Parker NitroFlow Lab User manual

Nitrogen Gas Generator
NitroFlow®Lab
Original Language
User Guide
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© 2011 Parker. All rights reserved.
No part of this publication may be reproduced and/or publicised by being printed,
photocopied, placed on microfilm or in any other manner without the prior written
permission of Parker.
Parker retains the right to make changes in parts at any point without first or directly
notifying the customer. The contents of this manual can also be changed without prior
warning.
This manual is valid for the generator in its standard version. Parker can therefore not be
held liable for specifications of the delivered system that may deviate from the standard
version.
For information concerning adjustments, maintenance or repairs not contained in this
manual, please contact Parker.
This manual has been prepared with all possible care, but Parker cannot accept
responsibility for possible errors in this document or for the consequences thereof.

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1 INTRODUCTION ...................................................................................................................................................4
1.1 General...........................................................................................................................................................4
1.2 Pictograms .....................................................................................................................................................4
1.3 Use in accordance with purpose ....................................................................................................................5
1.4 User instructions.............................................................................................................................................5
1.5 Liability............................................................................................................................................................5
2 HEALTH, SAFETY AND ENVIRONMENTAL ASPECTS ....................................................................................6
2.1 General...........................................................................................................................................................6
2.2 Nitrogen and oxygen ......................................................................................................................................6
2.3 Electricity ........................................................................................................................................................6
2.4 Safety precautions..........................................................................................................................................6
2.5 Environmental aspects ...................................................................................................................................7
3 DESCRIPTION OF THE APPLIANCE..................................................................................................................8
3.1 General...........................................................................................................................................................8
3.2 Separation principle........................................................................................................................................8
3.3 Parts ...............................................................................................................................................................9
3.4 Process diagram ............................................................................................................................................9
3.5 Process scheme...........................................................................................................................................10
4 TECHNICAL SPECIFICATIONS.........................................................................................................................11
4.1 General.........................................................................................................................................................11
4.2 Capacity data ...............................................................................................................................................13
4.3 Maintenance parts........................................................................................................................................13
5 INSTALLATION ..................................................................................................................................................14
5.1 Transport ......................................................................................................................................................14
5.2 Define location..............................................................................................................................................14
5.3 Unpack and check equipment......................................................................................................................14
5.4 Connect nitrogen consumer .........................................................................................................................14
5.5 Connecting power ........................................................................................................................................14
5.6 Connect input and output signals.................................................................................................................15
6 OPERATION OF THE CONTROL SYSTEM ......................................................................................................16
6.1 Menu structure .............................................................................................................................................16
6.2 Main screen..................................................................................................................................................16
6.3 Settings menu .........................................................................................................................................17
6.3.1 Log on menu ....................................................................................................................................18
6.3.2 Alarm settings menu ........................................................................................................................18
6.3.3 Pressure switch menu ....................................................................................................................20
6.3.4 Options menu ..................................................................................................................................21
6.3.5 Local settings menu ........................................................................................................................21
6.3.6 Maintenance menu ..........................................................................................................................22
6.3.7 Data logging menu ..........................................................................................................................24
7 OPERATION .......................................................................................................................................................25
7.1 Commissioning generator ............................................................................................................................25
7.2 Start generator .............................................................................................................................................25
7.3 Adjusting the purity.......................................................................................................................................25
7.4 Control of the outlet pressure.......................................................................................................................26
7.5 Stop generator..............................................................................................................................................26
8 TROUBLESHOOTING ........................................................................................................................................27
8.1 Error list ........................................................................................................................................................27
8.2 Alarm messages ...............................................................................................................................27

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9 MAINTENANCE ..................................................................................................................................................29
9.1 Maintenance schedule .................................................................................................................................29
9.2 Calibrate oxygen sensor...............................................................................................................................29
9.3 Cleaning .......................................................................................................................................................29
10 ELECTRICAL SCHEME..................................................................................................................................30
11 DECLARATION OF CONFORMITY ...............................................................................................................31

