USER MANUAL - Matheson TRIGAS

USER MANUAL - Matheson TRIGAS

USER MANUAL

LCMS M-4

NITROGEN GENERATOR FOR LC/MS

MATHESON TRI-GAS

166 Keystone Drive

Montgomeryville, PA 18936

Phone: 215-641-2700

Fax: 215-641-2714

Email: [email protected]

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USER MANUAL ........................................................................................... 1

1 INTRODUCTION ................................................................................... 4

1.1 General........................................................................................... 4

1.2 Pictograms ..................................................................................... 5

1.3 Identification and service................................................................ 6

1.4 Certificates ..................................................................................... 6

1.5 Use in accordance with purpose .................................................... 6

1.6 User instructions............................................................................. 6

1.7 Liability............................................................................................ 7

2 HEALTH, SAFETY AND ENVIRONMENTAL ASPECTS .................... 7

2.1 General........................................................................................... 8

2.2 Nitrogen and oxygen ...................................................................... 8

2.3 Electricity ........................................................................................ 9

2.4 Safety precautions.......................................................................... 9

2.5 Environmental aspects ................................................................. 10

3 DESCRIPTION OF THE APPLIANCE ................................................ 11

3.1 General......................................................................................... 11

3.2 Separation principle...................................................................... 11

3.3 Parts ............................................................................................. 12

3.4 Process diagram .......................................................................... 13

3.5 Process scheme........................................................................... 14

3.5.1 Process scheme HP.............................................................. 14

3.5.2 Process scheme LP .............................................................. 15

4 TECHNICAL SPECIFICATIONS......................................................... 16

4.1 General......................................................................................... 16

4.2 Capacity data ............................................................................... 19

4.3 Maintenance kit ............................................................................ 19

5 INSTALLATION .................................................................................. 20

5.1 Transport ...................................................................................... 20

5.2 Define location.............................................................................. 20

5.3 Unpack and check equipment ...................................................... 21

5.4 Connect nitrogen consumer ......................................................... 21

5.5 Connecting power ........................................................................ 21

5.6 Connect input and output signals ................................................. 22

6 OPERATION OF THE CONTROL SYSTEM ...................................... 23

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6.1 Menu structure ............................................................................. 23

6.2 Main screen .................................................................................. 23

6.3 Settings menu ......................................................................... 25

6.3.1 Log on menu .................................................................... 26

6.3.2 Alarm settings menu ........................................................ 27

6.3.3 Pressure switch menu .................................................... 29

6.3.4 Options menu .................................................................. 30

6.3.5 Local settings menu ........................................................ 31

6.3.6 Maintenance menu .......................................................... 32

6.3.7 Data logging menu .......................................................... 35

7 OPERATION ....................................................................................... 37

7.1 Commisioning N2-MISTRAL-4® .................................................. 37

7.2 Start N2-MISTRAL-4®.................................................................. 38

7.3 Adjusting the purity....................................................................... 38

7.4 Control of the outlet pressure ....................................................... 39

7.5 Stop N2-MISTRAL-4®.................................................................. 40

8 TROUBLESHOOTING ........................................................................ 41

8.1 Error list ........................................................................................ 41

8.2 Alarm messages ............................................................... 42

9 MAINTENANCE .................................................................................. 44

9.1 Maintenance scheme ................................................................... 44

9.2 Replace inlet filter element ........................................................... 44

9.3 Replace oxygen sensor................................................................ 46

9.4 Calibrate oxygen sensor............................................................... 46

9.5 Replace compressor .................................................................... 47

9.6 Software updates ......................................................................... 49

10 ELECTRICAL SCHEME.................................................................. 50

11 INDEX .............................................................................................. 51

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1 Introduction

1.1 General

This manual forms an integral part of the product. The manual describes the installation, daily operation, maintenance and troubleshooting.

Content

Read the manual carefully before you start with the LCMS M-4. Familiarize yourself with the content.

Condition of change

Only execute changes to the LCMS M-4 after explicit prior written permission by the manufacturer. Non-conformance to this rule, as well as any consequential damage, loss and costs are the responsibility of the owner and the user.

Information

All information in this manual, including additional drawings and technical descriptions, remains the property of the producer and may not be used

(otherwise than for the use of this product), copied, multiplied or published to or for a third party without explicit prior written permission by the manufacturer.

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1.2 Pictograms

In this manual and on the generator, the following pictograms are used:

Warning

A warning shows a hazard that can cause death or serious injury. Follow the instructions.

Caution

A caution shows a danger that can cause damage to the equipment. Follow the instructions.

Electricity

High voltage: danger of electric shock.

Warning

Risk for death due to suffocation.

Risk of fire

Oxygen-enriched air leads to an increased risk of fire in the event of contact with inflammable products.

High-pressure risk

Follow the instructions with respect to compressed gasses.

Environment

Instructions with respect to the environment.

Read instructions in the manual.

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1.3 Identification and service

The identification plate is located on the right hand side of the LCMS M-4.

