TECHNICAL INFORMATION Installation, Operation, and Maintenance Balston 75-96 and 75-98 Nitrogen Generation System Tower Pressure Gauge 5'-1" 3'-6" 7'-4" 6'-10 1/2" PLAN VIEW Figure 1 - Balston 75-96 and 75-98 Nitrogen Generation System These instructions must be thoroughly read and understood before installing and operating this product. If you have any questions or concerns, please call the Technical Services Department at 800-343-4048, 8AM to 5PM Eastern Time (North America only). For other locations, please contact your local representative. Please save product packaging for future use. General Description Engineered system The Balston 75-96 and 75-98 Nitrogen Generators are completely engineered systems which will convert a compressed air supply into 95-99.9% purity compressed nitrogen. The systems are based on state-of-the-art monobed Pressure Swing Adsorption (PSA) technology. The adsorption bed converts compressed air into a concentrated nitrogen output stream. The Balston 75-96 and 75-98 Nitrogen Generators include all the components required to convert compressed air into high purity nitrogen. The user need only connect a supply of compressed air to the inlet of the nitrogen generator and connect the outlet of the generator to the process requiring high purity nitrogen. The system can be broken down into four primary functional groups. These functional groups are: prefiltration, nitrogen generation, flow controls, and final filtration. Prefiltration Two high efficiency coalescing filters are incorporated into the nitrogen generator to protect the PSA tower and valves from contamination. The coalescing filters are located beneath the front panel (see Figure 1). They remove liquids and particulate matter from the incoming air supply. These filters are equipped with automatic float drains to empty any liquids accumulated within the filter housing. For assistance, call toll-free at 800-343-4048 Parker Hannifin Corporation Bulletin TI-7596/98 1 A
Description Pressure Swing Adsorption Final Filtration Flow Controls Electrical Controls The nitrogen is extracted from the compressed air in the PSA tower. Solid state timers coordinate the nitrogen production and tower purge cycles. An oxygen-rich exhaust stream is discharged through a purge port at the rear of the monobed (see Figure 1). A receiver tank has been integrated into the designs of the 75-96 (120-gallon) and 75-98 (240-gallon) to smooth the pressure fluctuations inherent to PSA operation. Use of the tank ensures delivery of high purity nitrogen at a constant pressure and flow to the user s application. The final filter on the Balston Nitrogen Generator is a Balston Grade SA (Sterile Air) filter. The final filter removes particulate contamination with an efficiency of 99.9999+% at 0.1 micron, assuring the user a clean, commercially sterile supply of high purity nitrogen. The final filter is located behind the control panel (see Figure 1). The flow and pressure controls are comprised of an outlet pressure regulator and gauge, and an outlet flow meter and flow controller (See Figure 2). Proper use of these controls will assure the user of a 95% to 99.9% purity nitrogen outlet stream. The outlet pressure regulator and gauge are used to set and monitor the nitrogen outlet pressure from the generator. The flow controller and flow meter are used to set and monitor the nitrogen flow rate through the system. The Nitrogen Purity Label on the control panel is used to set the flow controller to achieve desired purity and flow characteristics. (See the Operation section of this manual for detailed instruction on setting flows.) The electrical controls on the Balston 75-96 and 75-98 are a power switch and a mode switch. The power switch is located on the right side of the control panel. This switch is used to energize the nitrogen generator. The mode switch permits the operator to select the generating ( GENERATE ) mode or the shutdown ( DESORB ) mode. The normal mode for nitrogen generation is GENER- ATE. The DESORB mode is used only for maintenance and shutdown. Figure 2 - Control Panel Installation General The Balston Nitrogen Generation System is a free-standing unit. The inlet port (3/4" female NPT for the 75-96, and 1" female NPT for the 75-98) on the generator is located on the left side of the control panel. The outlet port is 1/2" female NPT (on both units) and is located on the right side of the control panel. Use male connectors which will withstand 140 psig and 2284 SCFH for the 75-96, and 150 psig and 4500 SCFH for the 75-98 (or equivalent fittings) to connect to the nitrogen generator. 2 Parker Hannifin Corporation Bulletin TI-7596/98 A
