Intelligen INS-1500 Page 53 Installation, Operation And Instruction Manual Download

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19

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Summary of Contents for INS-1500

Page 1: ...Manual 5403646 F 04 19 St Louis MO 800 325 3936 www pottersignal com INS 1500 2000 Nitrogen Generators Installation Operation and Instruction Manual ...

Page 2: ...der 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 parts were original components DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLYAGREED THAT EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED OR STATUTORY IN...

Page 3: ...ing 27 Maintenance and Part Replacements 29 Standard Maintenance Every 1 000 Compressor Operating Hours 30 Compressor Air Intake Filters 31 Air Tank Blow down Strainer 32 Lubricated Air Compressor Oil 32 Filter Elements 33 Resetting Maintenance Alert and Checking for Leaks 35 Air Compressor Replacement 35 Nitrogen Membrane Replacement 36 Maintenance Alerts and Actions 37 Trouble Alerts and Probabl...

Page 4: ...ing of 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 occurred during transit Make sure to tighten fittings bolts etc before putting unit into service Do not operate if damage occurred during shipping handling or use Contact Potter immediately General...

Page 5: ...ipe 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 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 nitro...

Page 6: ...Controller The IntelliGen Nitrogen Generator Series is the only line of intelligent nitrogen generators 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 performing optimally The IntelliGen Controller monitors pressure runtime power connectivity and operational...

Page 7: ...ior Cabinet View Fig 1 1 2 3 4 5 6 7 1 Upper Cabinet Latches Qty 2 2 IntelliGen Display 3 Control Power Only Switch 4 Compressor Sensor Wire Cord Grip 5 Nitrogen Tank Connection 1 2 FNPT 6 Air Tank Connection 1 2 FNPT 7 3 8 Drain Tube Connection 10 ft Supplied ...

Page 8: ...or Wire Connection 9 PLINK Connection 10 BMS Connection 11 Pressure Transducer PI01 12 Nitrogen Sample Port SP 13 N2 Bleed Valve V04 14 Bypass Solenoid Valve XV03 15 Water Separator WS01 16 Coalescing Filter 1µm F01 17 Coalescing Filter 01µm F02 18 Activated Carbon Filter with Drain Valve F03 19 3 8 Drain 20 Excess Air Regulator PRV01 21 Membrane Inlet Air Solenoid XV01 22 Instrument Air Regulator...

Page 9: ...3646 REV F 04 19 INS 1500 2000 Nitrogen Tank View Fig 3 1 1 2 FNPT N2 Tank Inlet Valve V02 2 Nitrogen Tank Pressure Gauge 3 Pressure Safety Valve PSV01 4 1 2 FNPT N2 Tank Outlet Valve V03 5 N2 Tank Drain Ball Valve 1 2 4 3 5 ...

Page 10: ...Filter 3 1 2 FNPT Air Tank Outlet Valve V01 4 1 2 MNPT Flexible Hose 12 Provided 5 Electrical Panel 6 Compressor Sensor Wire 20 ft Provided 7 Blow Down Solenoid With Controller 120V Plug Connection 8 1 4 Drain Tubing 10 Provided 9 Air Compressor Pressure Switch 10 Oil Sight Glass 11 Oil Drain Port 1 11 10 2 3 4 5 6 7 8 9 ...

Page 11: ...en 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 The amber PURGING LED indicates the IntelliGen Nitrogen Generator detects that a networked INS PV is in a purge process MAINTENANCE The amber MAINTENANCE LED indicates the IntelliGen Nitrogen Generat...

Page 12: ...rogen generator to be installed meeting these requirements Dry clean and well ventilated Dimensions 70 X 31 X 13 H x W x D for cabinet 53 X 20 H x W for nitrogen tank and 74 X 37 X 24 H x W x D for tank mounted air compressor Ambient temperatures above 50º F at all times Access to front for service Conveniently located near fire sprinkler system connections Conveniently located near a drain Near a...

Page 13: ...e tank mounted air compressor to the floor using the supplied vibration pads and user supplied 4 standard 3 8 bolts See Fig 8 Fig 8 Fig 10 9 Mount the nitrogen tank to the floor using user supplied 4 standard 3 8 bolts See Fig 9 10 Install the supplied flexible hose to the Air Tank Outlet valve See Fig 10 Ø9 16 Mounting Holes 4 A A Fig 9 Ø9 16 Mounting Holes 4 ...