The identification plate shows the characteristics of the LCMS M-4.

For service and technical assistance, please contact your distributor and/or the manufacturer.

WARNING: in case of a warranty failure of the compressors, the manufacturer requires the SD card (MEMORY CARD) to be send together with the compressor. The user will of course get his SD card

send together with the new replacement compressor.

1.4 Certificates

The LCMS M-4 meets the following requirements:

Directive for electromagnetic compatibility (EMC)

Low Voltage Directive

Pressure equipment directive (PED)

Quality assurance

Environmental care

EN-50081-1, EN50082-2

NEN EN 60204-1

Sound engineering practice

ISO 9001:2000

ISO 14001:1996

1.5 Use in accordance with purpose

The LCMS M-4 is intended to make nitrogen out of normal ambient air. The system is based on gas separation membranes. Each different or further use will not be in conformity with the purpose. The manufacturer will not accept any liability for improper use.

The LCMS M-4 is in compliance with the prevailing directives and standards. Only use this LCMS M-4 in a technically perfect condition, in conformity with the purpose as described above.

Only well-trained personnel are allowed to work on the LCMS M-4. The user must be aware of hazards related to operating the LCMS M-4 and

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processes connected to the LCMS M-4. The user is responsible for the safety of the personnel. All personnel working on the LCMS M-4 must have free access to the applicable manuals.

1.7 Liability

The producer will not accept any liability if:

• The instructions in this manual are ignored.

• Replacement parts are used which are not approved by the manufacturer.

• The system is fed with other gasses than air. manufacturer.

• Maintenance and repair are not carried out according to the instructions.

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2 Health, safety and environmental aspects

2.1 General

Correct use of the LCMS M-4 nitrogen generator is important for your

personal safety and for trouble-free functioning of the LCMS M-4. Incorrect use can cause damage to the LCMS M-4 or can lead to incorrect gas supply.

Warning

Read this manual before you start the installation and

putting into operation of the LCMS M-4. Prevent

accidents and damage to the LCMS M-4.

Contact your supplier if you detect a problem that you

cannot solve with this manual.

Use the LCMS M-4 in accordance with its purpose.

Refer to §1.5.

Only service-engineers, that are qualified to work on

electric and pneumatic equipment, are allowed to do the installation, maintenance and repairs. Unqualified people are not allowed to repair the equipment. Refer to §1.6. Lift the LCMS M-4 with a forklift. Follow the legislation and instructions for operating the forklift.

Do not tamper or experiment with the equipment. Do

not exceed the technical specifications for the LCMS

M-4. Refer to chapter 4.

2.2 Nitrogen and oxygen

The LCMS M-4 generates nitrogen as a product. Oxygen enriched air is released as waste.

Warning

Nitrogen can cause suffocation!

Oxygen-enriched air leads to increased risk of fire in

the event of contact with flammable products. Make sure that there is adequate ventilation at all times!

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The LCMS M-4 is not designed for installation in an

Exx-classified area.

Do not install the LCMS M-4 in an area where

explosive mixtures may occur.

2.3 Electricity

Warning

Only service-engineers, that are qualified to work on

electrical equipment, are allowed to do the installation, maintenance and repairs.

Disconnect the main power supply before you do the

maintenance or repair.

If a service-engineer has to work on the LCMS M-4

while the electric power it is connected, the serviceengineer must be very careful with respect to the electric hazards.

Warning

Make sure that the ventilation rate is sufficient in the

room where the enriched oxygen is ventilated, or lead the enriched air outside. Keep the ambient temperature between 10 and 35 °C.

Install the peripheral equipment, piping and nitrogen

storage vessels according to standard procedures.

The manufacturer cannot take responsibility for this.

Do regular maintenance to the LCMS M-4, to ensure

proper and safe operation. Refer to chapter 8.

Make sure that instructions concerning health and

safety are compliant with the local legislation and regulations.

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The use and maintenance of the LCMS M-4 does not include environmental dangers. Most parts are made of metal and can be disposed in the regular way. The packaging of the LCMS M-4 is 100% recyclable.

Optimal sizing of buffer tanks and setting of the pressure switch will result in minimal energy consumption. The lower the delivery pressure, the longer the lifetime of the system.

According to EC-regulations electrical systems have to be disassembled and recycled at the end of their life.

Make sure that instructions concerning health, safety and environment are compliant with the local legislation and regulations.

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3 Description of the appliance

3.1 General

The LCMS M-4 separates compressed air produced by an on-board compressor into nitrogen and an oxygen enriched air stream. The separation system is based on membranes.

There are two versions of the LCMS M-4:

• The Low Pressure (LP) version, suitable for delivery of nitrogen at low pressure (2.0 bar(g) max.) and

• The High Pressure (HP) version, suitable for delivery of nitrogen at elevated pressures (8.0 bar(g) max.)

B

A

C

H2O - H2

F

O2

Fig. 3-1: Separation principle

A Pressurized air inlet

N2

S

Ambient air contains nitrogen (78.1%), oxygen (20.9%), argon (1%), carbon dioxide, water vapor and traces of other inert gasses. Pressurized air (A) is led through hollow fibre membranes(B). The various air components diffuse through the porous wall of the membranes.

