USER`S MANUAL N2-MISTRAL-0 / 25 L/min
Contents
1. MATHESON TRIeGAS ask The Gas Professionals USER S MANUAL N2 MISTRAL 0 25 L min NITROGEN GENERATOR Rev 3 August 2008 MATHESON TRI GAS 166 Keystone Dri Montgomeryvi ville PA 18936 Phone 215 641 2700 Fax 5215 641 2714 Email mtgmmville matheson trigas com User s Manual N2 MISTRAL 0 25L Page 2 21 Content 1 INTRODUCTION 4 gt 1a CN m rn 4 Mee sPiGIOQ AM Ib 4 15 iidentilicattomana SErVIGet Wero 5 ne 6 400 AN ER 5 159 CONECT G LU As cS set a 5 150 USePIDnstr cHoriS A a 5 teat clan S 5 2 HEALTH SAFETY AND ENVIRONMENTAL ASPECTS 6 Pell Generali iii toe i al 6 22 S 67214215 52 e tran 6 23 borreu a a A 6 ZA 5 creron a a na 7 2 5 Environmental aspetisi Guia essc ium Msc 7 3 DESCRIPTION OF THE APPLIANCE 8 SOMME CI C MED 8 32 separeatioti PrINCIPIE mi E Nae eee 8 39 Process Parametet na 8 IA Process SCEME a aia Le vcr boul 9 229 om 10 4 TECHNICAL SPECIFICATIONS 11 All General Tec 11 4 2 Performance Ta2. 19i 262 838 407 a izba aj 1322 209 287 1366 448 Table II Mistral 0 Standard Factory set Max Nitrogen capacity min capacity 30 at nominal conditions Air consumption Air consumption in Nm3 hr at min capacity Nitrogen Purity By feed pressure of 4 bar g 2 47 2 80 3 09 3 34 3 63 5 bar g 3 08 350 3 86 4177 453 6 bar 9 3 81 4 39 4 83 MEET 570 7 9 444 512 564 608 665 000000778 bar g 508 5 96 64 635 7 760 jbar g 586 674 746 804 882 iis 10 bar g 6 45 732 806 8 69 7950 1 Tbar g 741 842 916 998 1060 12 0 8 05 51811000 1100 1170 Fable lil SSCS Changes of the relevant parameters will affect the purity of the Nitrogen Any changes have to be done by qualified service personal from Matheson Tri Gas or trained personal from our official repre sentatives Otherwise Matheson Tri Gas cannot take any responsibility for possible poor performance of the Mistral 0 User s Manual N2 MISTRAL 0 25L Page 12 21 5 Installation 51 Transport Warning N e Put the Ns MISTRAL 0 in the original box during transport over longer distances For qualifications of personnel refer to chapter 2 1 5 2 Location 1 Install the Ns MISTRAL 0 in a location meeting following requirements e Indoors fixed to a wall e Dry e Vibration fr
3. the switch will close valve Y1 Note This hysteresis can be changed with set screw C after lock nut D is released It is strongly rec ommended NOT to change this setting as there is NO need for it Misadjustment can lead to fast ON OFF switching and damage If settings have been changed and the PSH seems to react improperly the default settings 7 bar up per 6 bar lower set point can be restored by positions of the set screws as shown in for Fig 4B Set screw B Lock nut A Set screw C Lock nut D Distance to top of set screw B 63 6 mm Distance to top of set screw C 48 mm _ _ Fig 4B User s Manual N2 MISTRAL 0 25L Page 18 21 7 Maintenance 7 1 Maintenance scheme Filter Kit P N MMO25 FILT KIT Replace filter elements Annual Refer to chapter 7 2 amp 7 4 or earlier when the pressure loss in Contains filtering media each filter becomes 2 1 bar p n 0299 p n MFTR 0300 XX AFD40P p n MFTR 0301 XX AMF EL250 Filter Kit p n MMO25 FILT KIT Filtering media Filtering media P N MFTR 0300 XX P N MFTR 0299 XX Filtering media P N MFTR 0301 XX Fig 5 User s Manual Nz MISTRAL 0 25L Page 19 21 7 2 Replace filter elements in AFM40 F02D amp AFD40 F02D 1 Close the air supply with input valve 2 Let the system depressurize until the pressure gauge in Fig 2 reads 0 bar 3 if necessary turn knob A CCW Fig 6 to make sure the filter is d
4. 1 l l A Fig 2 F 01 F 02 0 3 um and 0 01 um particle size Coalescing filters F 03 Carbon filter AMF250 F02 Y1 Pneumatically controlled valve M1 M2 Gas separating membranes only M1 is available in Model 0 25 L min FCV Flow control valve V1 Non return valve PCV1 pressure regulator 2 Pressure gauges PSH Pneumatical pressure switch controls valve Y1 AFM40 F02D and AFD40 F02D Air from the external compressor supply travels through the filters F 01 8 F 02 8 F 03 and enters the membranes when the pneumatic valve Y1 is closed This depends on the output pressure PI2 gauge visible on the front panel and is controlled by means of the pressure