USER MANUAL - Matheson TRIGAS
Contents
1. Fig 3 4 INT 0262 XX rev B 10 of 23 3 5 Process Schematic N1 INT 0262 XX rev B PSV2 10bar PSV1 4 5bar Air inlet Inlet carbon filter Air compressor Start up valve Gas separation mem brane Membrane pressure indicator Flow control valve Nitrogen compressor Nitrogen pressure relief valve Pressure switch Nitrogen pressure in dictor Check valve Nitrogen outlet Ball valve Depressurisation valve 11 of 23 4 Technical specifications 4 1 General Maximum delivery pressure 115 psig 8 bar g Temperature 50 to 95 F 10 to 35 C Air quality Normal clean ambient air relative humidity lt 90 Noise level Basic lt 58 dB A Dimensions H x W x D inch 27 1 2 x 35 1 2 x 12 1 4 Dimensions H x W x D cm 70 x 90 x 31 Net weight 204 Ibs 92 5 kg Connections Outlet 1 4 FPT Voltage frequency 110VAC 60Hz 230VAC 50Hz Power consumption 1 4 kW LCMS M 4 nitrogen generator 1x LCMS M 4 nitrogen generator 1x Instruction Manual Options on demand Storage vessel Table 4 1 General data INT 0262 XX rev B 12 of 23 4 2 Production capacity 4 2 1 Capacity LCMS M 4 nitrogen generator Purity 99 9 99 7 99 5 99 98 97 96 95 93 NLPM 7 6 12 13 18 23 26 30 32 38 Table 4 3 Capacity Nominal conditions e Ambient temperatu2. 1 Open the packaging 2 Make sure that all components are delivered Refer to Table 4 1 5 4 Connect to application Warning N Do not connect the power at this time e Make sure that the tubes are free of dust particles metal parts and curls liquids and grease before you connect the LCMS M 4 nitrogen generator e Connect the outlet of the unit to the application 5 5 Set up the LCMS M 4 nitrogen generator 1 Make sure that the connections are correct and fixed properly 2 Leak check the connections and tubing between the LCMS M 4 nitrogen generator and the application INT 0262 XX rev B 14 of 23 6 Operation 6 1 Start LCMS M 4 nitrogen generator Turn the power to the LCMS M 4 nitrogen generator switch in the back Switch on the LCMS M 4 nitrogen generator switch in the front It will take 3 minutes before the LCMS M 4 nitrogen generator will start to run The system is ready for use The LCMS M 4 nitrogen generator will deliver as much nitrogen as required excess nitrogen will be vented Oo RON 6 2 Stop LCMS M 4 nitrogen generator 1 Switch off the power switch before you perform maintenance 2 Depressurize the system by venting the nitrogen outlet 3 Make sure that the system is fully depressurized by checking the pressure gauges in the system INT 0262 XX rev B 15 of 23 6 3 Control panel The control panel see Figure 6 1 consists of a display and two buttons menu and reset The
3. 5 mm tip is required to adjust i Fig 8 2 Calibrate oxygen sensor the potentiometer 19 alibrate oxyg The value should read 174mV Adjust the oxygen level if the value in the display differs Turn the small adjustment screw B to set the level to 174mV which corre sponds to 20 9 level cap E with the sensor C Span Potentiometer Fig 8 3 Oxygen sensor print board INT 0262 XX rev B 19 of 23 8 5 8 5 1 0262 rev B Pressure switch control Adjusting the pressure switch The pressure switch PSH can switch the LCMS M 4 on and off depending on the pressure level in a storage vessel The pressure switch PSH setting can be read at the front of the pressure switch inside the cabinet of the LCMS M 4 The pressure at which the unit switches off can be read off on the range scale The switch on pressure can be set using the differential scale The switch on pressure is equal to the shut off pressure minus the differential Pon Poff DIFFERENTIAL The default switch off pressure is 115 psig 8 0 bar g If desired it may be set to a lower value DANFOSS 60 473 10 10 Fig 8 4 Pressure switch DANFOSS 60 474 14 20 of 23 8 5 2 Control of the outlet pressure The outlet pressure of the LCMS M 4 nitrogen generator can be controlled in two ways depending on whether the nitrogen is stored in a vessel or not No storage vessel installed excess nitrogen will be v