Installation A shutoff valve, pressure-relieving pressure regulator, and pressure gauge should be installed directly upstream from the Balston Nitrogen Generator. The shutoff valve isolates the unit from the compressed air line for maintenance and troubleshooting tasks. The pressure regulator maintains a constant inlet air pressure to the generator. Maintaining a constant inlet air pressure is critical to the performance of the system. The shutoff valve and pressure regulator should be at least 3/4" NPT (75-96) or 1" NPT (75-98). If smaller pipe connections are used, there will be an excessive pressure drop in the compressed air supply to the generator and the nitrogen purity will be compromised. The pressure regulator upstream from the generator must be a pressure-relieving regulator. This will allow the user to depressurize the generator for maintenance activities. Location Utilities The Balston Nitrogen Generation System should be located in an area where the ambient temperature is between 40 F and 110 F (4 C and 43 C). Installation of the unit in an area where the ambient temperature exceeds 110 F (43 C) or falls below 40 F (4 C) may affect the performance and/or life of the system and void the warranty. The environment surrounding the nitrogen generator should also be adequately ventilated. The generator creates an oxygen-rich permeate stream which may pose a flammability problem in an oxygen-sensitive environment. Nitrogen is nontoxic and largely inert. It can act as a simple asphyxiant by displacing oxygen in air. Inhalation of nitrogen in excessive concentrations can result in unconsciousness without any warning symptoms such as dizziness, fatigue, etc. Install the generator in a well ventilated area. Compressed Air - The Balston Nitrogen Generation System requires a source of clean, dry compressed air for optimal operation. The compressed air should be of instrument quality and supplied at a pressure equal to or above 110 psig. Consult the factory for flows and purities at operating pressures other than 110 psig. If the incoming air pressure is greater than 150 psig, the system may be damaged and the warranty will be void. The supply air should also be at room temperature and relatively free of water, compressor oil, hydrocarbons, and particulate matter. In order to produce nitrogen with a purity greater than 99.9%, the compressed air supply must have a dewpoint less than 40 F (4 C). Parker Balston recommends a dedicated compressed air system which includes a 15 to 20 hp compressor for the 75-96 or a 20 to 25 hp compressor for the 75-98, an aftercooler, and a membrane dryer to supply compressed air at a dew point below ambient temperature. The compressor should provide enough air flow to prevent excessive pressure drops during the cycling of the PSA beds. Compressed air consumption rates at different outlet flows and purities are detailed in the Specifications section at the end of this manual. Note: Excessive quantities of water, compressor oil, hydrocarbons, or particulate in the compressed air supply will contaminate the PSA towers and valves. If contamination of the system occurs as a result of an inferior compressed air supply, nitrogen purity specifications will not be met and the warranty will be void. Power - A 120 VAC/60 Hz, 2 amp power supply will be required to energize the Balston 75-96 and 75-98 Nitrogen Generation Systems. Piping - The inlet air piping and all associated accessories (i.e. valves and regulators) should be at least 3/4" NPT (75-96) or 1" NPT (75-98) to eliminate any line restrictions which could lead to excessive pressure drops during operation. The nitrogen outlet port is 1/2" female