARATION PRINCIPLE....................................................................................12

3.3 P

ARTS NITROFLOW

®

HP ..................................................................................13

3.4 P

ROCESS DIAGRAM ..........................................................................................14

3.5 P

ROCESS SCHEME ...........................................................................................15

4 TECHNICAL SPECIFICATIONS.........................................................................16

4.1 G

ENERAL.........................................................................................................16

4.2 P

RODUCTION CAPACITY.................................................................................... 19

4.2.1 A

IR CONSUMPTION.........................................................................................20

4.3 M

AINTENANCE KIT ............................................................................................20

4.4 E

XPANSION KIT (OPTION) ..................................................................................20

5 INSTALLATION ..................................................................................................21

5.1 T

RANSPORT AND STORAGE............................................................................... 21

5.2 D

EFINE LOCATION ............................................................................................21

5.3 C

OMPRESSED AIR SUPPLY ................................................................................22

5.3.1 Ambient temperature of NitroFlow

®

HP ....................................................22

5.3.2 Checklist for compressed air supply.........................................................22

5.4 U

NPACK AND CHECK EQUIPMENT ......................................................................23

5.5 C

ONNECTING TO PRESSURIZED AIR SUPPLY.......................................................23

5.6 C

ONNECTING TO MAINS ELECTRICITY ................................................................23

5.7 C

ONNECT NITROGEN CONSUMER ......................................................................25

5.8 C

ONNECT INPUT AND OUTPUT CONTACTS ..........................................................26

6 CONTROLLER.................................................................................................... 28

6.1 M

ENU STRUCTURE ...........................................................................................28

6.2 C

ONFIGURE SOFTWARE PARAMETERS ...............................................................28

K3.1.141e Manual NitroFlow HP_EN.doc - 4 -

6.2.1 Main screen .............................................................................................. 28

6.2.2 Settings menu

......................................................................................30

6.2.3 Log-on menu

.......................................................................................31

6.2.4 Alarm menu

..........................................................................................32

6.2.5 Pressure switch menu

..........................................................................35

6.2.6 Options menu

.......................................................................................36

6.2.7 Local settings menu

.............................................................................37

6.2.8 Maintenance menu

...............................................................................38

6.2.9 Data logging menu

...............................................................................41

6.3 S

OFTWARE UPDATES........................................................................................42

7 COMMISSIONING AND OPERATION ...............................................................43

7.1 C

OMMISSIONING THE NITROFLOW

®

HP .............................................................43

7.2 S

TART NITROFLOW

®

HP ..................................................................................43

7.3 S

TOP NITROFLOW

®

HP .................................................................................... 43

7.3.1 Alarm messages.......................................................................................44

8 TROUBLESHOOTING ........................................................................................45

8.1 T

ROUBLESHOOTING LIST...................................................................................45

9 MAINTENANCE ..................................................................................................47

9.1 M

AINTENANCE SCHEME ....................................................................................47

9.2 R

EPLACE INLET FILTER ELEMENT....................................................................... 48

9.3 R

EPLACE AUTOMATIC DRAINS OF FILTERS..........................................................49

9.4 R

EPLACE OXYGEN SENSOR...............................................................................49

9.5 C

ALIBRATE OXYGEN SENSOR ............................................................................50

9.6 R

EPLACE FUSE.................................................................................................51

10 ELECTRICAL SCHEME AND TERMINAL CONNECTIONS........................... 52

11 INDEX ...............................................................................................................54

12 APPENDIX A: NITROVIEW QUICK REFERENCE V1.0 ................................. 55

13 APPENDIX B: FIRMWARE UPGRADE INSTRUCTIONS V2.03 NITROFLOW

®

SERIES .....................................................................................................................58

K3.1.141e Manual NitroFlow HP_EN.doc - 5 -

1 Introduction

1.1 General

NitroFlow

®

HP is a product of Parker Filtration & Separation B.V. This manual forms

an integral part of the product. The manual describes the installation, daily operation,

maintenance and troubleshooting.

