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11.  Troubleshooting

1. Insufficient inlet pressure

2. Electrical Fault

3. Moist or contaminated CMS

 
4. Too high air consumption

5. Excessive inlet air temperature 

6. Insufficient purge air
7. Exhaust silencer blocked

1. Adjust inlet pressure settings. (check rating plate). 

2. Ensure the power is on and the generator display panel is 
illuminated; check the generator is cycling correctly.
3. Eliminate the cause of contamination. Check external inlet
filtration (inc. Water separator) for failed auto-drains or
condensate build up. Replace inlet AMT dryer cartridges 
(where fitted) & CMS – do not re-use
4. Ensure the performance of the generator matches the 
system and required N2 outlet delivery.
5. Check against technical specification (Remove heat 
source).
6. Consult service personnel to adjust settings.
7. Replace silencer/muffler & Consult service personnel if 
problem pirsists.

Poor N2 purity or 

product performance

Problem Caused

Problem

Solution

8. Controller not functioning correctly

9. Controller not illuminated                       
10. Insufficient inlet pressure

11. Failure to de-pressurize when 
cycling 

12. Outlet flow stops

8. Ensure the controller is powered; check the on screen 
column status to ensure it is powering the solenoid valves. 
9. Check power to unit & fuse.
10. Inlet pressure = min 88psig (6barg). If not adjust inlet 
pressure settings (check rating plate).
11. Solenoid valve not functioning correctly; if there is power 
to the coil, replace valve. A correctly working valve outputs an 
audible click when it energizes. 
12. Check inlet air supply, purity valve & N2 purity.  
(check alarm status)

Failure of generator 

to cycle

13. Failure to initialize Generator

14. Erratic air flow from exhaust

13. Switch off and restart generator. Ensure generator is 
pressurized before powering it to allow generator to initialize 
before commencing operation.
14. Faulty or damaged valve; service required.

Constant 

depressurization

Reference to known misuse

•  Opening the inlet valve too quickly

Valve should be opened slowly allowing the pressure to build up gradually.

•  Inlet/outlet head pipe

Pipe diameter too small or pipe work unsupported.
Inlet pipe work from low point in system, allowing bulk water to collect and enter generator.

•  Electrical controller

Incorrect fuse fitted or fuse blown. Check the main I.E.C Connection for fuse (see page 16).

•  Additional Items

Use of non-authorized components.
Untrained / unauthorized maintenance / installation personnel used.
Increase in nitrogen consumption without relation to the flow capacity of the product.
Purging the product with cleaning agents that could damage the components or the CMS.
Covers removed or loose during operation.
Failure to carry out a service when indicated by the product.

Summary of Contents for GEN2-1110

Page 1: ...GEN2 NITROGEN GENERATOR USER GUIDE...

Page 2: ...ipment Overview 9 7 System Layout 10 7 1 Site Location 11 7 2 Mechanical Installation 11 8 Electrical Control Panel 12 8 1 Remote Alarms 13 8 2 Remote Start Stop 13 8 3 Start up Procedure 13 8 4 HMI I...

Page 3: ...ation site and be kept in an easily accessible place NOTES highlight important sections of information where particular care and attention should be paid CAUTIONS indicate any situation or operation t...

Page 4: ...r your own safety when carrying out work on this product all relevant national safety regulations must be complied with relating to pressurized and electrical systems This product is only designed to...

Page 5: ...oduction When a generator is specified with an internal dryer each CMS column has a unique adsorption media tube technology dryer fitted into the bottom of each column The unique intergrated dryer doe...

Page 6: ...top cover can be removed by removing the screws and lifted off in multiple pieces Damage to Packaging Check immediately to establish whether damage has occurred to the external packaging and if the d...

Page 7: ...den crate It is recommended that the crate be moved into position using a forklift truck or pallet truck Remove the generator from the wooden crate using an overhead crane Use the following illustrati...

Page 8: ...15 03 382 71 33 1812 6 37 162 12 48 317 31 57 802 68 20 1732 5 GEN2 3130 1 36 18 919 21 65 550 71 33 1812 6 37 162 12 48 317 31 57 802 68 20 1732 5 GEN2 4130 1 42 79 1087 28 26 718 71 33 1812 6 37 16...

