PublicFiles/PDF/User manual nitrogen generators
Contents
1. RR RRRR RR RRSR RR RR iii 5 PLACING THE GENERATOR m 5 SYMBOLS USED ON THE RR RR RR iii 5 GAS CONNECTIONS 5 lup a T 0 TT 6 Sii 6 e E 6 7 VM E 7 7 PA CIR E O O E RAAR 7 coge tes licei 7 SPECIAL FUNCTION clara 8 PRE ALARMS AND ALARMS RR RR RR RR ROSE RR RR SR 8 Wick ls iii 8 hl mmc 8 Lili 9 IENE Lucci 9 ROUTINE A INNER M iii 9 AE c 10 Ecc 10 4000 HOURS SERVICE 11 ei ico 17 SPARE PARTS 5 RR iii 182. MM M DI REM RD MED M Rd REN 18 RETURNING THE eR 18 APPENDIX HOW TO REPLACE THE 19 APPENDIX B HOW TO REPLACE THE FUSES i sscirini dani ian 24 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Introduction Introduction Scope of the manual This manual provides operation and maintenance instructions for model ZEFIRO 35 25 20 nitrogen generators Specifications Specifications of the nitrogen generator 40 I min 8 bar at STP for ZEFIRO 40 35 I min 8 bar at STP for ZEFIRO 35 Standard nitrogen flow rate 25 I min 8 bar at STP for ZEFIRO 25 20 I min 8 bar at STP for ZEFIRO 20 8 I min 4 bar at STP for ZEFIRO 8 HP Weight 9 Fuse NA 6 x32 mm 20A type F N2 5x20 mm 10 type F_ Microprocessor controlled La display Graphic display 128 x 64 pixels Index of protection e Operating conditions Temperature Relative humidity Pollution degree STP Standard temperature and pressure 20 C 1 bar 15 C to 35 C 0 80 non condensing Notes on FCC compliance This equipment has been tested and found to comply with the limits for a Class B digital de vice pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and
3. STRUMENTI SCIENTIFICI E 8 Fw E L Es Nitrogen generator model ZEFIRO 40 35 25 20 8 HP User s manual Version 2 07 Strumenti Scientifici Cinel via dell Artigianato 14 14 A 35010 Vigonza PD Tel 049725022 Fax 0498931881 e mail info cinel com www cinel gas com Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Index Index liec cibi 0 NER ODU TION o 1 SCOPE OF THE MANUAL RSS RR SR RENE 1 Ei a PTT 1 NOTES ON COMPLIANCE REIR SR SR REIR S SR RES Rar RPM rS 1 El iii 2 HEALTH AND iii 2 WARNING NITROGEN AND OXYGEN nun hu sh na RR SR RR RR RR SR 2 GELA 3 WARNING SAFETY RR RR REESE RR RR 3 PIT ici iii 4 E PERE RENE O O TT OM MU SEA 4 Dalila 5 RECEIVING THE GENERATOR
4. ambient pressure e unscrew the filter element and replace it with the new one Filter element for compressed air A 13 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance 2 Exchange the silencer for outlet gas C e remove the left plastic panel Silencer for exaust gas C 14 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance 3 Exchange the inlet filter for atmospheric air N 3 Quick con nections N 2 Screws C Unscrew the N 6 screws of the filter element 15 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance D Remove the cover Internal Internal grid sponge E Remove the internal sponge and sobstitute it and pay attention to place the grid in the right position Internal grid Internal sponge F Reassemble G Reconnect the power line and switch on the unit Enter the menu go to the special functions and insert the number This procedure reset the 4000 h work time counter Go to the main menu and press Start The next service will be at 8000 h 16 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance 8000 hours service kit ask to service the code Z03 8000 for Zefiro 20 25 35 40 ask to service the code Z06 8000 for Zefiro 8 HP Every 8000 hours the user must replace some parts of the generator A specific maintenance kit is available as spare part This kit i
5. are integral in the genera tor and theirs purpose is to compress air up and force it into the tubes containing the carbon molecular sieve The generated nitrogen gas is accumulated in a specific reservoir The internal pressure is controlled by a pressure transducer The outlet pressure is controlled by a proportional valve The nitrogen then passes through outlet port at the rear RESERVOIR No OUTLET CHECK 8 BAR VALVES N CHECK lt 7 VALVE VALVE COOLING COIL LINE 1 LINE 2 AIR INLET COMPRESSOR i T m COMPRESSOR RESIDUAL O2 IN AIR The nitrogen compressor is not placed in the Zefiro 8 HP there are only the air inlet compressors Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Installation Installation Receiving the generator All units have been carefully inspected before transport Visual checks for damage and func tional tests should be performed upon receipt Any damage must be immediately noted and reported The generator must only be returned according to the shipping instructions pro vided Placing the generator The nitrogen generator must be placed on a flat level vibration free shock free surface Do not place the generator over a source of heat as this may cause the device to overheat The unit should not be in contact with any other objects on any side and the air inlet must not be blocked Leave at least 30 cm of free space at rear for ventilatio