4. meaning of the codes also indicated on the front panel is as follows C1 Warming up The heater is warming the module inlet C2 Run System is producing nitrogen C3 Stand by Nitrogen production has been stopped automatically by pressure switch because storage vessel is full Alarms A1 Poor nitrogen quality A2 Oxygen sensor failure A3 High internal temperature z ap bead bah lE OG maar Dal ane 1 Sariy a Ten ura ia us high RESET Figure 6 1 By repeatedly pressing the menu button you can scroll through a short cyclic menu of parameters Figure 6 2 This will not influence the unit When the function buttons have not been pressed for 2 minutes the display will show the status of the unit e After pressing the menu button once the oxygen level will be displayed range 0 0 9 9 e After pressing the menu button another time the display will show H 0 This indicates the running hours of the compressor s The running hours are stored in 5 digits the first being the digit to the right of the digit hour The next digits can be read by pressing the reset button twice and writing down the consecutive digits to 5 digits number e g H 0 0 0 1 2 is 12 running hours e Pressing the menu button again will return the status indicator Menu Press the Menu button once Reset Press the Reset button once Satus j 1 2 3 Menu Menu hou
5. the equipment Refer to section 1 6 Lift the LCMS M 4 nitrogen generator with a forklift Follow the instructions for operating the forklift Do not tamper or experiment with the equipment Do not exceed the technical specifications for the LCMS M 4 nitrogen generator Refer to chapter 4 2 2 Nitrogen and oxygen The LCMS M 4 nitrogen generator generates nitrogen as a product Oxygen enriched air is released as waste 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 The LCMS M 4 nitrogen generator is not designed for installation in an explosion proof classified area Do not install the LCMS M 4 nitrogen generator in an area where explosive mixtures may occur 2 3 Electricity Warning e installation maintenance and repairs Only service technicians that are qualified to work on electric equipment are allowed to do the Disconnect the main power supply before you do the maintenance or repair If a service technician has to work on the LCMS M 4 nitrogen generator while electricity is connected then the service technician must be very careful with respect to the electric hazards 2 4 Safety precautions Make sure that the ventilation rate is sufficient in the room where the enriched oxygen is Warning e ventilated or lead the enriched air outside INT 0262 XX rev B Kee
6. MATHESON TRIeGAS ask Gas Professionals USER MANUAL LCMS M 4 NITROGEN GENERATOR MATHESON TRI GAS C 166 Keystone Drive Montgomeryville PA 18936 150 9001 2000 Phone 215 641 2700 KEMA Fax 215 641 2714 Email mtgmmville matheson trigas com 14001 0262 rev 2005 Matheson Tri Gas All rights reserved No part of this publication may be produced and or publicized by being printed photocopied and or placed on microfilm or in any other manner with out the prior written permission of Matheson Tri Gas Matheson Tri Gas 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 LCMS M 4 nitrogen generator in its standard version Matheson Tri Gas 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 Matheson Tri Gas INT 0262 XX rev B 2 of 23 USER MANUAL 1 2 A 9 10 INTRODUC TION E T cubs ca coos E E EE A T TT 1 1 General asoka nn aa aa a R I ent tete cui rei Cena 4 1 27 vPictograms 18 this manual ree e RHEIN te av ine sg ace RA E 4 1 3 Identification and service oo eee te e 5 L4 C
7. Unpack and check equipmient esee etie e 14 5 4 Connect to application ien eee ee ede eei e 14 5 5 Start up the LCMS M 4 nitrogen 14 OPERA TION ror 6 1 Start LCMS M 4 nitrogen generator 15 6 2 Stop LCMS M 4 nitrogen 15 6 3 Control panel ao roit be er mee Du IRE 16 TROUBLESHOOTING n op bene deae esee sco 7 1 Eitor l0 vere tat EIE Raves He 17 MAINTENANCE ec E M Oa 8 1 Maintenance schedule oe tee ace GR e eee OR RI Get e Ere i ERE dee qud 18 82 filter element replacement 18 8 3 Oxygen sensor 18 8 4 Oxygen sensor calibration 19 8 5 Pressure switch 20 ELECTRICAL SCHEMATIC aoee eere eene xee eee pe veu ep crea pe ves ee voee e EUR In qe M INT 0262 XX rev B 1 Introduction 1 1 General The LCMS M 4 nitrogen generator is a product of Matheson Tri Gas 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 you start with the LCMS M 4 nitrogen generator Familiarize yourself with the con
