Parker Balston FID 1000 User manual

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
1
Parker Balston®FID 1000 and
FID 2500 Gas Stations
Installation, Operation, and Maintenance Manual

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
2
Parker Balston FID 1000 and
FID 2500 Gas Stations
Installation, Operation, and Maintenance Manual
®
Figure 1 - FID Gas Stations
FID Gas Stations (see Figure 1) are completely engineered systems designed to produce
ultra pure, dry hydrogen gas from deionized water using a Proton Exchange Membrane cell.
The hydrogen generator utilizes the principle of electrolytic dissociation of water and hydrogen
proton conduction through the membrane. The hydrogen stream is dried using a coalescing
lter,a drying tube and dessicant. The outlet pressure of the hydrogen unit is 60 psi
(4.08 Barg) with a maximum hydrogen delivery ow rate of 90 cc/min for Model 1000, and
250 cc/min for Model 2500. The FID gas stations are ideal for use as fuel gas in Flame Ion-
ization Detectors (FID’s), Trace Hydrocarbon Analyzers, and other general laboratory equip-
ment requiring a source of pure hydrogen.
Parker Balston Gas Stations also incorporate a Zero Air Generator (ZAG) which will replace
inconvenient high pressure gas cylinders as a source of hydrocarbon-free air. This will purify
on site compressed air to a total hydrocarbon concentration of less than 0.1 ppm (measured
as methane). The ZAG may be used to generate fuel for Flame Ionization Detectors (FID’s)
or for a zero reference for any instruments which measure hydrocarbon concentration. Model
1000 is capable of producing 1000 cc/min of zero grade air and will serve up to three FID’s,
and Model 2500 will serve up to six FIDs.
General Description
These instructions must be thoroughly read and understood before installing and
operating this product. Any modication of the product will void the warranty. Failure
to operate this product in accordance with the instructions set forth in this manual and
other safety governing bodies could jeopardize the safety of the operator and void the
safety certication of this product.
If you have any questions or concerns, please call the Technical Services Department
at 800-343-4048, 8AM to 5PM Eastern Time or email at [e-mail]
(North America only). For other locations, please contact your local representative.
Do not use a Hydrogen gas storage vessel in conjunction with the Hydrogen generator.
Stored quantities of hydrogen pose an explosion hazard.
Normal precautions for any hydrogen supply should be taken when using the hydrogen
generator. DO NOT USE IN A SEALED OR UNVENTED ROOM.
CAUTION: DO NOT USE AN OPEN FLAME OR OTHER IGNITION SOURCE WITHIN
10 INCHES (25cm) OF THE OXYGEN VENT!
FRONT VIEW RIGHT SIDE VIEW

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
3
Regulatory Compliance The FID Gas Stations are certied to the electrical safety requirements as specied by the
IEC, CSA, and UL standards. These units bear the CSA marking on the product label. Prod-
ucts supplied to Europe carry the CE mark (220, 230, 240 VAC units only). The generator
meets EMC compliance.
Zero Air System
The Parker Balston FID Gas Station includes all of the components necessary to purify
compressed air into zero-grade hydrocarbon-free air. The generator comprises three primary
functional groups: preltration, hydrocarbon removal and nal ltration (see Figure 2).
A high efciency coalescing lter has been incorporated into the design of the Parker Balston
FID 1000 and FID 2500 as a prelter to remove oil, water, and particulate contamination from
the incoming compressed air supply. The prelter assembly is equipped with an solenoid au-
todrain to eliminate any liquids which have accumulated within the lter housing. The solenoid
drain opens to dump condensate once per hour for 1 second. If the condensate capacity
exceeds the volume of the lter housing, condensate can be carried into the catalyst module.
Refer to the compressed air utility section to eliminate this occurrence.
The catalyst module is a stainless steel housing lled with proprietary catalyst and assembled
with a heater. The catalyst module oxidizes hydrocarbons from the compressed air supply into
carbon dioxide and water. The module is sized to deliver 1000 cc/min or 2500 cc/min of zero-
grade hydrocarbon-free air to the instrumentation downstream.
The nal lter on the Parker Balston FID Gas Station is a high efciency sintered metal lter
which removes particulate contamination to 0.5 micron. This nal lter ensures that the outlet
air from the Parker Balston Gas Station is particle-free.
Preltration
Hydrocarbon Removal
Final Filtration
Figure 2 - Flow Schematic Zero Air

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
4
Hydrogen System
The Parker Balston FID Gas Station also includes a system to generate and purify hydrogen
gas. This portion of the generator includes: water feed system, proton exchange membrane
cell, and desiccant dryer (See gure 3).
The water reservoir for the hydrogen system includes and integral deionizer resin cartridge.
The resin cartridge sets inside the water bottle and all deionized water fed to the system
passes through this resin. The purpose of the cartridge is to ensure good quality (greater than
5 Megohm) water is circulated through the electrolyzer cell. Note: The deionizer cartridge is
not intended to purify tap water.
Electrolysis occurs inside the electrochemical cell assembly (Figure 3). Positively charged
hydrogen ions are transported across the solid polymer electrolyte along with excess water
molecules. The hydrogen ions then recombine to create molecular hydrogen. Negatively
charged oxygen ions recombine to form molecular oxygen. The water saturated oxygen is fed
into a water/oxygen separator, where the water is returned to the water tank, and the oxygen
escapes to the atmosphere. Small deionizer bags in the separator ensure the quality of the
water returned to the water tank.
The nal stage of the hydrogen process is purication through the desiccant drying bed. Any
liquid water or moisture carried over in the electrolysis process is removed to purity 99.9995%.
When the desiccant becomes saturated, the orange beads indicating color will turn clear. At
this point, the expended cartridge can be exchanged or regenerated as per the procedure in
the Maintenance section.
Water Feed
PEM Cell
Desiccant Dryer
Figure 3 - Flow Schematic Hydrogen
Deionizer
Resin
Cartridge

