Parker MAXIGAS MX104, MAXIGAS MX108, MAXIGAS MX106, MAXIGAS MX110, MAXIGAS MX112 User Manual

EN

MAXIGAS

MX104 - MX120

User Guide

Original Language

aerospace
climate control
electromechanical

filtration

fluid & gas handling
hydraulics
pneumatics
process control
sealing & shielding

CONTENTS

EN

1 Safety Information............................................................................................................................................................................................... 4

1.1 Markings and Symbols................................................................................................................................................................................ 5

2 Description........................................................................................................................................................................................................... 6

2.1 Technical Specification ............................................................................................................................................................................... 6

2.1.1 Dimensions............................................................................................................................................................................................. 7

2.2 Unpacking the equipment ........................................................................................................................................................................... 7

2.3 Overview of the equipment ......................................................................................................................................................................... 8

3 Installation ........................................................................................................................................................................................................... 9

3.1 System layout and location ........................................................................................................................................................................ 9

3.2 Mechanical Installation.............................................................................................................................................................................. 10

3.3 Electrical Installation ................................................................................................................................................................................. 10

3.3.1 Generator Supply ................................................................................................................................................................................. 11

3.3.2 Dryer Supply......................................................................................................................................................................................... 11

3.3.3 Remote Switching ................................................................................................................................................................................ 11

3.3.4 Alarm Contacts..................................................................................................................................................................................... 11

3.3.5 4–20mA Analogue Output .................................................................................................................................................................... 11

4 Operating the Generator................................................................................................................................................................................... 12

4.1 Overview of controls ................................................................................................................................................................................. 12

4.2 Starting the generator ............................................................................................................................................................................... 13

4.3 Stopping the generator ............................................................................................................................................................................. 13

4.4 Menu Interface............................................................................................................................................................................................ 14

4.4.1 Hour Meters.......................................................................................................................................................................................... 14

4.4.2 Fault Log .............................................................................................................................................................................................. 14

4.4.3 Customer Settings................................................................................................................................................................................ 15

4.5 Start Clean Up ............................................................................................................................................................................................ 16

4.6 Economy Mode .......................................................................................................................................................................................... 16

4.7 Oxygen Analyser Calibration 17

4.7.1 Entering the calibrated level 17

5 Servicing ............................................................................................................................................................................................................ 18

5.1 Cleaning 18

5.2 Service Intervals ........................................................................................................................................................................................ 18

5.3 Service Kits ................................................................................................................................................................................................ 18

5.4 Service Procedures ................................................................................................................................................................................... 19

5.4.1 Exhaust Silencer Replacement ............................................................................................................................................................ 19

5.4.2 Dust Filter Element Change ................................................................................................................................................................. 19

5.4.3 Oxygen Sensor Replacement .............................................................................................................................................................. 19

5.5 Service Record........................................................................................................................................................................................... 20

6 Troubleshooting ................................................................................................................................................................................................ 21

7 Warranty............................................................................................................................................................................................................. 22

1 Safety Information

Important: Do not operate this equipment until the safety information and instructions in this user guide have been read and
understood by all personnel concerned.

WARNING - USER RESPONSIBILITY

FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE
DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.

This document and other information from Parker-Hannifin Corporation, its subsidiaries and authorized distributors provide product or system
options for further investigation by users having technical expertise.

The user, through its own analysis and testing, is solely responsible for making the final selection of the system and components and assuring
that all performance, endurance, maintenance, safety and warning requirements of the application are met. The user must analyze all aspects of
the application, follow applicable industry standards, and follow the information concerning the product in the current product catalog and in any
other materials provided from Parker or its subsidiaries or authorized distributors.

To the extent that Parker or its subsidiaries or authorized distributors provide component or system options based upon data or specifications
provided by the user, the user is responsible for determining that such data and specifications are suitable and sufficient for all applications and
reasonably foreseeable uses of the components or systems.

Only competent personnel trained, qualified, and approved by Parker domnick hunter should perform installation, commissioning, service and
repair procedures.

Use of the equipment in a manner not specified within this user guide may result in an unplanned release of pressure, which may cause serious
personal injury or damage.

When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related regulations,
health & safety procedures, and legal requirements for safety.

Ensure that the equipment is depressurised and electrically isolated, prior to carrying out any of the scheduled maintenance instructions
specified within this user guide.

Note: Any interference with the calibration warning labels will invalidate the gas generator’s warranty and may incur costs for the re-calibration of
the gas generator.

Parker domnick hunter can not anticipate every possible circumstance which may represent a potential hazard. The warnings in this manual
cover the most known potential hazards, but by definition can not be all-inclusive. If the user employs an operating procedure, item of equipment
or a method of working which is not specifically recommended by Parker domnick hunter the user must ensure that the equipment will not be
damaged or become hazardous to persons or property.

Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and
procedures. Accidents can be avoided by recognising that any machinery is potentially hazardous.

Details of your nearest Parker domnick hunter sales office can be found at www.domnickhunter.com

Retain this user guide for future reference.