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The diffusion rate differs for the various gasses:

• Oxygen and water vapor have a high diffusion rate and diffuse rapidly through the membrane wall.

• Nitrogen has a low diffusion rate and diffuses slowly through the membrane wall.

Pressurized nitrogen enriched air is released at the outlet of the membranes (E) which can be stored in a nitrogen storage vessel.

3.3 Parts

A Nitrogen compressor

B Hollow fiber membrane

and heat exchanger (M)

C Air compressor

J SD-card

K Pressure relief valve

L Non-return valve

D Inlet carbon adsorber

E purity control valve

F Oxygen sensor

G O2 sensor adjustment valve (do not adjust)

H Touch screen display

I Pressure control valve

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M Main switch/automatic

fuse

N Electrical feed cable

O Product outlet

P Ventilation outlet

(keep clear)

The LCMS M-4 can be connected directly to the nitrogen consumer (Fig. 3-

3) or to a buffer vessel (Fig. 3-4).

N2-MISTRAL-4®

Nitrogen

Consumer

Fig. 3-3

Buffer

Vessel

N2-MISTRAL-4®

Nitrogen

Consumer

Fig: 3-4

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C

RKV

PI1

FCV

HP

PCV

PSH

PI2

V1

N2

V2

Inlet carbon adsorber

Start up valve membrane

Membrane pressure indicator

Flow control valve

Nitrogen compressor

Nitrogen pressure relief valve

Pressure switch

Nitrogen pressure indictor

Non return valve

Nitrogen outlet

Ball valve

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C

RKV

PI1

FCV

PCV

PSH

PI2

V1

N2

V2

Inlet carbon adsorber

Start up valve membrane

Membrane pressure indicator

Flow control valve

Nitrogen pressure relief valve

Pressure switch

Nitrogen pressure indictor

Non return valve

Nitrogen outlet

Ball valve

4.1 General

Delivery pressure

Maximum delivery pressure

Ambient conditions

Temperature

Air quality

Max. ambient relative humidity

Noise level

Dimensions and connections

Dimensions (H x W x D) [mm]

Dimensions (H x W x D) [inch]

Net weight

Connections

Electrical data

Voltage/frequency

1

Power consumption

Low Pressure: 2 bar(g)/29 psig

High Pressure: 8 bar(g)/116 psig

10 to 35 °C / 50 to 95 °F

Normal clean ambient air, relative humidity < 90%

<80 %

< 58 dB(A) @ 1 meter

700 x 900 x 310

27.6 x 35.4 x 12.2

92.5 kg / 204 lbs outlet: G ¼ “ / ¼” NPT

100Vac/50Hz, 100Vac/60Hz,

120Vac/60Hz, 230Vac/50Hz

1400 W

1

Main supply voltage fluctuations not to exceed +/- 10% of nominal voltage.

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Default software settings

Logs

Local settings

Local settings

Local settings

Local settings

Alarm settings

Alarm settings

Alarm settings

Alarm settings

Language English

Pressure Bar

Flow LPM

Purity %O2

O2 high

O2 low

Pin high

Pin low

Active: No

Stop: 0

Level: 5

Delay: 30

Active: No

Stop: 0

Level: 0.0

Delay: 30

Active: No

Stop: 0

Level: 13

Delay: 30

Active: No

Stop: 0

Level: 2

Delay: 30

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Alarm settings

Alarm settings

Pressure switch

Pressure switch

Pressure switch

Options

Options

Options

Options

Table 4-1: General data

Pout high

Pout low

Active: No

Stop: 0

Level: 10

Delay: 30

Active: No

Stop: 0

Level: 2

Delay: 30

P-switch No

Unit on

Unit off

2.0

7.0

Auto restart No

Remote No

Pincode No

Show Flow No

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Type

Nominal production capacity Nlpm*

Purity% 99.9 99.7 99.5 99 98 97 96 95 93

LP** 10 15 18 24 31 35 40 43 50

HP** 7.6 12 13 18 23 26 30 32 38

*Table 4-3: Capacity at nominal conditions:

Ambient temperature: 20 °C /68 °F

Ambient pressure: 1013 mbar(a).

**LP = Low Pressure, max. 2 bar(g) / 29 psig nitrogen pressure

**HP = High Pressure, max. 8 bar(g)/ 116 psig nitrogen pressure

Maintenance kit

• 1x Carbon adsorber

Oxygen sensor

N2-4-005

N2-4-004

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5 Installation

Follow the paragraphs in this chapter to install the LCMS M-4.

5.1 Transport

Warning

Transport the LCMS M-4 upright.

Put the LCMS M-4 in the original box to transport the

LCMS M-4 over longer distances.

Lift the LCMS M-4 with a forklift.

For qualifications of personnel, refer to §2.1.