NPT. All piping and fittings used with the nitrogen generator should be clean and rated to 150 psig, minimally. Parker Balston recommends installing a vent valve downstream from the generator, upstream from the process which requires nitrogen. Use this vent valve to divert the nitrogen during the startup period. This will prevent the nitrogen, which contains high levels of oxygen, from contaminating the downstream piping and process. Drain Lines - The 1/4" plastic drain lines from the first two stages of prefiltration (see Figure 1) should be piped away to an appropriate disposal container. The drainage will consist primarily of water and compressor oil and should be disposed of properly according to local regulations. For assistance, call toll-free at 800-343-4048 3
Operation Startup The Balston Nitrogen Generation System requires at least two hours of start-up time to achieve rated purity. Nitrogen generated during this period should be vented to atmosphere to avoid contaminating downstream processes. Calibrate the oxygen analyzer prior to starting the nitrogen generator. After the inlet and outlet piping has been connected to the generator, plug the power cord into a 120 VAC/60 Hz power source. Switch the power switch to ON. Set the mode switch to the GENERATE position. The unit will power on in the desorbtion cycle; therefore, any residual pressure in the towers will be vented. System adjustment for desired outlet purity Atmospheric pressure applications (<10 psig) Open the inlet air (customer installed) valve to pressurize the system, set the inlet air pressure to between 110 psig and 140 psig, and check for leaks. Check all upstream and downstream fittings thoroughly. The unit will perform optimally when the monobed tower operates between 110 psig and 140 psig. The tower pressure is displayed by a pressure gauge located at the top of the PSA tower (this gauge is for diagnostic purposes only). After the Balston Nitrogen Generation System has been powered on and pressurized, determine the outlet pressure and purity of nitrogen which is required for the application. Set the pressure and flow parameters as follows: The following adjustment procedure to adjust the Balston Nitrogen Generation System should be used in applications where the nitrogen output is at or near atmospheric pressure (e.g. purging, blanketing). 1 Pressure - To adjust the outlet pressure from the generator, close the flow control valve and turn the outlet pressure regulator (see Figure 2) until the outlet pressure gauge displays the desired outlet pressure. (Note: Not all flows are available at all pressures. Refer to the Nitrogen Purity Label, located on the control panel of the unit and below, to confirm the availability of flow at the desired outlet pressure.) 2 Flow - The flow meter settings for the generator, at different purities and outlet pressures, are listed on the Nitrogen Purity Label on the front of the unit, and in the table below. Set the outlet flow after setting the outlet pressure, by turning the flow controller (see Figure 2) until the desired flow meter reading is displayed on the flow meter. Always read the flow meter at the largest diameter of the floating ball. Avoid exceeding the output capacity of the generator. If outlet capacity is exceeded, the nitrogen generated will not meet purity specifications. NITROGEN PURITY % NITROGEN FLOW (SCFH) 75-96 FLOWMETER READING AT VARIOUS OUTLET PRESSURES 10 psi 20 psi 30 psi 40 psi 50 psi 60 psi 70 psi 80 psi 99.9 245 3.4 2.8 2.4 2.2 2.0 1.9 1.8 1.7 99.5 400 4.4 3.8 3.4 3.2 2.9 2.8 2.3 99.0 490 5.2 4.6 4.0 3.8 3.4 3.3 98.0 630 6.8 6.2 5.4 5.0 4.6 97.0 735 7.2 6.4 6.0 96.0 815 8.2 7.2 95.0 880 8.6 ABOVE DATA BASED ON 110 PSIG INLET PRESSURE NITROGEN PURITY % NITROGEN FLOW (SCFH) 75-98 FLOWMETER READING AT VARIOUS OUTLET PRESSURES 10 psi 20 psi 30 psi 40 psi 50 psi 60 psi 70 psi 80 psi 99.9 490 9.3 6.5 5.3 4.6 4.1 3.8 3.5 3.3 99.5 800 14.5 10.3 8.4 7.3 6.5 5.9 5.5 99.0 980 18.5 13.1 10.7 9.3 8.3 7.6 7.0 98.0 1260 16.8 13.7 11.9 10.6 9.7 97.0 1470 19.6 16.0 13.9 12.4 96.0 1630 21.5 17.6 15.2 13.6 95.0 1760 19.1 16.5 14.8 ABOVE DATA BASED ON 110 PSIG INLET PRESSURE Example: If the application requires 99.5% purity nitrogen delivered at 50 psig, the maximum flow rate will be 400 SCFH (75-96) or 800 SCFH (75-98), and the flow meter setting will be 3.2 (75-96) or 6.5 (75-98). Note: Until the purity is stable, the nitrogen flow should be vented to atmosphere. Start-up time is approximately 2 hours for a cold startup (i.e., the nitrogen receiver is not pressurized with high purity nitrogen). 4 Parker Hannifin Corporation Bulletin TI-7596/98 A
