Zaiput Flow Technologies BPR-1000 User manual

Zaiput Flow Technologies
Separation Made Simple
Instruction Manual
BPR-1000
Zaiput Flow Technologies
101a 1st Ave,
Waltham, MA - 02451
ph/fax [phone]
Email: [e-mail]
http://www.zaiput.com

Copyright
Zaiput Flow Technologies
101a 1st Ave,
Waltham, MA 02451
All rights, including translation, reserved.
No part of this manual may be copied, reproduced, or processed without prior explicit written permission
of Zaiput Flow Technologies
This manual has been prepared with care. If you are unsure of operation contact a Zaiput representative
for assistance. Zaiput assumes no liability for direct, subsequent, or consequential damages arising from
an incorrect use of the devices.
While using BPR-10, the specifications of this manual must be followed.
“Zaiput” and Zaiput’s logo are Trademarks of Zaiput Flow Technologies LLC.
The device is covered by issued and pending patents in several jurisdictions.
Subject to change without notice.

Table of Contents
1 General Information ............................................................................................................................. 1
1.1. Box Content .................................................................................................................................... 1
1.2. Technical Data ................................................................................................................................ 1
1.3. Principle of operation ..................................................................................................................... 1
1.4. Device Schematics .......................................................................................................................... 2
2 Safety Precautions ................................................................................................................................ 2
3 Setup & Operation................................................................................................................................ 2
3.1 Methods of operation........................................................................................................................... 4
3.3 Technical Notes & Best Practices ......................................................................................................... 5
4 Maintenance.............................................................................................................................................. 5
4.1 Cleaning the Device After Use .............................................................................................................. 5
4.2 Periodic Maintenance........................................................................................................................... 6
4.1.1. Opening the device.................................................................. Error! Bookmark not defined.

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1 General Information
This manual provides information about the installation, operation, and safety precautions of
Zaiput Flow Technologies laboratory scale Back Pressure Regulator (BPR-1000). We recommend
keeping this manual near the device for quick and easy reference.
The device is designed for the maintenance and use of a user selected value of back-pressure in a
flow system or batch vessel. The device has two methods of operation: “Set It and Forget It”,
“Pressure Relief” or “Adjustable on Demand”.
1.1. Box Content
•BPR Unit – 1 Piece
•Link to this instruction manual
•A connector for the charging valve.
•4 Peek nuts 2 PFA Swagelok front ferrules for ¼” tubing
•2 PFA Swagelok back ferrules for ¼” tubing
1.2. Technical Data
Operating parameters
Total Flow Rate
20-500 ml/min (error <2%)
500-1000 mL/min (error <5%)
Dimensions
97 x 97 x 64 mm
Set Point Pressure Range
0.2-2 Mpa (29-290 PSI)
Maximum Inlet Pressure
5 MPa
Ports
¼ UNF - 28 flat bottom
Wetted materials
Fluorinated Polymers (ETFE, PFA)
Max operating temperature
130 °C
Internal volume
8 mL
1.3. Principle of operation
This Back-Pressure Regulator compares the pressure of the process fluid (main stream) to a
reference pressure. Flow of the main stream is allowed only if its pressure meets or exceeds
the reference pressure. This reference pressure is set by charging the BPR with gas through the
valve on the top of the device.

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1.4. Device Schematics
2 Safety Precautions
All users of the Back Pressure Regulator BPR-1000 device must read the safety precautions section
of this manual before attempting to operate the unit. If this equipment is used in a manner not
specified by the manufacturer, the protection provided by the equipment may be impaired.
Device Not for Medical Use.
DO NOT OPERATE the device IF any of the following conditions exist:
•The device has not been installed properly.
•The device is partially dismantled.
•Service has been attempted by unauthorized or unqualified personnel.
•The device is not correctly assembled or leaks.
•The system pressure is above 2MPa.
•The system temperature is above 130 °C.
3 Setup & Operation
The BPR-1000 has four ports: an inlet port, an outlet port, and two charging ports to set the
pressure. Please note the directionality of the inlet and outlet ports denoted by the arrow on the
side of the device.
Inlet
Figure 1: BPR-1000 Schematic
Outlet
Charging port with valve
Charging gas port
Directionality
Figure 2: BPR-1000 Setup

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Charging ports: There are two different connection available to fill with compressed air the top
cavity of your BPR-1000:
1) Specialty fitting specifically selected for the BPR-1000 that contains a valve to seal off the
device once fille dup with compressed air. The dedicated connector is provided with the
device.
2) 1/8” Swagelok fitting port. This port comes capped, it does not include a valve and it is
recommended for permanent installations or during dynamic set point operations (see
below)
Process fluids connections: Ports are designed to accommodate ¼’’ OD tubing (typically PFA or
FEP) with the Swagelok PFA ferrules and the Nuts supplied with the device. Swagelok ferrules are
part# PFA-424-1 (back ferrule) and part# PFA-423-1 (front ferrule).
Please refer to Swagelok documentation on how to correctly use their ferrules
(https://www.swagelok.com/downloads/webcatalogs/EN/MS-01-05.PDF ).