switch PSH When the generator leaves the factory the PSH is set such that valve Y1 opens when the output pressures reaches 7 bar and closes again when the output pressure drops below 6 bar hysteresis of ca 1 bar can be ad justed The back pressure regulator PCV1 is fully open fully CW Output flow is adjusted with the needle valve FCV and affects the nitrogen purity FCV is factory set for 98 purity at nominal condi tions of the corresponding model The pressure gauge is not visible when the front panel is in stalled The pressure drops to zero when valve Y1 opens For more details on operation please see sections 6 2 amp 6 5 The non return valve V1 is necessary to avoid that the stored nitrogen from a connected buffer tank would be released
5. MISTRAL 0 25L Page 14 21 6 Operation 6 1 Start up of N2 MISTRAL 0 1 Open the compressed air supply 2 system is ready for use now 3 system will start to produce nitrogen as soon as the nitrogen outlet is opened The specified purity will be available according to the air inlet pressure and flow adjustment Important Note When the feed pressure is too low lt 0 5 bar the inlet filters will remain open and air leaves through the automatic drain port Water vapour from the compressor air will condensate in the filter housing and automati cally be released through the drain port 6 2 Modes of Operation The generator can work in continuous mode or in ON OFF mode A Continuous mode This mode is used when the generator supplies directly to an application Assume following starting conditions requirements 1 Feed pressure of compressed air is 9 bar 2 PSH upper pressure is set for 7 bar default hvsteresis 1 bar 3 the required output pressure is 5 bar Procedure Shut off the air supplv and remove the front panel in order to have access to the pressure regula tor and gauge 2 a Connect a needle valve or flow controller in series with a flow meter rotameter to the out put of the generator Open this needle valve flow controller NOT the FCV in Fig 2 such that a small flow can be expected b Applv the air supplv Since the PSH is set to switch off at 7 bar default it will open valve Y1
6. arts and system The sudden escape of compressed air can cause serious injury or damage e Do not tamper or experiment with the equipment Do not exceed the technical specifications for the No MISTRAL O 2 3 Nitrogen and oxygen The N2 MISTRAL 0 generates nitrogen as a product Oxygen enriched air is released as waste Warning e Nitrogen can cause suffocation e Oxvgen enriched air leads to increased risk of fire in the event of contact with in flammable products Make sure that there is adequate ventilation at all times AN The Nz MISTRAL 0 can be used for installation in Exx classified area electric parts all pneumatic 2 4 Safety precautions Warning N e Make sure that the ventilation rate is sufficient in the room where the enriched oxygen is ventilated or lead the enriched air outside e Keep the ambient temperature between 10 and 40 C 50 to 104 F User s Manual N2 MISTRAL 0 25L Page 6 21 e Install the peripheral equipment piping and nitrogen storage vessels according to standard procedures The Matheson Tri Gas cannot take responsibility for this Do regular maintenance to the Ns MISTRAL 0 to ensure proper and safe opera tion Refer to chapter 7 e sure that instructions concerning health and safety are compliant with the local legislation and regulations 2 5 Environmental aspects The use and maintenance of the Ns MISTRAL 0 does not represent environmental dangers Most p
