Parker Balston GC-4000 User manual

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
www.labgasgenerators.com
1
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 certification
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!
Shelf Life is 3 months. The generator should be run every 3 months. See Operating and
Storage instructions for more detail
Figure 1 - FID Gas Station
FRONT VIEW RIGHT SIDE VIEW
Installation, Operation, and Maintenance Manual
Parker Balston®GC Gas Stations
GC-4000 and FID-4000

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
2
General Description
Regulatory Compliance The GC Gas Station is to be certified to the electrical safety requirements as specified by the
IEC, CSA, and UL standards. These units bear both the CSA and UL markings on the product
label. Products supplied to Europe carry the CE mark (220, 230, 240 VAC units only). The
generator meets EMC compliance.
The Parker Balston Generator includes all of the components necessary to purify compressed
air into zero-grade hydrocarbon-free air. The generator comprises three primary functional
groups: prefiltration, hydrocarbon removal and final filtration (see Figure 2).
A high efficiency coalescing filter has been incorporated into the design of the Parker Balston
GC Gas Station as a prefilter to remove oil, water, and particulate contamination from the
incoming compressed air supply. The prefilter assembly is equipped with an solenoid au-
todrain to eliminate any liquids which have accumulated within the filter housing. The solenoid
drain opens to dump condensate once per hour for 1 second. If the condensate capacity
exceeds the volume of the filter 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 filled 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 4000 cc/min of zero-grade
hydrocarbon-free air to the instrumentation downstream.
The final filter on the Parker Balston GC Gas Generator is a high efficiency filter which
removes particulate contamination to 0.5 micron. This final filter ensures that the outlet air
from the Parker Balston Gas Station is particle-free.
Zero Air System
Prefiltration
Hydrocarbon Removal
Final Filtration
GC 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
filter, a palladium purifier. The outlet pressure of the hydrogen unit is regulated. With delivery
pressure up to 100 psi with a maximum hydrogen delivery flow rate of 500 cc/min. The GC Gas
Station is ideal for use as fuel or carrier gas in GC applications, Trace Hydrocarbon Analyzers,
and other general laboratory equipment requiring a source of pure hydrogen.
The Parker Balston Gas Generator also incorporates 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 0.05 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.
It is capable of producing 4000 cc/min of zero grade air .
Figure 2 - Flow Schematic Zero Air
(Model GC-4000, FID-4000)

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Technical Information GC Gas Stations GC-4000, FID-4000
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Hydrogen System Diagram
Fill
Reservoir
Deionizer
Resin
Cartridge
Main
Reservoir
Main
Reservoir
Fill pump
Water
Pump
Cell
Water Fill
Solenoid
Cell
Water
Dump
Solenoid
PEM Cell
Hydrogen
Vessel
Hydrogen
Palladium
Purifier
Outlet
Pressure
Regulator
Hydrogen
Outlet
Pressure Relief
Valve
PCB
Water
Quality
Sensor
Left Side Drain port
Right
Side
Drain
port
The Parker Balston GC 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 palladium
purifier (See figure 3).
The main water tank contains the water required for the electrolysis process. When operating the GC
Gas Station, the hydrogen cell takes water, continuously, from the main water tank. The tank has a
float switch which monitors water level, if the water level gets too low, the ADD WATER message ap-
pears on the LCD. Water is then added to the fill tank- the water quality is checked- and the main wa-
ter tank is refilled. The generator will continue to run with the ADD WATER message displayed. If the
LOW WATER LEVEL message is displayed the generator is disabled and an audible alarm will sound.
The fill tank holds 1 liter of water. The main tank holds 3.5 liters of water. If the fill tank is manually
filled to the top, the generator will have a minimum of 30 hours of operation before the ADD WATER
message is displayed. However, the generator will continue to operate for an additional 105 hours
from the water in the main tank (with the ADD WATER message displayed), once the main reservoir
is depleted, the LOW WATER LEVEL message is displayed the generator is disabled and an audible
alarm will sound.
The unit may be run in either auto water feed or manual mode. See Filling the Water Reservoir sec-
tion for detailed information.
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.
The final stage of the hydrogen process is purification through the palladium purifier. Any liquid water
or moisture carried over in the electrolysis process is removed to purity 99.99999%. In the purifier,
the hydrogen is heated and then passed through a palladium membrane. Only hydrogen atoms can
permeate the palladium membrane, thus providing ultra high purity hydrogen. The heated hydrogen
gas is cooled on the way to the pressure regulator. The pressure regulator governs pressure of the
outgoing gas supply. This output pressure is displayed on the front panel liquid crystal display, or LCD.
You can adjust the output pressure using the control on the top of the unit.
PEM Cell
Palladium Purifier
Hydrogen System
Water Feed
Figure 3 - Hydrogen System Diagram

