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User Guide

GEN2 i4.0 nitrogen gas generator

revision: 2022-059 document: 17-100-0145

www.n-psi.co.uk

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Summary of Contents for GEN2 i4.0

Page 1: ...User Guide GEN2 i4 0 nitrogen gas generator revision 2022 059 document 17 100 0145 www n psi co uk ...

Page 2: ...port our products or the machine builders who depend on them as protection for their equipment They are the contractors who install them the manufacturers who use them in their processes and the service people who maintain them At nano we have developed our products packaging and support materials to ensure they exceed all of our Customers expectations At nano we recognise that world class custome...

Page 3: ...view 10 2 5 typical system layout 11 2 6 site location and installation 12 2 7 electrical installation 13 2 8 remote start stop control 14 2 9 remote alarms dryer control 15 3 3 1 user interface 16 17 3 2 start up procedure 18 3 3 shutdown procedure 18 3 4 economy 19 3 5 purity dependent energy saving PDES 19 4 4 1 maintenance 20 4 2 cleaning 20 4 3 daily checks 20 4 4 purity generator service sch...

Page 4: ...internet www n psi co uk e mail sales n psi co uk nano purification solutions inc address 509 David Cox Road Charlotte NC 28269 USA telephone 1 704 897 2182 internet www n psi com e mail support n psi com nano purification solutions inc address 7 Petrie Street St Catharines Ontario L2P 3J6 Canada telephone 1 905 684 6266 internet www n psi com e mail support n psi com nano purification solutions G...

Page 5: ...e If there is damage to a product contact the relevant supplier immediately Under no circumstances must a damaged product be used in operation Using damaged products can lead to irreparable functional faults or cause serious physical harm 1 6 general safety No modifications must be made to the product Any modifications may reduce the operational safety of the product and invalidate the manufacture...

Page 6: ... CMS Oxygen is preferentially adsorbed by the CMS allowing nitrogen to pass through After a pre set time the control system automatically switches the bed to equalization mode where the online bed pressure is equalized with the second regenerated bed Once equalized the online bed is switched to regenerative mode and oxygen is vented from the CMS A small portion of the outlet nitrogen gas is expand...

Page 7: ...EMA 2 model connections compressed air inlet to buffer vessel from buffer vessel nitrogen outlet GEN2 i4 0 1110 1 BSPP or NPT 1 BSPP or NPT 1 2 BSPP 1 2 BSPP GEN2 i4 0 2110 GEN2 i4 0 3110 GEN2 i4 0 2130 GEN2 i4 0 3130 GEN2 i4 0 4130 GEN2 i4 0 6130 GEN2 i4 0 8130 GEN2 i4 0 10130 GEN2 i4 0 12130 2 1 specification symbol description symbol description always take caution while using the equipment ear...

Page 8: ...466 699 932 1398 1864 2143 2489 500ppm Nm3 h 3 0 6 0 9 0 11 4 17 1 22 8 34 2 45 6 52 4 60 9 SCFH 105 211 317 402 603 805 1207 1610 1850 2150 250ppm Nm3 h 2 5 5 0 7 5 10 0 15 0 20 0 30 0 40 0 46 0 53 3 SCFH 88 176 264 353 529 706 1059 1412 1624 1882 100ppm Nm3 h 2 0 4 0 6 0 8 9 12 6 16 8 25 2 33 6 38 6 44 9 SCFH 70 141 211 314 444 593 889 1186 1363 1586 50ppm Nm3 h 1 7 3 4 5 1 7 2 10 8 14 4 21 6 28...

Page 9: ...30 1823 71 77 400 15 75 773 30 43 161 6 34 1731 68 15 311 12 24 615 24 21 379 14 92 3130 1823 71 77 400 15 75 941 37 05 161 6 34 1731 68 15 311 12 24 615 24 21 547 21 53 4130 1823 71 77 400 15 75 1109 43 66 161 6 34 1731 68 15 311 12 24 615 24 21 715 28 15 6130 1823 71 77 400 15 75 1445 56 89 161 6 34 1731 68 15 311 12 24 615 24 21 1051 41 38 8130 1823 71 77 400 15 75 1781 70 12 161 6 34 1731 68 1...

Page 10: ...re gauge 4 nitrogen outlet 11 compressed air inlet pressure gauge 5 IEC mains power 12 nitrogen outlet pressure gauge 6 RS485 Modbus or EthernetIP Optional 13 enclosure panel lock 7 generator interface display 14 exhaust silencers mufflers 2 4 product overview symbol description symbol description compressed air inlet nitrogen outlet to buffer mixing vessel column A from buffer mixing vessel colum...

Page 11: ...buffer mixing vessel Only personnel trained qualified and approved by the supplier should perform installation commissioning service and repair procedures It is essential that the system into which the product is installed is fitted with a pressure limiting relief device This device should be between the compressor and the generator The device must be set to prevent the maximum working pressure of...

Page 12: ...en enrichment surrounding the generator Ensure the area surrounding the generator is adequately ventilated Once the generator has been located into position install ball valves and the pipework ready for connection to the buffer 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 applicatio...