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
5
Note: All installation, operation and maintenance activities for the FID Gas Stations should be
performed by suitable personnel using reasonable care.
The FID 1000 and FID 2500 generators are a free-standing bench-top unit. Do not suspend the
generator from the wall or ceiling. The weight and size could pose a falling hazard. The generator
should be located indoors, protected from severe weather conditions and free from excessive ambient,
dust or dirt. Do not install the generator outdoors.
The ambient temperature of the air surrounding the generator must be between 60°F-100°F (16°C-
40°C ). Do not place the generator where there is a chance of freezing. Place the generator in an
upright position, on a level surface, in close proximity to the electrical power supply and the equipment
requiring both hydrogen and hydrocarbon-free air.
The Zero Air Generator compressed air inlet port is brass 1/4" female NPT. The inlet port is located
at the top center of the generator. The Zero Air outlet port is brass 1/8" compression union, located
below the Inlet port. Male 1/4" NPT compressed air inlet pipe ttings rated for 125 psig (8.5 Barg) line
pressure should be used to connect to the generator. The Hydrogen vent is also a brass 1/4" female
NPT, located at the right hand side of the generator and the Hydrogen outlet is a SS 1/ 8" Com-
pression Union, located directly below the hydrogen vent.
A shut-off valve and a pressure regulator should be installed directly upstream from the Parker Balston
FID Gas Station. The shut-off valve isolates the unit from the air line for maintenance and trouble-
shooting tasks. The pressure regulator controls the inlet air pressure and should be set to maintain a
constant pressure between 40 psig and 125 psig (2.7 barg and 8.5 barg ). Maintaining a constant inlet
air pressure will minimize system pressure uctuations which may affect the purity of the zero grade air.
Parker offers a pressure regulator, complete with a pressure gauge, as an accessory
(P/N 72-130-V883).
The FID 1000 and FID 2500 Gas Stations should be located in close proximity to the electrical power
supply, and the downstream equipment to which it supplies both Hydrogen and Zero grade air. There is
no limit to the distance between the generator and the point of use as long as tubing size, cleanliness,
and pressure drop are taken into consideration. The generator should be located indoors, protected
from severe weather conditions. The installation location should be free from excessive ambient dust
or dirt. Do not install the generator outdoors. The ambient temperature of the air surrounding the
generator must be between 60°F to 100°F (16°C to 40°C) to ensure optimal operation of the unit.
See page 20 for a list of the symbols displayed on the generator and referred to in this Manual.
The FID 1000 and FID 2500 generator weigh 53 lbs (24 kg). Use proper equipment and lifting tech-
niques for transporting this equipment to its installation location. The FID/Hydrogen is intended to
remain stationary when lled with water. If necessary, the generator may be transported over short dis-
tances when lled. Do not grasp the front panel Bezel when moving the generator; lift only from
the bottom. Keep the generator in an upright position.
Remove all red tape from the top cover, the back panel, and any other surfaces. Open the top cover of
the FID Gas Station. Unscrew the desiccant cartridge cap (see Figure 6). Remove the red caps/tape
sealing the back panel outlet ttings.
Do not attempt to remove desiccant cap until generator pressure reads 0 psig.
Desiccant - Wipe any drops of moisture with a lint free cloth or paper towel from the desiccant cap and
housing. Remove the desiccant cartridge from the sealed bag. Use a drop of deionized water to wet the
o-rings. Insert the cartridge into the housing, nipple end rst (see Figures 4, 5,6, and 7). Firmly push
down on the cartridge to create a hydrogen-tight seal at the bottom of the housing, making sure the
cartridge is seated.
Before replacing the desiccant cartridge cap, make sure the large Viton o-ring is centered inside the cap
(see Figure 7). Screw the cap on and tighten securely by hand. Make sure that the o-ring is centered
and that the o-ring has created a dark ringed seal.
Note: Most leaks occur due to improper sealing of the cap to the housing on the desiccant cartridge.
Preparation
Installation and Operation
General
Location
Symbols
Transporting

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
6
Figure 4 - Unscrew desiccant cap Figure 5 - Insert new desiccant cartridge
Figure 6 - Press down rmly
on desiccant to seat o-ring
Figure 7 - Make sure the o-ring is
centered in the cap before replacing it
Power - The Parker Balston FID Gas Station may be operated by a 120 VAC, 220 VAC, 230 VAC,
or 240 VAC, 50/60 Hz power supply. Main supply voltage uctuations must be within ±10% of
the nominal main supply voltage. The generator is shipped with a tag at the power receptacle
which species the factory setting of the voltage selector. For optimal performance of the genera-
tor, the operator should set the voltage selector to match the local power supply. To change the
setting on the voltage selector, simply remove the selector/fuse drawer from the receptacle using a
small screwdriver, turn the selector so the desired voltage shows in the window, and reassemble.
To connect the generator to the power supply, simply plug the female end of the electrical cord
into the receptacle on the right side of the generator, and the opposite end into a three-pronged
earthed power receptacle.
Before plugging power cord into power receptacle, check the voltage selector setting. The
voltage setting must match the local power supply voltage. (Note: "NA" versions of the
generator are designed for 120 VAC operation only.)
Utilities

