Agilent Membrane Nitrogen Generator Service Guide © Parker Hannifin Corporation, 2002

Agilent Membrane Nitrogen Generator Service Guide Technology Overview Troubleshooting Guide Routine Maintenance Guide Membrane Replacement Guide Nitrogen Generator Manuals Global Technical Service Contacts How to use this guide Click buttons to forward to section

Coalescing Prefilters Agilent Nitrogen Generators utilize prefilters to protect the membrane from oil, water and solids usually found in compressed air. Prefiltration is comprised of two stages of Balston coalescing filters and are efficient to 99.99% at 0.01. Wet, dirty compressed air flows through the Balston microfibre filter tube from the inside to the outside. Liquid releases from the filter tube to an automatic drain as rapidly as it enters the filter. This allows the filters to continue removing liquids for an unlimited time without the loss of efficiency or flow capacity. Solid particles are permanently trapped on the inner surface and throughout the depth of the Balston microfibre filter tube. The outlet air is free from virtually all liquids and solids.

Selective Permeation Membrane Agilent Nitrogen Generators utilize Selective Permeation Membranes to separate nitrogen from compressed air. These membranes are made into long, thin, hollow, fibers. Thousands of fibers are combined to make a bundle and used to separate compressed air. Each bundle contains several miles of fiber. Compressed air is made up of many components. The most common are nitrogen, oxygen, CO2, H2O and argon. Selective permeation membranes are designed to allow “faster” gasses (ie: oxygen, CO2, H2O and others) to permeate the membrane wall. At the end of the fiber the gas produced has a high concentration of nitrogen. By controlling the flowrate the generator is able to produce purities of up to 99.94% nitrogen. The lower the flow, the higher the purity. Permeate (waste gas) Compressed Air Inlet Nitrogen Outlet Medium - CO2, O2 Fast - H2O, H2, He, H2S Slow - Ar, N2, CH4

Engineered Systems Engineered System: Agilent Nitrogen Generators are engineered to produce nitrogen from house compressed air. House air can be of varied quality so each system has been designed to provide high efficiency filtration to protect the membrane from solids and liquids. Carbon Filter No Moving Parts, No Electricity Needed: Nitrogen Generators use the pressure from compressed air pressure to separate nitrogen from air. There are no moving parts and they require no electricity (except for units equipped with oxygen monitor.) This makes these systems inherently explosion proof. System Components: Coalescing pre-filtration; - 99.99% at 0.01 microns. Activated Carbon Filter Membrane Module Flow and Pressure Controls Final Filtration

Routine Maintenance Guide Maintenance should be performed every 6 months. This process requires the 3 filters and the carbon module to be changed. This procedure will take approximately 20 minutes to complete Tools Required: Phillips head screwdriver 7/16” socket or nut driver Other Materials needed: Maintenance Kit (includes 3 filters and Carbon Module) Depressurize System Disconnect Nitrogen Generator from compressed air and allow system to depressurize Remove Filter Access Panel Remove the filter access panel by turning the 4 screws counter clockwise (1/4 turn only).

Routine Maintenance Guide Replace Filter Elements: 1) Remove the collar and bowl from each of the three filter housings. The collar is removed by turning it counter clockwise if looking at the housing from the bottom. 2) The bowl is removed by pulling down on it. 3) Remove blue plastic element retainer 4) Remove filter element and replace with new one. 5) Install bowl and tighten collar 6) Repeat steps 1-5 for the other two filters Note: there are three filters, each is a different grade and care should be taken to ensure they are replaced in the correct housing. Please refer to Figure 2 for proper location for filter elements. Figure 1 - Removal of filter bowl, element retainer and element. DX Filter Assembly BX Filter Assembly Final Filter Assembly Carbon Module Figure 2 - Filter locations

Routine Maintenance Guide Change Carbon Module 1) Disconnect tubing from the fitting at the top of Carbon Module (Figure 1, highlighted in red) Tubing is released by pushing in on the tubing and the grey collar on the fitting at the same time, while continuing to push on the collar - pull the tubing from the fitting. 2) Remove the four bolts from the base of the carbon tower (Figure 1, highlighted in green.) 3) Extract tower from nitrogen generator 4) Remove tubing at base of Carbon Module 5) Install replacement Carbon Module by reversing steps 1 - 4. 6) Pressurize system and check for leaks at fittings. 7) Replace Filter Access Panel