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1 Introduction
1.1 General
The NitroFlow®Lab is a product of Parker. This manual forms an integral part of the product. The manual describes
the installation, daily operation and troubleshooting.
Content
Read the manual carefully before you start with the generator. These instructions must be thoroughly understood
before installing and operating this product. Failure to operate this product in accordance with the instructions set
forth in this manual and by other safety governing bodies will void the safety certification of this product. If you have
any questions or concerns, please call your local representative or the technical services department:
Europe [phone]
Condition of change
No changes may be made to the generator as supplied, without explicit prior written permission by Parker. Non-
conformance to this rule, as well as any consequential damage, loss and costs are the responsibility of the owner
and the user.
Information
All information in this manual, including additional drawings and technical descriptions, remains the property of
Parker and may not be used (otherwise than for the use of this product), copied, multiplied or published to or for a
third party without explicit prior written permission by Parker.
1.2 Pictograms
In this manual and on the generator, the following pictograms are used:
Warning
A warning shows a hazard that can cause death or serious injury. Follow the instructions.
Caution
A caution shows a danger that can cause damage to the equipment. Follow the instructions.
Electricity
High voltage: danger of electric shock.
Warning
Risk for death due to suffocation.
Risk of fire
Oxygen-enriched air leads to an increased risk of fire in the event of contact with inflammable
products.
High-pressure risk
Follow the instructions with respect to compressed gasses.
Environment
Instructions with respect to the environment.
Read instructions in the manual.

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Disconnect the Mains supply before removing this cover.
NITROGEN (N2),
DO NOT BREATHE
Asphyxiant in high concentrations. No odour. Slightly lighter than air.
Ensure adequate ventilation. Breathing 100% nitrogen will produce
immediate unconsciousness and death due to lack of oxygen.
NON-FLAMMABLE COMPRESSED GAS
Warning: More than one Live circuit.
Mains supply cable gland
1.3 Use in accordance with purpose
The NitroFlow®Lab is intended to produce nitrogen out of normal ambient air. The system is based on gas
separation membranes. Each different or further use will not be in conformity with the purpose. Parker will not
accept any liability for improper use.
The generator is in compliance with the prevailing directives and standards. Only use this generator in a technically
perfect condition, in conformity with the purpose as described above.
1.4 User instructions
Only well-trained personnel are allowed to work on the generator. The user must be aware of hazards related to
operating the generator and processes connected to the generator. The user is responsible for the safety of the
personnel. All personnel working on the generator must have free access to the applicable manuals.
1.5 Liability
Parker will not accept any liability if:
xThe instructions in this manual are ignored.
xReplacement parts are used which are not approved by the manufacturer.
xThe generator is operated incorrectly.
xThe system is fed with other gasses than air.
xThe generator is modified without notification and authorisation of Parker.

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2 Health, safety and environmental aspects
2.1 General
Correct use of the nitrogen generator is important for your personal safety and for trouble-free functioning of the
generator. Incorrect use can cause damage to the generator or can lead to incorrect gas supply.
Warning
xRead this manual before you start the installation and putting into operation of the
generator.Prevent accidents and damage to the generator.
xIf the equipment is used in a manner not specified in this user guide, the protection
provided by the equipment may be impaired.
xContact your supplier if you detect a problem that you cannot solve with this manual.
xUse the generator in accordance with its purpose. Refer to §1.3.
xOnly competent personnel trained, qualified and approved by Parker Industrial Division are
allowed to perform installation, commissioning, service and repair procedures.
xUnqualified people are not allowed to repair the equipment. Refer to §1.4. Lift the generator
with a forklift. Follow the legislation and instructions for operating the forklift.
xDo not tamper or experiment with the equipment. Do not exceed the technical
specifications for the generator. Refer to chapter 4.
2.2 Nitrogen and oxygen
The generator generates nitrogen as a product. Oxygen enriched air is released as waste.
Warning
xNitrogen can cause suffocation!
xOxygen-enriched air leads to increased risk of fire in the event of contact with flammable
products. Make sure that there is adequate ventilation at all times!
xThe generator is not designed for installation in an Ex-classified area.
xDo not install the generator in an area where explosive mixtures may occur.
2.3 Electricity
Warning
xOnly service-engineers, qualified to work on electrical equipment, are allowed to do the
installation, maintenance and repairs.
xDisconnect the main power supply before you do the maintenance or repair.
xIf a service-engineer has to work on the generator while the electric power it is connected,
the service-engineer must be very careful with respect to the electric hazards.
2.4 Safety precautions
Warning
xMake sure that the ventilation rate is sufficient in the room where the enriched oxygen is
ventilated, or lead the enriched air outside. Keep the ambient temperature between 10 and
35 °C.
xInstall the peripheral equipment, piping and nitrogen storage vessels according to
standard procedures. Parker cannot take responsibility for this.
xEnsure that regular maintenance to the generator is undertaken, to ensure proper and safe
operation. Refer to chapter 8.
xMake sure that instructions concerning health and safety are compliant with the local
legislation and regulations.