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
4
Note: All installation, operation and maintenance activities for the GC Gas Stations should
be performed by suitable personnel using reasonable care.
The GC Gas Station is 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 1/4” NPT. The Zero Air Outlet port is
¼ NPT, which is in the outlet filter and is located to the left of the Inlet port. The Hydrogen
Outlet is a SS 1/ 4” Compression Union. The Drain Port is 1/4”NPT and is for compressed air
condensate and water vapor from the hydrogen purifier. It is located at the bottom right hand
side of the generator (see Figure 4).
General
Installation
Hydrogen Outlet
Compressed Air Inlet
and Inlet Filter
Zero Air Outlet
and Outlet Filter
Drain Port
Water Fill Port
Figure 4 - Right Side with Cover Removed

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
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A shut-off valve and a pressure regulator should be installed, on the compressed air line,
directly upstream from the Parker Balston GC Gas Station. The shut-off valve isolates the unit
from the air line for maintenance and troubleshooting 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 fluctuations, 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 GC Gas Station 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-100°F (16°C-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 GC Gas Station weighs 67 lbs (30 kg). Use proper equipment and lifting techniques for
transporting this equipment to its installation location. The GC Gas Station is intended to
remain stationary when filled with water. If necessary, the generator may be transported over
short distances when filled. 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 GC Gas Station. Remove the red caps/ tape sealing the back panel outlet
fittings.
Power -The Parker Balston GC Gas Station may be operated by a 120 VAC, 220 VAC, 230 VAC,
or 240 VAC, 50/60 Hz power supply. Main supply voltage fluctuations must be within ±10% of
the nominal main supply voltage. The generator is shipped with a tag at the power receptacle
which specifies the factory setting of the voltage selector. For optimal performance of the
generator, 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.)
Deionized Water – The GC Gas Station / 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
HydroGen Mate (P/N 72-230 or 72-231) that provides high purity water (>5 Meg-Ohm/cm)
from tap water for manual filling or autofilling the generator.
Caution: Cell contamination is a cumulative and irreversible process which will eventually
cause an over-voltage fault, automatically shutting down the generator.
Location
Symbols
Transportation
Preparation
Utilities

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
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Filling the Water
Reservoir
Compressed air - The Parker Balston GC Gas Stations 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 flow 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. Contamination 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 prefiltration upstream from the unit (see
Recommended Accessories).
Chlorinated hydrocarbon compounds and chlorofluorocarbons (or freons) will permanently
contaminate the hydrocarbon catalyst module in the GC Gas Station. 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 GC 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.
Piping Components, GC Source Gas / Zero Air - Connect the compressed air supply to the inlet port
for the Parker Balston GC Gas Station, which is 1/4” NPT and is located as shown in Figure 4. Inlet
tubing and fittings should be clean and rated for 125 psig (8.5 Barg), minimally. The tubing and
fittings used downstream from the GC Gas Station should be clean stainless steel or pre-cleaned
refrigeration-grade copper (1/8” OD) and rated for 125 psig (8.5 Barg) . Connect downstream
delivery lines (Zero Air Outlet) to the 1/4” NPT port on the outlet filter of the generator.
Do not use plastic tubing downstream from the generator. Out gassing from the plastic may
contaminate the zero-grade gas. Use PTFE tape on all inlet and outlet NPT fittings. (Thread
sealing compounds may contaminate the process stream). 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 specifications.
Piping Components,GC Gas Station / Hydrogen - The outlet connection for the GC Gas Station/
Hydrogen is a 1/4 compression fitting. All tubing and fittings downstream 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 acceptable results, there is
no need to alter an existing piping configuration to install the hydrogen generator.
Flow Controller - A flow control device should be installed downstream from the zero air and
hydrogen outlets if one is not integral to the instrumentation used (P/N Model W-FM7583). If
the flow capacity of the generator is exceeded, the GC Gas Station / Zero Air will fail to meet its
hydrocarbon specification.
Pressure Regulation -The GC Gas Station / Hydrogen pressure can be regulated up to 100psig. The
output pressure can be monitored using the front panel digital display. There is an internal Pressure
Relief Valve that is preset to 175 psig in case of excess internal pressure build up. The expelled gas
is channeled through the pressure relief valve. The GC Source Gas Zero Air can also be regulated
down from its supply pressure. However, the zero air outlet pressure is not displayed on the
generator and is not regulated by the generator.
Use only 5 Meg-ohm/cm (0.2 µS) deionized water in the generator to prevent contamination
of the cell assembly. Water containing metallic impurities will damage the cell and will be
cause for voiding the warranty. Cell contamination is a cumulative and irreversible process,
eventually resulting in an OVERVOLTAGE condition and cell failure. Use only clean glass or
plastic (HDPE only) containers to supply water to the generator.
If poor quality water is added to the generator a “Change water” message will be displayed.
User must then drain the water from the Fill reservoir, through the right-side drain port. Once
the poor quality water is drained, the deionizer resin cartridge must be changed as shown in
the Maintenance section.

