Parker NitroFlow HP User manual

K3.1.141e Manual NitroFlow HP_EN.doc - 1 -
USER MANUAL
NitroFlow®HP
NITROGEN GENERATOR
Parker Filtration & Separation B.V.
PO Box 258
4870 AG - Etten-Leur
The Netherlands
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
www.parker.com/pfs

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© 2009 Parker Filtration & Separation B.V.
All rights reserved
No part of this publication may be reproduced and/or publicized by being printed,
photocopied, placed on microfilm or in any other manner without the prior written
permission of Parker Filtration & Separation B.V.
Parker Filtration & Separation B.V. retains the right to make changes in parts at any
point without first or directly notifying the customer. The contents of this manual can
also be changed without prior warning.
This manual is valid for the NitroFlow® HP in its standard version. Parker Filtration &
Separation B.V. can therefore not be held liable for specifications of the delivered
system that may deviate from the standard version.
For information concerning adjustments, maintenance or repairs not contained in
this manual, please contact Parker Filtration & Separation B.V.
This manual has been prepared with all possible care, but Parker Filtration &
Separation B.V. cannot accept responsibility for possible errors in this document or
for the consequences thereof.

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USER MANUAL..........................................................................................................1
1INTRODUCTION ...................................................................................................5
1.1 GENERAL...........................................................................................................5
1.2 PICTOGRAMS .....................................................................................................6
1.3 IDENTIFICATION AND SERVICE .............................................................................7
1.4 CERTIFICATES.................................................................................................... 7
1.5 USE IN ACCORDANCE WITH PURPOSE ..................................................................8
1.6 USER INSTRUCTIONS .......................................................................................... 8
1.7 LIABILITY............................................................................................................8
2HEALTH, SAFETY AND ENVIRONMENTAL ASPECTS.....................................9
2.1 GENERAL...........................................................................................................9
2.2 NITROGEN AND OXYGEN .....................................................................................9
2.3 ELECTRICITY .................................................................................................... 10
2.4 SAFETY PRECAUTIONS...................................................................................... 10
2.5 ENVIRONMENTAL ASPECTS ............................................................................... 11
3DESCRIPTION OF THE APPLIANCE ................................................................12
3.1 GENERAL.........................................................................................................12
3.2 SEPARATION PRINCIPLE....................................................................................12
3.3 PARTS NITROFLOW®HP ..................................................................................13
3.4 PROCESS DIAGRAM .......................................................................................... 14
3.5 PROCESS SCHEME ........................................................................................... 15
4TECHNICAL SPECIFICATIONS......................................................................... 16
4.1 GENERAL.........................................................................................................16
4.2 PRODUCTION CAPACITY.................................................................................... 19
4.2.1 AIR CONSUMPTION.........................................................................................20
4.3 MAINTENANCE KIT ............................................................................................ 20
4.4 EXPANSION KIT (OPTION) ..................................................................................20
5INSTALLATION ..................................................................................................21
5.1 TRANSPORT AND STORAGE............................................................................... 21
5.2 DEFINE LOCATION ............................................................................................ 21
5.3 COMPRESSED AIR SUPPLY ................................................................................22
5.3.1 Ambient temperature of NitroFlow® HP ....................................................22
5.3.2 Checklist for compressed air supply......................................................... 22
5.4 UNPACK AND CHECK EQUIPMENT ......................................................................23
5.5 CONNECTING TO PRESSURIZED AIR SUPPLY....................................................... 23
5.6 CONNECTING TO MAINS ELECTRICITY ................................................................23
5.7 CONNECT NITROGEN CONSUMER ......................................................................25
5.8 CONNECT INPUT AND OUTPUT CONTACTS .......................................................... 26
6CONTROLLER....................................................................................................28
6.1 MENU STRUCTURE ...........................................................................................28
6.2 CONFIGURE SOFTWARE PARAMETERS ...............................................................28