6. gen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Brown cable Blue cable 26 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual How to replace the fuse First switch off the instrument and disconnect it from the power line Ln fuses box use the screwdriver 27 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual 110 V power connections for Zefiro 40 35 25 20 8 HP ALIMENT CABLE Power entry Blue cable m FS Blue cable 28 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual How to replace the fuse First switch off the instrument and disconnect it from the power line Fuse box box em fuses box use the screwdriver N 1 fuse 20 fast 29
7. if not installed and used in accordance Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Introduction with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the re ceiver is connected e Consult the dealer or an experienced radio TV technician for help WARNING Any changes or modifications to this equipment not expressly approved by the manufac turer may void the user s authority to operate the equipment Correct use Nitrogen generator is designed to produce nitrogen for laboratory use The unit must only be operated for this purpose according to the specifications and instructions provided in this manual In particular the following warnings must be observed at all times e Indoor use only e Never operate the unit in below zero temperatures e Only operate the unit in a room with sufficient ventilation see Placing the unit e Always unplug the unit from the mains power s
8. ions The main screen has three options at the bottom corresponding to the three buttons on the unit which are used to run the various functions and access the configuration and diagnos tics of the unit DATE HOURS FLOWRATE OPTIONAL OUTLET N2 PRESSURE OXYGEN LEVEL OPTIONAL In the main screen the three buttons have the following function Left button start stop Central button reset the alarms Right button enter menu In the menu the three buttons change their function Left button scroll Central button select Right button exit the selected menu voice Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Initial start up Menu structure Parameters Item Descripion Options Range Default the pressure units the temperature the flow rate N Auto start Sets whether the unit automatically YES NO O starts production when power is switched on play Sets the alarm beep on off YES NO ES Pre alarms in list Sets the possibility to see the pre YES NO NO alarms in the alarm history list Standby Mode Activated only for the external tank YES NO Diagnostic Description 5 1 temp Shows the instant temperature in the section 1 of the cabinet Sec2 temp Shows the instant temperature in the section 2 of the cabinet Out Pres Shows the instant output pressure S 1 Pres Shows the instant pressure the internal reservoir Shows the instant pressure in the external tank if in
9. n Do not operate the generator in a sealed or unventilated room Do not operate the generator at below freezing temperatures Operation is guaranteed at operating temperatures between 15 and 35 WARNING Normal precautions for any nitrogen supply should be taken when using the generator DO NOT use in sealed or unventilated rooms Nitrogen can cause suffocation Symbols used on the generator Earth symbol This symbol marks the earth connections to the chassis of the nitro m gen generator Electrical shock This symbol marks the risck of electrical shock Gas connections Pure nitrogen at regulated pressure is available at the nitrogen outlet port at the rear of the generator This port has a thread of 4 and pressure at this port is shown on the display WARNING The line from the relief port should never connect in such a way that back pressure can de velop Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Initial start up Initial start up Start the generator Switch on the unit Press start It will be at least 20 minutes before the nitrogen produced will reach the stated purity In he Zefiro 8 HP it is neessari to wait 90 minutes The system is ready for use now Operation The operating status of the unit is shown on the main screen on the graphic display It is possible to see the outlet pressure level of 8 bar on the display when the generator is con nected to its applicat