4

EN

1.1 Markings and Symbols

NITROX

NITROGEN (N2)

GAS

NON-FLAMMABLE

DO NOT BREATHE

COMPRESSED

Asphyxiant in high
concentrations. No odour
Slightly lighter than air.
Ensure adequate ventilation.
Breathing 100% nitrogen will produce
immediate unconsciousness and death
due to lack of oxygen.

The following markings and international symbols are used on the equipment:

Caution, Read the User Guide. Pressurised components on the system

Safety Information

Risk of electric shock.

Wear ear protection Read the User Guide

Use a forklift truck Conformité Européenne

The following symbols are used within this user guide:

Highlights actions or procedures which, if not performed
correctly, may lead to personal injury or death.

Highlights actions or procedures which, if not performed
correctly, may lead to damage to this product.

Remote control. Generator may start automatically
without warning.

NITROGEN (N
NITROX

DO NOT BREATHE
Asphyxiant in high concentrations. No odour. Slightly lighter than air.
Ensure adequate ventilation. Breathing 100% nitrogen will produce

)

2

immediate unconsciousness and death due to lack of oxygen.

NON-FLAMMABLE COMPRESSED GAS

Highlights actions or procedures which, if not performed
correctly, could lead to electric shock.

When disposing of old parts always follow local waste
disposal regulations.

5

2 Description

The MAXIGAS range of nitrogen generators operates on the Pressure Swing Adsorption (PSA) principle to produce a continuous stream of
nitrogen gas from clean dry compressed air.

Pairs of dual chamber extruded aluminium columns, filled with Carbon Molecular Sieve (CMS), are joined via an upper and lower manifold to
produce a two bed system. Compressed air enters the bottom of the ‘online’ bed and flows up through the CMS. Oxygen and other trace gases
are preferentially adsorbed by the CMS, allowing nitrogen to pass through.

After a pre-set time the control system automatically switches the bed to regenerative mode. All of the contaminants are vented from the CMS
and a small portion of the outlet nitrogen gas is expanded into the bed to accelerate the regeneration. At the same instant the second bed
comes on-line and takes over the separation process.

The lower purity (%) generators use an equalisation phase designed to reduce energy consumption and enhance the overall performance of the
generator. Immediately after the adsorption phase the inlet, outlet and exhaust valves close on both beds. The upper and lower equalisation
valves open, allowing the pressure to equalise between the beds.

Once equalised the bed entering regeneration is depressurised. The oxygen adsorbed during the adsorption phase is vented to atmosphere via
an exhaust valve and silencer. The bed entering the adsorption phase is pressurised using a controlled flow of nitrogen gas from the nitrogen
buffer vessel (Back Fill) and a controlled flow of clean, dry, particulate free compressed air (Front Fill).

The CMS beds alternate between separation and regeneration modes to ensure continuous and uninterrupted nitrogen production.

The oxygen concentration in the nitrogen stream is analysed continuously. If the concentration exceeds the required production level, the
nitrogen outlet is closed and the gas is vented to atmosphere. Normal operation will resume when the purity recovers.

2.1 Technical Specification

Parameter Units

Inlet Air Quality ISO 8573.1: 2001 Class 3.2.2

Inlet Pressure

Inlet Temperature

Port Connections

Air Inlet G1”

N2 Outlet to Buffer G1”

N2 Inlet from Buffer G1/2”

N2 Outlet G1/2”

Supply Voltage

Powe r W 38

Fuse A

Ambient Temperature

Humidity

IP Rating IP20 / NEMA 1

Pollution Degree 2

Installation Category II

Altitude

Noise dB(A) <75 <80

barg

(psig)

o

C

o

F)

(

V ac

(50/60Hz)

o

C

o

(

F)

m

(ft)

104 106 108 110 112 116 120

(88 – 145) and (145 - 261)

(Anti Surge (T), 250v, 5 x 20mm HBC,

Breaking Capacity 1500A @ 250v, UL Listed)

50% @ 40

MAXIGAS

6 – 10 and 10 - 18

5 – 50

(41 – 122)

115 / 230 ± 10%

3.15

5 – 50

41 – 122

o

C (80% MAX d 31oC)

< 2000

(6562)

6

EN

2.1.1 Dimensions

Please refer to diagram A1 in Annex A.

Description

Model

104

106

108

110

112

116

120

A

mm

(ins)

692

(27.24)

861

(33.90)

1029

(40.51)

1198

(47.17)

1368

(53.86)

1765

(69.49)

2043

(80.43)

B

mm

(ins)

322

(12.68)

491

(19.33)

660

(25.98)

829

(32.64)

998

(39.29)

1314

(51.73)

1652

(65.04)

C

mm

(ins)

1895

(74.59)

1895

(74.59)

1895

(74.59)

1895

(74.59)

1895

(74.59)

1895

(74.59)

1895

(74.59)

D

mm

(ins)

550

(21.65)

550

(21.65)

550

(21.65)

550

(21.65)

550

(21.65)

550

(21.65)

550

(21.65)

E

mm

(ins)

500

(19.68)

500

(19.68)

500

(19.68)

500

(19.68)

500

(19.68)

500

(19.68)

500

(19.68)

F

mm

(ins)

366

(14.41)

G

mm

(ins)

861

(33.90)

H

mm

(ins)

981

(38.62)

I

mm

(ins)

1724

(67.87)

Weight

Kg

(lbs)

336

(741)

394

(869)

488

(1076)

582

(1283)

676

(1490)

864

(1905)

1052

(2319)

2.2 Unpacking the equipment

The generator is supplied in a wooden crate. It is recommended that the crate be moved into position using a forklift truck or pallet truck.