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
7
Deionized Water - The FID 1000 and FID 2500 / hydrogen must be supplied with deionized water with
a resistivity of at least 5 Meg-Ohm/cm. Parker Balston provides a point of use accessory, the Hydro-
Gen Mate (P/N 72-230 or 72-231) that provides high purity water (>5 Meg-Ohm/cm) from tap water for
manual lling or autolling the generator. Water pressure from a deionized source or from the Hydro-
Gen Mate to the FID Gas Station should not exceed 30-60 psig.
Resin Bed - FID gas stations are supplied with a resin bed to be installed in the water ll reservoir.
This is to ensure proper water quality is being supplied to the Hydrogen system. A message on the
front display reading "check resin bed or 75% usage" is a reminder to occasionally check resin. It
needs to be replaced only if color has changed to orange on more than 75% of the cartridge.
To install resin bed, remove water bottle cap. Remove resin cartridge from sealed bag and set resin in
bottle. Screw cap securely on water bottle (see Figures 8 and 9).
Caution: Cell contamination is a cumulative and irreversible process which will eventually
cause an over-voltage fault, automatically shutting down the generator. The deionizer resin bed
is for a nal decontamination stage and should not be used to purify low grade water.
Figure 8 - Set resin bed in bottle Figure 9 - Screw cap securely on water bottle
Compressed air - The Parker Balston FID 1000 and FID 2500 Zero Air Generators require a source
of clean compressed air for optimal operation. The compressed air should be as close to instrument
quality as possible, and supplied at a pressure and ow rate above that required at the point of use.
The temperature and/or dewpoint of the supply air should be at room temperature (or lower), and
it should be relatively free from compressor oil, hydrocarbons, and particulate matter. Contamina-
tion of the catalyst bed may occur if it is exposed to certain compounds (see warning below). If the
compressed air supply has excess water, oil, or particulate contamination, install extra preltration
upstream from the unit (see Recommended Accessories, page 20).
Chlorinated hydrocarbon compounds and chlorouorocarbons (or freons) will permanently
contaminate the hydrocarbon catalyst module in the FID ZAG generator. Extreme care should
be taken when specifying an air supply for the generator to ensure that these compounds are
not present in the air supply nor likely to get into the compressor providing air to the generator.
The hydrocarbon catalyst module can also be contaminated by high concentrations of lead,
sulfur, or phosphorous compounds, heavy metals, and long chain polymers. Care should be
taken to avoid introducing these compounds into the Parker Balston FID Gas Station. None of
these compounds are to be stored near the inlet to the compressor supplying the system with
compressed air. The intake for the compressor should be vented to the outdoors.
Connect the compressed air supply to the 1/4" NPT (female) inlet port in the top center of the genera-
tor, back of instrument (see Figure 10).
Piping Components, FID 1000 and FID 2500 / ZAG - The inlet port for the Parker Balston FID 1000
and FID 2500 Zero Air Generator is a 1/4" NPT (female) and is located at the top center of the rear
panel (see Figure 10). Inlet tubing and ttings should be clean and rated for 125 psig (8.5 Barg),
minimally. The tubing and ttings used downstream from the FID 1000 and FID 2500 should be clean
stainless steel or pre-cleaned refrigeration-grade copper (1/8" od x .030" wall) and rated for 125 psig
(8.5 Barg).

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
8
Do not use plastic tubing downstream from the generator. Outgassing from the plastic may
contaminate the zero-grade gas. Use PTFE tape on all inlet and outlet NPT ttings. (Thread sealing
compounds may contaminate the process stream).
Note: The use of plastic piping components or unclean copper or stainless steel piping components
will result in the FID Gas Station failing to meet zero air purity specications.
Connect downstream delivery lines (Zero Air Outlet) to the 1/8" compression union port on the middle
of the generator.
Piping Components, FID 1000 and FID 2500 / Hydrogen - The outlet connection for the FID 1000
and FID 2500 / Hydrogen is a 1/8" compression tting (see Figure 10). All tubing and ttings down-
stream from the hydrogen generator should be clean stainless steel to minimize contamination of the
hydrogen stream. If copper tubing has been used with hydrogen in the past and has yielded accept-
able results, there is no need to alter an existing piping conguration to install the hydrogen generator.
Flow Controller - A ow control device should be installed downstream from the zero air outlet if one
is not integral to the instrumentation used (P/N Model W-FM7583). If the ow capacity of the genera-
tor is exceeded, the FID 1000 and FID 2500 / ZAG will fail to meet its hydrocarbon specication
(0.1 ppm for FID 1000, or 0.05 ppm for FID 2500).
Pressure Regulator - The FID 1000 and FID 2500 / Hydrogen pressure is preset to 66 psig inter-
nally. In order to optionally regulate the output pressure, the customer needs to install a pressure
regulator down stream from the unit. The output pressure can be monitored using the front panel
digital display. There is an internal Pressure Relief Valve that is preset to 150 psig (10 Barg) in case
of excess internal pressure build up. The expelled gas is channeled through the pressure relief port,
hydrogen vent, located in the back of the unit.
Figure 10 - Rear View of Unit