Page 14: ...sor to the floor drain in the sprinkler room Do not pipe the drain tubing upward See Fig 14 Fig 11 11 Plumb NPT piping from the MNPT flex hose connection to the FNPT air inlet connection on the nitrogen cabinet See Fig 11 12 Install NPT piping from the FNPT nitrogen outlet connection on the nitrogen cabinet to the FNPT N2 Tank Inlet Valve on the nitrogen tank See Fig 12 A A B B Air Tank Drain Tube...

Page 15: ...gram Installing the purge valve upside down will not allow the system to purge Also ensure that there is NO water in the pipe to the purge valve 111 4 7 1 2 NPT TEE CONNECTION AND CLOSE NIPPLE SUPPLIED BY SPRINKLER CONTRACTOR PIPE FROM SPRINKLER SYSTEM INSPECTOR S TEST VALVE PURGE ORIFICE N2 SAMPLING PORT NGP SPV PIPE PLUG INSTALL AFTER PURGE COMPLETE REMOVE PLUG WHEN SAMPLING N2 LEVELS AND PURGIN...

Page 16: ... of the tank mounted air compressor 120V Nitrogen cabinet 120V Four items must be wired on the INS 1500 or INS 2000 models 1 Run a dedicated electrical circuit with an electrical disconnect switch to the sprinkler room 2 Open the panel on the air compressor to access wiring connections See Fig 18 Motor Starter 3 Depending on the voltage selected follow the wiring diagram in this manual on page 48 ...

Page 17: ...2 Run the wire to the nitrogen cabinet through the cord grip provided on the right side of the nitrogen cabinet labeled Compressor Sensor Wire 3 Inside the nitrogen cabinet connect the wires to the Compressor Sensor Wire terminal blocks Wire the black wire to CS B and the white wire to the CS W See Fig 20 Fig 19 Fig 20 CS W C Compressor Sensor Wire C ...

Page 18: ...en cabinet to access the wiring terminal blocks Use any of the or knockouts on the upper part of the cabinet away from low voltage components See Fig 22 1 Locate the air tank blow down on the bottom of the air tank See Fig 21 Fig 22 Fig 21 Nitrogen Cabinet Power Terminal Blocks 120 VAC Knockouts 2 Using the provided 10 of 120V cord plug the blow down into a dedicated wall outlet 3 Ensure the power...

Page 19: ...ng another 1 2 knockout on the cabinet wire the IntelliPurge Nitrogen Purge Valve to the IntelliGen Controller using 3 wire cable See the IntelliPurge Section on page 27 for more details Connect the PLINK to the terminal blocks next to the controller See Fig 24 3 Using another 1 2 knockout on the cabinet wire any BMS Building Management System to the BMS terminal blocks See Fig 25 PL G PL B PL A B...

Page 20: ...nce Device If multiple Nitrogen Air Maintenance Devices are used ensure all valves are in the closed position 5 Close the N2 Tank Outlet Valve V03 on the nitrogen tank See Fig 26 6 Turn power ON to the nitrogen generator using the Control Power Only switch on the nitrogen cabinet See Fig 27 V03 Nitrogen Generator Operation Initial Set Up Fig 27 Fig 26 7 The IntelliGen Display will turn on indicati...

Page 21: ...175 PSI the air compressor will turn off 13 If the nitrogen generator is isolated from the sprinkler system The air compressor of the INS 1500 and INS 2000 should take no longer than 10 minutes to pressure both tanks and turn off If the air compressor is not turning off or it is taking longer than expected go to the Troubleshooting section in this manual on page 40 14 Once the two tanks are pressu...

Page 22: ...ogen Generating Mode before trying again 5 Immediately begin timing to see how long it takes to reach approximately 80 PSI in the nitrogen tank while the nitrogen generator is in Nitrogen Generating Mode 6 If the nitrogen generator is isolated from the sprinkler system a The INS 1500 should take no longer than 8 minutes to pressurize the nitrogen tank to 80 PSI b The INS 2000 should take no longer...