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2.5 Environmental aspects
The use and maintenance of the generator does not include environmental dangers. Most parts are made of metal
and can be disposed in the regular way. The packaging of the generator is 100% recyclable. Optimal sizing of
buffer tanks and setting of the pressure switch will result in minimal energy consumption. The lower the delivery
pressure, the longer the lifetime of the system.
According to EC-regulations electrical systems have to be disassembled and recycled at the end of their life.
Parker can support you in this.
Make sure that instructions concerning health, safety and environment are compliant with the
local legislation and regulations.

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3 Description of the appliance
3.1 General
The generator separates compressed air produced by an on-board compressor into nitrogen and an oxygen
enriched air stream. The separation system is based on membranes.
3.2 Separation principle
A Pressurised air inlet
B Hollow fibre membrane
C Nitrogen outlet
F Fast permeation
S Slow permeation
Ambient air contains nitrogen (78.1%), oxygen (20.9%), argon (1%), carbon dioxide, water vapor and traces of
other inert gasses. Pressurised air (A) is led through hollow fibre membranes(B). The various air components
diffuse through the porous wall of the membranes.
The diffusion rate differs for the various gasses:
xOxygen and water vapor have a high diffusion rate and diffuse rapidly through the membrane wall.
xNitrogen has a low diffusion rate and diffuses slowly through the membrane wall.
Pressurised nitrogen enriched air is released at the outlet of the membranes (E) which can be stored in a nitrogen
storage vessel.
A
FS
H2O - H2 O2 N2
B
C
Fig. 3-1: Separation principle

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3.3 Parts
1 Removable Front Cover 6 Main Switch / Circuit Breaker
2 Oxygen Sensor 7 Electrical Supply Cable Inlet
3 Pressure Control Valve (PCV) 8 Nitrogen Outlet
4 Purity Adjustment Valve (FCV) 9 Ventilation Outlet (Keep Clear)
5 Touch Screen Display
3.4 Process diagram
The generator can be connected directly to the nitrogen consumer (Fig. 3-3) or to a buffer vessel (Fig. 3-4).
Fig. 3-3
Fig: 3-4
NitroFlow®Lab Nitrogen
Consumer
NitroFlow®Lab
Buffer
Vessel
Nitrogen
Consumer

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3.5 Process scheme
N1 Air inlet
N2 Nitrogen outlet
C Inlet carbon adsorber
LP Air compressor
RKV Start-up valve
M Gas separation membrane
PI1 Membrane pressure indicator
FCV Flow control valve
HP Nitrogen compressor
PCV Nitrogen pressure relief valve
PSH Pressure switch
PI2 Nitrogen pressure indictor
V1 Non-return valve
N2 Nitrogen outlet
V2 Ball valve
V4 Depressurisation valve

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4 Technical specifications
4.1 General
Delivery pressure
Maximum delivery pressure 8 bar(g) / 116 psig
Ambient conditions
Temperature 5 to 40 °C / 41 to 104 °F
Humidity 50% @ 40°C (104°F) (80% MAX < 31°C (87.8°F))
IP Rating IP20 / NEMA 1
Pollution Degree 2
Over Voltage Category II
Altitude < 2000 m
(6562 ft)
Air quality Normal clean ambient air, relative humidity < 90%
Max. ambient relative humidity <80 % to 31°C, 50% at 40°C
Noise level < 58 dB(A) @ 1 meter/3 ft
Dimensions and connections
Dimensions (H x W x D) [mm] 700 x 900 x 310
Dimensions (H x W x D) [inch] 27.6 x 35.4 x 12.2
Net weight 92.5 kg / 204 lbs
Connections outlet: G ¼ “ / ¼” NPT
Electrical data
Voltage/frequency1230Vac 50 / 60Hz
Power consumption 1500 W
Voltage/frequency2120Vac 60Hz
Power consumption 1980 W
1Mains supply voltage fluctuations not to exceed +/- 10% of nominal voltage.
2Mains supply voltage fluctuations not to exceed +/- 10% of nominal voltage.