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3.1 Methods of operation
Method 1: Set it and Forget it
To pressurize, connect your pressurized gas source to the top of the BPR. Open the valve by
turning the small valve counterclockwise with a small screwdriver and then set the gas pressure
from its source. After compressing the air in the gas chamber of the device, manually close the
valve on top of the device using a small flat screwdriver (to seal the valve only tighten to finger
tightness, otherwise the valve may be damaged or broken by excessive torque). The device is
now sealed, and the pressure stays in the device. The user can now disconnect the BPR from the
pressure source (e.g., gas tank). If another set point is required, this procedure can be repeated
by setting the pressure of the top chamber to the new value. The advantage is that a gas tank is
not required for operation. The BPR should be repressurized every 48 hours for consistent
results.
Method 2: Dynamic Set Point
Some processes require the fluid pressure to dynamically change over the course of operation.
The Zaiput BPR can provide a continuous pressure setting as well. To achieve this, the user
connects the Zaiput BPR to the gas/pressure source by leaving the valve open. By changing the
pressure of the gas source (e.g., the regulator of the gas tank), the set point, P, is dynamically
changed.
Figure 3: Set it and Forget it
Figure 4: Dynamic Set Point
Figure 5: Pressure Relief Mode
Method 3: Pressure Relief Valve
Zaiput’s BPRs can also be used for static pressure
control. They will maintain an “at least” pressure
which allows them to act as a pressure relief valve. If
the pressure in the reactor or system surpasses the set
value of the BPR it will allow flow throug
h the device
until the pressure is below the set point of the BPR.

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3.3 Technical Notes & Best Practices
Technical Notes
•The device sets an “at least pressure”: This device sets a minimum level of pressure for the main
stream, therefore, if more devices are placed in series, the main stream pressure will be equal to
the highest device set point of (and not the sum of their set points).
•Robustness to clogging: While this device is not designed for slurries, users observe an increased
robustness to clogging when particles/solids are present with respect to conventional devices. The
reason has l to do with the redundancy of internal passages present inside the device.
•Error: These devices are very accurate and precise, providing small errors (~<1%). For reference, a
standard spring-based device has a typical error of 10%. The device can be run outside the
suggested range of flow rates, but the error will increase.
•Use with hot liquids: If the device is used in the “Set It and Forget it Mode”, it will heat up when
used with hot liquids. As a result, the pressure set point may change because the reference gas will
heat up.
•Dynamic Set Point: “When using the dynamic set point, the precision of the device depends on the
precision and stability of the compressed gas source. If pressure of the gas fluctuates, so will the
set point of the device.”
Best Practices
•To prevent damage to the valve, do not over tighten the valve,finger tight with a small flat head
screwdriver is sufficient for tightening.
•The same carefulness needs to be taken with the connector for the “charging” or set point gas (if
using the port with the valve). Finger tight will allow the user to charge the device to their desired
setpoint without the need to overtighten the fitting with a wrench. If using a wrench, only
provide the slightest amount of torque.
•To prevent damage to the connector used to pressurize the device, do not torque the connection
tube when it is connected to the BPR. This can cause the fitting to break off in the valve. The seal
between the valve and the connector is achieved via an O-ring and tightening hard will only
damage the connector. As a result, connection tubing and BPR should only be moved gently
when connected.
4 Maintenance
4.1 Cleaning the Device After Use
The wetted parts of the BPR-1000 are all made with inert polymers, therefore minimal care is
required. However, rinsing with a solvent/water stream after use is suggested. The rinse is
especially recommended if liquids carrying salts are used. The liquids use to flush the device should
be selected as not to react with the process fluids. The rinse should be focused on dissolving any
potential precipitates inside the BPR.

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4.2 Opening the Device for Cleaning
While we do not recommend opening the device, in some instances it may be required to
eliminate solids. To open the device:
1. Open the valve on top of the device to depressurize it.
2. Unscrew the four corner M8 bolts.
3. Open the device.
4. Clean the fluid passages in the base with a small needle or drill bit to make sure they are not
blocked.
5. Remove the PFA diaphragm from the aluminum foil. Ensure that no solvent comes in contact
with the foil.
a. It is important to not damage the foil physically or chemically – this must be
replaced by Zaiput. If it is damaged the device will leak.
6. Clean the PFA foil by wiping it down with an adequate solvent to remove the built-up solids.
Ensure the diaphragm is completely dry before placing back on the foil.
7. The diaphragm can similarly be replaced with a new part.
8. Carefully close the device back up. Tighten the screws to 14 N.m.
4.3 Periodic Maintenance
If the valve is damaged or has begun to leak, it can easily be replaced by the user. Please contact a
Zaiput representative for part replacement. Similarly, if the connector is lost or damaged, it can be
easily replaced and your Zaiput representative can provide pricing for a replacement.
The PFA diaphragm can be replaced, however periodic cleaning should replace the need to replace
this part.
Should the device begin leaking or a hole develops in the foil above the PFA diaphragm, the
device will need to be returned for repairs and requalifying before returning to the users. If your
device is leaking, please ensure that all your fittings are fully tightened before returning the
device to Zaiput.
Note: Often 1/16” fittings cannot be fit deep enough into the device to make a good connection.
Attempt new fittings or tightening with pliers.
If you have a question about the Zaiput BPR or need assistance, please contact Zaiput
Customer Service immediately at: +1.617 -714- 9806 or [email protected]
If you want to return a device or send it for service, contact us first for a Return Authorization
(RA) number. Equipment sent in without out prior authorization will be returned at the
customer’s expense.

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We are looking forward to assisting you with your questions, support needs, or to
discuss your application.
You may contact us by phone, [phone] or by email:
Technical Questions
Product Inquiries
Orders
[e-mail]
[email protected]
[e-mail]
Copyright ©
Zaiput Flow Technologies
101a 1st Avenue,
Waltham, MA -02451
www.zaiput.com
Last update: February 2021