Parker Balston NitroFlow60 User manual

Bulletin TI-NITROFLOW60-G Installation, Operation and Maintenance Manual
NitroFlow60 and NitroFlow60D Generators
www.labgasgenerators.com
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1-800-343-4048
NitroFlow60
and NitroFlow60D
Installation, Operation, and Maintenance Manual

Bulletin TI-NITROFLOW60-G Installation, Operation and Maintenance Manual
NitroFlow60 and NitroFlow60D Generators
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Symbol Description
Caution, refer to accompanying documents
for explanation.
Refer to the caution note indicated for
explanation.
Caution, risk of electric shock.
Refer to the warning note indicated for
explanation.
1
1
Explanation of Warning Symbols

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These instructions must be thoroughly read and
understood before installing and operating this product.
Any modification 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. Retain these instructions for
future reference.
If you have any questions, please call the Technical services
department at 1-800-343-4048, 8AM to 5PM Eastern Time or
e-mail at [e-mail]. For other locations,
please contact your local representative.
Please refer to page 2 for an explanation of the caution/warning
symbols used throughout this manual.
Installation, Operation, and Maintenance Manual
Parker Balston
Nitroflow60 Generator Series
Figure 1 Model NitroFlow60 & NitroFlow60D Nitrogen Generator

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The NitroFlow60 Nitrogen Generator System Series are available in two models (Figure 1):
(1) NitroFlow60 Nitrogen Generator System(No Dry Air output)
(2) NitroFlow60D Nitrogen Generator System(Dry Air output)
The integrated system is engineered to produce pure nitrogen gas and clean, dry -40°F dew point
air gas from compressed air delivered by a carefully matched scroll compressor. The system is
housed in two fully integrated cabinets: the lower cabinet produces the compressed air using an
oil-less rotary scroll compressor. The upper cabinet removes contaminants and separates the
compressed air into the two gases.
General Description
The generator is certied to the electrical safety requirements as specied by the IEC, UL,
and CSA standards. These units bear the CSA marking on the product. Product supplied
internationally also carries the CE mark. The product meets EMC compliance. Internal pressure
receivers are CRN and ASTM certied or CE certied.
Regulatory
Compliance
The NitroFlow60 generator contains the necessary components to produce reliable, oil-free
compressed air, pure nitrogen, and dry air gases. The system consists of ve functional
technologies: (1) compressed air, (2) liquid water removal, (3) preltration, (4) oxygen/carbon
dioxide/water vapor removal, and (5) nal ltration. The nitrogen generator ow schematic (gure
2) shows the airow through the intake lter, compressor pump, aftercooler, receiver tank, and
check valve. The compressed air then ows through a water separator and preltration where
additional water (liquid and vapor) is removed. After ltration, the compressed air ow passes
through a 3-way pneumatic valve, an activated carbon prelter, nitrogen module, pressure
regulator, and post carbon lter, providing the nitrogen gas. The second ow path passes through
a back pressure regulator to maintain a 100% duty cycle of the compressor. The third ow path
passes through a dryer membrane providing dry air. Dry air available on NitroFlow60D series only.
Integrated System
The oil-less rotary scroll compressor is based on the theory of scroll compression. It offers high
reliability and quiet operation. The scroll set consists of two identical spirals; offset 180° with
respect to the other so the scrolls mesh. One scroll is orbited around the xed scroll, trapping and
compressing gas pockets as the pockets move to the center of the xed scroll. The compressed
gas is discharged from the pump through the center outlet.
The air-cooled aftercooler on the scroll compressor is a series of cooling ns and a high output
fan. The cooling features allow the scroll compressor to operate at lower temperatures and
extend bearing, tip seal and grease life. The aftercooler cools the temperature of the discharge
air. The temperature of the discharge air is lowered, producing trapped water in the tank. The
water is then discharged through the automatic electric drain valve and collected in a disposal
container.
Compressor Pump
Compressor
After Cooler
Figure 2, Nitrogen Generator Flow for NitroFlow60 and NitroFlow60D