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6.2.1 Main screen ..............................................................................................28
6.2.2 Settings menu ......................................................................................30
6.2.3 Log-on menu .......................................................................................31
6.2.4 Alarm menu ..........................................................................................32
6.2.5 Pressure switch menu ..........................................................................35
6.2.6 Options menu .......................................................................................36
6.2.7 Local settings menu .............................................................................37
6.2.8 Maintenance menu ...............................................................................38
6.2.9 Data logging menu ...............................................................................41
6.3 SOFTWARE UPDATES........................................................................................ 42
7COMMISSIONING AND OPERATION ...............................................................43
7.1 COMMISSIONING THE NITROFLOW®HP .............................................................43
7.2 START NITROFLOW®HP ..................................................................................43
7.3 STOP NITROFLOW®HP ....................................................................................43
7.3.1 Alarm messages.......................................................................................44
8TROUBLESHOOTING ........................................................................................45
8.1 TROUBLESHOOTING LIST................................................................................... 45
9MAINTENANCE ..................................................................................................47
9.1 MAINTENANCE SCHEME .................................................................................... 47
9.2 REPLACE INLET FILTER ELEMENT....................................................................... 48
9.3 REPLACE AUTOMATIC DRAINS OF FILTERS..........................................................49
9.4 REPLACE OXYGEN SENSOR...............................................................................49
9.5 CALIBRATE OXYGEN SENSOR ............................................................................50
9.6 REPLACE FUSE.................................................................................................51
10 ELECTRICAL SCHEME AND TERMINAL CONNECTIONS........................... 52
11 INDEX ...............................................................................................................54
12 APPENDIX A: NITROVIEW QUICK REFERENCE V1.0 ................................. 55
13 APPENDIX B: FIRMWARE UPGRADE INSTRUCTIONS V2.03 NITROFLOW®
SERIES .....................................................................................................................58

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1 Introduction
1.1 General
NitroFlow®HP is a product of Parker Filtration & Separation B.V. This manual forms
an integral part of the product. The manual describes the installation, daily operation,
maintenance and troubleshooting.
Content
Read the manual carefully before the installation and operation of the NitroFlow® HP.
These instructions must be thoroughly understood before installing and operating
this product. Failure to operate this product in accordance with the instructions set
forth in this manual and by other safety governing bodies will void the safety
certification of this product. If you have any questions or concerns, please call your
local representative or the technical services department:
Europe +(44) 1622 7233 00, USA +(1) 800 343 4048
Condition of change
No changes may be made to the NitroFlow®HP as supplied, without the explicit prior
written permission of Parker. Non-conformance to this rule, as well as any
consequential damage, loss and costs are the responsibility of the owner and the
user.
Information
All information in this manual, including additional drawings and technical
descriptions, remains the property of Parker and must not be used (otherwise than
for the use of this product), copied or published to or for a third party without the
explicit prior written permission of Parker Filtration & Separation B.V.

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1.2 Pictograms
In this manual and on the product the following pictograms are used:
Warning
A warning shows a hazard that can cause death or serious injury.
Follow the instructions.
Caution
A caution shows a danger that can cause damage to the equipment.
Follow the instructions.
Electricity
High voltage: danger of electric shock.
Warning
Risk for death due to suffocation.
Risk of fire
Oxygen-enriched air leads to an increased risk of fire in the event of
contact with inflammable products.
High-pressure risk
Follow the instructions with respect to compressed gasses.
Environment
Instructions with respect to the environment.

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1.3 Identification and service
The identification plate is located on the back of the
NitroFlow®HP. The identification plate shows the
characteristics of the NitroFlow®HP.
For service and technical assistance, please contact
our local representative or:
PARKER FILTRATION & SEPARATION
Hermitage Court, Hermitage Lane,
Maidstone, Kent ME16 9NT
England
Tel: [phone]
Fax: [phone]
1.4 Certificates
The NitroFlow®HP meets with the following requirements:
Subject Applicable standard
Directive for electromagnetic
compatibility (EMC)
EN 61326 (1997) + A1 (1998) + A2
(2001) + A3 (2003)
EN 61000-3-2 (2000)
EN 61000-3-3 (1995) + A1(2001)
Low Voltage Directive NEN-IEC 60204-1(1997)
Pressure equipment directive (PED) Sound engineering practice
Quality assurance ISO 9001:2000
Environmental care ISO 14001:2004
Fig. 1-1: Identification plate