IMPORTANT

The LCMS M-4 contains compressors that generate

heat; for optimal performance and lifetime it is necessary that cooling air can be vented without resistance. A minimum clearance distance from walls or other objects of at least 50 cm/ 20 inches on all sides (back, left, right and top) is a necessity; also efficient local ventilation at the ventilation outlet is highly recommended especially when the device is installed under a bench

Install the LCMS M-4 on a fixed location. The location must meet the following requirements:

• Minimum clearance of 50 cm on all sides (back, left, right and top) as to facilitate heat removal

• Indoors

• Dry

• No continuous direct irradiation by sunlight

• Away from heat sources

• Properly ventilated room.

• Easy accessibly for operating and service

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5.3 Unpack and check equipment

• Open the packaging.

• Make sure that all components are delivered. Refer to Table 4-1.

Warning

Do not connect the power at this time.

Make sure that the inlet and outlet tubes are free of

dust, particles, metal parts and curls, liquids and grease before you connect the LCMS M-4.

• Connect the product outlet to the application or to a buffer vessel.

1. Connect the mains plug to a suitable wall socket with earth connection

2. The control system has in- and output contacts for remote control and alarm signaling (refer to §5.6).

Warning

The main supply line voltage must be within 10% of nominal rated voltage for the generator. In case of larger variations the LCMS M-4 will stop and not restart; continued use under these circumstances will inevitably lead to motor damage.

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5.6 Connect input and output signals

In- and put signals can be connected to the terminal strip on the printed circuit board.

Clamp Function

UD5

UD6

UD7

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Start stop signal to external booster

Alarm oxygen level low

Alarm oxygen level high

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6 Operation of the control system

The menu structure of the control system is built up as shown below. One can always go back to a higher level in the menu by pushing the -button.

Main screen

Alarm display

Settings Switch on/off unit

Log on Set alarms

Pressure switch

Options Local settings

Maintenance Data logging

Access:

Function:

This is the start-up screen that automatically appears when the generator is switched on.

Gives access to the different menus.

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A

Symbol/data Information/result

When flashing there is an alarm; touch the symbol and the current alarm will be shown.

Status of unit (A) Can be OFF/RUN/STAND-BY/ALARM/P-RELIEF

Menu button, touch to go to settings menu

Switch ON/OFF button, generator will turn ON or

OFF

To turn the unit on, touch the switch -button. The status will switch to P-

RELIEF. The compressors will start three minutes (180 seconds) after the unit has been switched on. The delay time countdown time is shown next to the text P-RELIEF (see below).

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When the unit is switched on the controller will show:

• Actual outlet pressure

• Actual oxygen or nitrogen level

• Flow indication (when selected, refer to §6.3.4)

Access:

Function:

Touch settings menu button in the main screen

(refer to §6.2)

Access to different menus

Symbol Menu

Access to log on menu (refer to §6.3.1)

Access to alarm settings menu (refer to §6.3.2)

Access to pressure switch menu (refer to § 6.3.3)

Access to options menu (refer to § 6.3.4)

Access to local settings menu (refer to § 6.3.5)

Access to maintenance menu (refer to § 6.3.6)

Access to data logging menu (refer to § 6.3.7)

Returning to previous menu

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6.3.1

Access:

Log on menu

Touch log on menu button in settings screen (refer to

§6.3)

Function:

ATTENTION: When you start-up the system for a first time you do not need to enter a PIN CODE

Protect the settings in the system with a (personal) pin code.

In the log on menu:

• Enter the default pin code (1234) after selecting PINCODE YES under the options menu (refer to §6.3.4).

• Change the default pin code to a personal pin code of 4 digits

(refer to §6.3.4)

• Return to default factory settings by entering pin code 7833 (refer to §4.1)

• In case you lost your pin code, please contact your supplier

Caution:

When returning to factory settings, the alarms, p-switch, options and settings must be reset. Also the log on pincode is back to default value 1234

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6.3.2 Alarm settings menu

Access: Touch alarm settings menu button in settings screen

(see § 6.3.2)

Function:

Set different alarms

In the alarm settings menu it is possible to set 6 different alarms.

Screen Alarm

1/6 O2 high

2/6

3/6

O2 low

Pres. Inlet high

4/6

5/6

6/6

Pres. Inlet high

Pres. Outlet high

Pres. Outlet low

Explanation

oxygen level too high oxygen level too low inlet pressure too high inlet pressure too high outlet pressure too high outlet pressure too low

1. To activate an alarm touch button A. When the button is touched you can select the options YES, AUTO RESET or NO by pressing the arrow keys.

Default all alarms are set to NO, which means they are not activated; activating the alarms or not is the choice of the user; alarms do not influence the output and purity.

2. When you select YES or AUTO RESET, the rest of the alarm parameters that need to be set will pop-up automatically (see screen below).