Remove the generator from the wooden crate using an overhead crane. The following illustrations give guidance on the safe slinging and lifting
techniques. Please refer to diagram A2 in Annex A.

Remove the silencer from the generator prior to unpacking it.

Care should be taken and inspection undertaken during unpacking to ensure that the product is not damaged.

Verify that all component parts have been supplied with the generator as listed below:

Description Part Number Qty

User Guide 17 650 0000 1

Ball valve Kit Comprising of:

1/2” Ball Valve

1/2” 3 – way Ball Valve

1” BSPP Ball Valve (x 2)

Dust Filter AR020CBMX 60 446 2300 1

Access door key 27 650 0044 1

Non-return valve *. 60 650 0024 1

* The non-return valve is only supplied with high purity generators (10ppm and 100ppm).

60 650 0001 1

7

2.3 Overview of the equipment

Please refer to diagram A3 in Annex A.

Key:

Outlet port to buffer (G1”) *

1

N

2

Outlet port (G1/2”) *

5

N

2

2 Cable Glands

3 Pressure Gauges

4

Pre-treatment dryer power supply
cable gland. (Rating: 115V 1A /
230V 0.5A)
External start / stop circuit cable
gland.

Pre-treatment dryer purge economy
cable gland.

Remote alarm circuit cable gland.

Mains supply cable gland

Column A pressure gauge

Column B pressure gauge

N

Outlet pressure gauge

2

Air inlet pressure gauge

N

inlet port from buffer vessel

2

(G1/2”) *

6 Air Inlet port (G1”) *

7 User control interface with 20 x 2 line menu display.

8 Access door

9Facia

10 4 – 20mA cable gland

Analyser calibration port

11

O

2

* Connection available on both sides of the generator.

8

3 Installation

Only competent personnel trained, qualified, and approved by Parker domnick hunter should perform
installation, commissioning, service and repair procedures.

3.1 System layout and location

Please refer to diagram A4 in annex A.

Ref Description Ref Description

1 Compressor 8 Buffer Vessel

2 Oil / Water Separator 9 Pressure Relief Valve

3 Wet air receiver 10 Dust Filter

4 Water separator 11 Maxi Generator

5 Dryer pre-filtration 12 Nitrogen Outlet

6 Pre-treatment Dryer 13 Non Return Valve

Installation

EN

7 Dust Filter Isolation Valve

The generator should be located indoors on a flat surface and protected from direct
sunlight, moisture, and dust (Refer to section 2.1 of this user guide for the generators
environmental specification). When considering the final location, take into account the
noise generated when in use.

Lift the generator by the lower manifold, using a fork lift truck or similar, and position it
in a suitably ventilated area close to the application.

Note: Due to the nature of operation there is a possibility of oxygen enrichment
surrounding the generator.

Ensure that there is sufficient free space for maintenance access and lifting
equipment.

DO NOT position the generator so that it is difficult to operate or disconnect.

When positioned in its final location, secure the generator to the floor using M20 bolts
through the support legs.

Due to the nature of operation there is a possibility of oxygen enrichment surrounding the generator. Ensure that the
area is adequately ventilated. Where the risk of oxygen enrichment is high, such as a confined space or poorly ventilated
room, the use of oxygen monitoring equipment is advisable.

9

3.2 Mechanical Installation

Please refer to diagram A5 in annex A

Once located fit the ball valves to the ports on the generator. All ppm generators are supplied with a non return valve, this should be fitted to the
ball valve on the port marked “To Buffer Vessel”. Install the pipe-work ready for connection to the buffer vessel and compressed air supply. The
diameter of the pipes must be sufficient to allow unrestricted inlet air supply to the generator and nitrogen supply to the application as shown in
the table below.

Connection Pipe-work

(1) 1” Ball Valve (a) 1” NB / 28mm ID

(2) 1” Ball Valve (b) 1” NB / 28mm ID

(3) 1/2” Ball Valve (c) 1/2” NB / 16mm ID

(4) 3 Way Ball Valve (d) 1/2” NB / 16mm ID

Ensure that all piping materials are suitable for the application, clean and debris free. All outlet piping must be solid and non-porous to minimise
the ingress of oxygen. When routing the pipes ensure that they are adequately supported to prevent damage and leaks in the system.

The nitrogen buffer vessel must be rated to at least the maximum operating pressure of the generator and must be fitted with suitable pressure
gauge and pressure relief valve

It is recommended that the system be protected with suitably rated pressure relief valves upstream of the generator.

