CompAir CN20033 User manual

ZS*******. 176510020./ 000 07/2012
EN Original Language
Nitrogen Gas Generator
CN20033 - CN20090
User Manual

Warranty
This warranty applies to the generator and associated parts (the equipment) supplied by CompAir.
Use of the generator without the recommended inlet air quality or genuine parts will expressly invalidate the warranty.
Should the equipment be defective as to materials or workmanship, the company warrants that it will remedy such defect. Where the Equipment
is agenerator, the warranty period will be 12 months from date of commissioning or 18 months from date of manufacture, whichever is the
earlier. In the case of equipment other than agenerator, the warranty period shall commence from the date of despatch. Should any defect
occur during the warranty period and be notified in writing to the company or its authorised distributor within the said period, the company will,
as its sole option, remedy such defect by repair or provision of areplacement part, provided that the equipment has been used strictly in
accordance with the instructions provided with each item of equipment and has been stored, installed, commissioned, operated and maintained
in accordance with such instruction and with good practice. the company shall not be under any liability whatsoever under the warranty, if, before
giving notification in writing to the company as aforesaid, the Customer or any third party meddles, interferes, tampers with or carries out work
whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the Equipment or any part thereof.
Any accessories, parts and equipment supplied by the company but not manufactured by the company shall carry whatever warranty the
manufacturer has given the company providing it is possible for the company to pass on such warranty to the customer.
To c l aim under the warranty, the equipment must have been installed and continually maintained in the manner specified in the User Guide. Our
product support engineers are qualified and equipped to assist youin this respect. They are also available to make repairs that may become
necessary in which event they will require an official order before carrying out the work. If such work is to be the subject of awarranty claim, the
order should be endorsed for consideration under warranty.
Where equipment is sold outside the UK mainland direct to the end user the warranty will cover parts only. Any substitution of parts not
manufactured or approved by the company will expressly invalidate the warranty.

CONTENTS
1 Safety Information ........................................................................................................................................................................................1
1.1 Markings and Symbols ........................................................................................................................................................................2
1.2 Approvals ..............................................................................................................................................................................................2
2 Description ....................................................................................................................................................................................................3
2.1 Technical Specification........................................................................................................................................................................3
2.1.1 Generator Weights and Dimensions ............................................................................................................................................4
2.2 Receiving and Inspecting the Equipment ..........................................................................................................................................5
2.2.1 Storage.........................................................................................................................................................................................5
2.2.2 Unpacking ....................................................................................................................................................................................5
2.3 Overview of the equipment..................................................................................................................................................................6
2.4 Locating the Equipment.......................................................................................................................................................................7
2.4.1 Environment .................................................................................................................................................................................7
2.4.2 Space Requirements....................................................................................................................................................................7
2.4.3 Ventilation Requirements .............................................................................................................................................................7
2.4.4 Air Inlet Quality .............................................................................................................................................................................7
2.4.5 Electrical Requirements ...............................................................................................................................................................7
3 Installation and Commissioning..................................................................................................................................................................8
3.1 Recommended System Layout ...........................................................................................................................................................8
3.1.1 Buffer vessel selection .................................................................................................................................................................8
3.1.2 Pre-treatment dryer selection .......................................................................................................................................................8
3.2 Mechanical Installation ........................................................................................................................................................................9
3.3 Electrical Installation..........................................................................................................................................................................10
3.3.1 Generator Supply .......................................................................................................................................................................11
3.3.2 Dryer Supply...............................................................................................................................................................................11
3.3.3 Purge Economy..........................................................................................................................................................................11
3.3.4 Remote Switching ......................................................................................................................................................................11
3.3.5 Alarm Contacts...........................................................................................................................................................................11
3.3.6 4–20mA Analogue Output ..........................................................................................................................................................11
4 Operating the Generator ............................................................................................................................................................................12
4.1 Overview of controls ..........................................................................................................................................................................12
4.2 Starting the generator ........................................................................................................................................................................13
4.3 Stopping and depressurising the generator.................................................................................................................................... 13
4.4 Start Clean Up.....................................................................................................................................................................................14
4.6 Menu Interface ................................................................................................................................................................................... 15
4.6.1 Menu Map ..................................................................................................................................................................................15
4.6.2 Password Protected Menus .......................................................................................................................................................16
4.6.3 Hour Meters............................................................................................................................................................................... 16
4.6.4 Fault Log ................................................................................................................................................................................... 16
4.6.5 Customer Settings......................................................................................................................................................................17
5 Servicing......................................................................................................................................................................................................18
5.1 Cleaning ..............................................................................................................................................................................................18
5.2 Service Intervals .................................................................................................................................................................................18
5.3 Service Kits .........................................................................................................................................................................................19
5.4 Service Procedures ............................................................................................................................................................................20
5.4.1 Exhaust Silencer Replacement ..................................................................................................................................................20
5.4.2 Oxygen Cell Replacement..........................................................................................................................................................20
5.4.3 Dust Filter Element Change ....................................................................................................................................................... 20
5.5 Oxygen Analyser Calibration ............................................................................................................................................................22
5.6 Service Record ...................................................................................................................................................................................24
6 Troubleshooting..........................................................................................................................................................................................25
Wiring Schematics....................................................................................................................................................................................173
006510005 Basic Schematic ............................................................................................................................................................173
006510006 Analysing Schematic ....................................................................................................................................................174