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Button Selection Result

Active No

Active Yes

Alarm function for this parameter is not active

Alarm function for this parameter is active; alarm messages must be reset manually

Active Auto reset

Stop

Stop

Yes

No

Alarm function for this parameter is active;

When alarm level is not exceeded any longer before manual reset, the alarm will reset itself

Generator will switch off in case alarm level is exceeded

An alarm signal will be given but generator will continue to run in case alarm level is exceeded

Level

Level

Level

Delay

0-16% O

2

100 – 84% N

2

0-13 BAR*

0-188.5 PSI*

0-10 BAR*

0-145 PSI*

0-300 sec

For screen 1/6 and 2/6: this is the oxygen- or nitrogen level* at which the alarm is set.

For screen 3/6 and 4/6.

This is the pressure level at which the alarm is set

For screen 5/6 and 6/6.

This is the pressure level at which the alarm will appear.

Delay time in seconds between the moment that the alarm level has been exceeded and signaling; this feature prevents false alarms in case of short spikes

*see also -menu (local settings)

ATTENTION:

It is impossible to set O

2

low at a higher level than O

2 high. The setting of O

2

-low is limited once O

2

-high has been set. Therefore first set O

2

high level before setting the O

2

low level.

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6.3.3 Pressure switch menu

Access: Touch pressure switch menu button in settings screen

(refer to § 6.3)

Function:

Set the pressure switch

In the pressure switch menu the levels at which outlet pressure the generator will switch on and off, can be set. To change the settings, touch the button in front of the text.

P-switch

P-switch

Unit on

Unit off

Yes

No

0-10 Bar*/

0-145 PSI*

0-10 Bar*/

0-145 PSI*

Pressure switch is active

Pressure switch is not active

Pressure level at which the unit will switch on

Pressure level at which the unit will switch off

*refer to local settings menu

To determine the correct switch on and off pressure, please check § 7.4.

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Access: Press option menu button in settings screen (refer to

§6.3)

Function:

Set different options

ATTENTION:

All options are default set to NO. Options do not affect the

output and purity.

Auto R.

Auto R.

Remote

Remote

Pincode

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Yes

No

Yes

No

Yes

After a power failure the unit will automatically restart itself and return to the same situation/status.

After a power failure the unit will not start automatically. Unit needs to be restarted manually.

Unit can be switch on and off from a remote location. Only select Yes after connecting the printed circuit board to an external device.

Unit cannot be controlled from a remote location.

Settings are instantly protected with a pin code. Return to log on menu and enter the default pin code 1234.

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Pin code

Pin code

No Settings can be changed without a pin code

Change Pin code can be changed to a personal 4 digits code. (In case you forget your

personal code, consult your supplier)

Show Flow Yes

Show Flow (D) No

Flow rate will be displayed in main screen

Flow rate will not be displayed.

Operate to adjust date and time

6.3.5 Local settings menu

Access: Touch local settings menu button in settings screen

(refer to § 6.3)

Function:

Set data to local requirements

Depending on the local situation it is possible to change the setting accordingly.

Button Selection

Language English, Francais, Deutsch,

Nederlands, Español

Pressure BAR/PSI*

Result

Text in the screen will appear in the chosen language.

Flow LPM/CFM

Pressure indications will appear in the chosen setting

Flow will appear in the chosen setting

Purity will appear in nitrogen Purity %N2/%O2

(%N2) or oxygen (%O2) percentage

* Select BAR, to display temperature in °C. Select PSI to display temperature in °F.

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Access: Touch maintenance menu button in settings screen

(refer to § 6.3)

Function:

Shows maintenance status and offers calibration possibility.

The maintenance menu consists of 5 different screens. Each screen displays maintenance status or calibration buttons.

SCREEN 1/5

Data Explanation

Type

O2 lifetime

Shows type of generator this unit is

Version Software number

Month-year when O

2

-sensor needs to be changed (3 years from data of order)

Hours countdown from 1 year to 0 hrs Filter life

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SCREEN 2/5

Data Explanation

Total

Comp. 1

Total running hours of the generator

Total running hours of compressor box 1*

Comp. 2 Total running hours of compressor box 2*

* Does not show up in LCMS M-4 HP

SCREEN 3/5

Data Explanation

C Inlet

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Compressed air inlet temperature in °C or °F

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SCREEN 4/5

Data Explanation

C1 overheated* YES or NO

Shows if compressor box 1 is overheated or not

C2 overheated* YES or NO shows if compressor box 2 is overheated or not

Remote YES or NO

Shows whether remote control option is on or off

* In the LCMS M-4 HP versions, these first 2 lines will not appear

SCREEN 5/5

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Button Explanation

O2 – 20.9% Calibrate O

2 explanation)

sensor to 20.9% (refer to §9.4for detailed

Flow Factor Only visible when selected Show Flow in the options menu

(refer to §6.3.4) and when the unit is running.

Calibrate the flow by entering the flow measured with an external flow meter.

Replace Filter When a filter has been replaced during maintenance, this button can be touched and the countdown for the new filter is set. System asks for confirmation. In maintenance screen 1/5 the filter lifetime should read

5500 hr. maintenance, this button can be touched and a new date to replace the O2 cell is set. System asks for confirmation. In maintenance screen 1/5 the O2 lifetime should read 3 year ahead from date of changing.