3.3 Electrical Installation

A fully qualified electrical engineer must undertake all field wiring and electrical work in accordance with local
regulations.

Please refer to diagram A6 in Annex A.

In order to maintain the IP rating of the generator, all cables entering the electrical enclosure must do so through the dedicated cable glands
located on the side of the generator. All cables used must be sized such that the voltage drop between the supply and the load does not exceed
5% of the nominal voltage under normal conditions. All cables external to the generator must be adequately supported and protected against
physical damage.

REF CONNECTION TERMINAL NOTES CABLE DIAMETER

L - Fuse terminal for the phase conductor.

A Generator Supply

B Dryer Supply

C Purge Economy

D

E Alarm Contacts

F

Remote Switching

MODBUS

4-20mA

O

2

L (Grey) Dryer Live conductor
N (Blue) Dryer Neutral conductor

(Yellow / Green)

JP17-2 (NC)
JP17-3 (NO)

JP19-7
JP19-8
A
B

JP18-1 (COM)

JP18-3 (NO)

Analyser - 6 (+ve) The screen should be bonded to the back plate
Analyser - 7 (-ve)

(INPUT 4)

RS485
MODBUS

N - Neutral conductor

- Earth conductor

Dryer Earth conductor.

Refer to installation instructions for the dryer. 3 – 7 mm

Remote switching is activated in the customer
Settings menu 3.11
For MODBUS communication setup details
refer to dh publication 17 650 012.

The relay is energised when no faults are
present

of the shroud.

6 - 12 mm

3 – 7 mm

3 – 7 mm

3 – 7 mmJP18-2 (NC)

3 – 7 mm

10

3.3.1 Generator Supply

Connection to the electrical supply should be made through a switch or circuit breaker rated at 250VAC, 15A with a minimum short circuit rating
of 10KA. All of the current carrying conductors should be disconnected by this device.

The device chosen should be clearly and indelibly marked as the disconnecting device for the equipment and be located in close proximity to the
equipment and within easy reach for the operator.

Overcurrent protection must be fitted as part of the building installation. This protection should be selected in accordance with local and national
code regulations with a minimum short circuit rating of 10KA.

The protective earth conductor should be longer than the associated phase conductors so that in the event of the cable slipping in the cable
gland, the earth will be the last to take the strain.

3.3.2 Dryer Supply

If a Parker domnick hunter pre-treatment air dryer is used, it should be connected to the generator at the dedicated DIN rail terminals.

Note: Refer the documentation provided with your dryer for additional information on installation requirements.

3.3.3 Remote Switching

The generator may be controlled remotely by connecting a remote start / stop circuit to digital input #4 on the control board. When the circuit is
open the generator should remain in standby mode, closing the circuit should initiate a start command.

To enable the remote switching function refer to 4.4.3 of this guide. Once the remote switching function has been enabled the local start control
will no longer function.

When the remote switching function is enabled the generator can start without warning.

3.3.4 Alarm Contacts

Each generator is fitted with a set of volt free relay contacts designed for remote alarm indication and are rated 1A max @ 250Vac (1A @
30Vdc). The alarm circuit should be connected between the “COM” and the NC terminals of JP18. Under normal operation the relay will be
energised and the alarm circuit will be open. When a fault occurs, e.g. power failure, the relay will de-energise causing the alarm circuit to be
complete.

If remote fault indication relay is used, the electrical enclosure will now contain more than one live circuit
and in the event of the mains supply being disconnected, the fault relay connections will remain live.

3.3.5 4–20mA Analogue Output

The oxygen content detected by the generators internal analyser may be re-transmitted to external peripherals using the 4-20mA linear
analogue output. The output is a linear current source, with 10 bit resolution, which increases from 4mA (Zero Oxygen) to 20mA (Full Scale
Deflection). The FSD of the internal analyser is factory set to a default value of twice the generators specified purity. For % purity generators the
maximum FSD is set to 6%.

Note: The oxygen purity setting of the generator is marked on the rating plate.

The table below shows the correlation between the purity settings of the generator and the output current. The FSD can be altered in menu 3.8
of the control software (refer to section 4.4.3 for details).

Generator

Purity

10ppm 0 - 20ppm 1ppm = 0.8mA

100ppm 0 - 200ppm 1ppm = 0.08mA

0.05% 0 - 0.1% 0.01% 1.6mA

0.1% 0 - 0.2% 0.01% = 0.8mA

0.5% 0 - 1% 0.01% = 0.16mA
1% 0 - 2% 0.01% = 0.08mA
2% 0 - 4% 0.01% = 0.04mA
3% 0 - 6% 0.01% = 0.026mA
4% 0 - 6% 0.01% = 0.026mA
5% 0 - 6% 0.01% = 0.026mA

Full Scale Deflection

4mA - 20mA

Resolution

11

4 Operating the Generator

4.1 Overview of controls

Local Start / Stop Controls

Local Start control – This control is inactive when the generator is configured for remote control.

