The HPCF Series is a floor-standing, skid-mounted PSA (Pressure Swing Adsorption) nitrogen generator designed for high-pressure cylinder filling. It generates nitrogen on demand from a customer-supplied compressed air source and boosts it to fill high-pressure cylinders, eliminating the need for frequent cylinder delivery and reducing operating costs. The system is fully automatic and controlled through an integrated full-color touchscreen PLC.
System Overview
The HPCF Series uses the Pressure Swing Adsorption process to separate nitrogen from compressed air using carbon molecular sieve media. Compressed air enters through an inlet filtration and regulation system, passes alternately through two adsorption beds where oxygen and other gases are captured, and exits as high-purity nitrogen. The nitrogen is stored in a low-pressure storage tank before being boosted to cylinder fill pressure by an integrated air amplifier. The system automatically cycles in and out of standby based on storage tank pressure.
Each unit is built to a specific configuration — 1, 2, 4, or 6 K-cylinders per day — and the outlet pressure (2200 or 3000 PSIG) is factory-set at the time of order. Confirm your unit's specific output parameters by referencing the specification sheet included in your documentation package.
Key Components
Incoming Air Filtration and Regulator
The system includes three inlet air filters arranged in series — a 5-micron particulate filter (ISO Class 3), a 0.01-micron coalescing filter (ISO Class 1), and a 0.003-micron activated carbon absorber filter (ISO Class 1) — followed by a built-in pressure regulator. This filter train removes solid particles, oil aerosols, and oil vapor from the compressed air supply before it enters the nitrogen generator. The booster air drive section includes its own particulate filter and pressure regulator as well.
Programmable Logic Controller (PLC) with Touchscreen
An integrated PLC controls all valve timing and sequencing throughout the system. The 3.5" full-color touchscreen displays real-time information including run hours, alarm status, sensor readings, and a two-hour pressure history graph. The system automatically enters and exits standby based on nitrogen storage tank pressure, requiring no manual intervention during normal operation.
Pressure Swing Adsorption Beds
Two pressurized vessels containing carbon molecular sieve media separate nitrogen from the compressed air stream. The beds cycle alternately — one producing nitrogen while the other regenerates — allowing continuous operation. Each bed includes a dedicated safety relief valve and pressure gauge. Beds over 4 inches in diameter are ASME certified.
Pressure Transducer
An electronic pressure transducer monitors the nitrogen storage tank and feeds this data to the PLC. The PLC uses the reading to automatically start and stop the generator and triggers an alarm if pressure drops below a user-configured threshold.
N2 Storage Tank
When supplied by South-Tek Systems, the nitrogen storage tank includes input and output ball valves, a safety relief valve, a pressure gauge, and a gas sample port. Some instruments may require field installation. Refer to the General Arrangement Drawing for connection sizes and instrument placement specific to your unit.
N2 Air Amplifier and High-Pressure Booster
An integrated air amplifier boosts the low-pressure nitrogen from the storage tank to the factory-preset cylinder fill pressure — either 2200 PSIG or 3000 PSIG depending on the unit configuration. The booster assembly includes a safety relief valve, pressure gauge, line pressure relief ball valve, and a metal-braided high-pressure fill line terminated with a CGA 580 or CGA 680 fitting to connect to the cylinder being filled.
Safety Relief Valves
ASME-approved safety relief valves are installed throughout the system. Follow all local and site codes for venting requirements.
Technical Specifications
| Parameter | Value |
|---|---|
| Installation | Floor standing, skid mount |
| Configurations Available | 1, 2, 4, or 6 K-cylinders per day |
| Nitrogen Purity | 95–99.999% (factory set) |
| N2 Outlet Pressure | 2200 PSIG or 3000 PSIG (factory preset at time of order) |
| High-Pressure Connection | CGA 580 or CGA 680 (per unit specification) |
| Display | 3.5" full-color touchscreen |
| Electrical Input | 110–220V / 50–60Hz / 1 Phase / <2 Amps |
| Air Supply | External — customer supplied compressor and dryer required |
| Cabinet Port Connections | NPT Female |
| Noise Level | <90 dBA |
Environmental Operating Limits
| Condition | Limit |
|---|---|
| Ambient Temperature | 40–104°F (4–40°C) |
| Installation | Indoors, non-hazardous area (unless unit was specifically designed for outdoor use) |
Optional Features
Oxygen Analyzer: A Zirconium Oxide oxygen sensor can be added to continuously monitor nitrogen purity in the storage tank. The sensor reads O2 content in parts per million (PPM) and displays the reading on the PLC screen. Units configured for 99.999% purity use a 10 PPM setpoint.
Outdoor Package: An optional outdoor enclosure package installs the system's electronics in a NEMA Type 4 cabinet with a nitrogen purge to maintain a low dew point inside the cabinet. A cooler and/or heater may be included depending on the outdoor environment. This option must be specified at time of order.
Related Articles
- HPCF Series — Site & Utility Requirements
- HPCF Series — Installation & Startup
- HPCF Series — Controls & Operation
- HPCF Series — Alarms & Troubleshooting
- HPCF Series — Filter & Preventive Maintenance
- HPCF Series — Safety Guidelines
- HPCF-SFI — Overview & Specifications
Contact South-Tek Systems
Phone: (910) 415-1880
Email / Ticket: support@southteksystems911.zendesk.com