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1.5 Use in accordance with purpose
The NitroFlow®HP is intended to make nitrogen out of normal ambient air. The
system is based on gas separation membranes. Each different or further use will not
be in conformity with the purpose. Parker Filtration & Separation B.V. will not accept
any liability for improper use.
The NitroFlow®HP is in compliance with the prevailing directives and standards.
Only use this NitroFlow®HP in a technically perfect condition, in conformity with the
purpose as described above.
1.6 User instructions
Only well-trained personnel are allowed to work on the NitroFlow®HP. The user
must be aware of hazards related to operating the NitroFlow®HP and processes
connected to the NitroFlow®HP. The user is responsible for the safety of the
personnel. All personnel working on the NitroFlow®HP must have free access to the
applicable manuals.
1.7 Liability
Parker Filtration & Separation B.V. will not accept any liability in case:
•The instructions in this manual are ignored.
•Replacement parts are used which are not approved by the manufacturer.
•The NitroFlow®HP is operated incorrectly.
•The system is fed with other gasses than air.
•The NitroFlow®HP is modified without notification and authorization of the
manufacturer.
•Maintenance and repair are not carried out according to the instructions.

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2 Health, safety and environmental aspects
2.1 General
Correct use of the NitroFlow®HP nitrogen generator is important for your personal
safety and for trouble-free functioning of the NitroFlow®HP. Incorrect use can cause
damage to the NitroFlow®HP or can lead to incorrect gas supply.
Warning
•Read this manual before you start the installation and commisioning
of the NitroFlow®HP. Prevent accidents and damage to the
NitroFlow®HP.
•Contact your supplier if you detect a problem that you cannot solve
with this manual.
•Use the NitroFlow®HP in accordance with its purpose. Refer to §1.5.
•Only service-engineers, qualified to work on electric and pneumatic
equipment, are allowed to do the installation, maintenance and
repairs. Unqualified people are not allowed to repair the equipment.
Refer to §1.6.
•Lift the NitroFlow®HP with a forklift. Follow the legislation and
instructions for operating the forklift.
•Do not tamper or experiment with the equipment. Do not exceed the
technical specifications for the NitroFlow®HP. Refer to chapter 4.
2.2 Nitrogen and oxygen
The NitroFlow®HP generates nitrogen as a product. Oxygen enriched air is released
as waste.
Warning
•Nitrogen can cause suffocation!
•Oxygen-enriched air leads to increased risk of fire in the event of
contact with inflammable products. Make sure that there is
adequate ventilation at all times! Refer to fig. 2-1 for indicative
graphic.
20
22
24
26
28
30
32
95 96 97 98 99 99,5
Product N2 % (retentate)
Waste O2 % (permeate)
Fig. 2-1

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•The NitroFlow®HP is not designed for installation in an Ex-
classified area.
•Do not install the NitroFlow®HP in an area where explosive
mixtures may occur.
2.3 Electricity
Warning
•Only service-engineers, qualified to work on electric equipment,
are allowed to do the installation, maintenance and repairs.
•Disconnect the main power supply before you do maintenance or
repair.
•If a service-engineer has to work on the NitroFlow®HP while the
electric power is connected, the service-engineer must be very
careful with respect to the electrical hazards.
2.4 Safety precautions
Warning
•Make sure that the ventilation rate is sufficient in the room where
the enriched oxygen is ventilated, or vent the enriched air outside.
•Only feed the NitroFlow®HP with air.
•Keep the air feed to the NitroFlow®HP clean and free of organic
solvent vapors and other contaminants. Do not place the
NitroFlow®HP in a room where organic solvent vapors may occur
in the air.
•Keep the ambient temperature for the NitroFlow®HP range
between 10°C and 40°C (50°F and 104°F).
•Adjust the NitroFlow®HP to the appropriate nitrogen
concentration for your application.
•Install the peripheral equipment, piping and nitrogen storage
vessels according to standard procedures. Parker Filtration &
Separation B.V. cannot take responsibility for this.
•Do regular maintenance to the NitroFlow®HP, to ensure proper
and safe operation. Refer to chapter 9.
•Make sure that instructions concerning health and safety are
compliant with the local legislation and regulations.