Page 13: ...e size of up to 1 00mm2 18AWG IMPORTANT This product must be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current This product is equipped with a plug with an appropriate grounding post The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes a...

Page 14: ...lly to the input of a switch or relay Once this connection has been made you will need to add an additional connection on the output of the switch or relay this should then be wired back to the PLC into terminal i0 see item No 4 for reference When the connection is made and the circuit is complete you can then start the generator using the HMI power ON button If for any reason this wired connectio...

Page 15: ...Next you will need to add an additional three connections on each relay terminal Q12 Q13 Q14 see item No 2 3 4 and 5 for reference Each relay output relates to a different alarm code 1 Terminal COM3 5 277V AC 125V DC 50 60Hz Max 7A 2 Terminal Q12 Alarm output 1 Low inlet pressure alarm 3 Terminal Q13 Alarm output 2 Low outlet pressure alarm 4 Terminal Q14 Alarm output 3 High oxygen purity alarm 5 ...

Page 16: ...tors manual After 10 minutes of inactivity the generators HMI will enter an energy saving mode where the HMI screen will go black A green LED will remain lit at all times to indicate the HMI is still fully functional If at any point the HMI detects human interaction the energy saving mode will deactivate and the screen will revert back to the mains display seen above ...

Page 17: ...rement optional extra 8 economy access total hours in economy percentage savings and total hours in PDES optional extra economy the generator is in it s final stage of economy and has shut down No symbol description 9 oxygen content when grey the generator is in standby oxygen content when amber the generator is starting up oxygen content when green the nitrogen outlet purity is within specificati...

Page 18: ...ig of the compressed air inlet pressure slowly open the outlet isolation valve of the buffer vessel until fully open Check all connections to and from the buffer vessel for any leaks as this could affect nitrogen purity Slowly open the nitrogen outlet isolation valve until fully open If the generator is working correctly the nitrogen outlet button and O2 symbol will turn green to show the purity i...

Page 19: ...ty dependent energy saving PDES When fitted the PDES system adds an additional O2 analyzer assembly which constantly monitors the oxygen content of the gas stored within the buffer vessel the purpose of the PDES system is to reduce air consumption and maximize efficiency The PDES system works along side with the standard O2 analyzer which monitors the purity of the gas being produced and supplied ...

Page 20: ...or to assembly Ensure all components are re fitted to the product before operation Check all connection and sealing faces for any leakage if any found resolve and check again Ensure the generator is left operating in a safe working condition after completion of maintenance 4 2 cleaning Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical connections If requ...

Page 21: ...ity Part No 46 110 XX XXXXX XXZC PXX XXX ref kit no time period months 12 24 36 48 60 72 84 96 108 120 A 31 100 XXXX ü ü ü ü ü ü ü ü ü ü B 31 100 1510 ü ü ü ü C 31 100 1521 ü ü D 31 100 1530 ü x2 ü x2 ppm purity generators without PDES functionality Part No 46 110 XX XXXXX XXZP NXX XXX ref kit no time period months 12 24 36 48 60 72 84 96 108 120 A 31 100 XXXX ü ü ü ü ü ü ü ü ü ü B 31 100 1510 ü ü...

Page 22: ...1171 NPT exhaust silencer muffler x2 B 31 100 1185 piston valve seals x8 required o ring seals C 31 100 1520 pilot valves seals x5 diaphragm valves x2 24V DC solenoid coils x2 O2 sensor solenoid valve x1 31 100 1521 pilot valves seals x5 diaphragm valves x2 24V DC solenoid coils x2 O2 sensor solenoid valve x2 D 31 100 1530 purity oxygen sensor x1 31 100 1531 PPM purity oxygen sensor x1 4 6 service...

Page 23: ...hours run date serviced by comments observations print sign 12 months 24 months 36 months 48 months 60 months 72 months 84 months 96 months 108 months 120 months part number serial number installed by installation date 4 7 service record ...

Page 24: ...24 nitrogen gas generator 4 8 process and instrumentation diagram CMS Column CMS Column CMS Column CMS Column CMS Column CMS Column CMS Column CMS Column ISO CLASS 2 2 1 OR BETTER ...

Page 25: ...xhaust silencer s muffler s Service B Replace piston valve seals and oxygen analyzer control valve s Service C Replace all pilot valves diaphragm valves and solenoid coils Service D Replace oxygen analyzer s For more information about service kits see pages 21 and 22 For more information about service schedules and prices please contact your service provider ...

Page 26: ...26 nitrogen gas generator 4 9 notes ...

Page 27: ...27 nitrogen gas generator notes ...

Page 28: ... 2182 support n psi com www n psi com nano purification solutions st catharines ontario canada tel 1 905 684 6266 support n psi com www n psi com nano purification solutions new bethlehem pennsylvania tel 1 724 297 3416 airtak airtak com www airtak com nano purification solutions erkelenz germany tel 49 0 2151 482 8218 sales n psi de www n psi de Experience Customer Service ...

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