HPCF-SFI — Safety Guidelines – South-Tek Systems

Applies to: HPCF-SFI — catalog numbers HPCF-SFI-0004, HPCF-SFI-0110, and HPCF-SFI-0130

Does NOT apply to: HPCF Series — see HPCF Series Safety Guidelines

This article outlines the safety requirements for installation, operation, and maintenance of the HPCF-SFI. All personnel involved in any aspect of this system must read and understand these guidelines before working with the equipment. The HPCF-SFI is an integrated system — hazards from the air compressor, refrigerant dryer, and motor-driven booster are all present on the same skid and are covered here.

🛑 Pressurized Gas and Rotating Machinery Hazard: The HPCF-SFI contains pressurized gases at pressures up to 4,500 PSIG and includes a motor-driven booster with rotating components and a V-belt drive. Both hazard types are present simultaneously during operation. Never work on any part of the system without first stopping the unit, disconnecting all power, and fully depressurizing the affected section.

General Safety Practices

Read this article and the full HPCF-SFI O&M manual before installing, operating, or performing any maintenance on the system.
Use the system only for its intended purpose. Do not tamper with, experiment on, or attempt to exceed the equipment's technical specifications.
Only authorized, trained, and competent personnel are permitted to perform installation, operation, maintenance, and repair. Work performed by unqualified personnel voids the warranty.
The equipment owner is responsible for maintaining the unit in safe operating condition at all times.
Always use South-Tek-specified replacement parts. Parts must meet or exceed the original specifications.
Follow all applicable OSHA regulations and local health and safety codes throughout installation, operation, and maintenance.
Contact South-Tek Systems for any problem that cannot be resolved using the O&M manual or this knowledge base.

Nitrogen — Asphyxiation Hazard

Nitrogen is an odorless, colorless, non-poisonous inert gas. In high concentrations, it displaces oxygen in the air and can cause rapid asphyxiation without warning. There is no smell or visible sign that nitrogen concentration is dangerous.

🛑 Asphyxiation Risk: Never operate the HPCF-SFI in a sealed or poorly ventilated space. The installation room must provide a minimum of 4 complete air changes per hour. Nitrogen accumulation can occur rapidly and without warning. If dizziness, headache, or lightheadedness occurs near the equipment, immediately evacuate, move to fresh air, and ventilate the space before re-entering.

Install and operate the system only in a well-ventilated room with a minimum of 4 room-volume air changes per hour.
Never directly inhale nitrogen gas from any port, vent, or cylinder connection on the system.
Do not discharge storage cylinders or vent nitrogen into an enclosed area.
If a nitrogen leak is suspected, evacuate immediately, move to fresh air, ventilate the space, and correct the leak before resuming operation.

Exhaust Gas and Room Ventilation

The PSA nitrogen generator exhausts oxygen-enriched waste gas during normal operation. This exhaust typically contains between 20.9% and 40% O2 — higher than normal air — and can significantly increase fire and combustion risk in confined spaces.

Route all PSA exhaust gas to the outside or to a large, well-ventilated room. Never allow exhaust to accumulate in enclosed spaces.
Keep all ignition sources, open flames, and combustible materials well clear of exhaust outlets.
Ensure the exhaust outlet is never positioned where it can re-enter a building through air intakes, doors, or windows.

Pressurized System Safety

The HPCF-SFI operates at pressures up to 4,500 PSIG in the high-pressure booster output and cylinder manifold — significantly higher than standard compressed air systems. Treat all pressurized components with appropriate caution.

Completely isolate all incoming and outgoing pressures and fully depressurize the affected section before any mechanical work, including routine filter changes. Confirm all gauges read 0 PSIG before opening any connection.
Never allow pressurized gas to exhaust from an unsecured hose. An unsecured hose under pressure can whip violently and cause serious injury or death.
If a hose bursts during operation, close all isolation valves immediately if safe to do so, then power down the unit using the E-stop.
Never disable, bypass, or tamper with any safety relief valve. All relief valves are ASME-approved and are the last line of protection against over-pressurization.
All high-pressure equipment — cylinders, CGA valves, and hoses — must be rated for the system's cut-off pressure. Visually inspect all high-pressure connections before each use.
Store all high-pressure cylinders upright and secured at all times. Never overfill cylinders beyond their rated pressure.
Replace high-pressure hoses and cylinder leads on schedule — refer to the Filter & Preventive Maintenance article for replacement intervals.

⚠ System Remains Pressurized After Shutdown: The generator, booster, and all interconnecting piping remain under pressure after the unit is stopped. Always verify all gauges read 0 PSIG and fully depressurize the relevant section before performing any maintenance or opening any connection.