Local Stop control – This control is active for both local and remote control.

Menu navigation keys

Moves upwards through the menus

Moves downwards through the menus

Selects the current menu

Generator status indicators

Green - Cycling
Amber - Start clean up, shutting down, N2 vent (No gas is delivered to the application), and entering economy
Red - Standby

Green - Economy mode

Amber - Service due
Red - Active Fault

12

Operating the Generator

EN

4.2 Starting the generator

Inspect all of the system connection points and verify that they are secure.

With both the inlet and outlet ball valves of the buffer vessel closed, open the ball valve on the air inlet port to allow the compressed air into the
generator.

Switch the electrical power on to the generator and wait whilst it runs through the controller initialisation routine.

If the generator was in standby mode when the electrical power was removed it will default to standby
mode on completion of the initialisation routine.

Press to initiate the start up routine.

If the start clean up option is enabled the generator will run through the Rapid Cycle / Pure Start
before opening the buffer valve and the N2 outlet valve.

[Refer to section 4.5 for more details on Rapid Cycle and Pure Start]

If the generator was running when the electrical power was removed (e.g. power failure) it will
automatically run through a start up cycle (if enabled) and then commence normal operation. Wait
until this cycle is complete and the menu displays “Running”. This may take several minutes in ppm
generators.

Slightly open the ball valve on the inlet to the buffer vessel and leave it to pressurise slowly. When the pressure gauge on the buffer vessel reads
within 0.5 barg (7psig, 0.05MPa) of the inlet pressure, check for leaks in the inlet piping and then fully open the ball valve.

Open the ball valve on the outlet of the buffer vessel and check for leaks in the piping between the vessel and the generator.

Open the ball valve on the Nitrogen outlet.

Note: If the purity of the gas is not within specification it will be vented to atmosphere through a vent solenoid within the generator and not
delivered to the application. When the required purity is achieved the gas will be delivered to the application.

4.3 Stopping the generator

Close the ball valve on the N2 Outlet port.

Press [ ] to initiate the shutting down sequence.

The generator will complete the current cycle and then exhaust both beds. This may take several
minutes particularly on ppm generators.

When the generator is depressurised it will revert to standby mode.

Note: There may be a residual pressure of approximately 1.5 bar within the columns due to the
release of oxygen from the CMS. This can be released by turning the Kaddis drain, or small ball valve
if fitted, on the inlet valve assembly.

13

4.4 Menu Interface

All of the operational parameters and data are accessed through the menu driven interface. To prevent unauthorised access to the configurable
parameters, the customers setting menu is password protected.

Menu Map

Please refer to diagram A7 in annex A.

The interface will automatically default back to the main operating menu if no key activity has been detected for one minute.

Note: After and additional two minutes of inactivity the display will shutdown. To bring the display back on-line press .

The customer settings menu contains the parameters that may be customised by the end user. To prevent unauthorised changes being
made this menu is password protected and cannot be accessed until the password has been entered correctly.

To enter the password from the main operating menu press and hold both the and keys for
approximately 5 seconds until the menu changes to the password prompt as shown

The flashing cursor will be positioned over the first digit.

Using the key change the first digit of the code and press . The cursor will move to the next digit.

Repeat the process and enter the following password 1 2 1 _ _ .

When the password has been entered correctly the Hour Meters menu will be displayed.

Use the key to navigate to page 3 “Customer Settings”.

4.4.1 Hour Meters

There are three hour meters available for viewing:

The time in hours that the generator has been producing gas.

The time in operating hours that the generator can produce gas before a service is required.

The time in hours that the generator has been operating in Economy mode.

4.4.2 Fault Log

The fault log menu allows the user to access the 10 most recent fault messages.

Each fault is represented by a fault code and is displayed along with the run hours at which the
fault occurred. If a fault is active the fault code displayed will flash.

Any faults that are active when the power is switched off and are still active when the power is re­applied will cause a new entry to be added into the fault log.

Fault Codes Notes

C1 Pressure Start Inhibit Low inlet pressure. Inhibits start.

P1 Inlet Pressure Fault Low inlet pressure during cycling.

P2 Pressure Sensor Fault Pressure sensor communication error.

E1 Power Failure

Alarm

Y1

Y2

Y3 Incorrect cell selected

Y4

Y5

S1 Service due

O

2

Communication failure Communication fault between O2 analyser and control board

O

2

high (out of range) Occurs when O2 > 25% (% generators) / O2> 1.05% (ppm generators)

O

2

zero drift error

O

2

Contact Parker domnick hunter

14

Operating the Generator

3.7 Fault Relay
On Stop = 1

EN

4.4.3 Customer Settings

The customer settings menu contains all of the generator parameters that may be altered by the end user. The following example
demonstrates the method of altering a parameter, however it is recommended that none of the parameters are altered until their
functionality is fully understood.

Use the and keys to scroll through to the desired menu and press .

Referring to the menu map select the desired.
The flashing cursor should be positioned over the “=” sign to indicate that the parameter may be
changed.