1
1 Safety Information
Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all
personnel concerned.
The pressure envelope of the generator must not be breached under any circumstances. Failure to comply may result in an unplanned release
of pressure, and may cause serious personal injury or death. All maintenance procedures that require the pressure envelope to breached must
only be performed by competent personnel trained, qualified, and approved by Compair.
Due to the nature of operation there is a possibility of oxygen enrichment surrounding the generator. Ensure that the area is adequately
ventilated. Where the risk of oxygen enrichment is high, such as a confined space or poorly ventilated room, the use of oxygen monitoring
equipment is advisable.
Nitrogen is not a poisonous gas but, in a concentrated form, there is a risk of asphyxiation. Depending upon the model and operating pressure,
the generator is capable of delivering nitrogen at a flow rate of 33.3 m3/hr. If the generator is operated within a confined space ensure that
adequate ventilation and oxygen monitoring equipment is fitted.
Use of the equipment in a manner not specified within this user guide may result in an unplanned release of pressure, which may cause serious
personal injury or damage.
When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related regulations,
health & safety procedures, and legal requirements for safety.
Ensure that the equipment is depressurised and electrically isolated, prior to carrying out any of the scheduled maintenance instructions
specified within this user guide.
Only competent personnel trained, qualified, and approved by Compair should perform installation, commissioning, service and repair
procedures.
Note: Any interference with the calibration warning labels will invalidate the gas generator’s warranty and may incur costs for the re-calibration
of the gas generator.
Compair can not anticipate every possible circumstance which may represent a potential hazard. The warnings in this manual cover the most
known potential hazards, but by definition can not be all-inclusive. If the user employs an operating procedure, item of equipment or a method of
working which is not specifically recommended by Compair the user must ensure that the equipment will not be damaged or become hazardous
to persons or property.
Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and
procedures. Accidents can be avoided by recognising that any machinery is potentially hazardous.
Details of your nearest Compair sales office can be found at www.compair.com
Retain this user guide for future reference.