7. arts are made of metal can be disposed in the regular way The packaging of the N2 MISTRAL O is 100 recyclable 49 Make sure that instructions concerning health safety and environment are compliant a with the local legislation and regulations ue User s Manual N2 MISTRAL 0 25L Page 7 21 3 Description of the appliance 31 General The No MISTRAL O separates compressed air into nitrogen and an oxygen enriched air stream The separation system is based on hollow fibre membranes The produced Nitrogen can be connected directly to the application or can be stored in a Nitrogen storage vessel In the latter case the Ne MISTRAL 0O switches on and off at specific pressure levels which can be adjusted and this with a frequency depending on the nitrogen demand 3 2 Separation principle 2 H20 02 2 g Fig 1 A Pressurized air inlet F Fast permeation B Hollow fibre membrane o Slow permeation C Nitrogen outlet Clean ambient air contains nitrogen 78 296 oxygen 20 896 Argon 196 carbon dioxide water va pour and traces of other inert gases Pressurized air A is led through hollow fibre membranes B The various air components diffuse through the porous wall of the membranes The diffusion rate differs for the various gases e Oxygen and water vapour have a high diffusion rate and diffuse rapidly through the membrane wall e Nitrogen has low diffusion rate and diffuses slowly through the m
8. as soon as the 7 bar is reached and pressure will decrease valve Y1 closes again etc c loosen the lock screw on the pressure regulator and adjust output pressure by turning the knob counter clockwise to get 5 bar output pressure As soon as the pressure drops below the 6 bar the PSH switch will keep valve Y1 closed Tighten the lock screw Note when the PSH switches back and forward between upper and lower setting short burst of nitrogen will be released through the top of the switch see Fig 4 This is NORMAL d adjust the needle valve to get a flow close to the specified capacity and see if the output pressure remains stable e Shut off the air supply and connect the application Verify correct operation Assume following starting conditions requirements 1 Feed pressure of compressed air is 10 bar 2 PSH upper pressure is set for 7 bar default hvsteresis 1 bar 3 the required output pressure is 8 bar Procedure a Connect a needle valve flow controller in series with a flow meter rotameter to the output of the generator Open the needle valve flow controller for a small flow b Apply the air supply Since the PSH is set to switch off at 7 bar default it will open valve Y1 as soon as the 7 bar is reached and pressure will decrease valve Y1 closes again etc c Loosen the lock nut A on the PSH switch Fig 4 while holding position of set screw C with another wrench Adjust screw B looking from the top turning Cloc
9. back into the generator after valve Y1 opens the circuit User s Manual N2 MISTRAL 0 25L Page 9 21 3 5 System components Air control Valve Y1 Pressure gauge PI2 FCV Pressure regulator PCV 1 Filter F 03 Pressure gauge Filters F 01 amp F 02 Inlet 51 4 Fig 3 User s Manual N2 MISTRAL 0 25L G14 Page 10 21 4 Technical specifications 4 1 General Delivery pressure N2 MISTRAL 0 25L Maximum delivery output pressure Inlet pressure minus 1 bar Maximum feed pressure bar g 12 bar g 175 psig 9 Air treatment sector Dimensions Capacity at nominal conditions 1 5 Nm hr 25 litres min Purity at specified capacity by volume 298 No Nominal conditions feed pressure at inlet 8 bar g ambient temperature 20 C ambient pressure 1013 mbar 1 Ns MISTRAL 0 unit Standard un ie 1 x Manual Optional Active carbon adsorber for air pre treatment Table User s Manual N2 MISTRAL 0 25L Page 11 21 4 2 Performance Table Minimum Production Capacity in Nm3 hr Nitrogen Purity BY feed Pressure 4 bar g 0 39 0 65 0 88 1 14 1 40 5 bar g 0 48 081 110 138 174 6 9 56i i105 i42 i80 219 7 bar 9 072 132 66 210 256 8bar g 0 82 1498 i90 240 288 p sbario 093 161 219 277 889 nn bar gy 102 174 237 800 868 puce bag
10. ble 8 Air consumption 2 12 5 INSTALLATION 13 Transpo u d tA g idna kt i ra tii d 13 52 Localo air ia a nm 13 5 8 JAUnpackahd check egulpmernt zee kein 13 5 4 Connection to compressed air feed and nitrogen consumer 13 5 5 Commissioning of a Ns MISTRAL 0 25L 13 6 OPERATION 15 61 Startup ot Ns MISTRAL O 25L dne de a 15 62 Moaes ee Operation Ems 15 Operation Ai ta A a i 16 av EMEN esee om 17 Adiusmmehnits On PSH isses ee HE te a oae 18 7 MAINTENANCE 19 Maintenance SCHEME auxi odes aduocatus He band 19 7 2 Replace filter element in AFM40 FO2D amp AFD40 FO2D _ 20 7 3 Automatic drain in AFM40 F02D 8 AFD40 FO2D 21 7 4 Replace filter amp O rings in 250 02 21 User s Manual N2 MISTRAL 0 25L Page 3 21 1 Introduction 1 1 General This manual forms an integral part of the product The manual describes the installation daily opera tion maintenance and troubleshooting Content Please read the manual carefully before you start with the operation of the Ns MISTRAL 0 Condition of change Changes to the Ns MISTRAL 0 can only be made after explicit written permission by Matheson Tri Gas N