6.3.7 Data logging menu

Access: Press data logging menu button in settings screen

(refer to § 6.3)

Function:

Read the logged (saved) data

Alarms as well as status of the sensors are saved on the SD-card. The time between the logging (saving) of this data to the memory card can be chosen in the data-logging menu.

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Interval

A

B

30-3600 Time in seconds between the logging

(saving) of alarm data

Shows all the alarms that have been saved on the memory drive (see below)

C

Button Explanation

A Date and time of alarm incident

C The number of logged alarms

It is also possible to read the logged data from the SD-card on a computer.

To read the files:

1. Switch off the unit.

2. Remove the SD-card

3. A new folder is saved on the SD-card every month. Each folder contains a almxxxx.csv and a logxxx.csv file.

4. Select the files needed.

5. Open the data-files with an Excel spread sheet

6. Place the SD-card back in the unit.

7. Switch the unit back on.

CAUTION:

Please check the alarm, p-switch, options and settings before you restart the unit.

The unit cannot run without the SD-card. This will generate an alarm (SD-card failed).

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7 Operation

1. Make sure that the connections are correct and fixed properly.

2. Switch on the LCMS M-4 with the button at the back of the generator (refer to §3.3).

3. Then touch the ON/OFF button on the touch screen display in the front of the generator.

CAUTION

Don’t use sharp objects to operate the screen.

4. It will take about 3 minutes before the LCMS M-4 will start to run.

The countdown in seconds is shown on the display.

Important

The LCMS M-4 must be run with sheet metal covers mounted on the unit; not doing so will affect the heat management of the system; prolonged running without sheet metal covers will shorten the life of the appliance and can lead to irreparable damage.

5. Check the inlet pressure level in the maintenance -menu (screen

3/5); in case this exceeds a level of 4.5 bar(g), the unit must be switched off and checked for blockades on the outlet. When a cause cannot be found, stop running the system and contact your supplier.

6. Check whether the connections of the tubing between the LCMS

M-4 and the application are free of leaks.

7. When the outlet is blocked the delivery pressure must not be higher than 8 bar(g) (HP-version) or 2 bar(g) (LP-version); the excess nitrogen is vented via an internal pressure relief valve or the unit is switched off in case of no nitrogen demand.

8. The purity of the LCMS M-4 is factory set as required. To adjust the oxygen content, adjust the purity control valve FCV. Refer to §7.3 for instructions.

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9. The pressure control of the LCMS M-4 is factory set as required.

Two modes of pressure control are possible.

• Switching on and off depending on the outlet pressure (e.g. when a nitrogen storage vessel is installed)(max. switch-off pressure = 8.0 bar(g) (HP-version)) or 2 bar(g) (LP-version))

Maximum nitrogen pressure 8.0 bar(g) (HP-version) or 2 bar(g)

(LP-version).

Refer to §7.4 for instructions.

1. Switch the button on the back of the LCMS M-4 to the ON-position.

2. Switch on the LCMS M-4 with the switch on the touch screen panel

(refer to §6.2).

3. There is a 3 minutes delay between stop and restarting the generator.

7.3 Adjusting the purity

The purity of the output can be read on the display.

1. The purity is determined by measuring the residual oxygen content in the nitrogen outlet.

2. To change the purity, change the setting of the purity control valve

(refer to § 3.3)

3. First unlock the needle valve by loosening the hexagonal lock nut on its spindle. (Fig. 7-1)

4. Turning the valve clockwise will result in a decrease of the oxygen level and vice versa. The oxygen level can be read on the main screen of the display.

Fig. 7-1 Needle valve

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ATTENTION

The response time of the measurement is slow. Change the flow in small steps of a quarter turn per step and wait until the display reading changes.

Do not close the purity control valve fully.

Adjusting the purity must preferably be done when the system is at normal operating temperature after it has run for some time (1-2 hrs).

Adjusting the purity must be done while all sheet metal

is mounted on the appliance.

5. Once the desired purity has been reached, fasten the lock not on the spindle of the purity control valve securely.

ATTENTION

Fastening the lock nut too tightly can have an influence on the purity of the output

7.4 Control of the outlet pressure

The outlet pressure of LCMS M-4 can be controlled in two ways depending

on whether the nitrogen is stored in a vessel or not.

No nitrogen vessel installed: excess nitrogen will be vented; LCMS M-4 will run continuously. The -function must be off

• Close the ball valve V2 (refer to §3.3) at the outlet while the system is running.

• Adjust the back pressure valve PCV such that the outlet pressure on the touch screen reads 8.0 bar(g) at maximum. The lower the pressure is set the better for energy consumption reasons and compressor life.

• Open the ball valve V2 at the outlet.

Nitrogen vessel installed: excess nitrogen will be stored; LCMS M-4 will start and stop automatically. To set the pressure (PSH) switch function in the software for this situation, proceed as follows:

• Close PCV completely (turn right) (refer to §3.3).

