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General Air Products NGP-1000D-M2, Installation, Operation And Maintenance Manual, Page: 25 / 34

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General Air Products NGP-1000D-M2 Installation, Operation And Maintenance Manual Download Page 25

1-800-345-8207

25

Section 15 - Maintenance

The Nitrogen Generator features durable components and construction for long-lasting value, reliable performance, and

require little maintenance.

WARNING

All pressure must be relieved from the entire nitrogen generator system BEFORE servicing. To avoid system damage and/or personal

injury, the nitrogen generator should be isolated from the compressed air supply and the generator systemfully depressurized

before any maintenance or service is performed. All maintenance and troubleshooting activities for the Nitrogen Generator

should be performed by qualified personnel using reasonable care. Before servicing, isolate all risers by closing all AMD valves

and relieving all system pressure from the Nitrogen Generator. Failure to do so could result in serious injury or death.

  Replacement Parts

Part

Replacement Part Number

MAINTENANCE KIT - M2-M5

NGP-MK 

AIR MAINTENANCE DEVICE

AMD-1 

NITROGEN ANALYZER

NGP-PSN2 

SENSOR ELEMENT 

F/NGP

VIBRATION KIT

NGP-VAK-30 

OIL-LESS MINOR REPAIR KIT(1 PER CYL)

OLP-MRK-2.75

CYLINDER REPAIR KIT (1 PER CYL)

OLP-CRK-2.75

SOLENOID VALVE-AIR TANK DRAIN, FILTER DRAIN

G-04F25C2

OIL-LESS COMPRESSOR INTAKE FILTER ELEMENT (1 PER CYL) 

OLP-IFK1

MEMBRANE - M2

NGP-M2

MEMBRANE - M3

NGP-M3

Air Compressor Maintenance Schedule

Weekly

•  Drain condensate from receiver and traps

•  Check for unusual noise or vibration

•  Clean air filters (only with non-petroleum based products)

•  Clean all external parts of the compressor and motor

Monthly

•  Manually test safety relief valve

•  Inspect air system for leaks

•  Tighten fittings, nuts and screws as required

Quarterly

•  Change Intake filter element

Schedule Maintenance Table

Part 

Frequency

Coalescing Filters

Annually

Nitrogen Purity Analyzer

Sensor Battery as Required

Pressure Settings

Inspected Quarterly

Summary of Contents for NGP-1000D-M2

Page 1: ...Nitrogen Generator NGP 1000D M2 M3 Installation Operation and Maintenance Manual Call 1 800 345 8207 or visit our web site for our complete product listing www GeneralAirProducts com 216442 REV 2 7 18 ...

Page 2: ...2 1 800 345 8207 ...

Page 3: ...and Inspection Section 4 Installation of Nitrogen Generator Section 5 Wiring Section 6 Standard Air Filling Method Section 7 Nitrogen Filling Procedure Section 8 Nitrogen Control Module Section 9 Alarms Troubleshooting Section 10 Nitrogen Generator Leak Check Method Section 11 Air Side Leak Check Method Section 12 Nitrogen Membrane Check Section 13 Sprinkler System Leak Check Section 14 Maintenanc...

Page 4: ...tions should be followed at all times Unpacking After unpacking unit carefully inspect all parts and equipment for any damage that may have occurred during transit Make sure to tighten fittings bolts etc before putting unit into service General Safety Information Important Read all of the safety information in this manual before operating this equipment Use of the equipment in a manner not specifi...

Page 5: ...lassified as non hazardous for transportation purposes and as non flammable for fire regulations This equipment is for indoor use only Do not operate outdoors Specific procedures must be developed for maintenance of the equipment on which the membrane separator is located Appropriate labels must be continuously displayed in all areas where personnel might be exposed to a nitrogen atmos phere under...

Page 6: ...g fire sprinkler system using a factory pre engineered air compressor These turn key systems include all air filtration equipment required to keep the generator operating at peak efficiency Figure 1 NGP 1000D M2 M3 System Diagram Product Designation Outlet Pipe Connections NPS Sprinkler System Capacity Bypass Capacity Gallon NPG 1000D M2 1 2 3880 925 NPG 1000D M3 1 2 6500 925 OPTIONAL ANALYZER QUI...