11. ee Nocontinuous direct radiation by sunlight e Away from heat sources e Properly ventilated room refer chapter 2 3 and 2 4 e Easy accessibly for operation and service Perform the complete installation procedure again if the No MISTRAL 0 is moved to a new loca tion 5 3 Unpack and check equipment 1 Open the packaging 2 Make sure that all components are delivered 3 Make sure that the supplied compressed air is correct fthe Ns MISTRAL 0 is connected to a house air system make sure that the compressed air pressure and quality fulfil requirements and that the flow capacity is sufficient lithe Ns MISTRAL 0 is connected to a stand alone compressor make sure that the com pressor works properly Refer to the instructions of the compressor supplier Make sure that the cooler and the water separator of the compressor work correctly Make sure that the oil content of the compressed air is below 0 01 mg m sure that the pressurised air dryer is of proper size and that it works fine 5 4 Connection to compressed air feed and nitrogen consumer Warning N sure that the inlet and outlet tubes are free of dust particles metal parts and curls liquids and grease before you connect the No MISTRAL O 1 Connect the generator outlet to the application or the storage vessel For tyre inflation mostly a special filling gun is used 2 Connect the compressed air supply to the generator air inlet 5 5 Co
12. embrane wall Pressurized nitrogen is released at the outlet of the membranes C which can be stored in a nitrogen storage vessel or directly used in e g an LCMS 3 3 Process parameters The nitrogen production depends on following parameters e Flow rate The lower the flow rate of nitrogen the more oxygen can diffuse through the membrane wall As result the nitrogen produced at the outlet will be more pure Adjust the purity of the ni trogen with the flow control valve Please consult the tables 11 111 later in this manual for more details on purity nitrogen production and required air consumption at different feed pressures User s Manual N2 MISTRAL 0 25L Page 8 21 e Temperature The N2 MISTRAL 0 operates optimally at a temperature of about 20 25 C If the temperature increases the pressurised air consumption will also increase Therefore do not place the sys tem in a room where the temperature may rise unnecessarily high e Membrane pressure A higher membrane pressure will increase the capacity of the No MISTRAL O e Permeate outlet There must be atmospheric pressure at the permeate outlet The capacity and the selectivity of the system decrease strongly if the external pressure exceeds the atmospheric pressure 3 4 Process scheme PERMEATE OUTLET N 2 NITROGEN 01 F 02 F 03 PONT VI OUTLET N 2 lil DX BX lt AHAH COMPRESSED AIR L INLET 2 l A L 5
13. epressurized Than close again 4 Turn the filter housing C counter clockwise while pushing knob B down until the markings amp II line up than pull the filter housing C from the filter head E Unscrew the old filter element F Fig 7 Clean the sieve and the filter housing if necessary Place a new filter element F Assemble the parts in the opposite direction o Input Open amp Close valve Filter head E black knob B Filter housing C Turn knob A CCW open to depressurize and close again Fig 6 Automatic drain port with Quick fitting to connect a drain tube User s Manual N2 MISTRAL 0 25L Page 20 21 Filtering media F Fig 7 7 3 Automatic drain When the automatic drain valve remains open when the black knob A is in the Closed S position fully CW replacement of the whole filter is recommended 7 4 Replace filter amp O rings in AMF250 F02 To open the filter housing remove the 4 screws from the top and replace the elements show in Fig 5 P N MFTR 0301 XX Remove 4 screws from the top to open the housing Fig 8 User s Manual Nz MISTRAL 0 25L Page 21 21