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Figure 5 - Gravity Feed Water Source / Pressurized Water Source
For Manual Fill operation, simply open the top cover, locate the Fill Reservoir, loosen
the cap and slowly add water until the Fill reservoir (see figure 6) is full. Once full,
and when water quality is verified by the generator’s sensors, the “Main Reservoir fill
pump” activates and the water is transferred to the Main reservoir. An “Add water”
message will be displayed until the main reservoir is full. This fill reservoir may
need to be filled multiple times. Approximately four liters of water are required to
completely fill the generator.
Caution: Fill slowly.
The GC Gas Station’s default mode of operation includes an auto water feed system. If that
system is NOT used, by the operator, then it will become disabled to prevent repeated, unnec-
essary actuation of the auto water feed solenoid valve. To reactivate the auto water feed, con-
nect a source of deionized water to the water fill port, as described previously, AND manually
top off the Fill reservoir. The generator will then re-enter auto water feed mode.
Manual Fill
The GC Gas Station’s default mode of operation includes an auto water feed system. If that
system is NOT used, by the operator, then it will become disabled to prevent repeated, un-
necessary actuation of the auto water feed solenoid valve. To reactivate the auto water feed,
connect a source of deionized water to the water fill port, as described below, AND manually
top off the Fill reservoir. The generator will then re-enter auto water feed mode.
Gravity Feed From External Reservoir
1. With the round external water fitting connected to the Water Inlet Port on the back of the
generator (see Figure 5), fill the external reservoir with deionized distilled water. The
‘‘external water insert’’ is supplied with a length of Tygon™ tubing for connection to the
reservoir.
2. The Fill reservoir will be filled first by the water feed solenoid. When the level switch
is activated and when water quality is verified by the generator’s sensors, the “ Main
Reservoir fill pump” activates and the water is transferred to the Main reservoir. An “Add
water” message will be displayed until the main reservoir is full. Approximately four
liters of water are required to completely fill the generator.
External Pressurized Source
1. With the hexagonal external water fitting connected to the Water Inlet Port on the back of
the generator (see Figure 5), connect the generator to the pressurized source and turn on
the water supply. The ‘‘external water insert’’ is supplied with a length of Tygon™ tubing
for connection to the water source.
2. Check to make sure that the Fill water reservoir is filling. Approximately four liters of
water are required to completely fill the generator.

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
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Zero Air Start up
Hydrogen Start up
Startup
Figure 6 - Location of items for water filling
Fill Reservoir
Right-side
Water Drain
Deionizer Resin
Cartridge
Hydrogen Outlet
Pressure
Regulator
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 the pressure regulator. Adjust the zero air output flow (using a customer
installed flow controller) to the rated flow 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 and
the purifier will begin to heat up. The Parker Balston GC Gas Station requires approximately
90 minutes to warm up and achieve hydrocarbon removal to 0.05 ppm (see Figure 5 Power Up
/ Start Up Sequence) and Hydrogen flow at the specified flow rate.
1. If the hydrogen line needs to be purged before the hydrogen can be used on the
equipment, make sure a 3-way valve is installed in line directly upstream from the
instrument.
Note: The recommended 3-Way Valve is Parker 4Z-B6XJ-SSP.
2. Make sure all gas connections are secure.
3. Set the Pressure Regulator under the top cover to minimal pressure by turning it in a
counter-clock-wise direction (the knob should move up) until it cannot be turned any
more.
4. On the back panel, the Power Switch should be in the ON position. The LCD will display
the WARMUP message. Next, the remaining warm-up time will be displayed (for
approximately 90 minutes )
Note: Except when the unit requires servicing, keep the Power
Switch on, to prevent damage to the palladium membrane in the
purifier.
5. When the warm up is complete, the LCD will show the Hydrogen outlet pressure and the
present flow rate as a percentage of the generator’s maximum rated capacity. It will also
display Zero Air “at temperature”.