Rotating Machinery and Mechanical Hazards

The HPCF-SFI includes an integrated motor-driven booster with a V-belt drive and rotating shaft. These create mechanical hazards not present in the HPCF Series.

Never access the booster belt shroud or any rotating component while the system is powered or running.
Always disconnect all electrical power and confirm the booster motor has fully stopped before removing the belt shroud for V-belt tensioning or inspection.
Keep hands, clothing, and tools clear of the belt and pulley area at all times when the system is energized.
Reinstall the belt shroud before returning the system to operation.
Booster and compressor components may be hot during and after operation. Allow adequate cooling time before touching any surface that may have been in contact with compressed gas or machinery.

⚠ Booster Oil Hazard: The motor-driven booster uses oil for lubrication. Oil spills create slip hazards and fire risks if near heat sources. Clean up any oil spills immediately. Dispose of used oil in accordance with local environmental regulations. Never allow oil to contact high-pressure lines, fittings, or seals.

Electrical Safety

The HPCF-SFI draws 22–32 Amps at 220 VAC — significantly higher current than typical office or light industrial equipment. Treat all electrical work on this system with corresponding caution.

Always disconnect all electrical power — flip internal breakers to OFF or unplug the CS6365 supply cable — before performing any electrical work or opening the electrical cabinet.
All electrical connections must be made by a qualified electrician in compliance with all applicable local and site codes.
Verify that the available supply is 220 VAC / 60 Hz / 1 Phase before connecting power.
Do not reroute, tap into, or replace any electrical component or wiring with non-manufacturer-specified parts.
Do not operate the system in the presence of liquids or in wet environments.

⚠ Lockout / Tagout: Apply lockout/tagout procedures to the main electrical disconnect and all pressure isolation points before beginning any maintenance or repair task. Verify zero energy state — electrical and pneumatic — before starting work. The compressor's built-in 2-minute restart delay does not substitute for a proper lockout.

Personal Protective Equipment (PPE)

Situation	Required PPE
Cabinet door open while system is running	Safety glasses
System operating (any proximity)	Hearing protection (up to 90 dBA at 3 ft)
Any maintenance or service task	Safety glasses, appropriate gloves; additional PPE per site safety requirements
Booster V-belt or shroud work	Safety glasses, gloves; confirm power is disconnected and motor is fully stopped before starting
High-pressure cylinder connections	Safety glasses, gloves; never position face in line with a cylinder valve or CGA fitting during connection or disconnection

Safety Relief Valves

ASME-approved safety relief valves are installed on the PSA adsorption beds, nitrogen storage tank, and booster output. They must never be blocked, capped, bypassed, or tampered with.

Inspect all relief valves periodically for corrosion, debris, or mechanical damage.
If a relief valve activates during normal operation, stop the system immediately — a relief valve lifting under normal conditions indicates an over-pressurization fault. Contact South-Tek Systems before restarting.
Follow all local and site codes for safe venting of relief valve discharge. Outlets must be directed to a safe location and must never be aimed at personnel.

Environmental Operating Limits

The HPCF-SFI has more restrictive environmental limits than the HPCF Series. Operating outside these limits risks system damage, reduced performance, and potential safety hazards:

Condition	Limit
Ambient temperature	40–90°F (4–32°C) — lower maximum than HPCF Series
Relative humidity	90% maximum
Maximum elevation	1,500 ft (457 m) above sea level — lower maximum than HPCF Series
Level tolerance	No more than 5° off level in any direction
Environment	Indoors, non-hazardous area, reasonably clear of dust and debris

Emergency Procedures

Emergency Situation	Immediate Action
Hose burst or sudden pressurized gas release	Press the E-stop button on the right side of the electrical enclosure immediately; close isolation valves if safe to do so; evacuate the area; do not re-enter until the system is confirmed fully depressurized
Suspected nitrogen leak / person feels dizzy or lightheaded	Evacuate immediately; move to fresh air; ventilate the space before re-entering; locate and correct the leak before restarting
Electrical fault or fire	Disconnect power at the main disconnect; use appropriate suppression for electrical fires; evacuate and contact emergency services
Booster oil leak or spill	Stop the system; clean up oil immediately to prevent slip and fire hazard; identify and correct the source of the leak before restarting; dispose of used oil per local environmental regulations
Any unsafe condition not covered above	Stop the system at the main power switch; evacuate if necessary; contact South-Tek Systems at (910) 415-1880 before restarting

Contact South-Tek Systems

Phone: (910) 415-1880

Email / Ticket: support@southteksystems911.zendesk.com