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
9
Water Reservoir
Start Up
The FID Gas Station is equipped with both an Automatic Fill and a Manual Fill Water design.
After carefully following all the preparation procedures in the Installation section, proceed as
follows:
For Autoll operation, the FID Gas Station incorporates a detection device which automati-
cally activates a Water Fill Solenoid when the water level is at the REFILL or EMPTY Level. In
order to function correctly, the FID gas station must be connected directly to a DI Water supply
(not to exceed 50 psig). The FID Gas Station/H2must be supplied with deionized water with
a resistivity of at least 5 Meg-Ohm /cm or greater. Both a Gravity Feed and a Pressure Feed
Tubing assembly can be located in the Accessories bag (P/N B02-0318). Select the required
tubing, depending on the DI source, and attach to the Water Fill Port at the back of the FID
Gas Station (see Fig 10).
When the DI set up is ready, turn the Power Switch to On. This automatically opens the inter-
nal Solenoid valve and the Resin Bed Reservoir/Water Reservoir will start to ll. The device
will continue to ll until the Water level reaches the REFILL mark. This triggers the internal
solenoid valve to close and the DI demand will cease, see Figure 11. Water level will be main-
tained within 1-2 inches of the REFILL line when Autoll is used - to ensure a fresh supply of
deionized water. Do not disconnect the DI water source if continuous hydrogen operation is
desired.
Autoll
Note: The hydrogen system of the FID Gas Station will automatically shutdown if the
water level becomes too low and LOW WATER is displayed on the Digital screen.
Figure 11 - Typical water levels for an FID Gas Station that is set up with auto water ll

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
10
After replacing any parts downstream of the generator, or upon initial startup, the system will
need to be purged to achieve the nal purity. To avoid contaminating the downstream equip-
ment, it is suggested that the user install a three way valve in-line nearest the equipment with
a variable restrictor (such as a needle valve) on the Hydrogen outlet port. Follow the simple
procedure below:
1 Close the three way valve that has been installed on the outlet or use the downstream
equipment.
2 Connect the power cord to the FID 1000 or FID 2500 and turn the power switch to ON.
The FID will start to generate Hydrogen. Wait until the internal pressure reaches the
desired pressure (approximately 15 minutes).
3 Set the output ow rate to 50 cc/min by using the downstream equipment or if a three way
valve was installed, then switch the ow to the outlet (or purge port) and set the ow rate
using a needle valve. Use the downstream equipment only if impure hydrogen will not
ruin the equipment.
4 Allow the system to vent in this manner for 30 minutes. The generator and lines should
now be purged of air and ready for use.
Controlled Venting
Quick Start Instructions
Startup
Manual Fill For Manual Fill operation, simply open the top cover lid, locate the DI Resin Bed Reservoir,
see gures 8 and 9, loosen the cap and slowly ll the device until the desired water level is
visible through the Front Panel Display. Generator should NOT be lled above the FULL line.
Replace the cap and close the side cover lid. It will take approximately 2 liters of deionized
water to ll the generator.
Caution: Fill slowly.
Before turning generator "ON", open the inlet air supply valve (customer supplied, see Instal-
lation section) and adjust the inlet pressure to be between 40 psig and 125 psig (2.7 barg and
8.5 barg) using a (customer installed) pressure regulator. Adjust the output ow (using a cus-
tomer installed ow controller) to the rated ow for the unit. Turn the generator on using the
power switch on the back panel. When power is supplied to the unit, the catalyst module will
begin to heat up. The Parker Balston FID 1000 and FID 2500 / ZAG requires approximately
55 minutes to warm up and achieve hydrocarbon removal to 0.1 ppm (see Figure 5 Power Up
/ Start Up Sequence).
1 Check the Water level. To ll, remove DI Resin Bed cap and slowly add >5 Meg-Ohm
water to full line.
2 Connect to suitable line power.
3 Supply compressed air regulated to 125 psi Max to Compressed Air Inlet.
4 Open user installed shut off valve at Zero Air Outlet and close user installed shut off
valve at Hydrogen Outlet.
5 Turn the power switch at the rear of the unit to ON.
6 Check display for current state of Hydrogen and Zero Air.
7 Time delay for Zero Air (55 minutes) allows it to reach operating temperature. Once time
has expired, the unit is ready to provide both Hydrogen and Zero Air.
8 Open Hydrogen outlet valve.
Warning: Operating the generator for extended periods of time without compressed air will
damage the heater within the catalyst module. Do not supply electrical power to the generator
until compressed air is at rated capacity.