Page 9: ...Buffer Tank Dimension H 1 2 Port 3 N2 Outlet Dimension G 1 2 Port 4 Main Power Inlet 5 HMI Screen Display 6 10 11 12 N2 Outlet pressure Gauge Sample Point 1 8 Port Top Cover 13 Silencers Mufflers Air...

Page 10: ...ustomers responsibility to ensure pressure relief valves are fitted to the compressed air system All vessels supplied by nano come with a pressure relief valves and pressure gauge as standard 2 Buffer...

Page 11: ...er vessel and compressed air supply The diameter of the pipes must be sufficient to allow unrestricted inlet air supply to the generator and nitrogen supply to the applications shown in the table belo...

Page 12: ...ontrol Panel Electrical Power Requirements Supply 88 264 VAC 47 63 Hz Input Current 1 3 0 8A 115 230 VAC Main Power Connection Remote Start Stop Alarm Outputs Main Connections fig 1 RS Remote Start Ca...

Page 13: ...wn procedure stop cycling and go into standby mode this can also be achieved by using the shutdown feature on the HMI screen displaying STANDBY on the display once completed Using remote stop start en...

Page 14: ...to the fault log Set Time This screen allows the end user to enter the correct time and date Login Access to the Menu structures there are 3 levels of pass code protection within the screen Service R...

Page 15: ...ff Pressure Units bar psi Installation Level 2 Access You are able to adjust the following Installation date Commissioned by Company name of commisioning engineer Service interval Service Details Leve...

Page 16: ...tion gas at 7 25 145 psi 0 5 10 bar Allow the display to stablize before moving on to the next step 4 Follow the Sensor Calibration Procedure page 18 5 Once calibrated close ball valve B remove the c...

Page 17: ...nd introduce calibra tion gas at 7 25 145 psi 0 5 10 bar Allow the display to stablize before moving on to the next step 4 Follow the Sensor Calibration Procedure page 18 5 Once calibrated close ball...

Page 18: ...sor will revert back to normal monitoring mode Using the Next increment button and the Previous decrement button set the display to that of the calibration gas level Press the Enter button This will S...

Page 19: ...he generator is left operating in a safe working condition after completion of maintenance 10 1 Daily checks Visual and functional check of the generator should be carried out daily Check the generato...

Page 20: ...130 A BSP 130 A NPT 130 GEN2 3130 GEN2 4130 GEN2 6130 GEN2 8130 GEN2 10130 GEN2 12130 Oxygen Analyzer Recommended Service Intervals E Galvanic Cell P P P P F Zirconian Cell P Service A A XXX 130HP 2 E...

Page 21: ...fuse 10 Inlet pressure min 88psig 6barg If not adjust inlet pressure settings check rating plate 11 Solenoid valve not functioning correctly if there is power to the coil replace valve A correctly wo...

Page 22: ...ir supplied from an oil lubricated compressor to keep its operating temperature low to minimize oil vapor Where this is not possible an additional activated carbon adsorber must be used To claim under...

Page 23: ...Page 23 17 110 0143 14 Electrical Schematic 14 1 GEN2 1110 2110 3110 2130 3130 4130 6130 8130 10130 12130...

Page 24: ...46 USE CONNECTIONS 3 4 5 EARTH GREEN WIRE TO TERMINAL 3 NEUTRAL BLACK WIRE TO TERMINAL 4 LIVE RED WIRE TO TERMINAL 5 CABLE DESCRIPTIONS 1 HMI POWER LEAD 2 OXYGEN SENSOR O2 CELL 3 OXYGEN SENSOR OUTLET...

Page 25: ...e Man ol nlet Pressure rans u er Com resse A r nlet U ER VESSEL Exhaust Control Valve Column Pressure Gauge Purge Control Valve NRV nlet Control Valve Outlet Control Valve Outlet Control Valve nlet Co...

Page 26: ...Page 26 17 110 0143 Notes...

Page 27: ...Page 27 17 110 0143 Notes...

Page 28: ...704 897 2182 Fax 704 897 2183 Internet www n psi com E mail support n psi com nano purification solutions ltd Dukesway Team Valley Trading Estate Gateshead NE11 0PZ United Kingdom Telephone 44 0 191...

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