2
1.1 Markings and Symbols
The following markings and international symbols are used on the equipment or within this user guide:
1.2 Approvals
Caution, Read the User Guide. Wear ear protection
Risk of electric shock. Pressurised components on the system
Highlights actions or procedures which, if not
performed correctly, may lead to personal injury or
death.
Remote control. Generator may start automatically
without warning.
Highlights actions or procedures which, if not
performed correctly, may lead to damage to this
product.
Conformité Européenne
Highlights actions or procedures which, if not
performed correctly, could lead to electric shock.
When disposing of old parts always follow local
waste disposal regulations.
Read the User Guide Waste electrical and electronic equipment should
not be disposed of with municipal waste.
NITROGEN (N2)
DO NOT BREATHE
Asphyxiant in high concentrations. No odour.
Slightly lighter than air. Ensure adequate
ventilation. Breathing 100% nitrogen will produce
immediate unconsciousness and death due to lack
of oxygen.
NON-FLAMMABLE COMPRESSED GAS
Use a fork lift truck to move the generator.
SAFETY and ELECTROMAGNETIC COMPATIBILITY
This equipment has been tested and complies with the following European Standards:
EN 61010-1: 2001 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory use -
Part 1: General Requirements
EN 61000-6-1:2007 Electromagnetic compatibility (EMC) - Part 6-1: Generic standards - Immunity for residential,
commercial and light-industrial environments
EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial
environments
EN 61000-6-3:2007 Electromagnetic compatibility (EMC) - Part 6-3: Generic standards - Emission standard for
residential, commercial and light-industrial environments
EN 61000-3-2:2006 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions
(equipment input current <= 16 A per phase)
EN 61000-3-3:1995
Including:
Amendment A1:2001
Amendment A2:2006
Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage supply systems, for equipment with rated current <=
16 A per phase and not subject to conditional connection.
This equipment has been tested to and complies with the following standard:
UL 61010-1 2nd Edition 2005, Electrical Equipment for Measurement, Control and Laboratory Use; Part 1: General
Requirements.
CAN/ CSA C22.2 No.61010-1 2nd Edition 2004, Electrical Equipment for Measurement, Control and Laboratory Use; Part 1:
General Requirements.
NITROGEN (N
2
)
GAS
NON-FLAMMABLE
DO NOT BREATHE
COMPRESSED
Asphyxiant in high
concentrations. No odour
Slightly lighter than air.
Ensure adequate ventilation.
Breathing 100% nitrogen will produce
immediate unconsciousness and death
LISTED
LABORATORY
EQUIPMENT 84NA

3
2 Description
The CN20033 - CN20090 range of nitrogen generators operate on the Pressure Swing Adsorption (PSA) principle to produce a continuous
stream of nitrogen gas from clean dry compressed air.
Dual chamber columns, filled with extruded beads of adsorbent (Carbon Molecular Sieve [CMS]) material, are joined via an upper and lower
manifold to produce a two bed system. Compressed air enters the bottom of the ‘on-line’ bed and flows up through the CMS. The oxygen,
carbon dioxide, humidity and non-methane hydrocarbons are preferentially adsorbed by the CMS allowing clean dry nitrogen to pass through.
After a pre-set time the control system automatically switches the bed to regenerative mode. All of the contaminants are vented from the CMS
and a small portion of the outlet nitrogen gas is expanded into the bed to accelerate the regeneration. At the same instant the second bed
comes on-line and takes over the separation process.
The CMS beds alternate between separation and regeneration modes to ensure continuous and uninterrupted nitrogen production.
The oxygen concentration in the nitrogen stream is analysed continuously. If the concentration exceeds the required production level, the
nitrogen outlet is closed and the gas is vented to atmosphere. Normal operation will resume when the purity recovers.
2.1 Technical Specification
Stated flows are for operation at 7 bar g (100 psi g / 0.7 MPa g) with reference to 25ºC.
UNITS 10ppm 100ppm 250ppm 500ppm 0.1% 0.5% 1% 2% 3% 4% 5%
Flowrate
CN20033 m3/hr 0.55 1.2 1.5 1.9 2.4 3.4 4.3 5.8 7.2 8.4 9.4
cfm 0.3 0.7 0.9 1.1 1.4 2.0 2.5 3.5 4.2 4.9 5.5
CN20072 m3/hr 1.2 2.4 3.2 3.9 4.7 6.9 8.5 11.6 14.3 16.7 18.8
cfm 0.7 1.4 1.9 2.3 2.8 4.1 5.0 6.8 8.4 9.8 11.1
CN20090 m3/hr 1.5 3.2 4.2 5.3 6.5 9.5 11.5 15.2 18.7 21.7 24.5
cfm 0.9 1.9 2.5 3.1 3.8 5.6 6.8 8.9 11.0 12.8 14.4
Outlet Pressure bar g 5.6 5.4 5.9 5.7 5.6 5.7 6.0 6.0 5.8 5.7 5.6
psi g 81.2 78.3 85.6 82.7 81.2 82.7 87.0 87.0 84.1 82.7 81.2
Inlet Parameters
Inlet Air Quality ISO 8573-1: 2010 Class 2.2.2
Inlet Pressure 6 – 13 bar g
88 – 188.5 psi g
Inlet Temperature 5 – 50 oC
(41 – 122 oF)
Port Connections
Air Inlet G1/2
N2Outlet to Buffer G1/2
N2Inlet from Buffer G1/2
N2Outlet G1/2
Electrical Parameters
Generator Supply †115 / 230 ± 10% Vac 50/60 Hz
Generator Power ‡80 W
Fuse
3.15 A
(Anti Surge (T), 250v, 5 x 20mm HBC,
Breaking Capacity 1500A @ 250v,
IEC 60127, UL R/C Fuse)
Max Dryer Power* 100W
Environmental Parameters
Ambient Temperature 5 – 50 oC
(41 – 122 oF)
Humidity 29% @ 50oC (80% MAX d31oC)
IP Rating IP20 / NEMA 1
Pollution Degree 2
Installation Category II
Altitude < 2000 m
(6562 ft)
Noise <80 dB (A)
Packed Weights and Dimensions
Dimensions
mm / (ins)
Weight
Kg / (lbs)
H W D
CN20033 612
(24.48)
1490
(59.6)
950
(38)
174
(383.6)
CN20072 612
(24.48)
1490
(59.6)
950
(38)
221
(487.2)
CN20090 612
(24.48)
1490
(59.6)
950
(38)
272
(597.7)
Notes:
†The generator does not require adjustment when connecting to 115v and 230v electrical supplies.
‡The power rating specified is for the generator alone and does not take in to account any pre-treatment dryer connected to the dryer supply terminals of the generator.
* The dryer is fed directly from the generator supply.