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6. Turn the pressure regulator in a clockwise direction to increase the outlet pressure. If
100 psig is required, turn the pressure regulator all the way in (clockwise) to the maximum
value. If 40 psig is the desired outlet pressure then turn the regulator approximately 3 full
turns (360°) clockwise and observe display.
Note: The greater the volume between the hydrogen generator and the
instrument, the longer it will take to pressurize the line and the longer it will
take for the display to indicate the set pressure.
7. Purging - If you have installed the Parker 3-Way valve in line and want to purge the lines,
first turn the valve to the middle position to pressurize the lines. Next turn the valve
to the vent port position to allow the hydrogen gas to vent for 2 minutes. Repeat the
pressurization/purge routine at least 5 times before allowing flow to the instrument.
8. Flowing - Turn the three-way valve to the instrument flow direction. Adjust the flow
controller (on the instrument) until the desired flow rate is reached, with a maximum of
500 cc/minute.
1. Check water level. Fill generator until the “Add Water “ message is no longer displayed,
either manually of through the auto water fill port.
2. Connect to suitable power line
3. Supply compressed air to 125psig maximum at the 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 (90 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. Set the Pressure Regulator by turning it in a counter clockwise
to decrease downstream pressure or clockwise to increase pressure.
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 genera-
tor until compressed air is at rated capacity.
Quick Start
Instructions
After replacing any parts downstream of the generator, or upon initial startup, the system will
need to be purged to achieve the final 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. Set the Pressure Regulator to minimal pressure by turning it in a counter clockwise direction
until it cannot be turned any further.
3. Connect the power cord to the GC Gas Station and turn the power switch to ON. The unit will
start to generate Hydrogen. Wait until the internal pressure reaches the desired pressure
(approximately 15 minutes).
4. Set the output flow rate to 50 cc/min by using the downstream equipment or if a three way
valve was installed, then switch the flow to the outlet (or purge port) and set the fl ow rate
using a needle valve. Use the downstream equipment only if impure hydrogen will not ruin
the equipment.
5. 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

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
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1-800-343-4048
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After the generator has warmed up, adjust the flow to meet the requirements of the application.
Do not exceed the rated flow of the unit. If the rated flow of the GC Gas Station/ ZAG is exceeded,
the life and performance of the unit will be adversely affected and the warranty will be void. The
outlet air will contain hydrocarbons in excess of 0.05 ppm.
The Parker Balston GC Gas Station 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 GC Gas Station’s hydrogen system should be run
continuously. Monitor the Hydrogen consumption of the downstream equipment to ensure flow
is within the capacity of the generator (see the System Specifications section for rated flows).
The Front panel Display should be illuminated.
The water level should be monitored regularly and refilled as necessary, if Manual Fill opera-
tion is in use. Otherwise, ensure that the Autofill tubing is installed correctly and connected to
a suitable DI water supply. The reservoir holds enough water for at least a week of continuous
operation. Water can be added manually by removing the reservoir cap and slowly adding water
to the Fill reservoir ( see the Water Reservoir section in Startup). Reinstall cap.
To maintain the integrity of the Hydrogen cell, follow the guidelines listed below:
1. Maintain a supply of deionized water in the main reservoir s indicated above or ensure that
the Autofill is directly connected to a DI 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. If Manual Fill operation is in use, the water level should be monitored regularly and
refilled as necessary. Otherwise, ensure that the Autofill tubing is installed correctly and
connected to a suitable DI water supply. The reservoir holds enough water for at least 5
days of continuous operation. The ADD WATER message will be displayed when the main
reservoir level drops, but the generator will continue to run normally until LOW WATER
LEVEL message is displayed. Water can be added manually by removing the reservoir cap
and slowly adding water to the Fill reservoir ( see the Water Reservoir section in Startup).
Reinstall cap.
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