8. ace inlet carbon filter e 1x per year Oxygen sensor Replace oxygen sensor e 1x per 3 years Table 8 1 Maintenance scheme 8 2 Inlet filter element replacement 1 Switch off the LCMS M 4 nitrogen generator 2 Let the system depressurize 3 Disconnect the inlet filter from the tubing 4 Unscrew the brackets 5 Remove the inlet filter 6 Replace the new filter and fix it with the brackets 7 Connect the inlet filter to the tubing 8 Switch the LCMS M 4 nitrogen generator back on 8 3 Oxygen sensor replacement 1 Switch off the LCMS M 4 2 Remove the right side cover from the LCMS M 4 3 Carefully remove the sensor cap E Do not pull at the tube 4 Unscrew the screw ring D 5 Disconnect connector A 6 Install the new sensor C 7 Switch on the LCMS M 4 8 Calibrate the oxygen sensor Refer to 8 4 INT 0262 XX rev B Fig 8 1 Replace oxygen sensor 18 of 23 8 4 Check the sample flow the sensor Remove the sensor cap E and expose The signal may be monitored using a Reconnect the tube F and the sensor Oxygen sensor calibration 300 cc min coming out of the tube F that is connected to the sensor cap E The flow can be adjusted with the needle valve FCV3 the sensor to ambient air multimeter inserted in CN2 fig 8 3 across a 10 Ohm precision resistor or by remote receiver A small non metallic screwdriver with a 1 2 x 0
9. acteristics of the LCMS M 4 nitrogen generator For service and technical assistance please contact MATHESON TRI GAS 166 Keystone Drive Montgomeryville PA 18936 Phone 215 641 2700 Fax 215 641 2714 Email mtgmmville matheson trigas com 1 4 Certificates The LCMS M 4 nitrogen generator meets the following requirements Directive for electromagnetic compati EN 50081 1 EN50082 2 bility EMC Low Voltage Directive NEN EN 60204 1 Pressure equipment directive PED Sound engineering practice Quality assurance ISO 9001 2000 Environmental care ISO 14001 1996 1 5 Intended uses The LCMS M 4 nitrogen generator is intended to make nitrogen out of normal ambient air The system is based on gas separation membranes The system is not to be used for any other purpose Matheson Tri Gas will not accept any li ability for improper use The LCMS M 4 nitrogen generator is in compliance with the prevailing directives and standards Only use this LCMS M 4 nitrogen generator in a technically perfect condition in conformity with the purpose as described above 1 6 User responsibilities Only well trained personnel are allowed to work on the LCMS M 4 nitrogen generator The user must be aware of hazards related to operating the LCMS M 4 nitrogen generator and processes connected to the LCMS M 4 nitrogen generator The user is responsible for the safety of the personnel All personnel working on the LCMS M 4 nitrogen gener
10. ator must have free access to the applicable manuals 1 7 Liability Matheson Tri Gas will not accept any liability if e instructions in this manual are ignored e Replacement parts are used which are not approved by the manufacturer e The LCMS M 4 nitrogen generator is operated incorrectly e The system is fed with other gasses than air e The LCMS M 4 nitrogen generator is modified without notification and authorization of the manufacturer e Maintenance and repair are not carried out according to the instructions INT 0262 XX rev B 5 of 23 2 Health safety and environmental compliance 2 1 General Correct use of the LCMS M 4 nitrogen generator nitrogen generator is important for your personal safety and for trouble free functioning of the LCMS M 4 nitrogen generator Incorrect use can cause damage to the LCMS M 4 nitrogen generator or can lead to incorrect gas supply Read this manual before you start the installation and putting into operation of the LCMS M 4 Warning e N nitrogen generator Prevent accidents and damage to the LCMS M 4 nitrogen generator Contact your supplier if you detect a problem that you cannot solve with this manual Use the LCMS M 4 nitrogen generator only for its intended purpose Refer to section 1 5 Only service technicians that are qualified to work on electric and pneumatic equipment are allowed to do the installation maintenance and repairs Unqualified people are not allowed to repair