10. ncludes all required parts opecifically each kit includes 1 New filter element for compressed air A 2 New inlet filter for atmospheric air B 3 New silencer for exaust gas C e See the 4000 h service kit the parts to sobstitue are the same of the 4000h service kit e Reconnect the power line and switch on the unit Enter the menu go to the special func tions and insert the number 26104 This procedure reset the 8000 h work time counter Go to the main menu and press Start The next service will be at 4000 h 17 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Spare parts list Spare parts list The table below provides a list and description of the spare parts of the nitrogen generator List of the spare parts ee 204 332 N 1 Air compressor 230V 50 60 Hz HP 204 302 N 2 Air for Zefiro 8 HP IMPORTANT The manufacturer reserves the right to change or modify its products without prior notice Returning the unit In the event of any faults or damage first notify the agent or distributor who supplied the unit Please also provide full details of the problem including the model and serial number Instructions will then be provided for the service or the return of the unit If the warranty has expired or the fault is due to misuse of the unit all repair and shipping costs are to be paid by the customer All other costs are borne by the customer except as other
11. nts of the nitrogen generator do not need to be cleaned and should not be accessed by the user for cleaning To clean the outside of the unit only use a damp cloth no detergents acids or aggressive or abrasive substances Service kits The service kits in the Zefiro generators are every 4000h The first starts at 4000h the second at 8000h and using the reset codes the cycle repeats The Service kit is composed by 1 Filter element for compressed air A 2 nlet filter for atmospheric air the internal sponge B 3 Silencer for exaust gas C For Zefiro 20 25 35 40 the services kits 4000h and 8000h are composed by Filter element for atmospheric air B Silencer for exaust gas C Filter element for compressed air A For Zefiro 8 HP the services kits 4000h and 8000h are composed by Filter element for atmospheric air B Filter element for compressed air A Silencer for exaust gas C 10 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance Difference between Zefiro 20 25 35 40 service 4000h 8000h and Zefiro 8 HP service 4000h 8000h Silencer for exaust gas C Zefiro 20 25 35 40 Silencer for exaust gas C Zefiro 8 HP WARNING Only qualified personnel should perform service on this product Any damage done to this product as a result of improper maintenance procedure will void the warranty 4000 hours service kit ask to se
12. r installation in an Exx classified area Do not install the ZEFIRO in an area where explosive mixtures may occur Warning electricity Only service engineers that are qualified to work on electric equipment are allowed to do the installation maintenance and reparations Disconnect the main power supply before you do the maintenance or repair If a service engineer has to work on the ZEFIRO while the electric power it is connected the service engineer must be very careful with respect to the electric hazards Warning safety precautions Make sure that the rate is sufficient in the room where the en riched oxygen is ventilated or lead the enriched air outside Keep the ambient temperature between 10 and 35 C Install the peripheral equipment piping and nitrogen storage vessels accord ing to standard procedures Do regular maintenance to the ZEFIRO Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Packing list Packing list List of items included in the shipment Nitrogen generator Instruction manual cd format pdf file Power cable Description The nitrogen generator produces pure nitrogen through the filtration of compressed air The key element of the generator is a carbon molecular sieve that is able to separate the nitro gen molecules from the oxygen ones present in the compressed air stream The carbon mo lecular sieve tubes are self regenerating cyclic The compressors
13. rature respects the specifications and if there is enough space in the rear side of the unit for the ventilation Otherwise remove the right panel of the machine and the cabinet panel and check if all the fans are work ing If it is all right call the service Press the reset button e Min pre alarm press section 1 the pressure in the internal reservoir is less than the lower limit Call the service Press the reset button e pre alarm oxygen only if the optional oxygen analyzer is installed the N purity is decreasing Call the service Press the reset button e Work time pre alarm compressor the compressors must be changed Call the ser vice Press the reset button e Pre alarm service 4000 h the filter must be changed See the maintenance section of this manual relatively to the 4000 h service kit Call the service to order the new kit Press the reset button e Pre alarm service 8000 h the filter and the silencer must be changed See the main tenance section of this manual relatively to the 8000 h service kit Call the service to order the new kit Press the reset button e Pre alarm clock failure the clock is broken Call the service Press the reset button Alarms e Max alarm cabinet temperature the temperature inside the cabinet is too high e Min alarm press section 1 the pressure in the internal reservoir is too low e alarm press section 1 the pressure in the internal reservoir is too high Check if