4
2.1.1 Generator Weights and Dimensions
Dimensions
mm / (ins)
Weight
Kg / (lbs)
H W D (a) (b) (c) (d) (e) (f) (g) (h)
CN20033 1034
(41.36)
450
(18)
471
(18.84)
375
(15)
298
(11.92)
408
(16.32)
682
(27.28)
754
(30.16)
869
(34.76)
203
(8.12)
233
(9.32)
98
(216.1)
CN20072 1034
(41.36)
450
(18)
640
(25.6)
375
(15)
467
(18.68)
408
(16.32)
682
(27.28)
754
(30.16)
869
(34.76)
203
(8.12)
233
(9.32)
145
(319.7)
CN20090 1034
(41.36)
450
(18)
809
(32.36)
375
(15)
636
(25.44)
408
(16.32)
682
(27.28)
754
(30.16)
869
(34.76)
203
(8.12)
233
(9.32)
196
(432.1)
H
W D
(a) (b)
(c)
(d)
(f)
(e)
(g)
(h)

5
2.2 Receiving and Inspecting the Equipment
The equipment is supplied in a sturdy wooden crate designed to be moved using a forklift truck or pallet truck. Refer to the technical
specification for packed weights and dimensions.
On delivery of the equipment check the crate and its contents for damage and verify that the following items have been included:
If there are an signs of damage to the crate, or there are any parts missing please inform the delivery company immediately and contact your
local Compair office.
2.2.1 Storage
The equipment should be stored, within the packing crate, in a clean dry environment. If the crate is stored in an area where the environmental
conditions fall outside of those specified in the technical specification, it should be moved to its final location (installation site) and left to stabilise
prior to unpacking. Failure to do this could cause condensing humidity and potential failure of the equipment.
2.2.2 Unpacking
Remove the lid and all four sides of the packing crate (A) and unscrew the exhaust silencer from the generator (B). Lift the generator on to its
feet using suitable slings and an overhead crane (C, D and E).
Carefully move the generator to its final location, using a forklift truck or pallet truck, and refit the silencer.
Ref Description Qty
1Dust Filter 1
2Access Key 1
31/2” Ball Valve 3
41/2” 3 – way Ball Valve 1
AC
DF
B
E