11. carbon dioxide water vapor and traces of other inert gasses Pressurized air A is led through hollow fiber membranes B The various air components diffuse through the porous wall of the membranes The diffusion rate differs for the various gasses e Oxygen and water vapor have a high diffusion rate and diffuse rapidly through the membrane wall e Nitrogen has a low diffusion rate and diffuses slowly through the membrane wall e Pressurized nitrogen enriched air is released at the outlet of the membranes E which can be stored in a nitrogen storage vessel INT 0262 XX rev B 8 of 23 front egy H Fig 3 2 LCMS M 4 Nitrogen Generator High low pressure compressor K Hollow fibre membrane M Low pressure compressor Inlet carbon filter Power switch Flow control valve FCV O display Delivery pressure gauge 2 Pressure control valve PCV Compressed air pressure gauge PI1 c c 7 T0onmuoou2 onNnouoz INT 0262 XX rev B side view back Flow control valve FVC3 Oz sensor Printed circuit board with two digit service display Pressure switch PSH Fuses Ball valve V2 Power inlet socket Main switch Cooling air exhaust outlet 9 of 23 3 4 Process Diagram The LCMS M 4 nitrogen generator can be connected directly to the application Fig 3 3 or to a buffer vessel Fig 3 4 LCMS M 4 Application Fig 3 3 Buffer Vessel LCMS M 4
12. ented The LCMS M 4 will run continuously the pressure switch serves as a safety To set the PSH for this situation do the following e Set the pressure switch such that the switch of pressure is 120 psig 8 5 bar g according to 8 5 1 e Open PCV completely turn left e Close the ball valve V2 at the outlet while the system is running e Adjust the back pressure valve PCV such that the pressure gauge 2 on the front reads no more than 115 psig 8 0 bar g Lower pressure settings will extend compressor life and reduce power usage e Open the ball valve V2 at the outlet Storage vessel installed excess nitrogen will be stored The LCMS M 4 will start and stop automatically To set the PSH for this situation do the following e Close PCV completely turn right e Set the pressure switch to the desired storage vessel pressure but no more than 115 psig 8 0 bar g Switch off pressure according to 8 5 1 Lower pressures will extend compressor life and reduce power usage e Set the differential at 12 psi 0 8 bar Smaller differentials will result in frequent switching which will shorten the life of the compressors NOTE After the unit switches off due to reaching switch off pressure in the storage tank the unit cannot switch on within 5 minutes after the switch off The switch on delay is there to prevent too frequent start up of the compressors that shorten the compressor life INT 0262 XX rev B 21 of 23 Electrical schemat
13. ertificates osos va tor oie oh lee AA vm eie in 5 1 5 Int ndedauseSs eh aue 5 16 7 edo Oe bid 5 L3 ioa diete dam ert es 5 HEALTH SAFETY AND ENVIRONMENTAL COMPLIANCE eee eee eene eene noto sete tuac 2 1 ERES 6 2 JNitrogen nd oxy gent esset ese ede diee iei e Rn teret dere Ee deos 6 2 3 Electricity idee ee EGRE E TER P ERR Ee 6 2 4 Safety precautions e reedeiietes decide chee cee REE EAR E erede 6 2 5 E vironimiental aspects teed ed nette Ga ge es ede ee 7 DESCRIPTION 3 1 Generali os nenas b dise REED UR 8 32 Separation principles ct trees eps et ea Bes Ae o Reus MM rA Red otc tates 8 3 3 P rts t meret Stemma ee neo etate beu 9 34 cu em ME inus 10 3 95 Process Schematics dE So ID Uni 11 TECHNICAL 4 1 General eee nui deed ee 12 4 2 Production capacity iore eed f secs e gl Se ed 13 4 3 Maintenance tems s eee eR Recette i e TEN D EE AN Ree ens 13 INSTALLATION 5 1 Transport cere oer T 14 e Le D M ata Ue IHE NITORE 14 53
14. ic 9 bx p q39 7 Ee X HOH DOL ARCNYIS Hos 2 viri TAR MES iem pad exc mmeg p EB qu LEH LY 22 of 23 INT 0262 XX rev B 10 Index A Ambient air 8 C Capacity 13 Caution 4 Certificates 5 Check equipment 14 Control panel 16 Cyclic menu 16 D Dimensions 12 Display 16 E Electrical data 12 Electrical schematic 22 Electricity 4 6 Environment 4 Environmental compliance 7 Error list 17 H High pressure risk 4 Identification plate 5 Inlet filter 18 Installation 14 Introduction 4 L Liability 5 Location 14 Maintenance 18 INT 0262 XX rev B N Nitrogen 6 Operation 15 Oxygen 6 Oxygen enriched air 6 P Parameters 16 Parts 9 12 18 Pictograms 4 Process schematic 11 R Risk of fire 4 Run 16 5 Safety precautions 6 Separation principle 8 Stand by 16 Start 15 Status indicator 16 Stop 15 I Technical specifications 12 Transport 14 Troubleshooting 17 U User responsibilities 5 Warning 4 6 23 of 23
