This article covers receiving and unpacking, installation, and startup procedures for the HPCF-SFI. Work through each section in order. Do not attempt startup until installation is complete and South-Tek Systems commissioning support has been scheduled.
Receiving
Inspect the shipment carefully before signing the bill of lading:
- Inspect all packaging and the crate exterior for signs of damage before unloading. If visible shipping damage exists, note it on the bill of lading before signing.
- After unloading, check the unit for damage out of the crate. Report any findings to the carrier and to South-Tek Systems immediately.
- Retain all packaging material until the inspection is complete — it may be required if the unit must be returned.
- Contact South-Tek Systems at (910) 415-1880 with the model number and serial number if any damage or discrepancy is found.
Unpacking and Moving
The HPCF-SFI ships bolted inside a wooden crate. A forklift or equivalent material handling equipment is required.
- Remove the door panel from the end of the crate assembly.
- Remove the four (4) bolts from each corner of the skid securing it to the crate floor.
- Use a forklift to carefully slide the skid assembly out of the crate and move it to the installation location.
Installation
Site Requirements
Confirm the installation site meets all of the following requirements before positioning the unit:
| Requirement | Value |
|---|---|
| Ambient temperature | 40–90°F (4–32°C) |
| Relative humidity | 90% maximum |
| Maximum elevation | 1,500 ft (457 m) above sea level |
| Level tolerance | No more than 5° off level in any direction |
| Clearance — front, left, right | 2 feet minimum on each side |
| Clearance — rear | 1 foot minimum |
| Environment | Indoors, non-hazardous area, reasonably clear of dust and debris |
Electrical Connection
The HPCF-SFI requires a single 220 VAC / 60 Hz / 1 Phase electrical connection for the entire integrated system.
- A 20-foot power cable with a CS6365 twist-locking receptacle is supplied with the system. Connect to a matching CS6365 outlet.
- Alternatively, a qualified electrician may hardwire the system directly to the electrical cabinet using the supplied electrical schematic.
- A certified electrician must review all electrical connections prior to system operation.
- Floor mounting is optional — bolt holes are provided on the bottom of the skid if anchoring is required by local code.
Cylinder Connections
Connect cylinders with the appropriate CGA fittings per the unit specification sheet. Confirm the CGA connection type for your unit (CGA 580 or CGA 680) before connecting.
- Secure up to 3 cylinders directly to the indented uprights on the cylinder rack. Additional cylinders should be secured in a "bowling pin" formation.
- Verify that all high-pressure equipment — cylinders, CGA valves, and hoses — is rated for the system's cut-off pressure as listed on the unit specification sheet.
- Visually inspect all high-pressure hoses and valves for damage before connecting. Actuate each valve to confirm it moves freely.
Leak Check
After all connections are made and the system is pressurized during initial startup, check all piping, fittings, and hose connections for leaks using an appropriate leak detection solution. Shut off the main power switch and fully depressurize the system before attempting to repair any leak.
Initial Startup
- Confirm the E-stop button on the right side of the electrical enclosure is not engaged. Twist to release if depressed.
- Confirm the PLC touchscreen is active and the Home Screen is displayed. The Start/Stop button in the upper left should be illuminated red (system stopped).
- Confirm the cylinder cut-off pressure by pressing the Info button on the PLC Home Screen. If no cut-off pressure was specified at the time of purchase, the default will be either 2,200 PSIG or 3,500 PSIG depending on the high-pressure connections package. Contact South-Tek Systems if the set pressure needs to be adjusted.
- Verify booster motor rotation direction:
- Navigate to Menu → Maintenance Menu.
- Briefly toggle the Booster Off button to momentarily energize the booster motor.
- Confirm the motor rotates in the direction indicated by the arrow on the booster unit.
- If rotation is reversed, stop immediately and contact South-Tek Systems before proceeding.
- Press the Start/Stop button on the Home Screen. The button should illuminate green to confirm the system has started. The compressor will begin running and building air pressure.
- Once the nitrogen storage tank reaches sufficient pressure, press the Start button in the Booster Controls box on the Home Screen. The booster will begin filling the connected cylinders toward the cut-off pressure.
- Perform a full leak check on all piping, fittings, and cylinder connections while the system is pressurized.
- Allow the system to run through at least one complete fill cycle, entering Standby when the cut-off pressure is reached. Confirm it restarts automatically when pressure drops to the cut-in value.
Normal Startup
For all routine startups after the initial startup has been completed:
- Confirm the E-stop is not engaged.
- Press the Start/Stop button on the Home Screen until it illuminates green.
- Press the Start button in the Booster Controls box once the nitrogen storage tank has built sufficient pressure.
Shutdown
Normal Shutdown
To stop the system, press the Stop button in the Booster Controls box, then press the Start/Stop button on the Home Screen until it illuminates red. All automatic valves will return to their normal (de-energized) positions.
Emergency Shutdown
In an emergency, press the physical E-stop button on the right side of the electrical enclosure. This immediately stops all system functions. The E-stop can also be triggered from the PLC screen. Nitrogen supply to cylinders can be shut off manually by closing the isolation valve on the manifold.
Disconnecting Cylinders After a Fill
- After the fill cycle is complete and the system has stopped or entered Standby, isolate each cylinder using its valve before disconnecting the CGA fitting.
- Bleed any residual manifold pressure through the service port on the manifold inlet before removing the CGA fittings.
- Remove cylinders with caution — ensure no high-pressure gas is released in large quantities during disconnection.
- Empty cylinders may then be connected for the next fill cycle.
Related Articles
- HPCF-SFI — Overview & Specifications
- HPCF-SFI — Controls & Operation
- HPCF-SFI — Alarms & Troubleshooting
- HPCF-SFI — Filter & Preventive Maintenance
- HPCF-SFI — Safety Guidelines
- HPCF Series — Overview & Specifications
Contact South-Tek Systems
Phone: (910) 415-1880
Email / Ticket: support@southteksystems911.zendesk.com