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Default software settings
Menu What Default setting
Logs Delay-time 180 sec
Local settings Language English
Local settings Pressure Bar
Local settings Flow LPM
Local settings Purity %O2
Alarm settings O2 high Active: No
Stop: 0
Level: 5
Delay: 30
Alarm settings O2 low Active: No
Stop: 0
Level: 0.0
Delay: 30
Alarm settings Pin high Active: No
Stop: 0
Level: 13
Delay: 30
Alarm settings Pin low Active: No
Stop: 0
Level: 2
Delay: 30
Alarm settings Pout high Active: No
Stop: 0
Level: 10
Delay: 30
Alarm settings Pout low Active: No
Stop: 0
Level: 2
Delay: 30
Pressure switch P-switch No
Pressure switch Unit on 2.0
Pressure switch Unit off 7.0
Options Auto restart No
Options Remote No
Options Pincode No
Options Show Flow No

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Parts
NitroFlow®Lab 1x Generator
1x Manual
Options (on demand) Storage vessel
Vac/Hz Plug Part number
230 / 50 EUR 159.003848
230 / 50 UK 159.004627
120 / 60 USA 159.003868
230 / 60 EUR 159.004404
230 / 60 UK 159.004628
4.2 Capacity data
Generator Nominal production capacity Nlpm*
Purity% 99.9 99.7 99.5 99 98 97 96 95 93
NitroFlow
®
Lab 7.6 12 13 18 23 26 30 32 38
*Capacity at nominal conditions:
xAmbient temperature: 20 °C / 68 °F
xAmbient pressure: 1013 mbar(a)
4.3 Maintenance parts
Part Part number
Maintenance kit: 1 x Carbon adsorber 159.003754
Oxygen sensor 159.005574
In case the compressor(s) need to be replaced, the correct part numbers are:
Part Part number
Air compressor LP/LP (230V/50Hz) 159.005576
Air compressor LP/LP (115V/60Hz) 159.005578
Nitrogen compressor LP/HP (230V/50Hz)159.005575
Nitrogen compressor LP/HP (115V/60Hz)159.005577

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5 Installation
Follow the paragraphs in this chapter to install the generator.
5.1 Transport
Warning
xTransport the generator upright.
xPut the generator in the original box to transport the generator over longer distances.
xLift the generator with a forklift.
xFor qualifications of personnel, refer to §2.1.
5.2 Define location
IMPORTANT
xThe generator contains compressors that generate heat; for optimal performance and
lifetime it is necessary that cooling air can be vented without resistance. A minimum
clearance distance from walls or other objects of at least 50 cm/ 20 inches on all sides
(back, left, right and top) is a necessity; also efficient local ventilation at the ventilation
outlet is highly recommended especially when the device is installed under a bench
Install the generator on a fixed location. The location must meet the following requirements:
xMinimum clearance of 50 cm on all sides (back, left, right and top) as to facilitate heat removal
xIndoors
xDry
xNo continuous direct irradiation by sunlight
xAway from heat sources
xProperly ventilated room.
xEasy accessibly for operating and service
5.3 Unpack and check equipment
xOpen the packaging per instructions on the crate.
xMake sure that all components are delivered. Refer to § 4.1.
5.4 Connect nitrogen consumer
Warning
xDo not connect the power at this time.
xMake sure that the inlet and outlet tubes are free of dust, particles, metal parts and curls,
liquids and grease before you connect the generator.
Connect the product outlet to the application.
5.5 Connecting power
1. Connect the mains plug to a suitable wall socket with earth connection
2. The control system has input and output contacts for remote control and alarm signaling (refer to §5.6).
Warning
The main supply line voltage must be within 10% of nominal rated voltage for the generator. In
case of larger variations the generator will stop; continued use under these circumstances will
inevitably lead to motor damage.

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5.6 Connect input and output signals
Input and output signals can be connected to the terminal strip on the printed circuit board.
Clamp Function Input/output signals
ID1 Remote start/stop Digital input
Nominal input current: 10 mA
Voltage: internal power supply
UA1 Oxygen concentration Analogue output
Input impedance to reach
0 mA – 20 mA: 200 Ohm
UA2 Outlet pressure
K5 Start stop signal to external booster Volt Free Relay Contacts
Maximum Switch voltage: 48V AC/DC
Switch current: 1A AC/DC
K6 General alarm (nc/no)
K7 General alarm (nc/no) (=K6)
K8 Spare
The circuits connected to the relay contacts must be supplied by a fused or current limited
power supply. All cables must be double insulated.