6
2.3 Overview of the equipment
Key:
Ref Description Ref Description
1User control interface 7Mains supply cable gland
2Column A pressure gauge 8O2Analyser calibration port
3Column B pressure gauge 9N2Outlet port to buffer (G12)
4N2Outlet pressure gauge 10 N2inlet port from buffer vessel (G1/2)
5Air inlet pressure gauge 11 N2Outlet port (G1/2)
6Cable glands 12 Air Inlet port (G1/2)

7
2.4 Locating the Equipment
2.4.1 Environment
The equipment should be located indoors in an environment that protects it from direct sunlight, moisture, and dust. Changes in temperature,
humidity, and airborne pollution will affect the environment in which the equipment is operating and may impair the safety and operation. It is the
customers' responsibility to ensure that the environmental conditions specified for the equipment are maintained.
2.4.2 Space Requirements
The equipment should be mounted on a flat surface capable of supporting its own weight plus the weight of all ancillary parts. There must be
adequate space around the equipment to allow airflow and access for maintenance purposes and lifting equipment. A minimum spacing of
approximately 500mm (20”) is recommended around all sides. Refer to table 2.2 for overall dimensions of the equipment.
Do Not position the equipment so that it is difficult to operate or disconnect from the electrical supply.
Once positioned the equipment should be secured to the floor using M20 bolts.
2.4.3 Ventilation Requirements
2.4.4 Air Inlet Quality
This generator is designed for use with clean dry compressed air in accordance with ISO 8573-1:2010 class 2.2.2.
ISO8573-1:2010 is an international standard that specifies the purity classes of compressed air with respect to solid particulates, water and oil.
Understanding the requirements of the standard falls outside of the scope of this manual, however the following table summarises the
classification for each contaminant.
ISO 8573-1:2010 class 2.2.2 equates to the following:
Class 2 (Solid Particulate)
In each cubic metre of compressed air, not more than 400,000 particles in the 0.1–0.5 micron size range are allowed.
In each cubic metre of compressed air, not more than 6,000 particles in the 0.5–1 micron size range are allowed.
In each cubic metre of compressed air, not more than 100 particles in the 1–5 micron size range are allowed.
Class 2 (Water)
A pressure dewpoint of -40oC or better is required.
No liquid is allowed.
Class 2 (Oil)
In each cubic metre of compressed air, not more than 0.1mg of oil is allowed.
Note. This is the combined level for aerosol, liquid and vapour.
2.4.5 Electrical Requirements
Connection to the electrical supply should be made through a switch or circuit breaker rated at 250VAC, 15A with a minimum short circuit rating
of 10KA. This device should have a disconnection time not exceeding 40mS and all current carrying conductors should be disconnected.
The device chosen should be clearly and indelibly marked as the disconnecting device for the equipment and be located in close proximity to
the equipment and within easy reach for the operator.
Overcurrent protection must be fitted as part of the building installation. This protection should be selected in accordance with local and national
code regulations with a minimum short circuit rating of 10KA.
Due to the nature of operation there is a possibility of oxygen enrichment surrounding the generator. Ensure that the
area is adequately ventilated. Where the risk of oxygen enrichment is high, such as a confined space or poorly ventilated
room, the use of oxygen monitoring equipment is advisable.
Nitrogen is not a poisonous gas but, in a concentrated form, there is a risk of asphyxiation. Depending upon the model
and operating pressure, the generator is capable of delivering nitrogen at a flow rate of 33.3 m3/hr. If the generator is
operated within a confined space ensure that adequate ventilation and oxygen monitoring equipment is fitted.