Page 7: ...1 800 345 8207 7 Figure 2 Typical NGP 1000D M2 M3 External View ...

Page 8: ...rol Panel 10 Separator 3 Filter Drain Solenoid Test 11 Clean Out Valve on Strainer 4 Bypass Valve Yellow Handle 12 Nitrogen Solenoid Valve 5 Nitrogen Tank Pressure Switch 13 Air Tank Drain Solenoid Test 6 Bypass Alarm Switch 14 Nitrogen Test Port Valve Green Handle 7 Nitrogen Inlet Valve Blue Handle 15 Nitrogen Outlet Valve Blue Handle 8 Coalescing Filter ...

Page 9: ...t Pipe per installation requirements and ensure the area surrounding the nitrogen generator is adequately ventilated The Nitrogen Generator should always be installed in an adequately ventilated room Nitrogen is nontoxic and largely inert Rapid release of nitrogen gas into an enclosed space displaces the oxygen and can cause an asphyxiation hazard Inhalation of nitrogen in excessive concentrations...

Page 10: ... minimum of one Air Maintenance Device AMD and one Inspectors Gas Analyzer Port iGAP per system Check to see these components have arrived Item Nitrogen cabinet Air storage tank top tank Nitrogen storage tank bottom tank Nitrogen membrane inside cabinet Manual inside cabinet 10 ft condensation drain tube Air Maintenance Device One per riser Nitrogen Analyzer One per job 30 Stainless Steel Flex Hos...

Page 11: ...PT piping from ball valve on the nitrogen storage tank to the sprinkler system Air Maintenance Device using standard accepted installation practices A flex hose can be used to prevent excess vibration Contractor Provided NPT Ball Valve 5 Pipe the drain tube on the back of the nitrogen cabinet to drain 6 Install the second included drain tube at the separator located next to compressor aftercooler ...

Page 12: ...M2 M3 Wire the NGP 1000D M2 M3 All wiring should be performed by a licensed electrician and conform to NEC and all applicable local standards For wiring instructions refer to the Wiring Diagram Wiring location is in the nitrogen cabinet See Figure 6 ...

Page 13: ...losed position 4 Open the Nitrogen cabinet 5 Open the Bypass Valve Yellow Handle 6 Close the Nitrogen Inlet Valve Blue Handle and the Nitrogen Outlet Valve Blue Handle 7 Close the Nitrogen Test Port Valve Green Handle 8 Ensure the ball valve installed by contractor at the nitrogen storage tank outlet is closed Also ensure air storage tank petcock and nitrogen storage tank petcock are closed Nitrog...

Page 14: ...ld take 11 minutes See Figure 11 12 Check all piping connections for leaks as pre plumbed piping may have loosened during shipping 13 Using the installed petcock at the bottom of the air storage tank relieve the pressure until the air compressor turns ON The air compressor should turn on at 85 3 PSI Close the petcock valve See Figure 12 14 The air compressor will run for 60 seconds The air compres...

Page 15: ...ressure NOTE This should finish in 30 minutes per the desired NFPA guidelines 19 As soon as sprinkler system supervisory pressure is reached put the sprinkler system back into service by placing the Air Maintenance Device in the maintenance position refer to the air maintenance device manual for proper operation See Figure 14 CAUTION If there is more than one AMD on the system then close the other...

Page 16: ...essure it is time to start injecting nitrogen 2 Close the Bypass Valve Yellow Handle 3 Open the Nitrogen Inlet Valve Blue Handle 4 Open the Nitrogen Outlet Valve Blue Handle Figure 15 1LWURJHQ 2XWOHW 9DOYH OXH DQGOH 1LWURJHQ 7HVW 3RUW 9DOYH UHHQ DQGOH 1LWURJHQ QOHW 9DOYH OXH DQGOH Bypass Valve HOORZ DQGOH ...