Operation Elevated Pressure Applications (>10 psig) Evaluation Temperature Considerations If the Balston 75-96 or 75-98 Nitrogen Generation System is being used to provide nitrogen at an elevated pressure (>10 psig), the previous procedure must be modified. First, install a flow control device downstream from the process or application which uses the nitrogen. This valve will be used to control the nitrogen flow. Next, open the flow control valve on the generator to its fully open position. Set the outlet pressure to the desired application pressure using the pressure regulator on the generator. Finally, use the downstream flow control device to adjust the flow so the flow meter on the generator reads the required setting for the desired purity. The performance and operating conditions of the Nitrogen Generation System should be monitored on a routine basis, as dictated by the application. This routine system check should include: confirming nitrogen purity stability, adjusting flow meter reading (if necessary), confirming tower cycling pressures (diagnostic pressure gauge on top of PSA tower), and checking outlet pressure. If any of these readings have changed significantly from their original settings, adjustments must be made as described in the (preceding) Adjustment Procedure section of this bulletin. If the nitrogen purity must be altered during operation of the system, allow approximately 1 hour for the purity to stabilize. The data represented in this manual is based on an ambient operating temperature of 77 F (25 C). The unit is designed to operate in the temperature range of 40 F to 110 F (4 C to 43 C). Please consult factory if the ambient temperature in the generator location will be outside this range. Shutdown There are two different shutdown procedures for the Balston Nitrogen Generation System. The Normal Shutdown procedure should be followed for filter maintenance, oxygen analyzer maintenance, and temporary operational shutdowns (i.e., overnight, weekends). After a Normal Shutdown, a supply of high purity nitrogen gas will remain in the receiver tank and system start-up time will be reduced when the generator is restarted. The Electrical Shutdown should be followed for servicing the electrical valves, timers, and for preparing the unit for shipment. After an Electrical Service Shutdown, the nitrogen receiver is empty; therefore, the start-up time for the generator will be 2 hours. Normal Shutdown 1 Switch the PSA Mode switch (see Figure 2) to the "DESORB" mode and allow 2 minutes for the PSA tower to safely depressurize. When the PSA tower is completely desorbed, the tower pressure gauge will read zero. 2 Turn the power switch to the off position. 3 Close the (customer installed) shutoff valve on the inlet air line. Turn the (customer installed) inlet air (pressure-relieving) pressure regulator down until the pressure in the air line is zero. 4 Close the ball valves at the inlet and outlet of the nitrogen receiver tank. The receiver tank pressure gauge should read zero. (Note: The receiver tank is pressurized with high purity nitrogen even though the receiver tank pressure gauge reads zero.) 5 Check to confirm that the inlet pressure regulator gauge, PSA tower pressure gauge, nitrogen receiver gauge, nitrogen outlet pressure gauge all read zero before attempting any maintenance. Electrical Shutdown 1 Switch the PSA Mode switch (see Figure 2) to the "DESORB" mode and allow 2 minutes for the PSA tower to safely depressurize. When the PSA tower is completely desorbed, the Tower Pressure Gauge will read zero. 2 Turn the power switch to the off position and unplug the generator from its power source. 3 Close the shutoff valve on the inlet air line. Turn the inlet air (pressure-relieving) pressure regulator down until the pressure in the air line is zero. 4 Empty the receiver tank by opening the 2-way valve beneath the receiver tank. 5 Check to confirm that the inlet pressure regulator gauge, PSA tower pressure gauge, nitrogen receiver gauge, nitrogen outlet pressure gauge all read zero before attempting any maintenance procedures. Warning: If the PSA tower gauge continues to rise, please consult factory. Do not attempt to For assistance, call toll-free at 800-343-4048 perform maintenance on valves or timers with the towers pressurized. 5