Low Outlet Pressure Troubleshooting Customer Comment: The outlet pressure from my generator is too low to operate my instrument. 1 2 3 Is the compressed air pressure supplied 10 PSI more than required for the instrument? Repair leaks: tighten fittings, replace tubing, control panel components, fix instrument as necessary YES Is the pressure drop across the generator more than 10 PSI? YES Are there any leaks within the system? YES NO NO NO 4 Replace membrane module Click “?” for procedure Increase pressure provided to Nitrogen Generator by removing restrictions or increasing pressure at compressor. Check pressure provided by compressed air source (step 1) Questions regarding troubleshooting? Call Parker Hannifin Technical Services. Please press button for contact information.

Low Outlet Pressure Troubleshooting Is the compressed air pressure provided 10 PSI more than required for the instrument? 1) Locate compressed air source 2) Verify that pressure supplied by the compressor is more than 10 PSI greater than that required for instrument. 3) Identify any restrictions in piping system which might cause pressure drop (regulators, valves, etc.) 4) Locate pressure gage near to and upstream of Nitrogen Generator. Verify that pressure provided is more than 10 PSI greater than that required for the instrument 5) Repair or replace compressor as needed 6) Increase pressure at compressor 7) Remove or isolate restrictions in piping which may cause pressure drop Click “?” button for more information Click here to close dialog box Low Outlet Pressure Troubleshooting Customer Comment: The outlet pressure from my generator is too low to operate my instrument. 1 2 3 Is the compressed air pressure supplied 10 PSI more than required for the instrument? Repair leaks: tighten fittings, replace tubing, control panel components, fix instrument as necessary YES Is the pressure drop across the generator more than 10 PSI? YES Are there any leaks within the system? YES NO NO NO 4 Replace membrane module Click “?” for procedure Increase pressure provided to Nitrogen Generator by removing restrictions or increasing pressure at compressor. Check pressure provided by compressed air source (step 1) Questions regarding troubleshooting? Call Parker Hannifin Technical Services. Please press button for contact information.

Low Outlet Pressure Troubleshooting Is the pressure drop across the generator more than 10 PSI: 1) Adjust Nitrogen Flow Meter to desired flow and purity as recommended on the Purity/Flow Label for a given operating pressure 2) Increase outlet pressure using Pressure Regulator (turn clockwise) note: regulator has locking mechanism, press knob in to adjust 3) Is the difference between Operating Pressure Gage and Outlet Pressure Gage more than 10 PSI? Click “?” button for more information Click here to close dialog box Low Outlet Pressure Troubleshooting Customer Comment: The outlet pressure from my generator is too low to operate my instrument. 1 2 3 Is the compressed air pressure supplied 10 PSI more than required for the instrument? Repair leaks: tighten fittings, replace tubing, control panel components, fix instrument as necessary YES Is the pressure drop across the generator more than 10 PSI? YES Are there any leaks within the system? YES NO NO NO 4 Replace membrane module Click “?” for procedure Increase pressure provided to Nitrogen Generator by removing restrictions or increasing pressure at compressor. Check pressure provided by compressed air source (step 1) Questions regarding troubleshooting? Call Parker Hannifin Technical Services. Please press button for contact information.

Low Outlet Pressure Troubleshooting Check For Leaks: 1) Check drain line for leaks 2) Check Control Panel for Leaks 3) Check internal fittings for leaks 4) Check instrument for leaks 5) Ensure that instrument is drawing less flow than generator can provide (consult flow chart) Click “?” button for more information Click here to close dialog box Customer Comment: The outlet pressure from my generator is too low to operate my instrument. 1 2 3 Is the compressed air pressure supplied 10 PSI more than required for the instrument? Repair leaks: tighten fittings, replace tubing, control panel components, fix instrument as necessary YES Is the pressure drop across the generator more than 10 PSI? YES Are there any leaks within the system? YES NO NO NO 4 Replace membrane module Click “?” for procedure Increase pressure provided to Nitrogen Generator by removing restrictions or increasing pressure at compressor. Check pressure provided by compressed air source (step 1) Questions regarding troubleshooting? Call Parker Hannifin Technical Services. Please press button for contact information.