14. kwise increases the switch off pressure setting such that valve Y1 remains closed Tighten lock nut A User s Manual N2 MISTRAL 0 25L Page 15 21 d Now adjust the pressure regulator for 8 bar output Increase flow with the needle valve until specified capacity is reached and see if pressure remains stable e shut off air supply connect the application and check for proper operation B ON OFF mode This mode is used in combination with a buffer tank Assume following starting conditions requirements 1 feed pressure of compressed air is 10 bar 2 PSH upper pressure is set for 7 bar default hysteresis 1 bar 3 the required output pressure switch OFF is 8 bar and Switch ON 7 bar Shut off the air supply and remove the front panel in order to have access to the pressure regula tor and pressure gauges a Connect a needle valve flow controller in series with a flow meter rotameter to the output of the generator Open the needle valve flow controller for some flow b Apply the air supply Since the PSH is set to switch off at 7 bar default it will open valve Y1 as soon as the 7 bar is reached at PI1 Pressure will decrease valve Y1 closes again etc Monitor the output pressure at 2 With the pressure regulator PCV1 fully CW default pres sure 1 and 2 are similar during the time the valve Y1 is closed c Loosen the lock nut A on the PSH switch Fig 4 while holding nut C with another wrench Adjust scre
15. mmissioning of a N MISTRAL 0 1 sure that the connections are correct and fixed well 2 Make sure that the compressed air pressure is as high as required default 8 bar User s Manual N2 MISTRAL 0 25L Page 13 21 3 sure that the instrument has no leaks which have arisen due to transport Remove the front panel and monitor the pressure gauges 5 Cap off the generator outlet open the compressed air supply and monitor both pressure gauges When the output pressure reaches 7 bar default the PSH opens valve Y1 and pressure drops to zero Pressure 2 slowly goes down due to a small consumption in the PSH and by ca 6 bar valve Y1 should close again until the output pressure reaches 7 bar valve Y1 opens etc For other pressure settings or modes of Operation please see section 6 2 Modes of Op eration 6 Shut off compressed air re install the front panel and connect the application or buffer tank 7 The system is ready for use now Note When NO buffer tank is used between Mistral O and consumer application the ON OFF modus should not be used Indeed depending on the flow and feed capacity the frequency and resulting noise of the valve Y1 switching may be so high that the user may believe some components are broken which is actually not the case However the fast ON OFF switching will likely lead to premature failure of some components and should be avoided iN User s Manual N2
16. on conformance to this rule as well as any consequential damage loss or any costs are the responsibility of the owner amp user Information All information in this manual including additional drawings and technical descriptions remains the property of the 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 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 instruc tions Caution A caution shows a danger that can cause damage to the equipment Follow the in structions Warning Hisk for death due to suffocation Risk of fire Oxygen enriched air leads to an increased risk of fire in the event of contact with in flammable products High pressure risk Follow the instructions with respect to compressed gasses Environment Instructions with respect to the environment ce OPP User s Manual N2 MISTRAL 0 25L Page 4 21 1 3 Identification and Service The identification plate is located on the side of the N2 MISTRAL 0 and shows the characteristics of the generator For service and technical assistance please contact your distributor 1 4 Certificates The N2 MISTRAL 0 meets the following requirements EC Pressure equipment directive PED Sound engineering
