Parker HPZA-3500 - User Manual

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Parker Hannifin Corporation

Industrial Gas Filtration and Generation Division

Haverhill, MA • 1-800-343-4048

Bulletin TI-HPZA-3500H Parker Balston Zero Air Generators

Models HPZA-3500, HPZA-7000, HPZA-18000, HPZA-30000

Installation, Operation, and Maintenance Manual

Parker Zero Air Generators

HPZA-3500, HPZA-7000, HPZA-

18000, HPZA-30000

Figure 1 - Parker Zero Air Generators

These instructions must be thoroughly read and understood before installing and operating

this product. Failure to operate this product in accordance with these instructions could

present a safety hazard to the user and will void the safety certification of the product.

Modification of the unit will result in voiding the warranty. If you have any questions or

concerns, please call the Technical Services Department at 800-343-4048, 8AM to 5PM

Eastern Time or email at GSFsupport@parker.com (North America only). For other

locations, please contact your local representative.

Please save product packaging for future use.

General Description

Engineered System

The Parker HPZA Series Zero Air Generators (Figure 1) are completely engineered systems

which replace the use of inconvenient high pressure gas cylinders as a source of

hydrocarbon-free air. The HPZA-30000 generators purify on-site compressed air to a total

hydrocarbon level of less than 0.1 ppm (measured as methane). The HPZA-3500, HPZA-

7000, and HPZA-18000 generators purify on-site compressed air to a total hydrocarbon

level less than or equal to 0.05 ppm, when operated at or below the unit’s maximum flow

rate. Zero-grade air from a Parker Zero Air Generator may be used as a source of fuel air for

Flame Ionization Detectors (FIDs) or as a zero reference for any instrument which measures

hydrocarbon concentration.

The Parker Zero Air Generators have been certified to the electrical safety requirements as

specified by the IEC, CSA, and UL standards. These units bear the Intertek (ETL) marking

on the product label and comply to US and Canadian Standards. Product supplied to carry

the CE mark (220/230/240 VAC units only) and comply to EMC standards. This unit has a

pollution grade of 2 to the intended environment.

The Parker Zero Air Generator is comprised of four functional component groups:

prefiltration, hydrocarbon removal, cooling, and final filtration (see Figure 2).

Technical

Information

Front View

Right Side View

Main Page

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The Parker Zero Air Generator, specifically the HPZA-3500, HPZA-7000, HPZA-18000, and HPZA-30000 models, is a completely engineered system designed to replace high-pressure gas cylinders as a source of hydrocarbon-free air. These generators purify on-site compressed air to achieve very low total hydrocarbon levels, making them suitable for applications such as fuel air for Flame Ionization Detectors (FIDs) or as a zero reference for instruments measuring hydrocarbon concentration.

Function Description:

The core function of the Parker Zero Air Generator is to produce ultra-pure, hydrocarbon-free air from a compressed air supply. This is achieved through a multi-stage process:

Prefiltration: Two stages of high-efficiency coalescing prefiltration protect the catalyst bed from oil and particulate contamination. These filters remove liquids and particulate matter down to 0.01 micron from the incoming air. They are equipped with float drains that automatically open to discharge collected liquids to the atmosphere via 1/4" O.D. plastic tubing.
Hydrocarbon Removal: A stainless-steel vessel containing a catalyst, cartridge heater, and controller forms the catalyst module. During operation, hydrocarbons in the air are oxidized into carbon dioxide and water vapor. The heater controller maintains the catalyst bed at the optimal temperature for efficient oxidation. A "Check System" light illuminates if the heater faults.
Cooling: A coiled copper aftercooler and fan (present in all models except HPZA-3500) cool the hot air exiting the hydrocarbon removal module.
Final Filtration: A Parker Balston Grade GS membrane filter serves as the final stage, removing particulate contamination down to 0.01 micron (absolute).

The generator features an operational status LED display on the front panel, providing real-time feedback on hydrocarbon concentration, flow rate, and system status. "Check System" and "Overflow" lights alert the operator to situations requiring attention.

Important Technical Specifications:

Max Flow Rate:
- HPZA-3500: 3.5 lpm
- HPZA-7000: 7 lpm
- HPZA-18000: 18 lpm
- HPZA-30000: 30 lpm
Total Hydrocarbon Content:
- HPZA-3500, HPZA-7000, HPZA-18000: <0.05 ppm (when operated at or below max flow rate)
- HPZA-30000: <0.1 ppm (measured as methane)
Min/Max Inlet Pressure: 40 psig / 125 psig (2.8 barg / 8.6 barg)
Min/Max Ambient Temperature: 60°F (16°C) / 100°F (38°C)
Max Relative Humidity: 80%
Max Inlet Hydrocarbon Content: 100 ppm
Pressure Drop at Max Flow Rate: 4 psid (0.3 bar)
Start-up Time: 45 min.
Electrical Requirements: 120 VAC, 220 VAC, 230 VAC, 240 VAC, ±10% nominal, 50/60 Hz models available. Voltage selector must match local power supply.
Current Rating:
- 1.0 A at 220 VAC, 2.0 A at 120 VAC (HPZA-3500)
- 2.0 A at 220 VAC, 4.0 A at 120 VAC (HPZA-7000, HPZA-18000, HPZA-30000)
Shipping Weight: 41 lbs. (19 kg) for all models.
Physical Dimensions: 11"w x 13"d x 16"h (27 cm x 34 cm x 42 cm) for all models.
Altitude: 2000 m
Fuse Type: Type T, 250 V, 1.0 A at 220 VAC, 2.0 A at 120 VAC (HPZA-3500) / Type T, 250 V, 2.0 A at 220 VAC, 4.0 A at 120 VAC (HPZA-7000, HPZA-18000, HPZA-30000)
Certifications: ETL listed to U.S. and Canadian Safety Standards (CAN/CSA 22.2 No. 61010-1-12 & 61010-2-010, UL 61010-1 & 61010-2-010), CE mark compliant (220/230/240 VAC units only) to EMC standards. Pollution grade 2.

Usage Features:

Installation: Can be used as a free-standing benchtop or wall-mountable unit. Mounting dimensions are provided. A shut-off valve and pressure regulator (e.g., Parker P/N 72-130-V883) should be installed directly upstream to maintain constant inlet pressure between 40-125 psig.
Location: Should be installed in an area free from excessive dust and dirt, with ambient temperatures between 60°F and 100°F (16°C and 43°C). Not for outdoor installation. Approximately 6" of space is recommended around the unit for proper ventilation.
Piping: Inlet and outlet ports are 1/4" NPT (female). Inlet tubing and fittings must be clean and rated for 125 psig. Downstream tubing and fittings should be clean stainless steel or pre-cleaned refrigeration-grade copper (1/4" O.D. x .030" wall), rated for 125 psig. Plastic tubing is not recommended downstream due to outgassing. PTFE tape should be used on NPT fittings.
Power: Features a voltage selector for 120 VAC, 220 VAC, 230 VAC, or 240 VAC, 50/60 Hz power supplies. Main supply voltage fluctuations must be within ±10% of nominal.
Operation: Designed for continuous 24/7 operation. A 45-minute warm-up period is required, indicated by sequential illumination of yellow "THC" LEDs, before the green "THC" LEDs illuminate, signifying hydrocarbon levels below 0.1 ppm (or 0.05 ppm for specific models).
Safety: Warnings are provided regarding potential contamination of the catalyst module by chlorinated hydrocarbons, chlorofluorocarbons (freons), lead, sulfur, phosphorous compounds, heavy metals, and long-chain polymers. An auxiliary activated carbon scrubber (P/N 76080) is recommended if the air supply is subject to halogenated hydrocarbon exposure.

Maintenance Features:

General: All maintenance procedures should be performed by suitable personnel with reasonable care, after turning off compressed air and power supplies and ensuring depressurization. Only genuine Parker replacement parts should be used.
Prefilter Cartridge Replacement: The Grade DX (P/N 100-12-DX) and Grade BX (P/N 100-12-BX) prefilter cartridges, located behind the removable panel on the right side, should be changed annually.
Final Membrane Filter Replacement: The GS membrane filter cartridge (P/N GS-050-05-95), also on the right side, should be changed annually or as needed to maintain flow and minimize pressure drop.
Catalyst Module Replacement: The catalyst module (P/N 76810 for HPZA-3500, 76820 for HPZA-7000, 76811 for HPZA-18000, 76821 for HPZA-30000) should be replaced when the "Check System" LED illuminates or blinks, typically indicating it's approaching 3 years of operation. Replacement requires disconnecting power, allowing the unit to cool for at least 2 hours, and using specific tools (Phillips head screwdriver, 11/32" nut driver, 7/16" or adjustable wrenches).
Maintenance Kit: A one-year supply of replacement cartridges is available as a maintenance kit (P/N MK7840), which includes one 100-12-DX, one 100-12-BX, and one GS-050-05-95 filter.
Fuse Replacement: Fuses are located in the power receptacle. Both phase and neutral fuses should be checked and replaced with specified ratings (e.g., 13192 for 120 VAC, 13191 for 220 VAC on HPZA-3500/7000).
Cleaning: The generator may be wiped clean with a dry cloth as needed. Water, aerosols, or other liquid detergents should not be used to avoid electrical hazards.
Troubleshooting Guide: Provides solutions for common issues such as "No Flow From Generator," "Low Pressure At Outlet," "Overflow" LED illuminated, "No Power," and "Check System" LED illuminated/blinking. Technical support is available via phone or email.