Page 17: ...id light should turn on at 60 3 PSI on the nitrogen tank pressure gauge 6 The membrane pressure gauge should read between 85 and 105 PSI See Figure 17 7 Record the time it takes for the nitrogen storage tank to reach 75 PSI It should typically take 14 minutes for the NGP 1000D M2 and 8 minutes for the NGP 1000D M3 NOTE The air compressor will cycle on and off during this process ...

Page 18: ... 11 Turn on the Nitrogen Analyzer See Figure 19 For more information on the Nitrogen Analyzer go to Nitrogen Analyzer Instructions 12 Attach the Nitrogen Analyzer to the Nitrogen Test Port 13 The nitrogen purity level reading should climb to 98 If not go to Troubleshooting 14 Close the Nitrogen Test Port Valve Green Handle and dis connect the Nitrogen Analyzer Make sure to power off the Nitrogen A...

Page 19: ...n does not require any operator input The display should read Nitrogen Generator Normal unless the generator is in alarm or log display mode To access the panel flip the casing up PLC Operation To view the log display information Press the Alt Key and then Press the down arrow Press the Alt Key again Use the UP and DOWN arrow key to scroll through the log screens below To get out of the log press ...

Page 20: ... when the unit has been placed in Nitrogen Mode It is designed to prevent the unit from being inadvertently left in Bypass Mode Answer 1 Turn the Bypass Valve Yellow Handle to the OFF position Open the Nitrogen Inlet Valve Blue Handle and the Nitrogen Outlet Valve Blue Handle Refer to Nitrogen Filling Procedure 2 If the unit is filling multiple systems or being left intentionally in Bypass Mode mu...

Page 21: ...all valves are open or closed where necessary 4 Check for alarms Issue The air compressor takes too long to fill Answer 1 Confirm all valves are in the correct position When filling the sprinkler system ensure the Bypass Valve Yellow Handle is OPEN Trying to fill the sprinkler system through the membrane will result in long fill times and possibly damage to the compressor See Standard Air Filling ...

Page 22: ... 9 Power ON the nitrogen generator The Power On light on the outside of the cabinet should turn green 10 Allow the pressure in the air storage tank and the nitrogen storage tank to rise The green Nitrogen Solenoid light should be ON 11 Once the air compressor and Nitrogen Solenoid light have both turned off record the pressure on the air storage tank and the nitrogen storage tank This should typic...

Page 23: ...m of the air storage tank The air storage tank pressure gauge should read zero 0 6 Power the nitrogen generator ON The Power On light should be green 7 Allow the pressure to build to 105 3 PSI Make note the time it takes to reach this pressure This should typically take less than 5 minutes for the NGP 1000D M2 M3 8 If the unit reaches 105 3 PSI and does not stop this could indicate a pressure swit...

Page 24: ...utes for the NGP 1000D M3 8 Check the membrane pressure gauge it should be between 85 105 PSI 9 Open the Nitrogen Test Port Valve Green Handle 10 Using a portable nitrogen analyzer check the nitrogen purity The purity should read 98 or greater when the pressure in the nitrogen storage tank reads at least 60 3 PSI Section 14 Sprinkler System Leak Check If no leak could be found in the nitrogen gene...

Page 25: ...erious injury or death Replacement Parts Part Replacement Part Number MAINTENANCE KIT M2 M5 NGP MK AIR MAINTENANCE DEVICE AMD 1 NITROGEN ANALYZER NGP PSN2 SENSOR ELEMENT F NGP VIBRATION KIT NGP VAK 30 OIL LESS MINOR REPAIR KIT 1 PER CYL OLP MRK 2 75 CYLINDER REPAIR KIT 1 PER CYL OLP CRK 2 75 SOLENOID VALVE AIR TANK DRAIN FILTER DRAIN G 04F25C2 OIL LESS COMPRESSOR INTAKE FILTER ELEMENT 1 PER CYL OL...