8
3 Installation and Commissioning
3.1 Recommended System Layout
3.1.1 Buffer vessel selection
The buffer selection should be sized according to the flowrate of the generator.
3.1.2 Pre-treatment dryer selection
The following pre-treatment dryers are supplied with filtration.
Only competent personnel trained, qualified, and approved by Compair should perform installation, commissioning,
service and repair procedures.
Ref Description Ref Description Ref Description Ref Description
1Compressor 4Dryer pre-filtration 7Generator 10 Dust filter
2Wet air receiver 5Pre-treatment dryer 8Buffer vessel 11 Ball valve
3Water separator 6Dust filter 9Pressure relief valve 12 Drain valve
Flowrate Vessel capacity
m3/hr cfm L
0 - 3 0 - 1.8 50
3.1 - 7.5 1.8 - 4.4 150
7.6 - 12.3 4.5 - 7.2 250
12.4 - 24 7.3 - 14.1 500
24.1 - 34 14.2 - 20 750
Outlet Flow Rate m3/hr
Model Part Number Up to 30oCUp to 45oCPurge Loss (m3/hr)
A2LX A51109474 6.3 5.3 1.7
A3LX A51109574 10.3 8.3 2.7
A4LX A51109674 12.6 10.6 3.4
A5LX A51109774 16.5 13.6 4.4
A6LX A51109874 18.9 15.9 5.1
A7LX A51109974 25.2 22.2 6.8
A7XS A51144874 38.6 33.1 7.31
A9XS A51144974 51.3 44.0 9.85
A12XS A51145074 67.4 57.7 12.91
A15XS A51145174 85.2 73.0 16.14

9
3.2 Mechanical Installation
A Fit one of the 1/2 ball valves supplied to the compressed air inlet port on the generator and attach the compressed air supply to this ball
valve. Ensure that the valve is in the closed position.
B Fit another of the 1/2 ball valves supplied to the port marked “To Buffer vessel”. Install 1/2” NB / 16mm ID piping between the ball valve and
the buffer vessel inlet port. It is recommended that a ball valve (not supplied) be installed at the inlet to the buffer vessel to allow it to be
isolated during maintenance.
C Fit the remaining 1/2 ball valve to the port marked “From Buffer vessel”. Install 1/2” NB / 16mm ID piping between the ball valve and the
outlet port of the buffer vessel. The AR010 dust filter provided should be installed in this line. Follow the installation instructions provided
with the filter taking note of the direction of flow. It is recommended that a ball valve (not supplied) be installed at the outlet of the buffer
vessel to allow it to be isolated during maintenance.
D Fit the 3-way ball valve supplied to the port marked “Nitrogen Outlet”. Connect this ball valve to the application using 1/2” NB / 16mm ID
piping.This piping must be solid and non-porous to minimise the ingress of oxygen.
Note. The nitrogen buffer vessel must be rated to at least the maximum operating pressure of the generator and must be fitted with a suitable
pressure gauge and pressure relief valve.
It is recommended that the system be protected with suitably rated pressure relief valves upstream of the generator.
A
C D
B

10
3.3 Electrical Installation
In order to maintain the IP rating of the generator, all cables entering the electrical enclosure must do so through the dedicated cable glands
located on the side of the generator.
Refer to the wiring schematics at the rear of the manual for details of the required terminations. All terminals are identified in the image below.
A fully qualified electrical engineer must undertake all field wiring and electrical work in accordance with local
regulations.
REF Connection Terminal Notes Cable Diameter
TB1 Generator Supply
L - Fuse terminal for the phase conductor.
6 - 12 mm
N - Neutral conductor
- Protective Earth conductor
TB1 Dryer Supply
L (Grey) Dryer Live conductor
3 – 7 mm
N (Blue) Dryer Neutral conductor
(Yellow / Green) Dryer Earth conductor.
JP 17 Purge Economy
JP17-1 (NC) Not Used
JP17-2 (COM) The relay is energised when the generator is in
standby.
Refer to installation instructions for the dryer.
3 – 7 mm
JP17-3 (NO)
JP 19
Remote Switching JP19-7 (INPUT 4) Remote switching is activated in the customer
Settings menu 3.11
3 – 7 mm
JP19-8
MODBUS ARS485
MODBUS
B
JP 18 Alarm Contacts
JP18-1 (NC)
The relay is energised when no faults are present 3 – 7 mmJP18-2 (COM)
JP18-3 (NO)
OA 1 O24-20mA Analyser - 6 (+ve) The mesh screen of the cable should be bonded
to the metal plate of the shroud. 3 – 7 mm
Analyser - 7 (-ve)
When wiring to the terminals of JP17, JP18 and JP19 ensure that the wires are secured so that, in the event of one
coming loose, they cannot short out against the surrounding terminals.
JP 17
TB 1
JP 18JP 19
OA 1

