Intelligen INS-1000 Installation, Operation And Instruction Manual Download Page 1

Page: 1 / 48

Manual #5403645 - A

6/17

St. Louis, MO

800-325-3936

www.pottersignal.com

INS-500/1000

Nitrogen Generators

Installation, Operation, and

Instruction Manual

Summary of Contents for INS-1000

Page 1: ...Manual 5403645 A 6 17 St Louis MO 800 325 3936 www pottersignal com INS 500 1000 Nitrogen Generators Installation Operation and Instruction Manual...

Page 2: ...r this warranty Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such part...

Page 3: ...or Air Intake Filters 24 Air Tank Blow down Strainer 24 Filter Elements 25 Resetting Maintenance Alert and Checking for Leaks 27 Air Compressor Replacement 28 Nitrogen Membrane Replacement 28 Maintena...

Page 4: ...gases as determined by local or national laws and regulations should be followed at all times Unpacking After unpacking unit carefully inspect all parts and equipment for any damage that may have occ...

Page 5: ...e The generator is classified 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 procedure mu...

Page 6: ...nerators for fire sprinkler systems At the heart of the IntelliGen units is the IntelliGen Controller The IntelliGen Controller monitors every aspect of the nitrogen generator to ensure the unit is pe...

Page 7: ...en Display 3 Air Compressor Power Switch 4 Nitrogen Tank 5 Nitrogen Tank Gauge 6 12 Flex Hose to Fire Sprinkler System 1 2 MNPT 7 N2 Tank Outlet Valve V03 8 N2 Tank Inlet Valve V02 9 Air Tank 10 Air T...

Page 8: ...lliGen Controller 7 Owner Supplied Power Connection 8 PLINK Connection 9 BMS Connection 10 Pressure Transducer PI01 11 Nitrogen Sample Port SP 12 N2 Bleed Valve V04 13 Bypass Solenoid Valve XV03 14 Co...

Page 9: ...Generator is silenced BYPASS The amber BYPASS LED indicates if the IntelliGen Nitrogen Generator is in Bypass Mode If the Bypass LED indicator is off the unit is in Nitrogen Generating Mode PURGING Th...

Page 10: ...1119784 or INS PV 1119478 Portable Nitrogen Analyzer one per job PNA 1119504 5 Find a location for the nitrogen generator to be installed meeting these requirements Dry clean and well ventilated Dime...

Page 11: ...ll not allow the system to purge Also ensure that there is NO water in the pipe to the purge valve Fig 6 111 4 7 1 2 NPT TEE CONNECTION AND CLOSE NIPPLE SUPPLIED BY SPRINKLER CONTRACTOR PIPE FROM SPRI...

Page 12: ...38 or use the wiring diagram on the inside of the nitrogen generator cabinet door 4 For internet connectivity see the IntelliView section on page 20 for more details wire a CAT 5 Ethernet cable using...

Page 13: ...wire cable 22 AWG recommended See the IntelliPurge Section on page 21 for more details Connect the PLINK to the terminal blocks next to the controller See Fig 11 Fig 12 BMS NO BMS NC BMS C Fig 11 6 Us...

Page 14: ...intenance Device If multiple Air Maintenance Devices are used ensure all valves are in closed position 5 Close the N2 Tank Outlet Valve V03 on the nitrogen tank See Fig 13 6 Turn power ON to the nitro...

Page 15: ...m the sprinkler system The air compressor of the INS 500 should take no longer than 8 minutes to pressurize both tanks and turn off The air compressor of the INS 1000 should take no longer than 6 minu...

Page 16: ...r to refill the tanks and the unit to return to Nitrogen Generating Mode before trying again 5 Immediately begin timing to see how long it takes to reach approximately 80 PSI in the nitrogen tank whil...

Page 17: ...by placing the Air Maintenance Device in the maintenance position refer to the Air Maintenance Device manual for proper operation 7 When the sprinkler system s are completely filled the nitrogen gene...