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
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Operational
Summary
The following list summarizes the operational procedure required for using the hydrogen generator.
Warning: Under no circumstances should the generator be operated with the covers removed.
1. Fill the water tanks with deionized water. To use the external water fill option, connect the deionized
water supply to the Water Inlet Port on the back panel of the generator using the proper fitting.
2. Connect your downstream equipment to the Hydrogen Outlet Port on the back panel of the
generator.
3. Properly adjust your external flow controlling devices so there is very little flow.
4. Set the Pressure Regulator to minimal pressure by turning it in a counter-clockwise direction until
it cannot be turned any more.
5. Open the inlet air supply valve (customer supplied, see Installation section) and adjust the inlet
pressure to be between 40 psig and 125 psig (2.7 barg and 8.5 barg) using the pressure regulator.
6. Check that the power switch on the back panel is in the ON position. Check that the normal display
mode is active. The LCD will display the output pressure and the flow rate percentage, to show that
hydrogen is being generated and zero air “at temperature”
7. If the generator has been idle for an extended period of time, or components have been replaced,
perform the controlled venting procedure.
8. Adjust the pressure with the Pressure Regulator and then adjust the flow (see page 14 for details).
Note: To prolong the life of the purifier assembly, maintain power to the system unless extended
periods of non-use are expected.
The Parker Balston GC Gas Station normal operation display shows the generator status, hydrogen flow
and zero air status of the unit. The 4-line display will show:
• Hydrogen usage in % of capacity- So 100% display indicates 500cc/min hydrogen is being
produced by the cell
• Hydrogen pressure at the outlet
• Zero air at temperature- indicating the zero air module can produce gas at the required purity.
Normal Operation
Display
The Parker Balston GC 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. Initial start up display will show Hydrogen and zero air “WARMING
UP” with a timer counting down from 90 minutes. After 90 minutes, both hydrogen and zero air can be
output to required specifications. The warm up is only required if the unit is powered on/off at the rear
switch, otherwise the zero air module and hydrogen purifier will remain at temperature and do NOT
require warm up.
The Control circuitry controls the hydrogen cell current to a safe level and eliminates the possibility
of excessive Hydrogen production. It also controls zero air module temperature to meet the zero air
purity requirements. 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 when the following error conditions are displayed:
• Add water / water level low / change water
• Over voltage of hydrogen cell
• Excess flow demand of hydrogen / overflow / low pressure*
• Reduced water circulation
• Zero air overflow / excess hydrocarbons
• Generator disabled/ Zero air and purifier low temperature
• Zero air service required
Once the error condition is corrected, the unit will resume operation.
*In the case of hydrogen overflow / low pressure, to clear the error message and resume
operation, the unit will have to be shut down and restarted.
Diagnostics

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Shutdown
Storage
Shipping
If the unit is to be idle for more than 24 hours, the generator can be turned off. However,
Parker recommends allowing the GC Gas Stations to run continuously, 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 and purifier
heater as well as the Electrolytic Proton Exchange Membrane Cell and eliminates the 90
minute warm up period.
To shut down the Parker Balston GC Gas Station, turn the power switch to the OFF position.
Maintain the compressed air flow 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 flow
rate through the unit is at the rated capacity (see Specifications section, page 18). 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 GC Gas Station OFF and allow the Hydrogen gas to purge slowly until all the
internal gas is removed.
2. Then cap the Hydrogen outlet on the back of the generator or leave it connected to the
downstream equipment.
3. Fill the Main Reservoir at least half full with deionized water.
4. 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 balstontechsupport@
parker.com for a Return Authorization (RA) number and new Packaging if the original is no
longer available.
1. Purge and bleed the GC Gas Station of all compressed air and hydrogen. Wait until the
outlet pressure display reads zero.
2. Drain the water from the Main and Fill reservoirs using the Water Drain Port Insert
(connected to a 3’ length of 3/8” OD tubing) and connect it to the drain ports located on
the right and left side 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. 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 assembly.

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
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13
Figure 7 - Shown with main cover removed
Main Reservoir
Water Pump
Zero Air
Module
Air fittings
Zero Air
Catalyst
Module
Figure 8 - Shown with side cover removed
Left side Main
Reservoir Drain
Right side
Fill Reservoir
Drain
Zero Air
filter
Fill
Reservoir
Deionizer
Resin
Cartridge
Hydrogen
Purifier
Zero Air
Module
Connector
PEM
Hydrogen
Cell
PEM Cell
Solenoid
Valve
Compressed
Air Filter
Hydrogen
Pressure
Regulator
Base
Access
Cover
Water Pump
Block
Main
Reservoir
Fill Pump