11
3.3.1 Generator Supply
The generator supply terminals are designed to accommodate a maximum conductor size of 2.5mm2(14 AWG). It is the users responsibility to
size the supply cable in accordance with local wiring regulations, taking in to account cable temperatures, installation methods and voltage drop.
The protective earth conductor should be longer than the associated phase conductors so that in the event of the cable slipping in the cable
gland, the earth will be the last to take the strain.
3.3.2 Dryer Supply
If a Compair pre-treatment air dryer is used, it should be connected to the generator at the dedicated DIN rail terminals. Refer to the
documentation provided with your dryer for additional information on installation requirements.
3.3.3 Purge Economy
If the pre-treatment dryer is fitted with a purge economy feature, it may be controlled using the volt free relay contacts on JP17. The relay is
energised only when the generator enters standby mode.
Refer to the documentation provided with your dryer for details on purge economy.
3.3.4 Remote Switching
The generator may be controlled remotely by connecting a remote start / stop circuit to JP19-7 and JP19-8 on the control board. When the
circuit is open the generator should remain in standby mode, closing the circuit should initiate a start command.
To enable the remote switching function refer to “Customer Settings ” on page 17 of this guide. Once the remote switching function has been
enabled the local start control will no longer function.
3.3.5 Alarm Contacts
The generator is fitted with a set of volt free relay contacts designed for connection to a remote alarm circuit. The contacts are rated 1A max @
250Vac (1A @ 30Vdc). Under normal operation the relay is energised, when a fault occurs the relay will de-energise causing the relay contacts
to change state.
3.3.6 4–20mA Analogue Output
The oxygen content detected by the generators internal analyser may be re-transmitted to external peripherals using the 4-20mA linear
analogue output. The output is a linear current source, with 10 bit resolution, which increases from 4mA (Zero Oxygen) to 20mA (Full Scale
Deflection). The FSD of the internal analyser is factory set to a default value of twice the generators specified purity. For% purity generators the
maximum FSD is set to 6%.
Note: The oxygen purity setting of the generator is marked on the rating plate.
The table below shows the correlation between the purity settings of the generator and the output current. The FSD can be altered in menu 3.8
of the control software (refer to “Customer Settings ” on page 17 of this guide for details).
For safety reasons the generator must be connected to earth at the earth terminal provided on TB1.
When the remote switching function is enabled the generator can start without warning.
If the generator is connected to a remote alarm circuit, the electrical enclosure will contain more than one live circuit. In
the event of the generator electrical power supply being disconnected, the fault relay connections will remain live. It is
the users responsibility to provide a disconnection device so that these connections can be safely isolated.
Generator
Purity
Full Scale Deflection
Resolution
4mA -20mA
10ppm 0 - 20ppm 1ppm =0.8mA
100ppm 0 - 200ppm 1ppm =0.08mA
250ppm 0 - 500ppm 1ppm =0.032mA
500ppm 0 - 1000ppm 0.01% 0.016mA
0.1% 0 - 0.2% 0.01% =0.8mA
0.5% 0 - 1% 0.01% =0.16mA
1% 0 - 2% 0.01% =0.08mA
2% 0 - 4% 0.01% =0.04mA
3% 0 - 6% 0.01% =0.026mA
4% 0 - 6% 0.01% =0.026mA
5% 0 - 6% 0.01% =0.026mA