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
11
Operation
After the generator has warmed up, adjust the ow to meet the requirements of the applica-
tion. Do not exceed the rated ow of the unit. If the rated ow of the FID 1000 or FID 2500
ZAG is exceeded, the life and performance of the unit will be adversely affected and the war-
ranty will be void. The outlet air will contain hydrocarbons in excess of 0.1 ppm.
The Parker Balston FID 1000 and FID 2500 ZAG is designed to operate continuously, 24
hours per day, as long as the compressed air supply is not interrupted.
To maintain the highest purity, the FID 1000 and FID 2500 H2should be run continuously.
Monitor the Hydrogen consumption of the downstream equipment to ensure ow is within the
capacity of the generator (see the System Specications section for rated ows). The Front
panel Display should be illuminated as seen in Figure 12.
The water level should be monitored regularly and relled as necessary, if Manual Fill opera-
tion is in use. Otherwise, ensure that the Autoll tubing is installed correctly and connected to
a suitable DI supply. The reservoir holds enough water for at least a week of continuous op-
eration. Water can be added manually by removing the DI Resin bed cap and slowly adding
enough water to reach the FULL mark on the FID 1000/FID 2500 front panel (see the Water
Reservoir section in Startup). Reinstall the Resin Bed cap.
To maintain the integrity of the Hydrogen cell, follow the guidelines listed below:
1 Keep a supply of deionized water in the reservoir above the REFILL line at all times or
ensure that the FID Autoll is directly connected to a DIO water source.
2 Minimize the “dead-volume”in the piping between the generator and the downstream
equipment.
3 Never expose the equipment to temperatures below freezing.
4 Never abruptly disconnect the Hydrogen outlet port from the downstream equipment
and expose the unit to large ow volumes. The sudden, large demand can permanently
damage the cells membrane, causing irreparable damage to the unit. A large demand
will trigger the overow condition and cause the FID 1000 and FID 2500 hydrogen side to
shutdown.
If the built-in diagnostics trigger a fault condition, and the symptom is displayed, consult the
Troubleshooting section of this manual for further instructions.
Operation
Diagnostics
The Parker Balston FID gas station has built-in system diagnostics to monitor the operation of
the generator and alert the operator both visually and audibly in case of a failure.

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
12
Figure 12 - Front Panel Display
NORMAL
OPERATION
REFILL
WATER
POWER UP
SEQUENCE
HYDROGEN
LOW PRESSURE
HYDROGEN OVER-
FLOW IF PRESSURE
DROPS BELOW 10 psi
ZERO AIR
OVERFLOW
HYDROGEN Overow
in Use 0% 0.0 psi
ZERO AIR Low temperature
Excess Hydrocarbons
HYDROGEN Overow
in Use 0% 0.0 psi
ZERO AIR
At temperature
HYDROGEN
in Use 79% 66.5 psi
ZERO AIR
At temperature
HYDROGEN add water
in Use 79% 66.5 psi
ZERO AIR
At temperature
PARKER HANNIFIN
ZERO AIR & HYDROGEN
GAS GENERATOR
NORMAL
OPERATION
WITH RESIN
REMINDER
HYDROGEN
in Use 70% 66 psi
Check Resin for 75% Usage
HYDROGEN
in Use 80% 66.2 psi
Desiccant
Check the indicator
NORMAL
OPERATION
WITH DESICCANT
REMINDER
EMPTY
WATER
HYDROGEN low water
in Use 0%
ZERO AIR
At temperature
ZERO AIR
SERVICE
REQUIRED
CELL VOLTAGE
ABOVE LIMIT
(See Troubleshooting
Guide)
H2 cell = 2.85 V
in Use 89% 65.2 psi
ZERO AIR
At temperature
HYDROGEN Low Pressure
in Use 105% 20 psi
ZERO AIR
At temperature
HYDROGEN
in Use 80% 66 psi
Zero Air Service
The Parker Balston FID gas station has built-in system diagnostics to monitor the operation of
the generator and alert the operator both visually and audibly in case of a failure.
Upon Power Up, the front panel Digital Display will be illuminated and the Hydrogen/Zero Air
operational status will be displayed (see Figure 12).
The Control circuitry controls the membrane cell current to a safe level and eliminates the pos-
sibility of excessive Hydrogen production. If a fault occurs and a fault condition is displayed,
follow instructions in the Troubleshooting section to clear and rectify the fault condition.
An audible alarm will sound with the following error conditions are displayed:
• Add water / water empty
• Over pressure of hydrogen cell
• Excess ow demand of hydrogen / overow / low pressure*
• Zero air overow / excess hydrocarbons
• Zero air service required
Once the error condition is corrected, the unit will resume operation.
*In the case of hydrogen overow / low pressure, to clear the error message and resume
operation, the unit will have to be shut down and restarted.