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
14
No Power
Troubleshooting / Error Messages
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.
Check power source and connections to the power source.
Check terminal connections and power cord.
Check power source fuses.
Check generator fuses.
Completely fill the “Fill” Reservoir with deionized water. Once full, and when water quality
is verified by the generator’s sensors, the water is transferred to the Main reservoir. An “Add
water” message will be displayed until the main reservoir is full. The fill reservoir may need
to be filled multiple times.
Main reservoir fill pump is not working. Verify operation and replace pump if necessary.
Auto -Water fill 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 refill.
Operator has switched from manual to auto water feed mode. The user must follow
instructions in Filling the Reservoir section to reactivate the auto water feed system.
Completely fill the “Fill” Reservoir with deionized water. Once full, and when water quality is
verified by the generator’s sensors, the water is transferred to the Main reservoir. An “Add
water” message will be displayed until the main reservoir is full. The fill reservoir may need to
be filled multiple times.
Cell water fill solenoid not working. Verify operation and replace solenoid if necessary.
Main reservoir fill pump is not working. Verify operation and replace pump if necessary.
Auto -Water fill port is blocked / plugged.
Check tube fittings for leaks or connection to tubes.
Water drain tubing kit still installed. Remove kit to allow unit to refill.
DI water supply shut off, ie.. Gravity or Pressure lines closed off.
Consult factory if display does not change status.
Operator has switched from manual to auto water feed mode. The user must follow instruc-
tions in Filling the Reservoir section to reactivate the auto water feed system.
An insufficient amount of water is being pumped through the cell.
Check tubing for leaks.
Check tube fittings for leaks or connection to tubes.
Pump malfunction. Check electrical connections. If OK then replace pump.
Water flow in cell has been restricted. Eliminate cause of restriction and restart.
If restriction is internal to the cell- cell replacement is required by factory.
Water flow sensor in pump block malfunction. Consult factory for replacement.
Add Water
Reduced Water
Circulation
Symptom Course of Action
Low Water Level

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
www.labgasgenerators.com
15
Change Water
Low Cell Pressure
Cell Over Voltage
No Hydrogen Delivered
Low Output Pressure
Symptom Course of Action
Low Zero Air Pressure
Excess Hydrocarbons
Service Zero Air Module
Poor quality water added to fill reservoir. See maintenance section for Deionizer Resin
Cartridge replacement.
Hydrogen Overflow due to a leak detected in system or downstream. If the hydrogen pressure
drops below 10 psi, the “Cell Pressure Low” will be displayed. To clear error message, shut
down then restart generator.
Hydrogen demand exceeds generator capacity. Check capacity of equipment and piping
downstream and install a flow control device. To clear error message, shutdown then restart
generator.
Check internal system piping for leaks. To clear error message, shutdown then restart
generator.
Adjust regulator to desired output pressure.
Hydrogen demand exceeds generator capacity. Check capacity of equipment and piping down-
stream and install a flow control device.
Check external system piping for leaks.
Check internal system piping for leaks.
Check power connections (see "No Power").
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.
Heater defect. Low temperature. Allow purifier to heat up OR heater problem. Consult
factory
Cell voltage is out of normal operating range.
Change water and refill. Restart unit. If error message was due to poor water quality then
message would be cleared. If message not cleared, consult factory for cell replacement.
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 flow demand and overflow condition. Flow demands in excess of capacity may cause high
pressure drop through generator.
Low temperature. Allow purifier to heat up OR heater problem. Consult factory.
Check generator for leaks.
The Zero Air has not reached adequate temperature . Allow a minimum startup, warm up
period of 55 minutes .
Check downstream Zero Air flow demand. If flow 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 flow controller downstream from the zero air output.
Display message indicates the 2 year service is required for zero air module. Replace per
maintenance instructions of consult factory

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
16
Maintenance
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 GC Gas Station are: changing
the deionizer resin cartridge, changing the compressed air filter cartridge (annually),
changing the zero air filter (annually), and replacing the catalyst module (3 years), replacing
the water pump (3 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 7 and 8 for the
locations of the maintainable components.
Additional coalescing compressed air prefilter cartridges and final filter cartridges for
the Parker Balston GC Gas Stations may be ordered through your local representative.
For convenience, the replacement filter cartridge, final filter, DI resin cartridge have been
assembled into a maintenance kit. With proper care and maintenance, the GC Gas Station 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 GC Gas Station, isolate the unit from the compressed
air source and electrical supplies. Decrease hydrogen output pressure to zero. Turn
power switch, at the rear of the unit OFF and unplug.
Warning: Unit must cool down for 2 hours prior to any zero air catalyst or purifier service.
The compressed air filter is located on the outside rear panel of the generator. Isolate the
generator from the compressed air supply and let outlet pressure drop to zero. The filter
cartridge inside the housing should be changed on an annual basis to maintain efficient
operation of the system. Remove the filter cartridge housed in this filter assembly by
unscrewing the filter bowl from the filter head. Insert the new filter cartridge (P/N 050-05-BX)
and re-assemble the filter housing in reverse order.
The zero air filter is located on the outside rear panel of the generator. Isolate the generator
from the compressed air supply and let outlet pressure drop to zero. The GS050-05-95 filter is
inside the housing and should be changed on an annual basis to maintain efficient operation of
the system. Remove the filter cartridge housed in this filter assembly by unscrewing the filter
bowl from the filter head. Insert the new filter cartridge (P/N GS050-05-95) and re-assemble
the filter housing in reverse order.
General
Compressed Air Filter
Cartridge Replacement
Zero Air Filter Cartridge
Replacement
Switch power OFF to unit and unplug generator from power. Allow the compressed air
to continue to flow 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 6 screws from the right side cover. See figure 8.
Remove Base Access cover from beneath the zero module- 2 screws. This allows the zero air
module to be lowered away from the hydrogen purifier
Disconnect Catalyst Module connector located on rear, right side of the unit (see Figure 8).
Make note of its orientation for replacement of the module.
Disconnect inlet and outlet air fittings, as shown in figure 8, using two 7/16” wrenches. One
wrench holds the fitting, while the other loosens the compression nut closest to the zero air
module.
Zero Air Catalyst Module
Replacement

