Potter Intelligen INS-2500 Installation, Operation And Instruction Manual Download

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Manual #5403680 - C

04/19

St. Louis, MO

800-325-3936

www.pottersignal.com

INS-2500

Nitrogen Generator

Installation, Operation, and

Instruction Manual

Summary of Contents for Intelligen INS-2500

Page 1: ...Manual 5403680 C 04 19 St Louis MO 800 325 3936 www pottersignal com INS 2500 Nitrogen Generator Installation Operation and Instruction Manual...

Page 2: ...his 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 w...

Page 3: ...working 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...

Page 4: ...f 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 oc...

Page 5: ...e 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 b...

Page 6: ...lows some gas to escape from the system which requires the nitrogen generator to supply nitrogen to maintain system pressure This process therefore increases the nitrogen concentration within the syst...

Page 7: ...net 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...

Page 8: ...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...

Page 9: ...0 REV C 04 19 INS 2500 Nitrogen Tank View Fig 3 1 1 2 FNPT N2 Tank Inlet Valve V02 2 Pressure Safety Valve PSV01 3 1 2 FNPT N2 Tank Outlet Valve V03 4 Nitrogen Tank Pressure Gauge 5 N2 Tank Drain Ball...

Page 10: ...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 Drai...

Page 11: ...erator 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 a...

Page 12: ...o see these components have arrived Nitrogen Air Maintenance Device one per riser NAMD 1119660 Nitrogen Purge Valve NGP SPV 1119784 or INS PV 1119478 Portable Nitrogen Analyzer one per job PNA 1119504...

Page 13: ...ank mounted air compressor to the floor using the supplied vibration pads and user supplied 4 standard 3 8 bolts See Fig 8 Fig 9 Fig 8 9 16 Mounting Holes 4 9 16 Mounting Holes 4 Fig 10 9 Mount the ni...

Page 14: ...unted air compressor to the floor drain in the sprinkler room Do not pipe the drain tubing upward See Fig 14 Drain Tube Fig 11 Fig 12 11 Plumb NPT piping from the MNPT flex hose connection to the FNPT...

Page 15: ...installed prior to implementing the Nitrogen Purging Procedure For installation instructions refer to Model NGP SPV Bulletin 5401520 or Model INS PV Manual 5401532 supplied with each purge valve See...

Page 16: ...m of the tank mounted air compressor 120V Nitrogen cabinet 120V Four items must be wired on the INS 2500 model 1 Run a dedicated electrical circuit with an electrical disconnect switch to the sprinkle...

Page 17: ...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 Compres...

Page 18: ...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 t...

Page 19: ...other 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...

Page 20: ...vice 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 nitr...

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 2500 should take no longer than 10 minutes to pressure both t...

Page 22: ...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 while the...

Page 23: ...lacing 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...

Page 24: ...eam 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 indica...

Page 25: ...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 26: ...nformation 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...

Page 27: ...se 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 Serie...

Page 28: ...ng 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 cont...

Page 29: ...Check 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...

Page 30: ...04 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 p...

Page 31: ...ce 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...

Page 32: ...n Strainer Screen 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...

Page 33: ...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...

Page 34: ...ight 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 co...

Page 35: ...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 Intelli...

Page 36: ...mbrane 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 m...

Page 37: ...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 38: ...lenoid 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 V...

Page 39: ...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 Warn...

Page 40: ...e 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 the blue N2 Bleed Valve V04 when you see the...

Page 41: ...e of the cabinet 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...

Page 42: ...l 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 main...

Page 43: ...ER to accept change 11 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 2500 is factory set...

Page 44: ...44 INS 2500 5403680 REV C 04 19 INS 2500 Cabinet Dimensional Drawings A CONNECTION CONNECTION C DRAIN CONNECTION 3 8 Fig 49...

Page 45: ...45 INS 2500 5403680 REV C 04 19 INS 2500 Nitrogen Tank Dimensional Drawings Fig 50 APART ON A...

Page 46: ...C SIGNAL CO PROPRIETARY DATA VENDOR CERTIFICATION 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 C...

Page 47: ...01 AIR COMPRESSOR F01 COALESCING FILTER 1 m F02 COALESCING FILTER 01 m F03 CARBON FILTER W DRAIN VALVE F04 INSTRUMENT AIR FILTER FCV01 FLOW CONTROL VALVE M01 NITROGEN MEMBRANE PI01 PRESSURE TRANSDUCER...

Page 48: ...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...

Page 49: ...ER 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...

Page 50: ...ER 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...

Page 51: ...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...

Page 52: ...e 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 Maintena...

Page 53: ...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 S...

Page 54: ...in 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 Maintena...

Page 55: ...ify 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...

Page 56: ...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 M...

Page 57: ...ttings 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...

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