Page 26: ...lters provided in the replacement kit 7 Check for leaks Air Compressor Replacement 1 Isolate the nitrogen generator and relieve pressure 2 Disconnect the power to the nitrogen generator 3 Disconnect wires in junction box on the air compressor 4 Loosen union after flex hose on compressor discharge 5 Remove flex hose from compressor discharge 6 Remove bolts holding compressor to rubber isolation mou...

Page 27: ...om the unit NOTE These are typical durations Actual times may be slightly longer or shorter These are typical pressure set points Actual pressure can be 3 PSI Operational State 1 3 5HFRUGHG 3DUDPHWHU LU RPSUHVVRU 2 3UHVVXUH 105 PSI LU RPSUHVVRU 21 3UHVVXUH 85 PSI 7LPH QWHUYDO WR EXLOG SUHVVXUH IURP 36 WR 36 LQ DLU VWRUDJH WDQN 1 Minute 1LWURJHQ 6ROHQRLG 2 3UHVVXUH 1LWURJHQ 7DQN 3UHVVXUH 75 PSI 1LW...

Page 28: ...on is required when The measured N2 percentage in 79 1 N2 is above 80 1 N2 The measured N2 percentage in 79 1 N2 is below 78 1 N2 The CAL reminder icon is blinking at the bottom of the LCD A simple calibration may be made with the sensor open to static ambient air Calibration Errors and Error Codes The nitrogen purity analyzer has a self test feature built into the software to detect faulty calibr...

Page 29: ...perform a calibration and begin displaying of oxygen HELPFUL HINT If unit does not function verify that the screws are tight to allow proper electrical connection Code Meaning Corrective Action E02 1R VHQVRU DWWDFKHG 2SHQ WKH KDQG KHOG QLWURJHQ SXULW DQDO HU DQG GLVFRQQHFW DQG UHFRQQHFW VHQVRU 8QLW VKRXOG SHUIRUP DQ DXWR FDOLEUDWLRQ DQG VKRXOG UHDG I QRW FRQWDFW XVWRPHU 6HUYLFH IRU SRVVLEOH VHQVRU...

Page 30: ...Be sure to orient the new sensor by aligning the red arrow on the sensor with the arrow in the back case A small tab is located on the back case that is designed to engage the sensor and prevent it from rotating within the case NOTE If the oxygen sensor is installed incorrectly the case will not come back together and the unit may be damaged when the screws are reinstalled Reconnect the oxygen sen...

Page 31: ...1 800 345 8207 31 Section 18 Wiring Diagrams ...

Page 32: ...ER CONNECTIONS RELAY SOCKET SCREW TERMINALS NOTES 1 GROUND MOTOR PRESSURE SWITCHES AND SOLENOID COILS 2 FIELD WIRING FOR NGP 2200D SEE MANUAL SW 1 BYPASS VALVE SWITCH G R 1 A2 A1 POWER STATUS RELAY SEE NOTE 2 SEE NOTE 2 SEE NOTE 2 3 4 NITROGEN GENERATOR WIRING DIAGRAM LABEL 208 230 460V 3PH 60HZ MODEL NGP 500D THRU NGP 2200D Drawing File Nitrogen Generators Non Certified Versions Wiring Diagrams A...

Page 33: ...tion ò HPDOH 137 Mounting Holes 4 Ø Max operating Pressure 105 PSI Temperature Range 50 F 10 C to 110 F 43 C A Size HxWxD 62 x 44 x 33 Weight 550 lbs Power Supply Available in 208V 11 6A 230V 11A single phase and 208V 9 2A 230V 9 2A 460V 4 6A three phase Fire Sprinkler System Connection ò HPDOH 137 Mounting Holes 4 Ø Max operating Pressure 105 PSI Temperature Range 50 F 10 C to 110 F 43 C A 1 2 60...

Page 34: ... days whichever is longer DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EX PRESSLY AGREED THAT EXCEPT AS TO TITLE THE COM PANY MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED OR STATUTORY INCLUDING ANY IMPLIED WAR RANTY OR MERCHANTABILITY THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE EXCLUSIVE AND ONLY REMEDY AVAILABLE TO THE PURCHASER AND IN NO CASE SHALL THE COMPANY BE SUBJ...

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