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
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Remove 2 screws, using a “stubby” screw driver, holding the catalyst assembly module cover
to the base of the hydrogen purifier.
Slowly lower the module though the access opening in the base of the generator- as far as
needed to free the module from the hydrogen purifier. The rear of the generator may be
propped up to allow more clearance for module removal. Then remove module.
Replace with new assembly. Lowering module into the access opening, first, then sliding it up
into the hydrogen purifier.
Reverse above procedure – reassemble module cover onto hydrogen purifier, reconnect air
lines.
Re-attach electrical connector. Electrical connector must snap into receptacle. Connector
must be fully engaged and is designed to be installed only 1 way.
Pressurize the system and check for leaks in the air lines and fittings.
Re-assemble covers to unit and supply power.
Water Pump
Replacement
1. Switch power OFF to unit and unplug generator from power. Allow the compressed air
to continue to flow through the unit to improve heat dissipation during cooling. Purifier/
Zero Air module and cooling coil will be hot. Allow unit to cool 2 hours before opening.
2. Close the (customer installed) inlet air valve.
3. Remove left-side cover. There are 3 screws on the left side of the unit and 3 under the
hinged cover.
4. Locate water pump (see figure 7). Disconnect water pump connector.
5. Disconnect water pump tubing from the base of the water pump block and from the PEM
hydrogen cell (figure 7).
6. Remove thumb screws holding water pump block cover to water pump block.
7. Remove the 2 M3 screws that mount water pump to the water pump block cover.
8. Remove the pump and replace, using pump replacement assembly B02-0602.
9. Install 2 M3 screws into mounting holes using gaskets provided. The two gaskets are
installed on each screw on both sides of the chassis.
10. Install screws into water pump.
11. Reinstall thumbscrews to mount water pump cover.
12. Reinstall connector on water pump.
13. Reconnect tubing to water pump block and PEM hydrogen cell.
14. Briefly connect unit to power and turn unit ON to verify pump operation and no tubing
leaks. Once operation is verified reinstall covers.
15. Reinstall left-side cover and operate per the manual.

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
18
See “Filling the Water Reservoir” (Page 7) for operation details.
Refill the water in the generator whenever the ADD WATER message is displayed on the front
panel. An audible beep will be heard as soon as the level is reached. If the GC Gas Station
is connected to an external DI Water source and is permanently connected, the unit will be
remotely filled using the Autofill function of the generator.
The water reservoir should last approximately 1 week when the main reservoir and the the
fill reservoir are filled.
If the LOW WATER LEVEL message is displayed, the generator will be disabled, until DI water
is added to the generator. The GC Gas Station will stop producing hydrogen to safeguard the
Hydrogen cell from permanent damage. Add water to the generator until the ADD WATER
message is no longer displayed. The unit will automatically start to produce Hydrogen as
soon as the LOW WATER LEVEL sensor is actuated.
If poor quality water is added to the generator a “Change water” message will be displayed.
User must then drain the water from the Fill reservoir ONLY, through the right-side drain port.
Once the poor quality water is drained, the deionizer resin cartridge must be changed. To
change cartridge, remove access door, depress tabs on the upper and lower quick-disconnect
fittings. Remove cartridge and replace.
Water Refill
Deionizer Resin Cartridge
Upper quick-
disconnect fitting
Figure 9 - Location of Drain Port & Deionizer Resin Cartridge
Right-side
Drain Port
Deionizer Resin
Cartridge
Lower quick-
disconnect fitting
Replacement Parts
Description Part Number Frequency
Fuses 117 vac A03-0066 As needed
Fuses 220 vac 13215 As needed
Maintenance Kit (compressed air filter ,zero air filter)
MKGCGS7890-12 1 Year
MKGCGS7890-36 3 Years
ZAG Catalyst Module B02-0603 3 years
Water Pump B02-0602 3 years
Main Reservoir Fill Pump B02-0553 As needed
DI Water Fill Solenoid B02-0491 As needed
Deionizer Resin Cartridge B02-0568 As needed