Is the pressure drop across the generator more than 10 PSI? Normal pressure drop across Nitrogen generator should not exceed 10 PSI. Higher pressure drops will indicate either leaks within the system or a failed membrane. Adjust Nitrogen Flow Meter to desired flow and purity as recommended on the Purity/Flow Label for a given operating pressure Increase outlet pressure using Outlet Pressure Regulator to maximum setting (turn clockwise) note: regulator has locking mechanism, press knob in to adjust Is the difference between Operating Pressure Gage and Outlet Pressure Gage more than 10 PSI? Outlet Pressure Gage Operating Pressure Gage Outlet Pressure Regulator Nitrogen Flow Meter Nitrogen Flow Valve Purity/Flow Label

Is the compressed air pressure provided 10 PSI more than required for the instrument? Normal pressure drop across Nitrogen generator should not exceed 10 PSI. The compressed air supplied must be at least 10 PSI greater than that required for the instrument. It is very common to have fluctuations within a house compressed air system. Applications or processes which demand large volumes of compressed air will cause system-wide shortages resulting in a decrease in pressure. It is recommended that the facility manager be consulted to establish if compressed air system is capable of maintaining minimum pressures required for the instruments. Things to check: Locate compressed air source. Verify that pressure supplied by the compressor is more than 10 PSI greater than that required for instrument. Identify any restrictions in piping system which might cause pressure drop (regulators, valves, etc.) Locate pressure gage near to and upstream of Nitrogen Generator. Verify that pressure provided is more than 10 PSI greater than that required for the instrument Repair or replace compressor as needed. Increase pressure at compressor. Remove or isolate restrictions in piping which may cause pressure drop.

Check For Leaks within Nitrogen Generator Normal pressure drop across Nitrogen generator should not exceed 10 PSI. Higher pressure drops will indicate either leaks within the system or a failed membrane. Check coalescing filter drain lines for leaks If leaking, air will be escaping from drain line. Most often this can be fixed by placing finger over drain line, letting pressure build and then taking finger off. Depressurize system, remove bowls from filter housings, wash bowl/drains with warm water and mild soapy solution. Replace and pressurize nitrogen generator. Replace drain assembly (Parker part number 21552)

Check For Leaks within Nitrogen Generator Check Control Panel for Leaks Depressurize System Disconnect Nitrogen Generator from compressed air and allow system to depressurize Remove Filter Access Panel Remove the filter access panel by turning the 4 screws counter clockwise (1/4 turn only).

Check For Leaks within Nitrogen Generator Check Control Panel for Leaks (cont.) Remove the the 4 phillips head screws located on the sides of the Nitrogen Generator (Figure 1, highlighted in red) counter clockwise. 2) While balancing Control Panel, remove fitting from left side of Nitrogen Generator using 3/4” box or open-end wrench (Figure 1, highlighted in green). Note: Control Panel will now be disconnected from chassis but tubing will still be connected, be careful not to damage tubing. Pivot Control Panel out from chassis Reconnect compressed air, pressurize system and check for leaks at connections at back of Control Panel (Figure 2, highlighted in green) Figure 1 Figure 2

Membrane Module Replacement Replacement of the Membrane Module will take approximately 40 minutes. It is recommended that the routine maintenance be performed at the same time. It is very important that you review the quality of the compressed air before performing this procedure. If the compressed air is not of sufficient quality then the membrane is likely to encounter problems again. Compressed Air Concerns Most often the cause for Membrane Module failure relates to the quality of the compressed air. It is very important to check that the compressor is not being run at too high a duty cycle. Please consult the compressor manufacturer for specifications for the compressor. Also, it is critical that the compressed air temperature not exceed 77º F (25º C). The reason for the maximum temperature is that the compressed air can contain excessive amounts of water vapour at temperatures above 77º F (25º C). The coalescing prefilters provided with the Nitrogen Generator are designed to remove liquid water, and can not remove water vapour. Liquid water will affect the Membrane Module and will cause premature failure. Please contact Parker Hannifin Analytical Gas Systems Technical Services at 800-343-4048 if you have any questions. Tools Required: Phillips head screwdriver 7/16” socket or nut driver 3/4” box or open-end wrench Other Materials needed: Membrane Module Optional: Maintenance Kit (includes 3 filters and Carbon Module) Note about Parker Presto-lock fittings: To disconnect tubing from fittings, press inward (towards body of fitting) on tubing and plastic collar to release tubing from the fitting. While maintaining pressure on plastic collar, remove tubing from fitting. To install tubing, press tubing entirely into fitting to get the best seal.