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2.5 Environmental aspects
The use and maintenance of the NitroFlow®HP does not include environmental
dangers. Most parts are made of metal and can be disposed in the regular way. The
packaging of the NitroFlow®HP is 100% recyclable. Optimal installation according to
instructions and according to good craftsmanship will result in minimal energy
consumption and maximal life of your system.
According to EC-regulations electrical systems have to be disassembled and
recycled at the end of their life. Parker Filtration & Separation B.V. can support you
in this.
Make sure that instructions concerning health, safety and
environment are compliant with the local legislation and regulations.

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3 Description of the appliance
3.1 General
The NitroFlow®HP separates compressed air into nitrogen and an oxygen enriched
air stream. The separation system uses membranes. The compressed air is supplied
from a central system or from a dedicated compressor.
The nitrogen produced can be connected directly to the application or can be stored
in a nitrogen storage vessel. The NitroFlow®HP then switches on and off, depending
on the nitrogen demand. The NitroFlow®HP has a residual oxygen analyzer. This
analyzer continuously monitors the quality of the produced nitrogen.
3.2 Separation principle
A
FS
H2O - H2 O2 N2
B
C
Fig. 3-1: Separation principle
A Pressurized air inlet
B Hollow fibre membrane
C Nitrogen outlet
F Fast permeation
S Slow permeation
Ambient air contains nitrogen (78.1%), oxygen (20.9%), argon (1%), carbon dioxide,
water vapor and traces of other inert gasses. Pressurized air (A) is led through
hollow fibre membranes (B). The various air components diffuse through the porous
wall of the membranes.
The diffusion rate differs for the various gasses:
•Oxygen and water vapour have a high diffusion rate and diffuse rapidly through
the membrane wall.
•Nitrogen has a low diffusion rate and diffuses slowly through the membrane
wall. Nitrogen enriched air is released at the outlet of the membranes (C).
Pressurized nitrogen enriched air is released at the outlet of the membranes (E).
This air can be lead to a nitrogen storage vessel.

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3.3 Parts NitroFlow®HP
Fig. 3-2: Parts of NitroFlow®HP
A Oxygen sensor
B Hollow fiber membrane
C Compressed air filters
D SD-card
E Printed circuit board
F Active carbon adsorber
G Flow control valve for purity adjustment
H Flow control valve for sample flow
I In- and outlet connections
J Drain outlet
K Power inlet
L Display
B
A
D
E
F
G
H
I
C
J
K
L

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3.4 Process diagram
The NitroFlow®HP can either be connected directly to the nitrogen consumer or to a
nitrogen reservoir. The latter is advised in case of discontinuous or variable peak
demands.
Fig. 3-3 Installation lay-out
NitroFlow
Consumer
NitroFlow
Nitrogen
reservoir
Pressurized
air in
Nitrogen out

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3.5 Process scheme
Y1 Solenoid valve PI1,2 Pressure indicator F01 Coarse filter F02 Fine filter C1 Carbon adsorber F03 Dust filter QIAhOxygen analyser
FCV1 Flow control valve for purity adjustment FCV3 Flow control valve for sample flow * Only in NitroFlow®HP2 and NitroFlow®HP3
** Only in NitroFlow®HP3
* **