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The NitroFlow60 generator series incorporates a water separator to remove liquid water from the
compressed air before it reaches the prelters.The liquids are collected in the supplied disposal
container. Refer to the included installation and service instructions, 2F101H, for maintenance
instructions.
Two stages of high efciency coalescing preltration are incorporated into the design of the
NitroFlow60 to remove water and particulate contamination to 0.01 micron. The generator is
equipped with oat drain valves to automatically discharge any liquids which have accumulated in
the lter bowls. The liquids are collected in the supplied disposal container. These lters protect
the membrane and associated components from contamination.
A 3-way pneumatic valve is located after the prelters to release any leftover liquid water that may
be present on startup.
An activated carbon module is located before the nitrogen module to remove any chlorinated
hydrocarbon contaminates that may exist in the room air. A particulate lter is located after this
carbon module to remove any carbon contaminates
The NitroFlow60 generator has a hollow ber membrane module which converts compressed
air into high purity nitrogen. The membrane module has no moving parts assuring years of
maintenance-free operation.
The water vapor in the compressed air passes through the hollow bers of the membrane for
removal, resulting in dry air. A small portion of the dry air is redirected along the bers to sweep out
additional water vapor laden air and vented to atmosphere in the cabinet. A dew point of -40°F is
achieved at a pressure of 100 psig and ow rate of 4 slpm. Available with NitroFlow60D only.
Prefilters
Water Separator
Inlet Carbon
Module and Filter
3-way Pneumatic Valve
Nitrogen Module
Dryer Membrane
There is one nal activated carbon module and particle lter located at the outlet gas that protects
the gas purity from environmental contaminants to assure medical/research grade is entering the
instrument.
There are two diagnostic indicator lights on the Parker Balston NitroFlow60 System:
High Temperature LED (red): The “High Temperature” LED indicator illuminates when the
compressor pump has reached its maximum temperature. The compressor will shut down by a
thermal switch opening, preventing power to the motor. Compressor restarts automatically as
soon as the over-temperature condition is corrected.
Power On LED (Green): This indicates the compressor is operating.
Outlet Carbon
Module and Filter
Diagnostics
Installation
All installation, operation, and maintenance activities for the NitroFlow60 Generator System
Series (NitroFlow60 and NitroFlow60D) should be performed by trained personnel using
reasonable care to avoid injury or damage.
The NitroFlow60 system has casters and is packed in a wooden shipping container. The
installation kit, consisting of plastic tubing, tube ttings, and a plug is packed in a box inside
the wooden container. Remove the wire L-shaped fasteners from the sides of the container
(see Figure 3). Do not attempt to lift the generator from the container. Remove and locate the
plywood ramp (see Figure 4). Release the locked casters. Move the generator down the ramp.
Move the generator and installation kit to its installation location.
Figure 3 Figure 4
Unpacking

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Location of the generator with proper ventilation is critical. Install the generator in a clean, well
ventilated area. To provide adequate ventilation and servicing for the generator, a minimum
clearance distance of 30 inches in front and in the rear is required (see Figure 5). Fresh intake
ventilation for the generator enters from the bottom and sides, while warm exhaust air exits from
the right, rear side. A minimum of 3 inches clearance is required on both sides of the generator
(see Figure 6).
For the NA Model: The NitroFlow60 Generator Series requires one electrical power outlet:
a dedicated grounded 208 to 254VAC, 60Hz, single phase, minimum 30 Amp circuit breaker
with a NEMA L6-30R receptacle (see Figure 7). Parker requires purchasing a step-down
transformer if your facility voltage is 255 or higher or a step-up transformer if your voltage
decreases below 208VAC. See the accessory section on page 17. Main supply voltage
uctuations must be within ±10% of the nominal main supply voltage.
For the JA and WD Models: The NitroFlow60 Generator Series, rated at 230V, 50 Hz, single
phase, 13A fully loaded installation requires the following electrical setup:
1The supply line should be dedicated to the generator. No other equipment should operate
using the same line.
2The service should be capable of carrying 20 amperes. The wire gauge should be sized
accordingly.
3The service should be protected by a minimum 20 amperes circuit breaker. The value is based
on the application/equipment requirements as well as the electrical components’ tolerance
and uncontrollable external variables.
The generator is for indoor use only. Do not install outdoors. The ambient temperature of
the air surrounding the generator should not exceed 90°F (32°C) or be below 60°F (15°C). If the
generator is located in a totally enclosed room without ventilation, an exhaust fan with access to
outside air must be installed. Do not locate the generator where hot exhaust air from other heat
generating sources may be drawn into the generator. The area should be free of excessive dust,
toxic or ammable gases, solvent fumes, and moisture. An exhaust vent attachment is available
to route exhaust away from generator(see Figure 5). The diameter of the exhaust vent ducting
must be six inches. An in-line duct fan, capable of exhausting 226 CFM, is required for ducting
greater than 15 feet. See Accessory Parts table on Page 17 for details.
The Parker Balston NitroFlow60 Generator Series creates minimal noise during operation. The
noise generated is about 49dB at one meter. Periodically there is an air discharge noise from the
drain port eliminating accumulated uids in the prelters and receiver tank. The noise and heat
generated by the unit should be considered when selecting an installation location. A silencer
kit is included for the drain discharge noise. There is also a pump “burp” noise lasting a few
seconds each time the generator is shut down. This is the compressor depressurizing the pump
during shutdown.
Figure 5 Figure 6
Location
Utilities