Use the / keys to change the parameter.

Press to accept the changes or press and simultaneously to cancel the changes.

Press and simultaneously to return to the customer settings menu and then again to return to the main operating menu.

All settings marked in bold text are the default settings.

When enabled the O
0 = Over-ride disabled, 1 = Override Enabled

[OVR]

O

cell calibration menu.

2

Refer to section 4.7 for details on calibration.

Sets the purity level at which an oxygen fault is initiated.
Default Settings:

% Generators - 0.05% above the selected production purity
ppm Generators - 5ppm above the selected production purity

If the purity level exceeds the oxygen alarm level for a period longer than the alarm delay, the
oxygen alarm will be activated and the gas will be vented to atmosphere..

alarm is over-ridden.

2

Delay Range = 0 – 600 Seconds, Default = 60 Seconds

When enabled the bed cleaning cycles will run whenever the generator is powered up, comes out
of standby mode and economy mode.

0 = Disabled, 1 = Enabled

Enables the economy mode.

0 = Disabled, 1 = Enabled

When enabled the actuation of the Stop control will generate an alarm.

0 = Disabled, 1 = Enabled

Sets the Full Scale Deflection value for the 4 – 20mA Analogue Output.

Sets the ppm O

cell calibrated offset value marked on the cell.

2

Note: This value must be entered only when the cell is changed.

Sets the address for the generator when communicating on a network via the
RS485 MODBUS port.

Address range is 1 – 32

Sets the mode of control for the generator

1 = Local Start / Stop control, 2 = Remote Start / Stop control via the digital input

15

4.5 Start Clean Up

The clean up cycles are designed to clean the CMS bed of impurities, bring the generator up to production purity more rapidly, and prevent poor
quality gas flowing into the buffer. The operation of the cycle is dependant upon the purity as described below:

Rapid Cycle – this cycle is used for lower purity generators (0.05 – 5.0%). The chambers are filled and exhausted alternately on a fixed
cycle time. The Rapid Cycle takes 160 seconds to complete.

Pure Start - The higher purity generators (10 - 100ppm) require a two stage cleaning process:

Pure Start A – with the N

Pure Start B – immediately following Pure Start A the N

The chambers are then filled and exhausted again.

The pure start cycle times are dependant upon the production purity of the generator.

On completion of the start up cycles the N

The Start clean up cycle can be disabled within the customer settings menu, however Parker domnick hunter
strongly recommend that the start up cycles remain enabled.

outlet to buffer valve closed, the chambers are filled and exhausted alternately.

2

outlet to buffer valve is opened to allow gas flow into the buffer vessel.

2

PRODUCTION PURITY

10 ppm 4 x 120 120/90

100 ppm 4 x 90 90/70

0.05% 4 x 90 90/70

outlet valve will open, allowing gas to be delivered to the application.

2

PURE START CYCLE

AB

4.6 Economy Mode

Economy mode is designed to switch the generator into standby mode when there is no demand for gas.

The generator monitors the outlet pressure and if it exceeds a pre-determined level for a sustained period of time (Economy Period *), the N
outlet valve will close. The generator will continue to cycle as normal without delivering gas to the application. If the back pressure is maintained

for an additional 5 minutes, the generator will stop cycling and enter Economy mode.

When the pressure falls below the regulated outlet pressure, the generator will resume normal operation. If the generator is in Economy mode
when this occurs, it will run through the relevant clean up cycle.

The economy mode can be disabled within the customer settings menu, however Parker domnick hunter
strongly recommend that this option remains enabled.

The Economy over-ride facility (optional) can be used to maintain the beds when the generator is in economy mode. If the over-ride is enabled,
a clean up cycle will be performed once every 20 minutes. This allows the generator to go straight on-line when the outlet pressure falls below
the regulated outlet pressure.

*The Economy Period is factory set to 5 minutes.

2

16

4.7 Oxygen Analyser Calibration

4

Select menu 3.1 and enable the O2 Alarm
Over-ride.

3.2 O2 Calibration
= 4.95%

3.2 O2 Calibration
= 5.00%

3.2 O2 Calibration
Please Wait...

3.2 O2 Calibration
= 5.00%

3.1 O2 Alarm
Over-ride = 1

O2 = 5.00 % CAL
Running

The O2 analyser should be calibrated at least once every three months against
a calibrated gas supply or a calibrated independent analyser.

Note. If using calibration gas, ensure that purity is as close to the production
gas purity as possible (minimum of 50ppm). Do not exceed 7barg pressure.

For low purity applications the calibration may be performed using compressed
air. This method is not recommended when the purity of the gas is critical.

3.1 O2 Alarm
Over-ride = 1

Operating the Generator

EN

Calibrated Gas Supply

Connect the gas supply to the O

Analyser calibration port (1) on the side of the

2

generator.

Locate the calibration ball valve (2) inside of the shroud and rotate the handle
clockwise so that it is pointing upwards as shown. Wait approximately fifteen
minutes for the O

reading to stabilise. Once stable enter the calibrated level

2

as specified below.