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6 Operation of the control system
6.1 Menu structure
The menu structure of the control system is built up as shown below. One can always go back to a higher level in
the menu by pushing the -button.
6.2 Main screen
Access: This is the start-up screen that automatically appears when the generator is switched on.
Function: Gives access to the different menus.
Symbol/data Information/result
When flashing there is an alarm; touch the symbol and the current alarm will
be shown.
Status of unit (A) Can be OFF/RUN/STAND-BY/ALARM/P-RELIEF
Menu button, touch to go to settings menu
Switch ON/OFF button, generator will turn ON or OFF
To turn the unit on, touch the switch -button. The status will switch to P-RELIEF. The compressors will start three
minutes (180 seconds) after the unit has been switched on. The delay time countdown time is shown next to the
text P-RELIEF (see below).
A
Main screen
Alarm
display
Settings Switch on/off unit
Data
logging
Log on Set
alarms
Pressure
switch
Options Local
settings
Maintenance

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When the unit is switched on the controller will show:
xActual outlet pressure
xActual oxygen or nitrogen level
xFlow indication (when selected, refer to §6.3.4)
6.3 Settings menu
Access: Touch settings menu button in the main screen
(refer to §6.2)
Function: Access to different menus
Symbol Menu
Access to log on menu (refer to §6.3.1)
Access to alarm settings menu (refer to §6.3.2)
Access to pressure switch menu (refer to § 6.3.3)
Access to options menu (refer to § 6.3.4)
Access to local settings menu (refer to § 6.3.5)
Access to maintenance menu (refer to § 6.3.6)
Access to data logging menu (refer to § 6.3.7)
Returning to previous menu

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6.3.1 Log on menu
Access: Touch log on menu button in settings screen (refer to §6.3)
ATTENTION: When you start-up the system for a first time you do not need to enter a PIN
CODE
Function: Protect the settings in the system with a (personal) pin code.
In the log on menu:
xEnter the default pin code (1234) after selecting PINCODE YES under the options menu (refer to §6.3.4).
xChange the default pin code to a personal pin code of 4 digits (refer to §6.3.4)
xReturn to default factory settings by entering pin code 7833 (refer to §4.1)
xIn case you lost your pin code, please contact your supplier
Caution:
When returning to factory settings, the alarms, p-switch, options and settings must be reset.
Also the log on pincode is back to default value 1234
6.3.2 Alarm settings menu
Access: Touch alarm settings menu button in settings screen (see § 6.3.2)
Function: Set different alarms
In the alarm settings menu it is possible to set 6 different alarms.
Screen Alarm Explanation
1/6 O2 high oxygen level too high
2/6 O2 low oxygen level too low
3/6 Pres. Inlet high inlet pressure too high
4/6 Pres. Inlet high inlet pressure too high
5/6 Pres. Outlet high outlet pressure too high
6/6 Pres. Outlet low outlet pressure too low
1. To activate an alarm touch button A. When the button is touched you can select the options YES, AUTO
RESET or NO by pressing the arrow keys
Default all alarms are set to NO, which means they are not activated; activating the alarms or not is
the choice of the user; alarms do not influence the output and purity.
2. When you select YES or AUTO RESET, the rest of the alarm parameters that need to be set will pop-up
automatically (see screen below).

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Button Selection Result
Active No Alarm function for this parameter is not active
Active Yes Alarm function for this parameter is active; alarm messages must
be reset manually
Active Auto reset Alarm function for this parameter is active; When alarm level is
not exceeded any longer before manual reset, the alarm will reset
itself
Stop Yes Generator will switch off in case alarm level is exceeded
Stop No An alarm signal will be given but generator will continue to run in
case alarm level is exceeded
Level 0-16% O2
100 – 84% N2
For screen 1/6 and 2/6: this is the oxygen- or nitrogen level* at
which the alarm is set.
Level 0-13 BAR*
0-188.5 PSI*
For screen 3/6 and 4/6.
This is the pressure level at which the alarm is set
Level 0-10 BAR*
0-145 PSI*
For screen 5/6 and 6/6.
This is the pressure level at which the alarm will appear.
Delay 0-300 sec Delay time in seconds between the moment that the alarm level
has been exceeded and signaling; this feature prevents false
alarms in case of short spikes
*see also local settings -menu
ATTENTION:
It is impossible to set O2low at a higher level than O2high. The setting of O2low is limited once
O2high has been set. Therefore, first set O2high level before setting the O2low level.
A