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• Set the switch on pressure at maximum 7.0 bar(g). Switch-off pressure 8.0 bar(g). The lower the pressure is set the better for the energy consumption reasons and compressor life.

• Set the difference between the switch on and off pressure preferably not less than 1 bar. Smaller differences will result in frequent switching which will shorten the life of the compressors.

NOTE

After the unit switches off due to reaching switch off pressure in the storage tank, the unit cannot switch on within 5 minutes after the switch-off.

The switch-on delay is there to prevent too frequent start-up of the compressors that shorten the compressor life.

1. Switch off the power switch before you perform maintenance.

2. Make sure the system is depressurized; check the internal pressure level in the maintenance menu (screen 3/5)

3. When you restart afterwards there is a 3 minutes delay before it starts again

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8 Troubleshooting

Error

No start and no display

Possible cause

Main switch is off

Possible solution

Switch main ON and push power switch ON.

No power to supply outlet Check electrical panel circuit breaker.

Delivery of nitrogen too low or absent

Ambient temperature is too Lower the temperature, if high possible

Check whether the minimum clearance between the LCMS

M-4 and the walls is large enough.

Inlet carbon adsorber filter is polluted

Replace the inlet filter

LCMS M-4 is switched off Switch on the LCMS M-4

Leak in piping Check for leaks in the piping.

Residual oxygen content too high blocked.

Temperature is too high

A.3.

• Ambient temperature is too high (over 35°C/ 95°F).

• In-/outlet gratings are clogged.

• Cooling fans are not or insufficiently functioning.

• Compressors are overloaded.

Pressure in nitrogen storage vessel over 8 bar(g) because

Reset pressure switch levels of erroneous setting of pressure switch

Ambient temperature lower

Increase temperature or than normal readjust purity (refer to §7.3)

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A

Error Possible cause

Purity setting has changed over time

Leak in piping

Table 8-1: Error list

Possible solution

Readjust purity (refer to §7.3)

Check for leaks in the piping.

When the Nitrogen Out symbol (A)

in the main screen is flashing, it means that an alarm is occurring. To see which alarm is occurring, touch the symbol for more information.

Default all alarms that can be set, are set to NO. This means they are not activated

.

What happens

Oxygen level too high

Oxygen level too low

Inlet pressure too high

Inlet pressure too low

Outlet pressure too high

Outlet pressure too low

Inlet temperature too high

Inlet temperature too low

Membrane pressure sensor fails

Alarm description

O2 high

O2 low

P-inlet high

P-inlet low

P-outlet high

P-outlet low

T-inlet high

T-inlet low

P-mem sensor fail

Default

Off

Off

Off

Off

Off

Off

On

On

On

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Outlet pressure sensor fails

Inlet temperature sensor fails

Status of temperature of compressor box 1

P-Outlet sensor fail

T-Inlet sensor fail

Temp comp1

On

On

On

Status of temperature of compressor box 2

Oxygen sensor needs to be calibrated

Temp comp2

Calibrate O2 cel

On

On

When an alarm is displayed there are two options:

1. Accept

2. Reset

When ACCEPT is touched, the alarm sound will disappear while the alarm level is still exceeded. If the alarm is not resolved the alarm message will appear again in 24 hours. This function gives you some time to work on the solution.

When RESET is touched the alarm status is cleared. However, if the alarm still exist it will appear again after the delay time that has been entered in the alarm settings menu (refer to § 6.3.2) has passed.

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9 Maintenance

Part Action

Filters Replace outlet carbon adsorber

Oxygen sensor Replace oxygen sensor

Oxygen sensor Calibrate oxygen sensor

Table 9-1: Maintenance scheme

Frequency

• 1x per year

• 1x per 3 years

• 1x per year

9.2 Replace inlet filter element

1. Switch off the LCMS M-4.

2. Let the system depressurize.

3. Take off the upper part of the front panel of the LCMS M-4

(refer to Fig. 9-1).No tools are required.

4. Unscrew the two screws on top of the front panel (refer to Fig.

9-2).

Fig. 9-1 Fig. 9-2

5. Open the front panel (refer to Fig. 9-3).

6. Disconnect the plug from the printed circuit board (refer to Fig.

9-4).

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Fig. 9-4

Fig. 9-3

7. Disconnect the tubing from the inlet filter (refer to Fig. 9-5).

8. Loosen the screws of the brackets (refer to Fig. 9-6).

Fig. 9-5 Fig. 9-6

9. Slide out the inlet filter and replace it with the new one. Follow the steps in reverse order.

10. Switch the LCMS M-4 back on.

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9.3 Replace oxygen sensor

1. Switch off the LCMS M-4.

2. Remove the front cover above the touch screen from the LCMS M-4 (no tools required) (refer to Fig. 9-1).

3. Carefully remove the sensor cap (E).

Do not pull the tube.