17. practice 1509001 0 Quality assurance ISO 9001 2000 ISO 14001 1996 1 5 Correct use The Ns MISTRAL 0 is intended to make nitrogen out of normal clean compressed ambient air The system is based on gas separating membranes If the generator is installed in a laboratory with air polluted by VOCS solvents or exhaust from GC instruments or any other contaminant the inlet filters may not be able to remove all of these contaminants and may require replacement more often than recommended later in this manual In the worst case the membranes can be damaged Conse quently Matheson Tri Gas will not accept any liability for improper use The Ns MISTRAL 0 is in compliance with the prevailing directives and standards Only use this Nz MISTRAL O in a technically perfect condition in conformity with the purpose as described above 1 6 User instructions Only a well trained user s is allowed to work on the Ns MISTRAL 0 The user s must be aware of hazards related to operating the Ns MISTRAL 0 and processes connected to it All personnel working on the N2 MISTRAL 0 must have free access to the manuals 1 7 Liability Matheson Tri Gas will not accept any liability if The instructions in this manual are ignored Replacement parts are used which not approved by Matheson Tri Gas The No MISTRAL O is operated incorrectly The system is fed with other gasses than compressed air e he No MISTRAL O is modified withou
18. t notification and authorization of Matheson Tri Gas e Maintenance and repair are not carried out by qualified service engineers and according to the in structions User s Manual N2 MISTRAL 0 25L Page 5 21 2 Health safety and environmental aspects 2 1 General Correct use of the No MISTRAL 0O nitrogen generator is important for your personal safety and for trouble free operation Incorrect use can cause damage to the N2 MISTRAL 0 or lead to incorrect gas supply Warning e Please read this manual before you start the installation and putting the generator into operation Prevent accidents and damage to the Ns MISTRAL 0 e Contact your supplier if you detect a problem that you cannot solve with this manual the Ns MISTRAL 0 in accordance with its purpose Refer to chapter 1 5 e Only service engineers qualified to work on electric and pneumatic equipment and properly trained on this equipment are allowed to do the installation mainte nance and repairs e Do not tamper or experiment with the equipment Do not exceed the technical specifications for the Ns MISTRAL 0 Refer to chapter 4 2 2 Compressed air Warning N sure that the inlet air pressure cannot exceed 12 bar g at any time e Make sure that the equipment and the pipes are connected correctly and speci fied to withstand the applied input air pressure Depressurise the Ns MISTRAL 0 and the connected systems before you discon nect p
19. w B turning Clockwise increases the switch OFF pressure setting such that valve Y1 opens at 8 bar Tighten lock nut A d verify that valve Y1 closes again at ca 7 bar PI2 otherwise repeat the procedure e shut off air supply and connect the buffer tank The tank volume should be big enough to avoid too frequent valve switching f Apply air supply and verify for correct operation 6 3 Stop operation of No MISTRAL 0O 1 Shut off the compressed air supply before you perform maintenance 2 Depressurise the system by venting the nitrogen outlet 3 Make sure that the system is fully depressurised by checking the pressure gauge TIP N Should the coalescing filters not be fullv depressurized it is possible to de pressurize these manually by turning the black knob CCW on the drain outlet Than close again User s Manual N2 MISTRAL 0 25L Page 16 21 6 4 Trouble shooting Delivery of Change or clean the air filters ar N Lower the temperature if possible MISTRAL 2 4 2 Table IV User s Manual N2 MISTRAL 0 25L Page 17 21 6 5 Adjustments on the PSH Reference is made to Fig 4 The switch off pressure is adjusted with top screw B Before an adjust ment can be done it is necessary to loosen lock nut A while holding nut C with another wrench to avoid changing the hysteris setting Turning screw B clockwise will increase the set point When the pressure drops below value upper set point hysteresis default 1 bar
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