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
13
If the unit is to be idle for more than 24 hours, the generator should be turned off.
Parker recommends allowing the FID 1000 and FID 2500 Generators to run continu-
ously, shutting down the unit only when compressed air is not available or when the
generator requires servicing. The continuous operation of the generator maximizes the
life of the catalyst heater as well as the Electrolytic Proton Exchange Membrane Cell.
To shut down the Parker Balston FID Gas Station, turn the power switch to the OFF position.
Maintain the compressed air ow through the unit for at least 10 minutes to improve heat dis-
sipation. After 10 minutes, turn off the compressed air supply to the generator.
Warning: Do not supply electrical power to the generator until the compressed air ow
rate through the unit is at the rated capacity (see Specications section, page 20). Op-
erating the generator for extended periods of time without compressed air will damage
the heater within the catalyst module and void the warranty.
To store the unit:
1 Turn the FID 1000 or FID 2500 OFF and allow the Hydrogen gas to purge slowly until
all the internal gas is removed.
2 Cap the Hydrogen outlet on the back of the generator or leave it connected
to the downstream equipment.
3 Fill the DI Reservoir at least half full with deionized water. Make sure that the cell
has at least 2" (5cm) of water showing in the cell assembly tube. This can be viewed
through the vents in the back panel.
4 Remove the desiccant cartridge and store in a moisture proof container.
5 Check the water level in the cell every 6 months to maintain the 2" (5cm ) height.
Contact The Technical Services Department at 800-343-4048 or email at balstontechsup-
[e-mail] for a Return Authorization (RA) number and new Packaging if the original is
no longer available.
1 Purge and bleed the FID 1000 or FID 2500 of all compressed air and hydrogen. Wait
until the outlet pressure display reads zero.
2 Drain the water from the DI reservoir using the Water Drain Port Insert (connected
to a 3' length of 3/8" OD tubing) and connect it to the drain port located on the
back panel. Drain the deionized water into a 4 liter container.
3 Press down on the metal tab on the top of the Water Drain Port Connector to remove
the Drain Port Insert and Tube once the unit has been drained.
4 Remove the desiccant cartridge and store in a moisture proof container. Cover the
side port on the inside of the desiccant cartridge with tape and replace the cap.
5 Pack the generator carefully in the original packing box or request new
packaging from Parker. Be sure to display the RA # on the outside of the box
for prompt response.
In order to maintain the warranty on the generator, ship the unit in a manner that will
prevent freezing. Freezing conditions will cause irreparable damage to the hydrogen cell as-
sembly.
Shutdown
Storage
Shipping

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
14
Limit
Troubleshooting
All troubleshooting activities should be performed by suitable personnel using reasonable
care.
Warning: Any troubleshooting or service activity which requires removal of the generator
cover should be done using extreme caution. Exposed AC may be present.
Symptom Course of Action
No Power Check power source and connections to the power source.
Check terminal connections and power cord.
Check power source fuses.
Check generator fuses.
Rell /Empty Water Completely ll DI Resin Bed Reservoir with deionized water.
Auto -Water ll port is blocked / plugged.
DI water supply shut off, ie.. Gravity or Pressure lines closed off.
Consult factory if display does not change status.
Water drain tubing kit still installed. Remove kit to allow unit to rell.
Hydrogen Overow Mass leak detected in system / downstream. If the hydrogen pressure drops below 10 psi, the “HY-
DROGEN OVERFLOW” will be displayed. To clear error message, shut down then restart generator.
Hydrogen demand exceeds generator capacity. Check capacity of equipment and piping down-
stream and install a ow control device. To clear error message, shutdown then restart generator.
Check internal system piping for leaks. To clear error message, shutdown then restart generator.
Low Output Pressure Hydrogen demand exceeds generator capacity. Check capacity of equipment and piping down-
stream and install a ow control device.
Check external system piping for leaks.
Check internal system piping for leaks.
No Hydrogen Delivered Check power connections (see above).
Check water level. Generator will shut down if water level is below the EMPTY level.
Customer installed shutoff valve is closed; open valve.
Check piping for leaks.
Consult factory.
Low Zero Air Pressure Check inlet air pressure. Pressure drop up to 4 psid (0.3 bar) is normal. Minimum inlet air pressure
is 40 psig (2.8 barg).
Check ow demand and overow condition. Flow demands in excess of capacity may cause high
pressure drop through generator.
Check generator for leaks.
Excess Hydrocarbons The Zero Air has not reached adequate temperature . Allow a minimum startup, warm up period of
55 minutes .
Check downstream Zero Air ow demand. If ow capacity of generator is exceeded, the ZAG tower
will be below the desired operating temperature and Hydrocarbon removal will be affected.
An excessive pressure drop (greater than 4 psig/0.3 bar) may cause a high pressure drop through
generator.
If demand exceeds capacity, install a ow controller downstream from the zero air output.
Excessive Moisture Desiccant is saturated; change desiccant.
in the Gas Stream
Cell Voltage Above Check resin bed. If color has changed to orange then replace resin. Drain and ush water from
system 3-4 times to remove impurities from water reservoir. Restart. If message still appears, then
run generator for 10-15 minutes to cycle water through cell, then drain and rell again. If problem still
persists consult factory. If no resin color change has occurred, consult factory.

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
15
Figure 13 - FID Gas Station, Exploded View