Maintenance All maintenance activities should be performed by trained personnel using reasonable care. The Balston Nitrogen Generation System must be de-energized and depressurized before performing any maintenance procedures. Refer to shutdown instructions on page 5. General Filter Cartridge Replacement The primary maintenance tasks required by the Balston 75-96 and 75-98 Nitrogen Generators are: changing the prefilter cartridges (bi-annually), and changing the final sterile air cartridge (annually). A summary of the replacement part numbers and recommended service frequency is shown at the end of this Maintenance section. Performance of the system should be checked on a regular basis, as detailed in the Operation section of this manual. All filter housings which require routine service are easily accessible from the front of the generator. No tools are required to change the filter cartridges in the prefilters or sterile air filter. The two coalescing prefilters on the 75-96 are Balston A962-DX and A962-BX filter assemblies. Replace these filter cartridges with Balston 150-19-DX and 150-19-BX filter cartridges. The two coalescing prefilters on the 75-98 are Balston A960-DX and A960-BX filter assemblies. Replace these filter cartridges with Balston 200-35-DX and 200-35-BX filter cartridges. When replacing the prefilter cartridges, be sure to install the proper grade filter in the proper housing (the housings are labeled). The final sterile air filter for the 75-96 is a Balston A917A-SA filter assembly. Replace this sterile air filter with a Balston 100-25-SA filter cartridge. The final sterile air filter for the 75-98 is a Balston A963-SA filter assembly. The replacement filter cartridge is a Balston 150-19-SA. The filter cartridges in the filter assemblies are removed by removing the collar from the filter assembly (turn clockwise), lowering the filter bowl away from the filter head, and unscrewing the element retainer from the base of the cartridge. Insert the new filter cartridge and re-assemble the housing in reverse order. The time required to service all three stages of filtration (above) is approximately 30 minutes. The electrical components on the nitrogen generator (timers, valves, and relays) are virtually maintenance-free. Occasionally, an electrical component may have to be replaced as a result of normal wear and tear. If an electrical component must be replaced, please consult the factory. Ordering Information 1st Prefilter 2nd Prefilter Final Filter Replacement Cartridge Model 75-96 150-19-DX 150-19-BX 100-25-SA Model 75-98 200-35-DX 200-35-BX 150-19-SA Change Frequency 6 Months 6 Months 1 Year Principal Specifications Monobed Nitrogen Generator Model 75-96 Model 75-98 Atmospheric Dewpoint (1) -40 F (-40 C) -40 F (-40 C) Commercially Sterile Yes Yes Particles > 0.1 micron None None Suspended Liquids None None Recommended Inlet Pressure (2) 110 psig 110 psig Min/Max Ambient Temperature 40 F/110 F (4 C/65 C) 40 F/110 F (4 C/65 C) Air Consumption See table on page 7 Inlet Port Size 3/4" NPT (female) 1" NPT (female) Outlet Port Size 1/2" NPT (female) 1/2" NPT (female) Electrical Requirements 120 VAC/60 Hz., 2 amp 120 VAC/60 Hz., 2 amp Dimensions 62"w x 43"d x 92"h 78"w x 50"d x 103"h (157cm x 109cm x 234cm) (198cm x 127cm x 262cm) Shipping Weight 1600 lbs. (726 kg) 2000 lbs. (908 kg) 1 For lower dewpoints, please consult factory. 2 For flow data at inlet pressures other than 110 psig, consult factory. 6 Parker Hannifin Corporation Bulletin TI-7596/98 A