Page 23: ... by placing the Nitrogen Air Maintenance Device in the maintenance position refer to the Nitrogen Air Maintenance Device manual for proper operation 7 When the sprinkler system s are completely filled the nitrogen generator will repressurize the air tank and nitrogen tank The air compressor will turn off and the unit will automatically return to Nitrogen Generating Mode Note The amber LED labeled ...

Page 24: ...upstream 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 indicator will begin blinking 10 The Purge Time Display will display the max number of purge days which is the maximum amount of time the unit is allowed to purge before indicating a trouble 11 The N2 ...

Page 25: ...essurized 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 approximately 14 days before returning to the job site and checking the exiting gas with the Portable Nitrogen Analyzer 9 Check the nitrogen purity to ensure the exiting gas is 98 or greater 10 If the gas...

Page 26: ...pany 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 page 5 Enter the unit s MAC ID Number and the Serial Number which can be found on the IntelliGen Controller inside the cabinet See Fig 33 IntelliView Dashboard Internet Connectivity 6 Add a name for th...

Page 27: ... to use a single twisted pair cable for PL A and PL B with the drain wire being used for PL G Do not connect any shield to the drain wire 4 Maximum number of INS PV devices networked to an IntelliGen Series Nitrogen Generator is 26 The maximum wire length for the network is 6500 ft 5 The PLINK network works as a Master and Slave network The INS generator is defined as the Master The other 5 wires ...

Page 28: ... wiring at right angles Do not coil or store excess cable in the INS PV Cabinet Doing so may cause communication errors or faulty readings Use the knockouts below the INS IntelliGen Nitrogen Generator control board to exit the nitrogen cabinet Keep excess wire to a minimum 1 The INS PV requires 35 watts of 24VAC DC power This must be supplied by a dedicated power supply An optional 120V 40A transf...

Page 29: ...activated carbon and coalescing filter elements Replace if necessary Check for unusual noise or vibration Clean all external parts of the compressor and motor Manually test safety relief valves Inspect system for leaks Tighten fittings 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...

Page 30: ...alve V04 located near the Nitrogen Sample Port SP and begin draining pressure from the nitrogen tank See Fig 38 5 Open the black handled valve located on the Activated Carbon Filter F03 and begin draining pressure from the air tank See Fig 39 7 8 wrench Channel Lock Rag Filter Element Replacement Kit 0090207 Compressor Oil and Air Intake Filter Kit 0090212 Tools Needed Standard Maintenance Every 1...

Page 31: ...replace the air intake filter element 7 Remove air filter cover from compressor by unscrewing wing nut on cover See Fig 40 8 Remove air filter element See Fig 41 9 Replace the air intake element 10 Return the air intake element to the enclosure and reattach cover Compressor Air Intake Filters Fig 41 Fig 40 ...

Page 32: ...een 11 Locate the inline blow down device mounted on the base of the compressor tank See Fig 42 Fig 42 13 Remove oil fill plug 14 Remove drain cap from oil drain port and drain oil into suitable container 15 Reinstall drain cap 16 Place funnel into oil fill port and add oil approximately 1 6 qts until visible at the top of the oil sight glass 17 Replace oil fill plug Blow down strainer Oil Fill Po...

Page 33: ...ogen generator cabinet See Fig 44 Note The Water Separator labeled WS01 does not have a replaceable element 19 Disconnect the drain tubes from the filter bowl by pushing up on the plastic releasing collar and pulling down on the tube See Fig 45 Fig 44 Filter Elements Fig 45 WS01 Releasing Collar ...

Page 34: ...the right is the 01 micron filter which has a BLUE element 5230017 d The filter body 5230010 on the far left is the activated carbon filter which has a BLACK element 5230018 Note This filter bowl is not connected to the drain and has a black handled valve Fig 46 DO NOT PLACE WRENCH HERE CAREFULLY WRENCH HERE ONLY Fig 48 Fig 49 Filter Body Filter Element Filter Bowl RED b WS a BLACK d BLUE c NO ELE...

Page 35: ...the cursor and pressing ENTER 32 The menu will display maintenance timer countdown hours Press ENTER again to confirm 33 To reset the maintenance timer press ENTER 34 The maintenance light on the IntelliGen Display will turn off and the maintenance timer has been reset 35 Turn power back on to the air compressor using the electrical disconnect The amber BYPASS LED will be ON since there is no pres...