Page 18: ...stream 8 If the INS PV unit is not connected to a nitrogen generator or an INS RA toggle the START PURGE switch to start the Purge Process 9 Once the Purge Process has started the yellow Purge LED ind...

Page 19: ...surized listen for flow You may also use your fingers to feel for flow If no flow is present there is a blockage such as a shut ball valve water in the pipe or a clogged orifice upstream 8 Wait approx...

Page 20: ...ny information and a valid e mail address 3 You will receive an e mail confirmation with an account verification link 4 Once logged in click the Register Generator button on the Dashboard Overview pag...

Page 21: ...S PV Maximum wire length for network is 6500 ft Maximum number of INS PV devices on network is 27 Maximum number of INS RA devices on network is 4 The INS PV s devices must be addressed as slave devic...

Page 22: ...nuts and screws as required Check the pressure settings Check the nitrogen purity using Portable Nitrogen Analyzer It should be 98 0 or greater Maintenance and Part Replacements All pressure must be...

Page 23: ...ed near the Nitrogen Sample Port SP and begin draining pressure from the nitrogen tank See Fig 24 5 Open the black handled valve located on the Activated Carbon Filter F04 and begin draining pressure...

Page 24: ...the INS 500 and four 4 on the INS 1000 See Fig 26 8 Using a 5 32 hex key unscrew the cover See Fig 27 9 Clean or replace the air intake element 10 Return the air intake element to the enclosure and re...

Page 25: ...drain tubes from the filter bowl by pushing up on the plastic releasing collar and pulling down on the tube See Fig 31 Filter Elements 12 Remove the screen and clean all debris Wipe the inside of the...

Page 26: ...0013 c The filter body 5230005 third from the right is the 0 01 micron filter which has a BLUE element 5230014 d The filter body 5230006 on the far left is the activated carbon filter which has a BLAC...

Page 27: ...set the maintenance timer press ENTER Press ENTER again to confirm 31 The maintenance light on the IntelliGen Display will turn off and the maintenance timer has been reset 32 Turn power back on to th...

Page 28: ...ee Phase model verify correct rotation 11 Check for leaks 1 Isolate the nitrogen generator from the sprinkler system and relieve pressure 2 Disconnect the power to the nitrogen generator using lockout...

Page 29: ...Leak Rate Excessive Issue Maintenance Timer expired after 1 000 hours and the nitrogen generator needs maintenance Action 1 Within 250 compressor operating hours complete standard maintenance followi...

Page 30: ...ane Outlet N2 Solenoid XV02 continuously ON for 30 minutes Probable Cause 1 Leak on nitrogen generator or sprinkler system 2 Air Compressor Power is turned off 3 Air Tank Outlet Valve V01 closed 4 Mem...

Page 31: ...Cause 1 Filling multiple sprinkler systems 2 Performing functionality testing on the nitrogen generator 3 Leak on nitrogen generator or sprinkler system Issue Sprinkler system leak rate is greater tha...

Page 32: ...itrogen cabinet locate the blue N2 Bleed Valve V04 near the Nitrogen Sample Port SP 5 Slightly open the blue N2 Bleed Valve V04 and begin draining the pressure out of the nitrogen tank 6 Quickly close...

Page 33: ...binet Whenever the nitrogen tank requires nitrogen the pneumatic valves open allowing air to flow from the air tank When the nitrogen tank reaches the desired set point the pneumatic valves close Peri...

Page 34: ...ical year This translates to a maximum pressure loss of 6 PSI in 24 hours This is the default Leak Rate Warning Set Point If the actual Leak Rate of the sprinkler system is greater than that value a m...

Page 35: ...11 Press ESC to return to main menu The Leak Rate is also calculated based on the size of the sprinkler system the nitrogen generator is protecting The INS 500 is factory set at 1 850 gallons max and...