Membrane Module Replacement Depressurize System Disconnect Nitrogen Generator from compressed air and allow system to depressurize Remove Filter Access Panel Remove the filter access panel by turning the 4 screws counter clockwise (1/4 turn only).

Membrane Module Replacement 1) Remove Control Panel Remove the the 4 phillips head screws located on the sides of the Nitrogen Generator (Figure 1, highlighted in red) counter clockwise. 2) Remove Control Panel, continued While balancing Control Panel, remove fitting from left side of Nitrogen Generator using 3/4” box or open-end wrench (Figure 1, highlighted in green). Note: Control Panel will now be disconnected from chassis but tubing will still be connected, be careful not to damage tubing. Figure 1

Membrane Module Replacement 3) Disconnect tubing from Control Panel. Be careful to note location of tubing: a) Remove tubing from regulator (highlighted in red) b) Remove tubing from top, right fitting on membrane module (highlighted in green) 4) Remove Control Panel from Nitrogen Generator The Control Panel should now be free from the Nitrogen Generator

Membrane Module Replacement 5) Remove Final-filter panel from Nitrogen Generator Remove the four 716” bolts from the back of the Nitrogen Generator. (Figure 1 highlighted in red) Remove the ¾” fitting from the left side of the generator (Figure 2, highlighted in green) Remove Final Filter Assembly as in Figure 3 Figure 2 Figure 3 Figure 1

Membrane Module Replacement 6) Remove Membrane Module Disconnect tubing from left fitting on module (Figure 1, highlighted in green) Remove 4 ea., 7/16” hex-nuts from top and bottom of membrane module using nut driver (Figure 2, top hex-nuts highlighted in red) Membrane Module Figure 2 Figure 1

Membrane Module Replacement 7) Replace Membrane Module Reverse steps 1-6 to install new membrane module into Nitrogen Generator 8) Check System for Leaks 9) Verify pressure drop across system 10) Connect outlet from generator to instrument and set outlet pressure and flow according to flow chart on front of Nitrogen Generator.

Parker Hannifin Technical Support Contacts North America and South America Parker Hannifin Corporation Toll Free Technical Service: 800-343-4048 Filtration and Separation Division Fax: 978-858-0625 100 Ames Pond Drive e-mail: mrutfield@parker.com Tewksbury, MA 01876 USA Europe   Parker Hannifin plc Technical Support Tel: +44 1622 723300 Filtration and Separation Division Fax: +44 1622 728703 Hermitage Court e-mail: balstonukinfo@parker.com Hermitage Lane Maidstone Kent, UK ME16 9NT Singapore Parker Hannifin Singapore Pte. Ltd. Technical Support Tel: (65) 887 6300 No 11 Fourth Chin Bee Road Fax: (65) 865 5125 Jorong Town e-mail: ykassim@parker.com Singapore 619702 Japan Parker Hannifin Japan Ltd Technical Support Tel: +81 3 6408 3901 626 Totsuka-Cho Fax: +81 3 5449 7202 Totsuka-Ku e-mail: wyao@parker.com Yohohama

How to Use This Guide Navigation Buttons Back one slide Use the following buttons to navigate through this guide: Back one slide Go to Table of Contents Advance one slide More information available Return to previous slide This guide is intended to be a supplement to the Installation Operation and Maintenance (IOM) guide supplied with the instrument. Please refer to the IOM for greater detail on the operation and maintenance for Agilent Nitrogen Generators. Please contact Parker Technical Services if you have any questions regarding the content of this guide.

Nitrogen Generator Manuals The following manuals can be found on the Service DVD Quick Start Summary (English Version) Full Manual (English Version)