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System Comments Region
NitroFlow60NA 230V-60Hz, cordset has U.S. plug North America
NitroFlow60DNA 230V-60Hz, cordset has U.S. plug North America
NitroFlow60WD 230V-50Hz, cordset matched to region Rest of world
NitroFlow60DWD 230V-50Hz, cordset matched to region Rest of world
NitroFlow60JA200 230V-50Hz, cordset has a JA PSE plug Japan
NitroFlow60DJA200 230V-50Hz, cordset has a JA PSE plug Japan
The generator drain tube is a black nylon ¼” tubing connecting the drain outlet to the provided
disposal container (see Figure 8). A blue silencer is provided for the discharge end of the tubing
to reduce the discharge noise. Periodically check the built in strainer to ensure it has not clogged.
The pre-lter and water separator drain tubes are also a black nylon ¼” tubing connecting the
drain outlets to the same provided disposal container (see Figure 9). Blue silencers are provided
for each drain line.
The two outlet gas ports consist of two ¼” NPT bulkhead ttings (NitroFlow60D only. See Figure 10).
The non dry-air version consists of one ¼” NPT bulkhead tting and a cap on the second outlet port.
Parker Balston recommends minimum 3/8” PFA plastic tubing with a minimum pressure rating of
125 psig (8.6 bar). Check all piping connections for leaks using a bubble-type leak detecting
solution.
Drains
Outlet Gases
Figure 8
There are six plastic tubing connections for the NitroFlow60 generator: (1) nitrogen outlet gas
connection; (1) dry air outlet gas connection (NitroFlow60D only); (4) drain connections. Press
the tubing into the quick-connect ttings. Assure tubing is fully inserted (about ½”). Tubing is
provided in the installation kit. For remote locations, additional length tubing is provided.
Piping
The following table describes the necessary cordset based on region. Do not replace the provided
cordset with an inadequately rated cordset. The plug on the cordset is the mains disconnect.
The electrical schematic for the generator is shown in Figure 34 on page 22.
Notes
- “D” designation indicates additional dry air supply for chip cube requirements
- JA-200 versions include an external step-up transformer and gages indicating pressure in kPa
- WD(World Design) requires assignment of appropriate cordset, see table below
A03-0430 NA.............................................................30A, 250V
A03-0344 EU, IND, UK (ROW 230V,50Hz)...............32A, 250V
A03-0345 AU.............................................................32A, 250V
A03-0407 JA..............................................................30A, 250V
A03-0347 CHINA.......................................................32A, 250V
Cordset Rating
Figure 7, NEMA L6-30R 30AMP/250V
Receptacle for Model: NA (North America)