Page 36: ...gen membrane then unscrew fitting from nitrogen membrane 8 Unscrew straight fitting from the bottom of nitrogen membrane 9 Install 90 degree fitting from old nitrogen membrane into the top of new nitrogen membrane then tighten jam nut when fitting is aligned correctly 10 Install straight fitting into bottom of nitrogen membrane 11 Remove plastic caps from side ports on the lower portion of the nit...

Page 37: ...ystem 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 following the procedure in this manual 2 Reset Maintenance Alert 1 by going into the Maintenance Menu on the display and following the procedure on page 29 Issue Sprinkler system leak rate is greater th...

Page 38: ...ir Solenoid XV01 and Membrane 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 Membrane Inlet Air Solenoid XV01 and or Membrane Outlet N2 Solenoid XV02 are blocked or closed 5 Instrument Air Regulator PRV03 is less than 60 PSI 6 Blockage in pathway from ai...

Page 39: ...lling 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 than Leak Rate Warning Set Point and has not been acknowledged for a week Probable Cause 1 Leak on sprinkler system 2 Leak on nitrogen tank 3 Leak Rate Warning Set Point not appropriate for application Issue Compr...

Page 40: ...ly open the blue N2 Bleed Valve V04 and begin draining the pressure out of the nitrogen tank 6 Quickly close the blue N2 Bleed Valve V04 when you see the red instrument air solenoid lights turn on This will happen at approximately 60 PSI Note If the pressure in the nitrogen tank drops below 55 PSI the nitrogen generator will return to Bypass Mode Wait for the nitrogen generator to refill the tanks...

Page 41: ...abinet 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 Periodic running of the air compressor is expected typically less than 24 times a day INS 1500 INS 2000 Recorded Parameter Air Compressor OFF Pressure 170 PSI 170 PSI Air Compressor ON Pressure 145 PSI 1...

Page 42: ...ypical 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 maintenance alert or a trouble will display on the nitrogen generator The Leak Rate Warning Set Point in the Potter IntelliGen Nitrogen Generator is a user adjustable set point for when a maintenance...

Page 43: ...1 Press ESC until returned to main menu The Leak Rate is also calculated based on the size of the sprinkler system the nitrogen generator is protecting The INS 1500 is factory set at 6 200 gallons max and the INS 2000 is factory set at 12 000 gallons max This can be adjusted lower if the units are servicing smaller systems 1 Press ENTER on the IntelliGen Display keypad 2 Select Settings using the ...

Page 44: ...44 INS 1500 INS 2000 5403646 REV F 04 19 INS 1500 2000 Cabinet Dimensional Drawings A CONNECTION CONNECTION C DRAIN CONNECTION 3 8 Fig 49 ...

Page 45: ...45 INS 1500 INS 2000 5403646 REV F 04 19 INS 1500 2000 Nitrogen Tank Dimensional Drawings 20 9 16 X 7 8 SLOT LOCATED 90 APART ON A 17 BOLT CIRCLE 4 PLCS 227 LITER 60 GALLON Fig 50 ...

Page 46: ...RIC SIGNAL CO PROPRIETARY DATA VENDOR CERTIFICATION APART APART ON A C DRAIN CONNECTION A ALL DIMENSIONS ARE FOR REFERENCE ONLY COMPRESSOR DETAIL D C A C DATE DO NOT SCALE DRAWING E F POTTER ELECTRIC SIGNAL CO PROPRIETARY DATA VENDOR CERTIFICATION APART APART ON A C DRAIN CONNECTION A ALL DIMENSIONS ARE FOR REFERENCE ONLY COMPRESSOR DETAIL D C A C DATE DO NOT SCALE DRAWING E F POTTER ELECTRIC SIGN...

Page 47: ...OID CA01 AIR COMPRESSOR F01 COALESCING FILTER 1μm F02 COALESCING FILTER 01μm F03 CARBON FILTER W DRAIN VALVE F04 INSTRUMENT AIR FILTER FCV01 FLOW CONTROL VALVE M01 NITROGEN MEMBRANE PI01 PRESSURE TRANSDUCER PRV01 EXCESS AIR REGULATOR PRV02 BACK PRESSURE REGULATOR PRV03 INSTRUMENT AIR REGULATOR PSV01 PRESSURE SAFETY VALVE SP NITROGEN SAMPLE PORT TCN01 TCA01 NITROGEN TANK V01 AIR TANK OUTLET VALVE V...