15. p the ambient temperature between 50 and 95 F 10 and 35 C Install the peripheral equipment piping and nitrogen storage vessels according to standard procedures Do regular maintenance to the LCMS M 4 nitrogen generator to ensure proper and safe operation Refer to section 8 Make sure that instructions concerning health and safety are compliant with the local rules and regulations 6 of 23 2 5 Environmental compliance The use and maintenance of the LCMS M 4 nitrogen generator does not include environmental dangers Most parts are made of metal and can be disposed in the regular way The packaging of the LCMS M 4 nitrogen generator is 100 recyclable ay Make sure that instructions concerning health safety and environment are compliant with the e local rules and regulations ug INT 0262 XX rev B 7 of 23 3 Description 3 1 General The LCMS M 4 nitrogen generator separates compressed air produced by an on board compressor into nitrogen and an air stream enriched with oxygen The separation system is based on membranes 3 2 Separation principle B QO 6 O E eb cos 000609 c oooeooeoo 9 H20 H2 02 N2 pF e s e Fig 3 1 Separation principle A Pressurized air inlet E Nitrogen outlet B Hollow fiber membrane F Fast permeation C Separation layer G Slow permeation D Support layer Ambient air contains nitrogen 78 1 oxygen 20 9 argon 1
16. re 68 F 20 C e Ambient pressure 14 7 psia 1013 mbar a 4 3 Maintenance items Maintenance kit LCMS FILT KIT e 1x Carbon filter Oxygen sensor LCMS O2 SEN INT 0262 XX rev B 13 of 23 5 Installation Follow the paragraphs in this chapter to install the LCMS M 4 nitrogen generator 5 1 Transport Warning e Transport the LCMS M 4 nitrogen generator upright e Use the original container to transport the unit over long distances e e Lift the LCMS M 4 nitrogen generator with a forklift For qualifications of personnel refer to section 2 1 5 2 Location IMPORTANT e The LCMS M 4 nitrogen 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 20 50 cm on all sides back left right and top is a necessity also efficient local ventilation at the unit s ventilation outlet is highly recommended especially when the unit is installed under a bench Install the LCMS M 4 nitrogen generator on a fixed location The location must meet following requirements e Minimum clearance of 20 50 cm on all sides back left right and top as to facilitate heat removal e Indoors e Dry e Avoid direct exposure to sunlight e Away from heat sources e Properly ventilated room e Easy accessibly for operating and service 5 3 Unpack and check equipment
17. rs Oxygen level iH 0 2 3 4 5 0 0 9 09 al i COT ha Reset Figure 6 2 Cyclic menu structure INT 0262 XX rev B 16 of 23 7 7 1 Troubleshooting Error list Delivery Ambient temperature is too Lower the temperature if nitrogen too high possible low or non Check whether the minimum existent clearance between the LCMS M 4 nitrogen generator and the walls is large enough Inlet carbon filter is spent Exchange the inlet filter LCMS M 4 nitrogen genera Switch on the LCMS 4 ni tor is switched off trogen generator Leak in piping Check for leaks in the piping Nitrogen outlet line is Check open the outlet line blocked Alarm A1 explained below poor nitrogen quality Alarm A2 explained below oxygen sensor failure Alarm A3 e Ambient temperature is too high internal temperature high over 95 F 35 C e In outlet gratings are clogged e Cooling fans are not or insufficiently functioning e Compressors are over loaded Residual Pressure in nitrogen storage Readjust pressure switch oxygen con vessel over 8 bar g because tent too high of erroneous setting of pres sure switch Ambient temperature lower Increase temperature or read than normal just purity Purity setting has changed Readjust purity over time Table 7 1 Error list INT 0262 XX rev B 8 8 1 Maintenance schedule Filters Repl
18. tent Changes to Product Only execute changes to the LCMS M 4 nitrogen generator after explicit prior written permission by Matheson Tri Gas 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 Matheson Tri Gas 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 Matheson Tri Gas 1 2 Pictograms in this manual In this manual 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 oP EEE ay Environment Ln A Instructions with respect to the environment INT 0262 XX rev B 4 of 23 1 3 Identification and service The identification plate is located on the right hand side of the LCMS M 4 nitrogen generator The identification plate shows the char
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