Content

Read the manual carefully before the installation and operation of the NitroFlow

®

HP.

These instructions must be thoroughly understood before installing and operating

this product. Failure to operate this product in accordance with the instructions set

forth in this manual and by other safety governing bodies will void the safety

certification of this product. If you have any questions or concerns, please call your

local representative or the technical services department:

Europe +(44) 1622 7233 00, USA +(1) 800 343 4048

Condition of change

No changes may be made to the NitroFlow

®

HP as supplied, without the explicit prior

written permission of Parker. Non-conformance to this rule, as well as any

consequential damage, loss and costs are the responsibility of the owner and the

user.

Information

All information in this manual, including additional drawings and technical

descriptions, remains the property of Parker and must not be used (otherwise than

for the use of this product), copied or published to or for a third party without the

explicit prior written permission of Parker Filtration & Separation B.V.

K3.1.141e Manual NitroFlow HP_EN.doc - 6 -

1.2 Pictograms

In this manual and on the product the following pictograms are used:

Warning

A warning shows a hazard that can cause death or serious injury.

Follow the instructions.

Caution

A caution shows a danger that can cause damage to the equipment.

Follow the instructions.

Electricity

High voltage: danger of electric shock.

Warning

Risk for death due to suffocation.

Risk of fire

Oxygen-enriched air leads to an increased risk of fire in the event of

contact with inflammable products.

High-pressure risk

Follow the instructions with respect to compressed gasses.

Environment

Instructions with respect to the environment.

K3.1.141e Manual NitroFlow HP_EN.doc - 7 -

1.3 Identification and service

The identification plate is located on the back of the

NitroFlow

®

HP. The identification plate shows the

characteristics of the NitroFlow

®

HP.

For service and technical assistance, please contact

our local representative or:

PARKER FILTRATION & SEPARATION

Hermitage Court, Hermitage Lane,

Maidstone, Kent ME16 9NT

England

Tel: (+44) 1622 7233 00

Fax: (+44) 1622 7287 03

1.4 Certificates

The NitroFlow

®

HP meets with the following requirements:

Subject Applicable standard

Directive for electromagnetic

compatibility (EMC)

EN 61326 (1997) + A1 (1998) + A2

(2001) + A3 (2003)

EN 61000-3-2 (2000)

EN 61000-3-3 (1995) + A1(2001)

Low Voltage Directive NEN-IEC 60204-1(1997)

Pressure equipment directive (PED) Sound engineering practice

Quality assurance ISO 9001:2000

Environmental care ISO 14001:2004

Fig. 1-1: Identification plate

K3.1.141e Manual NitroFlow HP_EN.doc - 8 -

1.5 Use in accordance with purpose

The NitroFlow

®

HP is intended to make nitrogen out of normal ambient air. The

system is based on gas separation membranes. Each different or further use will not

be in conformity with the purpose. Parker Filtration & Separation B.V. will not accept

any liability for improper use.

The NitroFlow

®

HP is in compliance with the prevailing directives and standards.

Only use this NitroFlow

®

HP in a technically perfect condition, in conformity with the

purpose as described above.

1.6 User instructions

Only well-trained personnel are allowed to work on the NitroFlow

®

HP. The user

must be aware of hazards related to operating the NitroFlow

®

HP and processes

connected to the NitroFlow

®

HP. The user is responsible for the safety of the

personnel. All personnel working on the NitroFlow

®

HP must have free access to the

applicable manuals.

1.7 Liability

Parker Filtration & Separation B.V. will not accept any liability in case:

• The instructions in this manual are ignored.

• Replacement parts are used which are not approved by the manufacturer.

• The NitroFlow

®

HP is operated incorrectly.

• The system is fed with other gasses than air.

• The NitroFlow

®

HP is modified without notification and authorization of the

manufacturer.

• Maintenance and repair are not carried out according to the instructions.