Page 48: ...AC 2A FA CONTROLLER CS B CS W 4 3 BLACK AWG18 WHITE AWG18 CABINET BLUE SEE NOTE 1 NOTE 1 OWNER SUPPLIED POWER CONNECTIONS SEE NOTE 2 SEE NOTE 2 COMPRESSOR BMS NO BMS NC BMS C PL A PL B PL G COMPRESSOR MOTOR 6T3 4T2 2T1 CB1 A1 A2 14NO 1L1 3L2 6T3 13NO 5L3 4T2 2T1 K1 MM1 L1 L2 L3 200 208VAC 3PH 60HZ SEE NOTE 1 AD01 BLOW DOWN TO 120VAC 60HZ 1PH COMPRESSOR NOTE 2 OPTIONAL BUILDING MANAGEMENT SYSTEM BM...

Page 49: ...NTROLLER CS B CS W 4 3 CABINET BLUE SEE NOTE 1 SEE NOTE 2 SEE NOTE 2 COMPRESSOR BMS NO BMS NC BMS C PL A PL B PL G L1 L2 L3 230 240VAC 3PH 60HZ SEE NOTE 1 SENSOR CS1 BLACK AWG18 WHITE AWG18 COMPRESSOR MOTOR 6T3 4T2 2T1 CB1 A1 A2 14NO 1L1 3L2 6T3 13NO 5L3 4T2 2T1 K1 MM1 AD01 TO 120VAC 60HZ 1PH COMPRESSOR COMPRESSOR SENSOR WIRE CS B CS W SEE NOTE 3 SEE NOTE 4 NOTE 1 OWNER SUPPLIED POWER CONNECTIONS ...

Page 50: ...NTROLLER CS B CS W 4 3 CABINET BLUE SEE NOTE 1 SEE NOTE 2 SEE NOTE 2 COMPRESSOR BMS NO BMS NC BMS C PL A PL B PL G L1 L2 L3 460 480VAC 3PH 60HZ SEE NOTE 1 SENSOR CS1 BLACK AWG18 WHITE AWG18 COMPRESSOR MOTOR 6T3 4T2 2T1 CB1 A1 A2 14NO 1L1 3L2 6T3 13NO 5L3 4T2 2T1 K1 MM1 AD01 TO 120VAC 60HZ 1PH COMPRESSOR COMPRESSOR SENSOR WIRE CS B CS W SEE NOTE 3 SEE NOTE 4 NOTE 1 OWNER SUPPLIED POWER CONNECTIONS ...

Page 51: ...04 19 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 Menu Tree 4 Menu Tree 5 Menu Tree 7 ...

Page 52: ...rouble 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 Maintenance Status Maintenance Code Description List for only troubled units Compressor or Membrane Runtime Average On Time Average Cycle Time State ON OFF Total Membrane Cycles Trouble Status Device Num...

Page 53: ...3 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 PV Scrollable list of all history from INS PV devices ...

Page 54: ... 4 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 Maintenance Timer Press Enter to Clear Maintenance Alert ...

Page 55: ... Specify 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 Scheduling 4 Reset Defaults Manual Purge 1 All Units 2 Specify INS PV Refresh N2 1 All Units 2 Specify INS PV Menu Tree 6 ...

Page 56: ...PV 1 1 Perfect Purge 2 IntelliDry 3 Single Shot Perfect Purge 1 14 days 2 21 days 3 30 days IntelliDry 1 14 days 2 21 days 3 30 days IntelliDry 1 14 days 2 21 days 3 30 days IntelliDry Dryness 1 Low Dry 2 Medium Dry 3 Heavy Dry IntelliDry Dryness 1 Low Dry 2 Medium Dry 3 Heavy Dry Single Shot Operation 1 14 days open then close 2 21 days open then close 3 30 days open then close 4 Indefinitely ope...

Page 57: ...ge 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 Default Gateway DNS_Server Learn Network Searches for New Devices on the Network BMS Relay Test Relay will Energize for 30 Seconds Firmware Version Number Set Leak Rate Warning Set Point Screen PSI per 24 hours Set Total ...

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