4. Unscrew the screw ring (D).

A B C D E F

6. Install the new sensor (C).

7. Switch on the LCMS M-4.

Fig. 9-1: Replace oxygen sensor

8. Calibrate the oxygen sensor. Refer to §9.4

1. Check the sample flow of the sensor (0.3 l/min.) coming out of the tube (F) that is connected to the sensor cap

(E). The flow can be adjusted with the needle valve

(FCV3).

2. Switch the unit off by touching the front switch off button (refer to §6.2).

3. Let the system depressurize

4. Remove the sensor cap (E) and expose the sensor to ambient air.

5. Wait for 60 seconds.

A B C D E F

Fig. 9-2: Calibrate oxygen sensor

6. Then enter again the maintenance menu , screen 3/5 wait until the oxygen level reads 20.9%.

7. Then go to screen 5/5 and touch O2 20.9% button. The system will ask for confirmation. Select YES.

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8. Reconnect the tube (F) and the sensor cap (E) with the sensor (C).

1. Switch off the LCMS M-4.

2. Let the system depressurize.

3. Remove both left and right-side cover from the LCMS M-4 by taking the

2 screws from each side. (Fig.8-3).

4. Then remove the second cover from each side(Fig. 8-3).

5. Use a 19mm spanner to undo all bull nose connections to the compressor. (Fig. 8-5).

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6. Use a 13mm spanner to unscrew the bolts holding the compressors to the unit on both sides.(Fig. 8-6).

7. Use a 10mm spanner to push the ring in with the pipe. Hold the spanner while pulling away the pipe. (Fig. 8-7).

8. Use an 8mm spanner to push ring in with the pipe. Hold the spanner while pulling away the pipe (Fig. 8-8).

Fig. 8-8 – pull away pipe

Fig. 8-6 – unscrew bolts from compressors

Fig. 8-7 – pull away pipe

9. Disconnect the multi-pin plug from the socket by squeezing the clips on each side. (Fig. 8-9).

10. Lift and withdraw the compressor assembly from the unit (Fig. 8-10)

11. Remove the new compressor from it s packaging. Remove the transit support blocks. (plaatje).

Fig. 8-9 – disconnect multi-pin plug

Fig. 8-10 – remove compressor

12. Remove the pipe fitting, which can be disposed of. (It’s only included for manufacturer’s use). (Fig. 8-12).

13. Install the new compressor in reverse order of removal.

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Fig. 8-11 – remove transit support blocks

Fig. 8-12 – remove pipe fitting

14. Retain compressor packaging to ship old compressor (if necessary).

15. Check for leaks before re-assembly.

The issue number of the software version for the controller of the N2-

MISTRAL-4® can be found in the maintenance

-menu (refer to §6.3.6).

When the producer would update the software in the future you can have full advantage of that. A new version can be put on the control system by following the instructions below.

1. Switch the unit off.

2. Allow the system to depressurize.

3. Remove the SD-card

4. Place the SD-card in a card reader connected to a computer

5. On the SD-card are 2 bin files: io.bin & lcd.bin. Just for safety you could save the old contents of the SD-card on your computer.

6. Replace the old files with new versions, which you receive from the producer.

7. Replace the SD-card in the control unit.

8. Switch the power back on.

9. Now the controller is updating, while beeping.

10. Turn the power off and on when the display shows “turn power off/on”.

11. Now the display is updating, while beeping.

12. Once the beeping stops the system

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11 Index

Air quality .................................17

Alarm messages ......................43

Alarm settings menu ................28

Ambient air...............................12

Ambient conditions ..................17 capacity....................................20

Caution.......................................6

Certificates .................................7

Check equipment .....................22

Connect power.........................22

Connections .............................17

Control panel............................24

Data logging menu...................36

Default settings ........................18

Delivery pressure .....................17

Dimensions ..............................17

Electrical data ..........................17

Electrical scheme.....................51

Electricity..............................6, 10

Environment...............................6

Environmental aspects ............11

Error list....................................42

High Pressure ..........................17

High-pressure risk......................6

Identification plate ......................7 inlet filter...................................45

Installation................................21

Introduction ................................5

Liability .......................................8

Local settings menu .................32

Location ...................................21

Log on menu ............................27

Low Pressure ...........................17

Maintenance ............................ 45

Maintenance kit........................ 20

Maintenance menu .................. 33

Net weight................................ 17

Nitrogen ..................................... 9 nitrogen consumer ................... 22

Noise level ............................... 17 outlet pressure ......................... 40

Oxygen ...................................... 9

Oxygen enriched air................... 9

Oxygen sensor calibration............................. 47

Oxygen-enriched air ................ 10

Parts................................... 14, 45

Pictograms................................. 6

Power consumption ................. 17

Pressure switch menu ............. 30

Process scheme ...................... 15 relative humidity....................... 17

Replace oxygen sensor...................... 47

Risk of fire.................................. 6

Safety precautions ................... 10

Separation principle ................. 12

Settings menu.......................... 26

Technical specifications........... 17

Temperature ............................ 17

Transport ................................. 21

Troubleshooting ....................... 42

User instructions ........................ 8

Voltage/frequency.................... 17

Warning ........................... 6, 9, 10

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