14. rvice the code Z03 4000 for Zefiro 20 25 35 40 ask to service the code Z06 4000 for Zefiro 8 HP Every 4000 hours the user must replace some parts of the generator A specific maintenance kit is available as spare part This kit includes all required parts opecifically each kit includes 1 New filter element for compressed air A 2 New inlet filter for atmospheric air B 3 New silencer for exaust gas C 1 Exchange the filter element for compressed air A e switch off the instrument and disconnect it from the power line e unscrew partially the two bottom screws of the front panel with the wrench 11 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance Righ Left side side Right side Right side Screws e remove the front panel e unscrew partially the three bottom screws of the left side panel with the wrench Screws e unscrew the three rear screws of the side panel and remove the panel Screws e In the left part of generator it is possible to find the air inlet filter 12 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance click the button rotate the cover of 1 8 turn in a left hand direction and then push it in the bottom direction If the cover of the filter is difficult to remove probably there is still pressure inside it solve the problem unscrew partially the bottom cap of the cover until the internal pres sure reach the
15. stalled Shows the instant oxygen content only if the optional analyzer is installed WT CMP Shows the work time of the compressor SRV 4000 Shows the work time for the 4000 h service SRV 8000 Shows the work time for the 8000 h service Alarm history Shows the history of the alarms occurred on the unit Set clock Allow the regulation of the clock of the unit The central button of the display increases the values and the left button passes to the next number Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Pre alarms and alarms Special function Allow the activation of some special function i e the reset of the working time counter of the filter with the digitations of a code The central button of the display increases the values and the left button passes to the next number MENU SPECIAL FUNCTION CODE SCROLL Codes e Reset of the compressor CO1 counter 26101 e Reset of the compressor CO2 counter 26102 e Reset of the 4000 h work time counter 26103 e Reset of the 8000 h work time counter 26104 Pre alarms and alarms There are a series of pre alarms and alarms on the unit When a pre alarm starts a sound advertise about a problem and the type of problem is displayed on the main screen When an alarm starts the unit also stops What do they mean and how to proceed Pre alarms e Max pre alarm cabinet temperature the temperature inside the cabinet is over the maximum limit Check if the room tempe
16. the generator will stop when the tank reach the maximum pressure of 8 bar and will restart at the minimum level of 7 bar The standard value of the maximum pressure that can be reached in the tank is 8 bar while the minimum is 1 bar In case other pressures are needed call the service If costumer wants that the generator stops automatically going in the stand by mode when the applications doesn t requires nitrogen there is the possibility to install as an optional the flowmeter In this way the generator will go in stand by mode when the flow of nitrogen re quired by the application is 0 0 l min at 8 Bar and will restart when the pressure in the line goes under the 3 Bar The generator can stay in stand by mode for 48 hours After this time the generator restarts and if application is still closed the generator goes in stand by mode for other two days Maintenance With proper care and maintenance your nitrogen generator should provide you with years of trouble free operation There are no adjustments to be made to the generator The only rou tine service operations are those described below Nonetheless the generator should be inspected approximately every 2 years Contact your supplier Routine maintenance The following section describes the maintenance operations required for the correct opera tion of the nitrogen generator Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Maintenance Cleaning The internal compone