Calibrated Independent Analyser

Connect the analyser to the nitrogen outlet port of the generator. Wait
approximately fifteen minutes for the O

reading to stabilise. Once stable enter

2

the calibrated level as specified below.

Compressed Air

Connect the O
ball valve (3), and the O

sample line between the elbow push in fitting, located on the

2

Analyser calibration port (1).

2

If a sample line other than the one provided by domnick hunter
is used ensure that it is suitable rated for the working pressure
of the generator.

Open the ball valve (3) and rotate the handle of the calibration ball valve (2) so that it is pointing upwards as shown. Wait approximately fifteen
minutes for the O

reading to stabilise. Once stable enter the calibrated level as specified below.

2

The sample line will need to be depressurised prior to disconnection. Close the ball valve (3) and wait until the pressure
shown on the pressure gauge (4) reaches zero. When the line is fully depressurised, rotate the handle of the calibration
ball valve (2) so that it is pointing downwards and disconnect the line from the generator.

4.7.1 Entering the calibrated level

Select menu 3.2. The current reading from the 02 analyser will be displayed on the controller.

Using the and keys enter one of the following as appropriate:

• the purity of the calibration gas,

• the purity reading from the independent analyser,

• Oxygen content of the compressed air (20.9%).

Press to send the calibration level to the O

On successful completion of the calibration the new O
display. If the calibration is not successful the original reading from the analyser will be loaded. Should this

occur repeat the above steps.

On completion of the calibration, return the calibration ball valve back to its original position and remove
the regulated calibration gas supply or independent analyser as applicable.

Disable the O

Alarm Over-ride.

2

When returning to the main operating menu, “CAL” will be shown on the top line of the display. This will
remain for a period of twenty minutes after the calibration. Throughout this time period the O2 alarm is
overridden, to allow the sensor to return to the required level.

analyser.

2

reading will be shown on the bottom line of the

2

17

5 Servicing

5.1 Cleaning

Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical sockets. If required you may use a mild
detergent, however do not use abrasives or solvents as they may damage the warning labels on the equipment.

5.2 Service Intervals

Description Of Maintenance Required Typical Recommended Maintenance Interval

Component Operation

Generator Check status indicators located on the control panel.

System Check inlet air quality

Generator Check for air leaks

Generator Check pressure gauges during purging for excessive back pressure

Generator Check condition of electrical supply cables and conduits

Generator Check cyclic operation

Generator

Filtration

Generator

Generator

Replace active exhaust silencers

Recommended Service A

Replace dust and control air filters.

Recommended Service B

Replace/Calibrate oxygen sensor

Recommended Service C

Replace/Service valves

Recommended Service D

Daily

(3-month)

2000 Hours

(6-month)

4000 Hours

(12-month)

8000 Hours

(24-month)

16000 Hours

- Check – Replace

5.3 Service Kits

Please refer to diagram A8 in Annex A.

Service Kit Description Kit No.

A – Silencer Service Exhaust Silencer Kit 608620090

B – Filter Service Filter Element Kit 020AR

PPM O

Cell Service

C – O

2

D – Valve Service

The valve overhaul (Service D) and all other repair and calibration work should be undertaken by a Parker domnick
hunter trained, qualified and approved engineer.

Cell Kit

2

% O

Cell Kit

2

PPM Valve Overhaul Kit (without
equalisation valve)

% Valve Overhaul (with equalisation valve) 606500005

18

606500002

606500003

606500004

EN

AB C

DE F

5.4 Service Procedures

Ensure that the generator is isolated from the mains power supply and fully depressurised before carrying out any of
the following service procedures.

5.4.1 Exhaust Silencer Replacement

The exhaust silencer is located under the inlet manifold assembly. Unscrew the silencer assembly from the exhaust flange plate and
remove. Slide the silencer element off the baffle (A) and replace.

Ensure that the replacement element is inserted into the groove of the baffle end cap and screw the exhaust silencer assembly back into
the exhaust flange plate.

When fitted correctly there should be no movement of the element on the baffle.

5.4.2 Dust Filter Element Change

Close the ball valves located on the inlet and outlet ports of the filter and de-pressurise it by opening the drain valve on filter bowl.

Once de-pressurised unscrew the filter bowl from the head (D) and remove the old filter element. Holding the replacement element by the
end caps, fit it into the bowl ensuring that the element is correctly seated (E).
Assemble the filter bowl back onto the filter and tighten. The markers on the filter head and filter bowl must line up with each other when
fully assembled (F).

Close the drain valve on the filter and slowly open the filter outlet valve and inlet valve.

Servicing

5.4.3 Oxygen Sensor Replacement

Disconnect the O2 cell lead from the O2 analyser. Terminals 1, 2 and 3 (% vol O2 cells) or 3, 4 and 5 (ppm vol O2 cells) (B)
Unscrew the tube nut holding the O
Fit the replacement sensor onto the t-piece and perform a leak test. All leaks must be repaired.

Refit the electrical connections to the O

.