Page 36: ...36 INS 500 INS 1000 5403645 REV A 6 17 INS 500 1000 Dimensional Drawings DRAIN CONNECTION...

Page 37: ...F04 ACTIVATED CARBON FILTER W DRAIN VALVE F05 INSTRUMENT AIR FILTER FCV01 FLOW CONTROL VALVE M01 NITROGEN MEMBRANE PI01 PRESSURE TRANSDUCER PRV01 EXCESS AIR REGULATOR PRV02 BACK PRESSURE REGULATOR PR...

Page 38: ...BLACK AWG18 RED AWG18 COMPRESSOR MOTOR PRESSURE SWITCH XDCR FAN BROWN AWG12 GREEN AWG12 BLACK AWG12 GREEN AWG12 WHITE AWG12 DISPLAY INTELLIGEN INTELLIGEN WHITE BLACK RED BLACK BLK wMARK WHITE AWG18 B...

Page 39: ...OR PRESSURE SWITCH XDCR FAN BROWN AWG12 GREEN AWG12 BLACK AWG12 GREEN AWG12 RED AWG12 DISPLAY INTELLIGEN INTELLIGEN WHITE BLACK RED BLACK BLK wMARK WHITE AWG18 BLUE AWG18 BROWN AWG18 GREY AWG18 BLACK...

Page 40: ...18 COMPRESSOR MOTOR PRESSURE SWITCH XDCR FAN BROWN AWG12 GREEN AWG12 BLACK AWG12 GREEN AWG12 BLUE AWG12 RED AWG12 WHITE BLACK RED BLACK BLK wMARK WHITE AWG18 BLUE AWG18 BROWN AWG18 GREY AWG18 BLACK AW...

Page 41: ...2 GREEN AWG12 BLUE AWG12 RED AWG12 WHITE BLACK RED BLACK BLK wMARK WHITE AWG18 BLUE AWG18 BROWN AWG18 GREY AWG18 BLACK AWG18 WHITE AWG18 RED AWG22 BLACK AWG22 GREEN AWG22 WHITE AWG22 WHITE AWG22 GREEN...

Page 42: ...17 1 Menu Tree 1 Menu Trees Title Screen Model Number Status Mode N2 Tank Leak Rate LR 1 System Status 2 View History 3 Maintenance 4 Purge 5 Settings User PW User PW User PW Menu Tree 2 Menu Tree 3...

Page 43: ...uble Status 2 Maintenance Status 3 Compressor Run Time 4 Membrane Run Time Viewable Parameters 1 Trouble Status 2 Sensor Status Trouble Status Error Code Description List for only troubled units Maint...

Page 44: ...Main Menu 2 View History History 1 Generator History 2 INS PV History Generator History Scrollable list of all history from N2 generator INS PV History Scrollable list of connected INS PV devices INS...

Page 45: ...Main Menu 3 Maintenance 2 Excessive Nitrogen Demand 1 Standard Nitrogen Maintenance Maintenance Timer Reset Maintenance Timer ENTER Excessive Nitrogen Demand Clear Maintenance Alert ENTER Reset Maint...

Page 46: ...pecify INS PV 2 Cancel Purge Cancel Purge 1 All Units 2 Specify INS PV 3 Settings Settings 1 Purge Settings 2 Manual Purge 3 Refresh N2 Lvl Purge Settings 1 All Units 2 Specify INS PV 3 Purge Scheduli...

Page 47: ...t Purge 2 IntelliDry 3 Single Shot Perfect Purge System Size 1 Below 500 2 500 1000 3 Above 1000 IntelliDry System Size 1 Below 500 2 500 1000 3 Above 1000 IntelliDry 01 Dryness 1 Below 500 2 500 1000...

Page 48: ...Blow Down 1 Change Settings 2 Test Blow Down BMS Test 1 Set Leak Rate Warning Set Point 2 Set Total Sprinkler System Capacity Admin View IP Settings Host Name MAC ID Subnet Mask IP Address Speed Defau...

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