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
16
When performing routine maintenance, carefully follow the instructions provided in this
section to avoid injury or damage. Service should be performed by persons familiar with
the service and safety requirements of electromechanical / electrochemical devices.
The primary maintenance tasks required by the Parker Balston FID 1000 and FID 2500 are:
changing the prelter cartridge (annually), changing the sintered metal lter assembly (annually),
and replacing the catalyst module (2 years). Each of these components are readily accessible
by removing the side panel of the generator. A summary of the replacement part numbers and
recommended Service frequency is shown at the end of the Maintenance section. See Figure 13
for the locations of the prelter, nal lter, and catalyst module.
Additional coalescing prelter cartridges and nal lter cartridges for the Parker Balston FID 1000
and FID 2500 Gas Stations may be ordered through your local representative. For convenience,
the replacement prelter cartridge, nal sintered metal lter, desiccant cartridge and DI resin
cartridge have been assembled into a maintenance kit (P/N MKFID1000). With proper care and
maintenance, the FID 1000 and FID 2500 / hydrogen generators will provide years of trouble free
operation. No adjustments or calibrations need to be made to the generator. Only routine service
is needed to maintain peak operational conditions.
Before Servicing the Parker Balston FID1000 or 2500 Gas Station, isolate the unit from the
compressed air and electrical supplies, the hydrogen output, depressurize the prelter and
turn the unit Off.
The only tool required to change the prelter cartridge is a Phillips head screwdriver. Use the
screwdriver to remove the generator side cover. The Grade BX prelter will be accessible from
the side of the generator, after the generator cover is removed. The lter cartridge inside the
housing should be changed on an annual basis to maintain efcient operation of the system.
Remove the lter cartridge housed in this lter assembly by unscrewing the lter bowl from the
lter head and unscrewing the element retainer disc from the tie rod. Insert the new lter cartridge
(P/N 050-05-BX) and re-assemble the lter housing in reverse order.
Maintenance
General
Prelter
Cartridge
Maintenance
• Switch power off to unit and unplug generator from power. Allow the compressed air to
continue to ow through the unit to improve heat dissipation during cooling. Allow the
generator to cool for at least 2 hours.
• Close the (customer installed) inlet air valve.
• Remove Main chassis cover. There are 2 screws on the left side and 2 under the hinged
cover of the generator (gure 13).
• Remove Right-side cover. There are 4 screws on the right side of the unit. (gure 13).
• Disconnect Catalyst Module connector located on right side of the unit (gure 13 and 14).
• Disconnect solenoid valve connector (gure 15).
• Locate main connector (gure 13). Using Wago tool, included in replacement module kit,
insert tool into main connector as shown in gure 16. Depress tool and remove yellow wire
from position 7 of main connector. Similarly remove brown wire from position 8.
• Remove connections to inlet and outlet air ports at the rear of the generator (gure 17).
• Remove 3 fasteners holding the catalyst assembly module at the rear of the generator – See
gure 17 for FID 2500 or gure 187 for FID 1000.
• Slowly remove Module from generator.
• Replace with new assembly- which includes a new zero air lter, nal lter, catalyst module,
and solenoid valve.
• Reverse above procedure – reassemble module into chassis, reconnect air lines, re-attach
electrical connectors and insert red and yellow thermocouple wires as shown previously.
• Pressurize the system and check for leaks in the air lines and ttings.
• Re-assemble covers to unit and supply power.
Catalyst Assembly
Module Replacement
1

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
17
Water Rell
Additional maintenance tasks required by the Hydrogen system in the generator are: chang-
ing the desiccant cartridge (when the beads turn color or clear), replacing the DI Resin Bed
cartridge (approximately every 6 months), and relling the water reservoir (weekly). See the
Installation and Operation section for details. A summary of the replacement part numbers
and recommended service frequency is shown at the end of the Maintenance section.
If necessary, the FID gas station may be wiped clean with a dry cloth on an as needed basis.
Do not use water, aerosols, or other cleaning agents to clean the unit. Use of any liquid
detergent to clean the generator could present an electrical hazard.
Do not use commercial leak detection uids on any Lexan plastic parts in the genera-
tor. These uids may cause cracking and crazing which leads to part failure. Use a solution
of 4-5 ml of liquid dish soap in one liter of water.
Rell the water in the generator whenever the water level reaches the REFILL level displayed
on the front panel. Two audio bleeps will be heard as soon as the Rell level is activated. If
the FID 1000 and FID 2500 is connected to an external DIO Water source and is permanently
connected, the unit will be remotely lled using the Autoll function of the generator.
The water reservoir should last approximately 1 week when the reservoir is lled to the FULL
level.
If the LOW WATER level indicator is activated, a distinct constant audio bleep will be heard,
until DI water is added to the generator. The FID 1000 generator will stop producing hydro-
gen to safeguard the Hydrogen cell from permanent damage. Add water to the generator until
the FULL level is reached. The unit will automatically start to produce Hydrogen as soon as
the Rell level has been passed, while lling the unit (see Figure 12 for Display Modes).
Figure 14 - Catalyst Assembly Module Items

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
18
Figure 15 - View Toward Rear of Unit, Model FID-2500
Figure 16 - Thermocouple wire
Figure 17 - Rear View (FID-2500 shown, FID-1000 similar)
Figure 18 - View Toward Rear of Unit, Model FID-1000
No tools are needed to change the Desiccant cartridge (P/N 1647727). The cartridge should be
replaced when the color of the indicator beads turns color. The orange beads turn clear. Once all
the indicating beads have turned clear, the cartridge will have approximately 2 days of life left at
90cc/min ow.
Do not attempt to remove desiccant cap until generator pressure reads 0 psig.
1 Turn the Power switch to OFF and leave the user installed shutoff in the open position in
order to vent the Hydrogen from the unit. Unit must be depressurized before removing des-
iccant cap (see Figure 4).
2 Lift the top cover lid and unscrew the cap covering the desiccant cartridge. Remove the
cartridge from the unit.
3 Remove the replacement desiccant cartridge from the moisture proof bag. Add a small
amount of deionized water to wet the o-rings on the nipple end of the desiccant cartridge.
Push down rmly to seat the o-rings at the bottom of the housing (see Figures 5,6, and 7).
4 Replace and center the large o-ring inside the desiccant cap. Tighten the cap securely by
hand. Be sure the o-ring seal remains centered and the seal is visible as a black ring around
the top and sides.
Note: Most internal leaks are found at the desiccant housing cap o-ring seal, due to improper
sealing of the cap. Be sure to seal the cap tightly.
Desiccant Change