Terminal Colour Function

1 Blue -ve % vol sensor

2 Red +ve % vol sensor

3 Green Ground

4 Blue -ve ppm vol sensor

5 Red +ve ppm vol sensor

Calibrate the sensor as detailed in section 4.7 (Note: PPM cells require the offset value to be entered prior to calibrating)

cell in place and remove the cell (C).

2

analyser

2

19

5.5 Service Record

Date of Commissioning

Service
(Hours)

8,000

16,000

20,000

24,000

28,000

32,000

36,000

40,000

Hours

Shown

Date

Serviced By

Comments / Observations

Print Initials

20

EN

6 Troubleshooting

In the unlikely event that a problem occurs on the equipment, this troubleshooting guide can be used to identify the probable cause and remedy.

Troubleshooting should only be attempted by competent personnel. All major repair, and calibration work should be
undertaken by a Parker domnick hunter trained, qualified and approved engineer.

Fault Probable Cause Remedy

Power Connected but LCD and status
indicators not illuminated.

No / Low gas outlet pressure Service Overdue Service the generator

High Oxygen concentration. Defective Oxygen cell. Replace.

Low inlet pressure Compressor or ring main pressure low. Check and Rectify

Excessive noise or vibration Silencer loose or defective. Check and Rectify

High outlet pressure. Outlet regulator defective. Reset or replace.

Fuse Blown Replace Fuse

Ribbon cable disconnected Reconnect Ribbon cable

Power disconnected Reconnect Power

Internal gas leak Check and Rectify

External gas leak Check and Rectify

Low inlet pressure Ensure pressure meets required specification

Leak in system piping. Check and Rectify

Inlet valve not open Check and Rectify

Defect on pre-treatment package. Refer to pre-treatment manual.

Solenoid valve wear or coil loose. Check and replace if required.

21

7 Warranty

This warranty applies to the Maxigas Generator and associated parts (the equipment) manufactured and supplied by Parker Hannifin ltd,
Parker domnick hunter division (the company).

Use of the Maxigas Generator without the recommended inlet air quality or genuine parts will expressly invalidate the warranty.

Should the equipment be defective as to materials or workmanship, the company warrants that it will remedy such defect. Where the Equipment
is a Maxigas Generator, the warranty period will be 12 months from date of commissioning or 18 months from date of manufacture, whichever
is the earlier. In the case of equipment other than a Maxigas Generator, the warranty period shall commence from the date of despatch. Should
any defect occur during the warranty period and be notified in writing to the company or its authorised distributor within the said period, the
company will, as its sole option, remedy such defect by repair or provision of a replacement part, provided that the equipment has been used
strictly in accordance with the instructions provided with each item of equipment and has been stored, installed, commissioned, operated and
maintained in accordance with such instruction and with good practice. the company shall not be under any liability whatsoever under the
warranty, if, before giving notification in writing to the company as aforesaid, the Customer or any third party meddles, interferes, tampers with or
carries out work whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the Equipment or any part
thereof.

Any accessories, parts and equipment supplied by the company but not manufactured by the company shall carry whatever warranty the
manufacturer has given the company providing it is possible for the company to pass on such warranty to the customer.

To claim under the warranty, the equipment must have been installed and continually maintained in the manner specified in the User Guide. Our
product support engineers are qualified and equipped to assist you in this respect. They are also available to make repairs that may become
necessary in which event they will require an official order before carrying out the work. If such work is to be the subject of a warranty claim, the
order should be endorsed for consideration under warranty.

Where equipment is sold outside the UK mainland direct to the end user the warranty will cover parts only. Any substitution of parts not
manufactured or approved by the company will expressly invalidate the warranty.

22

Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ. UK

Directives 97/23/EC

Declaration of Conformity EN

Parker Hannifin ltd, Industrial division

MAXIGAS Nitrogen Generator

MAXIGAS 102 - MAXIGAS 120

2006/95/EC
2004/108/EC
93/68/EEC, 92/31/EEC

Standards used EN 61010-1 : 2001

PED Assessment Route : B & D
EC Type-examination Certificate: COV 0623606/1
Notified body for PED: Lloyds Register Verification

Authorised Representative Derek Bankier

Divisional Quality Manager
Parker Hannifin ltd, Industrial division

EN 61000-6-2 : 2005
EN 61000-6-3 : 2007
EN 61000-3-2 : 2000
EN 61000-3-3 : 1995
Generally in accordance with ASMEVIII Div 1 : 2004.

71 Fenchurch St. London
EC3M 4BS

Declaration

I declare that as the authorised representative, the above information in relation to the supply / manufacture of this product, is
in conformity with the standards and other related documents following the provisions of the above Directives.

Signature: Date: 06/00/2010

Declaration Number: 0035/60110

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© Parker Hannifin Corporation. All rights reserved. Catalogue: 176500000

03/09 Rev: 02

Parker Hannifin ltd

Industrial division
Dukesway, Team Valley Trading Est
Gateshead, Tyne and Wear
England NE11 0PZ
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Fax: [phone]
www.domnickhunter.com