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
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Occasionally, the fuses in the GC 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 GC Gas Station, both the phase and the neutral
are fused separately. As a result of this configuration, 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 Specifications, Parts and Accessories sections of this bulletin.
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
(see Page 19).
If necessary, the GC 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 fluids on any Lexan plastic parts in the generator.
These fluids 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.
Fuse Replacement
Maintenance Notes
Hydrogen Purity 99.99999%
ZAG Purity <0.1 ppm Methane in Air Challenge
CSA Certification Standard CAN/CSA C22.2 No 1010.1-92 (in process)
IEC Certification Standard IEC 1010/EN61010-1 (in process)
IEC 1010 Installation Category Category 11
IEC 1010 Pollution Degree Degree 2
UL Safety Standard UL 3101-1, First Edition (in process)
EMC Compliance CISPR11:EN55011:1991/EN50082-1:1992 (in process)
Maximum Flow rate ZAG 4000cc/min
H2 500cc/min
Total Hydrocarbon Concentration < 0.05 ppm
Max Inlet Hydrocarbon Concentration 100 ppm
Pressure Drop at Max. Flow rate < 5 psid (0.3 bar)
Outlet Air Temperature ambient + 20°F (+ 11°C)
Discharge Pressure 0-100 psig ( 0-7 barg)
Hydrogen Outlet Port 1/4” compression, SS
ZAG Outlet Port 1/4” NPT
Hydrogen Relief Port 1/4” Female NPT
Compressed Air Inlet Port 1/4” NPT
Water Requirements Deionized Water (> 5 Meg-Ohm /cm) OR (0.2 µS)
Max. Ambient Relative Humidity 80 %
Min/Max Ambient Temperature 60°F/100°F (16°C/40°C)
Min/Max Inlet Pressure 40/125 psig (2.7 barg/8.5 barg)
Altitude 2000 M
Electrical Requirements 100-120/200-240 VAC,47-63Hz
Power Consumption 480 Watts @ 110 vac, 460 watts @ 220 vac
Start Up Time 90 minutes
Fuses 120 vac: 5 x 22 mm, Type T, 250 V, 6.3 Amp
220 vac: 5 x 22 mm, Type T, 250 V, 3.15 Amp
Product Dimensions 11”w x 17”h x 27”d (38cm x 43cm x 69cm)
Product Weight/Shipping Weight 67 lbs (30.4 kg)
Principal Specifications

Bulletin TI-GCGS-E Installation, Operation and Maintenance Manual
Technical Information GC Gas Stations GC-4000, FID-4000
1-800-343-4048
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1Complete and mail or fax in your warranty registration card (978-478-2501).
2Keep your product certification in a safe place.
3Call 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 locations,
please contact your local representative or email at [e-mail].
The serial number for the unit is located on the back of the unit. For your own 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.
Don’t Forget To:
Serial Numbers
WARRANTY NORTH AMERICA ONLY
FOR INFORMATION CONTACT YOUR LOCAL REPRESENTATIVE
Parker Hannifin guarantees to the original purchaser of this product, that if the product fails or is defective
within 12 months from the date of purchase, when this product is operated and maintained according to the
instructions provided with the product, then Parker guarantees, at Parker’s option, to replace the product,
repair the product, or refund the original price for the product. This warranty applies only to defects in
material or workmanship and does not cover: ring and valve wear on compressors, routine maintenance
recommended by the instructions provided with this product, or filter cartridges. Any modification of the
product without written approval from Parker will result in voiding this warranty. Complete details of the
warranty are available on request. This warranty applies to units purchased and operated in North America.
Explanation of Warning Symbols
Symbol Description
Caution, refer to accompanying documents
for explanation.
Caution, risk of electric shock.
Printed in U.S.A. Bulletin TI-GCGS-E 07/15© 2013, 2015 Parker Hannin Corporation
Parker Hannin Manufacturing Limited
Gas Separation and Filtration Division EMEA
Dukesway, Team Valley Trading Estate
Gateshead, Tyne and Wear, Angleterre NE11 0PZ
Tél.: [phone] Fax: + 44(0)1914826296
www.parker.com/gsfe [e-mail]
Parker Hannin Corporation
Industrial Gas Filtration and
Generation Division
4087 Walden Ave.
Lancaster, NY 14086
Tel: [phone] Fax: [phone]
www.parker.com/igfg
CELL: SPE
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