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A03-0286 voltage step-down transformer - If your facility supply voltage is 255V or higher,
then the use of this transformer is required.
A03-0281 voltage step-up transformer - If your facility supply voltage is 195V or lower, then
the use of this transformer is required.
Recommended
Accessories
Figure 11 Figure 12
Check that the power cord of the generator is properly connected to the generator receptacle.
Rotate clockwise to lock. Check that the power cord of the generator is connected to the proper
power supply outlet.
During normal operation, the generator’s power switch is illuminated green. The compressor
pressure gauge indicates a pressure between 115 to 120 psig (7.9 to 8.2 barg). If the pressure
drops below 115 psi, then the nitrogen ow is too high. Maximum nitrogen pressure should
not exceed 100 psi at the maximum ow rate of 60 slpm. The compressor operates on a
100% duty cycle (pump on continuously).
The generator has its own automatic water drain system. The 3 lters located on the back of
the generator are equipped with pneumatic drains that open when the water level reaches a
predetermined point. Compressor drain operate every 10 minutes, opens for 2 seconds; the two
internal lter bowls also drain every 10 minutes.
The generator cabinet has two LED indicators (see Figure 13): Power ON, and High Temperature.
The green LED remains illuminated during normal operation. The other LED indicator,
“High Temperature” remains unlit if the compressor is functioning properly. Red illumination
of the High Temperature LED signals a faulty condition and warns the operator that the unit
requires servicing.
Rotate, clockwise, the Power On (see Figure 11) on the front panel of the generator. The
generator will start and the green LED will illuminate. The pressure gauge indicates compressor
pressure. The pressure slowly increases to a maximum set pressure of 125 psig
(8.6 barg). Full pressurization will occur within 10 minutes.
Rotate the nitrogen regulator knob to set the desired outlet pressure as indicated by the nitrogen
output gauge (see Figure 12)
Start-up
Operation
Diagnostics
Operation
Figure 9 Figure 10
POWER

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Figure 13 Figure 14
If the compressed air pressure decreases less than 90 psig (6.2 barg), the nitrogen output purity
level will decrease. Once pressure is restored, purity level will be restored.
The compressor output pressure gauge should read 115 psig to 120 psig during normal
operation.
See the Troubleshooting section of this manual on pages 17-20 to resolve any abnormal or faulty
conditions.
If the electrical power is interrupted, the generator will start automatically when the power
returns.
For normal or emergency shutdown, pull out the plug on the cordset to disconnect the mains
power (see Figure 1). Full depressurization takes 1 hour. Do not remove cover while system
is pressurized.
Maintenance tasks for the NitroFlow60 and NitroFlow60D Generator should be performed by
trained personnel familiar with the service and safety precautions of electromechanical devices
to avoid injury or damage. Safety risks that may affect the service personnel are identied with
the necessary protective measures described.
Parker highly recommends service be performed by a Parker trained technician only. Call
the factory about PMP, the Preventative Maintenance Program. The service personnel will
verify the safe state of the generator after the maintenance or repair is completed.
Prior to servicing the generator, turn off the system and disconnect the cordset from the power
supply. Allow the system a minimum of 1 hour to depressurize. See shutdown section above.
To ensure product performance and reliability, periodic preventative maintenance must be
performed according to the following schedules (refer to the replacement parts section for
the part numbers when ordering); Schedule 1 is servicing the compressor and Schedule 2 is
servicing the generator.
Pressure Interruption
Power Interruption
Shutdown
Maintenance
The compressor has an hour meter to record the accumulated operating time of the compressor
for preventative maintenance scheduling of the serviceable components. The meter indicates
00000.0 hours. The hour meter is not re-settable.
POWER
POWER

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Schedule 1 (refer to gures 15 and 16)
Replace Quantity Hours¹
Intake Filter 2 8700 hours
Belts 2 8700 hours
Tip Seal Set 1 8700 hours
Grease 1 8700 hours
Pump 1 30,000 hours
Discharge Pipe Sleeve 1 8700 hours
Schedule 2 (refer to gure 17)
Replace Quantity Hours¹
Filter Element
(P/N 100-18-DX) 1 8700 hours
Filter Element
(P/N 100-18-BX) 1 8700 hours
Filter Silencer
(P/N 75117) 1 8700 hours
Filter Element
(P/N 100-09-BX) 2 8700 hours
Carbon Module
(P/N B04-0525) 2 8700 hours
Schedule 1
Compressor
Figure 16
Figure 15
Figure 17, Maintenance Items
Schedule 2
Nitroflow60 and
Nitroflow60D
Generator
¹ Frequency hours for NitroFlow60 and NitroFlow60D are recorded by an hour meter.
Note: The meter indicates 00000.0 hours. The hour meter does not reset.