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4 Technical specifications
4.1 General
Delivery pressure
Max. delivery pressure (vessel) inlet pressure minus pressure drop (max. 2
bar(g) / 29 psig)
Ambient conditions
Temperature 10°C to 40°C / 50°F to 104°F
Air quality Normal clean ambient air, relative humidity <
90%
Pressurized air specifications
Max feed pressure 13 bar(g) / 190 psig
Compressed air temperature range 10-50°C / 50-120°F
Pressure dew point < 5°C / < 41°F
Residual oil content < 3.0 mg/m3
Dimensions and connections
Dimensions (H x W x D) [mm]: 1224 * 725 * 270
Dimensions (H x W x D) [inch] 48.2 * 28.5 * 10.6
Connections: All connections: G 1”
Net weight:
NitroFlow®HP1
NitroFlow®HP2
NitroFlow®HP3
Kg
85
95
105
Lbs
187
209
231
Housing
Protection degree IP 44
Electrical data
Voltage/frequency 100-115-230Vac 1ph / 50-60Hz
Power consumption 30 W

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Parts
NitroFlow®HP 1x NitroFlow®HP
1x Manual
Table 4-1: General data

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Default settings software parameters
Menu What Default setting
Logs Interval 60 min
Local settings Language English
Local settings Pressure Bar(g)
Local settings Flow LPM
Local settings Purity %O2
Alarm settings O2 high Active: No
Unit stop: No
Level: 5%
Delay: 30 sec
Alarm settings O2 low Active: No
Unit stop: No
Level: 0.5%
Delay: 30 sec
Alarm settings Inlet pressure high Active: No
Unit stop: No
Level: 13 bar(g)
Delay: 30 sec
Alarm settings Inlet pressure low Active: No
Unit stop: No
Level: 2 bar(g)
Delay: 30 sec
Alarm settings Outlet pressure high Active: No
Unit stop: No
Level: 10 bar(g)
Delay: 30 sec
Alarm settings Outlet pressure low Active: No
Unit stop: No
Level: 2 bar(g)
Delay: 30 sec

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Pressure switch P-switch No
Pressure switch Unit on 2.0 bar(g)
Pressure switch Unit off 7.0 bar(g)
Options Auto restart No
Options Remote No
Options Pin code No
Table 4-2: Default settings software parameters NitroFlow®HP
NitroFlow®Part number
NitroFlow®HP1 159.004032
NitroFlow®HP2 159.004033
NitroFlow®HP3 159.004034
Table 4-3: Part numbers NitroFlow®HP
4.2 Production capacity
Type Nominal product capacity Nm³/hr
Nitrogen purity (%) 99.5 99 98 97 96 95
NitroFlow®HP1 1.7 2.5 3.8 5.0 6.3 7.5
NitroFlow®HP2 3.4 5.0 7.6 10.0 12.6 15.0
NitroFlow®HP3 5.1 7.5 11.4 15.0 18.9 22.5
Table 4-4: Capacity NitroFlow®HP (Nm3/hr 20°C 1013mbar) at nominal conditions:
•Feed pressure at inlet 7 bar(g) / 100 psig
•Ambient temperature: 20°C / 68°F
•Ambient pressure: 1013 mbar(a)

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4.2.1 Air consumption
Type Nominal air use Nm³/hr
Nitrogen purity (%) 99.5 99 98 97 96 95
NitroFlow®HP1 14.5 15.0 16.3 17.5 18.9 19.5
NitroFlow®HP2 28.9 30.0 32.7 35.0 37.8 39.0
NitroFlow®HP3 43.4 45.0 49.0 52.5 56.7 58.5
Table 4-5: Air use NitroFlow®HP (Nm3/hr 20°C 1013mbar) at nominal conditions:
•Feed pressure at inlet 7 bar(g) / 100 psig
•Ambient temperature: 20°C / 68°F
•Ambient pressure: 1013 mbar(a)
4.3 Maintenance kit
Part part number
Maintenance kit NitroFlow® HP (yearly or
after 8000 running hours, which comes first)
159.004045
O2-sensor (approx. every three years) 159.002284
Table 4-6: Maintenance kit
4.4 Expansion kit (option)
Part part number
Expansion kit NitroFlow® HP 159.004303
Table 4-7: Expansion kit