K3.1.141e Manual NitroFlow HP_EN.doc - 9 -

2 Health, safety and environmental aspects

2.1 General

Correct use of the NitroFlow

®

HP nitrogen generator is important for your personal

safety and for trouble-free functioning of the NitroFlow

®

HP. Incorrect use can cause

damage to the NitroFlow

®

HP or can lead to incorrect gas supply.

Warning

• Read this manual before you start the installation and commisioning

of the NitroFlow

®

HP. Prevent accidents and damage to the

NitroFlow

®

HP.

• Contact your supplier if you detect a problem that you cannot solve

with this manual.

• Use the NitroFlow

®

HP in accordance with its purpose. Refer to §1.5.

• Only service-engineers, qualified to work on electric and pneumatic

equipment, are allowed to do the installation, maintenance and

repairs. Unqualified people are not allowed to repair the equipment.

Refer to §1.6.

• Lift the NitroFlow

®

HP with a forklift. Follow the legislation and

instructions for operating the forklift.

• Do not tamper or experiment with the equipment. Do not exceed the

technical specifications for the NitroFlow

®

HP. Refer to chapter 4.

2.2 Nitrogen and oxygen

The NitroFlow

®

HP generates nitrogen as a product. Oxygen enriched air is released

as waste.

Warning

• Nitrogen can cause suffocation!

• Oxygen-enriched air leads to increased risk of fire in the event of

contact with inflammable products. Make sure that there is

adequate ventilation at all times! Refer to fig. 2-1 for indicative

graphic.

20

22

24

26

28

30

32

95 96 97 98 99 99,5

Product N2 % (retentate)

Waste O2 % (permeate)

Fig. 2-1

K3.1.141e Manual NitroFlow HP_EN.doc - 10 -

• The NitroFlow

®

HP is not designed for installation in an Ex-

classified area.

• Do not install the NitroFlow

®

HP in an area where explosive

mixtures may occur.

2.3 Electricity

Warning

• Only service-engineers, qualified to work on electric equipment,

are allowed to do the installation, maintenance and repairs.

• Disconnect the main power supply before you do maintenance or

repair.

• If a service-engineer has to work on the NitroFlow

®

HP while the

electric power is connected, the service-engineer must be very

careful with respect to the electrical hazards.

2.4 Safety precautions

Warning

• Make sure that the ventilation rate is sufficient in the room where

the enriched oxygen is ventilated, or vent the enriched air outside.

• Only feed the NitroFlow

®

HP with air.

• Keep the air feed to the NitroFlow

®

HP clean and free of organic

solvent vapors and other contaminants. Do not place the

NitroFlow

®

HP in a room where organic solvent vapors may occur

in the air.

• Keep the ambient temperature for the NitroFlow

®

HP range

between 10°C and 40°C (50°F and 104°F).

• Adjust the NitroFlow

®

HP to the appropriate nitrogen

concentration for your application.

• Install the peripheral equipment, piping and nitrogen storage

vessels according to standard procedures. Parker Filtration &

Separation B.V. cannot take responsibility for this.

• Do regular maintenance to the NitroFlow

®

HP, to ensure proper

and safe operation. Refer to chapter 9.

• Make sure that instructions concerning health and safety are

compliant with the local legislation and regulations.

K3.1.141e Manual NitroFlow HP_EN.doc - 11 -

2.5 Environmental aspects

The use and maintenance of the NitroFlow

®

HP does not include environmental

dangers. Most parts are made of metal and can be disposed in the regular way. The

packaging of the NitroFlow

®

HP is 100% recyclable. Optimal installation according to

instructions and according to good craftsmanship will result in minimal energy

consumption and maximal life of your system.

According to EC-regulations electrical systems have to be disassembled and

recycled at the end of their life. Parker Filtration & Separation B.V. can support you

in this.

Make sure that instructions concerning health, safety and

environment are compliant with the local legislation and regulations.