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
www.labgasgenerators.com
19
Cartridge Regeneration
5 Turn the power switch ON and perform the Controlled Venting purge as described in the
Startup section, then begin using the generator.
Note: For best results, purge the system for one hour to remove any residual oxygen and
moisture from the instrument and piping downstream.
When the desiccant becomes saturated with moisture, the orange indicating color will turn
clear. The expended desiccant cartridge can be regenerated for later use, so long as a mois-
ture proof container is available.
Cold Vacuum Oven - For best results, place the desiccant cartridge in a cold vacuum oven
and ramp the temperature at 2°C/minute to 150°C while supplying a vacuum. Do not exceed
175°C. Regeneration will be complete in 8 hours.
Conventional Oven - If only a conventional oven is available, place the cartridge upright
inside the oven to allow the moisture to leave from the top of the cartridge. Apply the following
ramp rate and procedure:
• 2 C/min from room temperature to 90°C ,hold at 90°C for two hours.
• 2 C/min from 90°C to 150°C and hold at 150°C for 24 hours.
• Cool the cartridge in a desiccator or low moisture environment until needed in the hydrogen
generator.
For either method, do not exceed 175°C. The temperature will not affect the desiccant
performance; however, once the orange beads remain clear, they can no longer be used as
a color indicator and the cartridge must be discharged. Apply a light coat of DI water to the
o-rings prior to inserting the cartridge into the generator plastic housing.
The DI Resin bed cartridge should be rinsed and the Resin bed replaced every 6 months, or
whenever the water quality deteriorates, which is detected by a color change in the Resin bed,
ie, the color changes from a Dark brownish color to a Orange color. If 75% of the Resin bed
has changed color, then the Resin bed should be replaced. No tools are required to change
the Resin bed.
1 Turn the Power Switch to OFF.
2 Lift the top cover lid and unscrew the water reservoir cap. Remove the Resin bed car-
tridge from the Reservoir bottle (see Figure 13).
3 Inspect the replacement Resin Bed Deionizer for damage prior to installation into the
water reservoir. Replace the Reservoir cap after the resin bed has been reinstalled.
4 Rell the unit with deionized water by using either the Autoll or by manually lling the
unit with approximately 2 liters of DI water.
NOTE: Do not allow the DI Resin bed to dry out; it must be immersed in water to perform.
5 Restart the generator in the same manner found in the Startup section.
Resin Bed Replacement
Fuse Replacement Occasionally, the fuses in the FID gas station may burn out. The fuses are located in the
power receptacle on the back side of the generator. Before servicing the fuse, turn the unit
off and disconnect the power cord from both the power supply and the generator power
receptacle.
To access the fuses, use a small screwdriver to remove the fuse holder located in the back of
the unit and in the power receptacle. In the FID Gas station, both the phase and the neutral
are fused separately. As a result of this conguration, both fuses should be checked any time
fuse replacement is warranted. Replace either one or both with the appropriate fuse and re-
assemble.
To maintain the safety and performance integrity of the product, use only the fuse of
the size and type detailed in the Specications, Parts and Accessories sections of this
bulletin.

Bulletin TI-FID1000J Installation, Operation and Maintenance Manual
Technical Information FID1000 and 2500 Gas Stations
1-800-343-4048
20
Water Pump
Replacement 1Switch power OFF to unit and unplug generator from power. Allow the compressed air to
continue to ow through the unit to improve heat dissipation during cooling. ZAG Catalyst
module and cooling coil will be hot. Allow unit to cool 2 hours before opening.
2 Close the (customer installed) inlet air valve.
3 Drain the water from the DI reservoir using the Water Drain Port Insert and connect it to
the drain port located on the back panel. Drain the deionized water into a 4 liter contain-
er.
4 Remove Main chassis cover. There are 2 screws on the left side and 2 under the hinged
cover of the generator (gure 13)
5 Remove Right-side cover. There are 4 screws on the right side of the unit. (gure 13)
6 Remove Front cover. There are 4 screws on the inside front of the chassis, at the top and
bottom.
7Disconnect water pump connector from printed circuit board- location J1-12.
8 Disconnect water pump tubing from the base of the water main reservoir and from the
hydrogen cell assembly (gure 13).
9 Remove the 2 M3 screws that mount water pump to the chassis.
10 Remove the pump and replace, using pump replacement assembly B02-0441
11 Install 2 M3 screws into mounting holes using gaskets provided. The two gaskets are
installed on each screw on both sides of the chassis.
12 Install screws into water pump.
13 Install connector on to PCB at J1-12 location. Blue wire should be on the right connector
pin and red on the left.
14 Reconnect tubing to main reservoir and hydrogen cell.
15 Fill unit with water to rell level.
16 Briey connect unit to power and turn unit ON to verify pump operation and no tubing
leaks. Once operation is veried reinstall covers.
17 Reinstall front cover
18 Reinstall main chassis cover and side covers and operate per the manual.
Don’t Forget To 1 Complete and mail or fax in your Warranty Registration Card.
2 Keep your product certication in a safe place.
3 Call the Technical Services Department at 800-343-4048, 8am to 5pm Eastern Time with
any questions (North America only) or email at [e-mail]. For other
locations, please contact your local representative.
Serial Numbers The serial number for the unit is located on the back of the unit. For your records, and in case
service is required, please record the following:
DATE IN SERVICE______________SERIAL NO_______________
Please have the serial number available when calling for assistance.