Flow Parameters Flow parameters at various purities Nitrogen Purity (%) Model 75-96 95.0 96.0 97.0 98.0 98.5 99.0 99.5 99.9 Air Consumption (SCFH) 2284 2150 2050 1990 1930 1888 1834 1807 Nitrogen Flow (SCFH) 880 815 735 630 530 490 400 245 Max. Outlet Pressure (psig)* 30 40 50 60 65 70 70 80 Nitrogen Purity (%) Model 75-98 95.0 96.0 97.0 98.0 98.5 99.0 99.5 99.9 Air Consumption (SCFH) 4500 4400 4211 4043 3900 3790 3658 3236 Nitrogen Flow (SCFH) 1760 1630 1470 1260 1120 980 800 490 Max. Outlet Pressure (psig)* 30 40 50 60 65 70 70 80 * For higher outlet pressures, please consult factory. Notes 1 Minimum purity shown on the purity label is in percent nitrogen. Higher accuracy is attainable if a trace analyzer is used. Consult factory for specification of trace analyzer). 2 All data shown on the nitrogen purity label is based on an ambient temperature of 77 F (25 C), 110 psig inlet pressure. 3 When changing flow to alter purity, allow at least one hour for the system to stabilize. Cautions 1 The Balston Nitrogen Generation System should be installed in an area with adequate ventilation to reduce the flammability of the oxygen-rich permeate stream. The system should not be located in an area where the permeate stream poses the risk of explosion or combustion. Do not block the purge port located behind the control panel. 2 Nitrogen is nontoxic and largely inert. It can act as a simple asphyxiant by displacing oxygen in air. Inhalation of nitrogen in excessive concentrations can result in unconsciousness without any warning symptoms such as dizziness, fatigue, etc. Troubleshooting and Service All troubleshooting and service activities should be performed by trained personnel using reasonable care. Troubleshooting Symptom Course of Action Loss of Outlet Pressure Loss of Outlet Flow Purity is Lower than Specified for Operating Conditions Air Leak Through Drains of Prefilters Check that the flow control valve on the generator is adjusted properly. Check inlet pressure to assure that it is greater than 110 psig. Check the system for leaks. Check inlet pressure to assure that it is greater than 110 psig. Check setting of flow control valve. Adjust if necessary. Check the system for leaks. Check power. Check setting of flow rate compared to purity label. Check the inlet air pressure to assure that it has not varied from the original reading. Check the system for leaks. Measure the temperature and dewpoint of the inlet air. The recommended temperature is 77 F (25 C) and the recommended dewpoint 60 F (15 C) or lower. In order to produce nitrogen with a purity greater than 99.9%, the compressed air supply must have a dewpoint less than 40 F (4 C) Calibrate oxygen analyzer (if needed). Check inlet pressure to assure that it is greater than 110 psig. Check inlet pressure. It should be greater than 15 psig to seal drain. Hold finger over drain opening for a few seconds to allow pressure to build and drain to seal. Remove bowl from filter assembly and rinse with water. If leak persists, replace automatic float drain (P/N 21552). If you have followed the troubleshooting procedures and are still having trouble, call toll-free 800-343-4048, 8AM to 5PM Eastern Time and request technical assistance. Please have serial number of generator available. For assistance, call toll-free at 800-343-4048 7
Don t Forget To: 1 Complete and mail your registration card. 2 Keep your product certification in a safe place. 3 Call the Technical Services Department at 800-343-4048, 8AM to 5PM Eastern Time with any questions. Serial Numbers A serial number for the 75-96 and 75-98 is attached to the left side panel, near the inlet port. For your own records, and in case service is required, please record the following: DATE IN SERVICE SERIAL NO. 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. Parker Hannifin Corporation Filtration and Separation Division 100 Ames Pond Drive, P.O. Box 1262 Tewksbury, MA 01876-0962 Tel: 978-858-0505 Fax: 978-858-0625 Parker Hannifin plc Hermitage Court, Hermitage Lane Maidstone, Kent ME16 9NT, England Tel: +44 (01622) 723300 Fax: +44 (01622) 728703 Parker Hannifin Corporation 2001 Printed in U.S.A. Bulletin TI-7596/98 A 8 Parker Hannifin Corporation Bulletin TI-7596/98 A