K3.1.141e Manual NitroFlow HP_EN.doc - 12 -

3 Description of the appliance

3.1 General

The NitroFlow

®

HP separates compressed air into nitrogen and an oxygen enriched

air stream. The separation system uses membranes. The compressed air is supplied

from a central system or from a dedicated compressor.

The nitrogen produced can be connected directly to the application or can be stored

in a nitrogen storage vessel. The NitroFlow

®

HP then switches on and off, depending

on the nitrogen demand. The NitroFlow

®

HP has a residual oxygen analyzer. This

analyzer continuously monitors the quality of the produced nitrogen.

3.2 Separation principle

A

F

S

H2O - H2

O2

N2

B

C

Fig. 3-1: Separation principle

A Pressurized air inlet

B Hollow fibre membrane

C Nitrogen outlet

F Fast permeation

S Slow permeation

Ambient air contains nitrogen (78.1%), oxygen (20.9%), argon (1%), carbon dioxide,

water vapor and traces of other inert gasses. Pressurized air (A) is led through

hollow fibre membranes (B). The various air components diffuse through the porous

wall of the membranes.

The diffusion rate differs for the various gasses:

• Oxygen and water vapour have a high diffusion rate and diffuse rapidly through

the membrane wall.

• Nitrogen has a low diffusion rate and diffuses slowly through the membrane

wall. Nitrogen enriched air is released at the outlet of the membranes (C).

Pressurized nitrogen enriched air is released at the outlet of the membranes (E).

This air can be lead to a nitrogen storage vessel.

K3.1.141e Manual NitroFlow HP_EN.doc - 13 -

3.3 Parts NitroFlow

®

HP

Fig. 3-2: Parts of NitroFlow

®

HP

A Oxygen sensor

B Hollow fiber membrane

C Compressed air filters

D SD-card

E Printed circuit board

F Active carbon adsorber

G Flow control valve for purity adjustment

H Flow control valve for sample flow

I In- and outlet connections

J Drain outlet

K Power inlet

L Display

B

A

D

E

F

G

H

I

C

J

K

L

K3.1.141e Manual NitroFlow HP_EN.doc - 14 -

3.4 Process diagram

The NitroFlow

®

HP can either be connected directly to the nitrogen consumer or to a

nitrogen reservoir. The latter is advised in case of discontinuous or variable peak

demands.

Fig. 3-3 Installation lay-out

NitroFlow

Consumer

NitroFlow

Nitrogen

reservoir

Pressurized

air in

Nitrogen out

K3.1.141e Manual NitroFlow HP_EN.doc - 15 -

3.5 Process scheme

Y1 Solenoid valve

PI1,2 Pressure indicator

F01 Coarse filter

F02 Fine filter

C1 Carbon adsorber

F03 Dust filter

QIA

h Oxygen analyser

FCV1 Flow control valve for purity adjustment

FCV3 Flow control valve for sample flow

* Only in NitroFlow

®

HP2 and NitroFlow

®

HP3

** Only in NitroFlow

®

HP3

*

**

K3.1.141e Manual NitroFlow HP_EN.doc - 16 -

4 Technical specifications

4.1 General

Delivery pressure

Max. delivery pressure (vessel) inlet pressure minus pressure drop (max. 2

bar(g) / 29 psig)

Ambient conditions

Temperature 10°C to 40°C / 50°F to 104°F

Air quality Normal clean ambient air, relative humidity <

90%

Pressurized air specifications

Max feed pressure 13 bar(g) / 190 psig

Compressed air temperature range 10-50°C / 50-120°F

Pressure dew point < 5°C / < 41°F

Residual oil content < 3.0 mg/m

3

Dimensions and connections

Dimensions (H x W x D) [mm]: 1224 * 725 * 270

Dimensions (H x W x D) [inch] 48.2 * 28.5 * 10.6

Connections: All connections: G 1”

Net weight:

NitroFlow

®

HP1

NitroFlow

®

HP2

NitroFlow

®

HP3

Kg

85

95

105

Lbs

187

209

231

Housing

Protection degree IP 44

Electrical data

Voltage/frequency 100-115-230Vac 1ph / 50-60Hz

Power consumption 30 W

K3.1.141e Manual NitroFlow HP_EN.doc - 17 -

Parts

NitroFlow

®

HP

1x NitroFlow

®

HP

1x Manual

Table 4-1: General data

K3.1.141e Manual NitroFlow HP_EN.doc - 18 -

Default settings software parameters

Menu What Default setting

Logs

Interval 60 min

Local settings

Language English

Local settings

Pressure Bar(g)

Local settings

Flow LPM

Local settings

Purity %O2

Alarm settings

O2 high Active: No

Unit stop: No

Level: 5%

Delay: 30 sec

Alarm settings

O2 low Active: No

Unit stop: No

Level: 0.5%

Delay: 30 sec

Alarm settings

Inlet pressure high Active: No

Unit stop: No

Level: 13 bar(g)

Delay: 30 sec

Alarm settings

Inlet pressure low Active: No

Unit stop: No

Level: 2 bar(g)

Delay: 30 sec

Alarm settings

Outlet pressure high Active: No

Unit stop: No

Level: 10 bar(g)

Delay: 30 sec

Alarm settings

Outlet pressure low Active: No

Unit stop: No

Level: 2 bar(g)

Delay: 30 sec

K3.1.141e Manual NitroFlow HP_EN.doc - 19 -

Pressure switch

P-switch No

Pressure switch

Unit on 2.0 bar(g)

Pressure switch

Unit off 7.0 bar(g)

Options

Auto restart No

Options

Remote No

Options

Pin code No

Table 4-2: Default settings software parameters NitroFlow

®

HP

NitroFlow

®

Part number

NitroFlow

®

HP1 159.004032

NitroFlow

®

HP2 159.004033

NitroFlow

®

HP3 159.004034

Table 4-3: Part numbers NitroFlow

®

HP

4.2 Production capacity

Type Nominal product capacity Nm³/hr

Nitrogen purity (%) 99.5 99 98 97 96 95

NitroFlow

®

HP1 1.7 2.5 3.8 5.0 6.3 7.5

NitroFlow

®

HP2 3.4 5.0 7.6 10.0 12.6 15.0

NitroFlow

®

HP3 5.1 7.5 11.4 15.0 18.9 22.5

Table 4-4: Capacity NitroFlow

®

HP (Nm

3

/hr 20°C 1013mbar) at nominal conditions:

• Feed pressure at inlet 7 bar(g) / 100 psig

• Ambient temperature: 20°C / 68°F

• Ambient pressure: 1013 mbar(a)

K3.1.141e Manual NitroFlow HP_EN.doc - 20 -

4.2.1 Air consumption

Type Nominal air use Nm³/hr

Nitrogen purity (%) 99.5 99 98 97 96 95

NitroFlow

®

HP1 14.5 15.0 16.3 17.5 18.9 19.5

NitroFlow

®

HP2 28.9 30.0 32.7 35.0 37.8 39.0

NitroFlow

®

HP3 43.4 45.0 49.0 52.5 56.7 58.5

Table 4-5: Air use NitroFlow

®

HP (Nm

3

/hr 20°C 1013mbar) at nominal conditions:

• Feed pressure at inlet 7 bar(g) / 100 psig

• Ambient temperature: 20°C / 68°F

• Ambient pressure: 1013 mbar(a)

4.3 Maintenance kit

Part part number

Maintenance kit NitroFlow® HP (yearly or

after 8000 running hours, which comes first)

159.004045

O

2

-sensor (approx. every three years) 159.002284

Table 4-6: Maintenance kit

4.4 Expansion kit (option)

Part part number

Expansion kit NitroFlow® HP 159.004303

Table 4-7: Expansion kit

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Parker NitroFlow HP User manual

Parker NitroFlow HP User manual

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