17. the output fitting is free If it is all right call the service e Min alarm press outlet the outlet pressure is too low Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Pre alarms and alarms e alarm press outlet the outlet pressure is too high Check if the output fitting is free If it is all right call the service e alarm oxygen only if the optional oxygen analyzer is installed the Ne purity is over the maximum limit e Work time alarm compressor the compressors must be changed e Alarm service 4000 h the filter must be changed See the maintenance section of this manual e Alarm service 8000 h the filter and the silencer must be changed See the mainte nance section of this manual e Alarm EEP failure failure of the static memory Call the service Flow control not presents in the ZEFIRO 8 HP If the costumer requires less flow than 35 25 20 l min at 8 bar nitrogen generator will run continuously and the exciding part of nitrogen will be blow away by a valve inside the ma chine If costumer wants to install an external tank 100 liters as minimum volume required it is possible to connect it in the outlet of generator Before installing the tank make the following operations e he generator must be running at standard way 35 25 20 l min at 8 bar e Enter the menu go to parameter and change the stand by mode option from no to yes MENU PARAMETER STANDBY MODE YES Using the stand by mode
18. ubes They are N 4 in Zefiro 8 HP Blue tube Blue tube Blue tube e Disconnect the N 2 tubes of the High Pressure stage with tubes White tube e Disconnect the alimentation cables of the two compressors from the main board using screwdriver 21 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Compressor Compressor CO2 BLUE BROWN Compressor CO1 BLUE BROWN Compressor CO1 ANA NA 1 1 E Ae cap Compressor CO2 Compressor CO1 22 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Disconnect the ground cables of the two compressors using screwdriver Ground cables e Unscrew the four screws of the two compressor s supports and remove them e For first remove the compressor CO2 and then the compressor Check the label each compressor to be sure to replace it with the same model e Remount the compressors in the opposite order first CO1 and after CO2 e Enter the menu go to the special functions and insert the number 26101 to reset the timer of the compressor CO1 26102 to reset the timer of the compressor CO2 23 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual APPENDIX B 24 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual 230 V power connections for Zefiro 40 35 25 20 8 HP Power entry 230 V Blue cable mem Brown cable cable tt 25 Nitro
19. upply before accessing the inter nal components for replacement e Only the parts described in the Spare parts list can be replaced by the user Health and safety Correct use of the ZEFIRO nitrogen generator is important for your personal safety and for trouble free functioning of the ZEFIRO Incorrect use can cause damage to the ZEFIRO or can lead to incorrect gas supply Warning e Read this manual before you start the installation and putting into operation of the ZEFIRO Prevent accidents and damage to the ZEFIRO e Contact your supplier if you detect a problem that you cannot solve with this manual e Only service engineers that are qualified to work on electric and pneumatic equipment are allowed to do the installation maintenance and repairs Un qualified people are not allowed to repair the equipment Lift the ZEFIRO with a forklift Follow the legislation and instructions for operating the forklift e Do not tamper or experiment with the equipment Do not exceed the technical specifications for the ZEFIRO Warning nitrogen and oxygen The ZEFIRO generates nitrogen as a product Oxygen enriched air is released as waste Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Introduction 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 ZEFIRO is not designed fo
20. wise expressly agreed upon WARNING If the unit has to be transported make sure to use suitable packaging The unit should be transported in an upright position this warning should be reported on the outside of the packaging 18 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual APPENDIX A 19 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual Removal of the compressors A First switch off the instrument and disconnect it from the power line Because of the two compressor models are different before open the box of the replace ment compressors check that the model number on the label of the box is different e Remove the right plastic panel and the removable sheet unscrewing the four screws e Now is possible to see the two compressors High pressure stage Compressor n 2 CO2 Compressor n 1 CO1 For Zefiro 20 25 35 40 the compr CO1 is the OF 312 service kit code Z04 312 For Zefiro 20 25 35 40 the compr CO2 is the OF 332 service kit code Z04 332 For Zefiro 8 HP the compressor is the OF 302 service kit code 204 302 For Zefiro 8 HP the compressor is the OF 302 service kit code 204 302 20 Nitrogen Generator ZEFIRO 40 35 25 20 8 HP User s Manual e Disconnect the N 2 flexible tubes using spanners n 17 and 20 Flexible tube on he com pressor CO2 Flexible tube on the com pressor CO1 e Disconnect the N 3 air inlets of the compressors Blue t
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