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4 Operating the Generator
4.1 Overview of controls
There are two control options available for this range of generators:
A–Control with O2Analyser.
When fitted with an O2analyser the controller provides a visual indication of the operating status of the generator. In addition to this the menu
driven interface provides access to essential information such as oxygen purity, hour meters and fault logs. By entering a three digit password,
trained personnel can view and adjust O2cell calibration settings, O2alarm settings and remote control functionality.
B–Control without O2Analyser.
The controller fitted to generators without an integrated O2analyser provides a visual indication of the operating status. The liquid crystal display
gives a reading of the total number of hours that the generator has been running.
Key:
Green - Cycling
Amber - Start clean up, shutting down, N2 vent (No gas is
delivered to the application), and entering economy
Red - Standby
Moves upwards through the menus
Green - Economy mode Moves downwards through the menus
Amber - Service due
Red - Active Fault Selects the current menu.
Local Start control (This control is inactive when the
generator is configured for remote control).
Toggles the generator between run and standby modes.
THIS IS NOT AN ISOLATION SWITCH
Local Stop control (This control is active for both local and
remote control).
A–Control with O2Analyser B–Control without O2Analyser

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4.2 Starting the generator
1 Make sure that all connection points are secure and all of the ball
valves on the system are closed.
2 Open the ball valve (BV1) on the compressed air inlet port.
3 Switch ‘ON’ the electrical power to the generator and wait for the
controller to complete the initialisation routine.
4 Press or to initiate the start up routine. If the start clean up option
is enabled the generator will run through “Rapid Cycle / Pure Start”
[Refer to section 4.4 for more details on Rapid Cycle and Pure Start].
Note. If the generator was running when the electrical power was
removed (e.g. power failure), the start up routine will be initiated
automatically.
On completion of the clean up cycle the N2outlet valve will open and
the N2outlet indicator will illuminate green.
5 Open the buffer inlet ball valves (BV2) approximately 10 degrees and
leave the buffer vessel to pressurise gradually. When the pressure
gauge on the buffer vessel reads within 0.5 barg (7psig, 0.05MPa) of
the inlet pressure, check for leaks in the connecting piping and then
fully open the ball valves.
6 Open the ball valves on the outlet of the buffer vessel (BV3) and check
for leaks in the piping between the vessel and the generator.
7 Open the ball valve (BV4) on the N2Outlet port.
Note: If the purity of the gas is not within specification (applies only to generators fitted with an O2analyser) it will be vented to atmosphere
through a vent solenoid within the generator. Gas will only be delivered to the application when the specified purity is achieved.
The generator is designed for continuous use and, once running, requires no further operator intervention.
4.3 Stopping and depressurising the generator
1 Close the ball valve on the N2Outlet port (BV4).
2 Press or to initiate the shutting down sequence.
3 The generator will complete the current cycle and then exhaust both
beds. This may take several minutes particularly on ppm generators.
4 When the generator is depressurised it will revert to standby mode.
Close the ball valve (BV1) on the compressed air inlet port and buffer
vessel ball vales (BV2) and (BV3).
5 To release the residual pressure disconnect the purge pipe (X) from
one of the flow regulators on the upper manifold.
Wait for the pressure gauges to drop to zero before continuing.
There may be a residual pressure of approximately 1.5
bar within the columns due to the release of oxygen
from the CMS. This must be released if the generator
is to be shipped or requires maintenance.

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4.4 Start Clean Up
The clean up cycles are designed to clean the CMS bed of impurities, bring the generator up to production purity more rapidly, and prevent poor
quality gas flowing into the buffer. The operation of the cycle is factory set and is dependant upon the purity as described below:
On completion of the start up cycles the N2outlet valve will open, allowing gas to be delivered to the application.
4.5 Economy Mode
Economy mode is designed to switch the generator into standby mode when there is no demand for gas.
The generator continually monitors the pressure at the outlet port. If the pressure exceeds a pre-determined level for a sustained period of time
(Economy Period *), the N2outlet valve will close. The generator will continue to cycle as normal without delivering gas to the application. If the
back pressure is maintained for an additional 5 minutes, the generator will stop cycling and enter Economy mode.
When the pressure falls below the regulated outlet pressure, the generator will resume normal operation. If the generator is in Economy mode
when this occurs, it will run through the relevant clean up cycle.
The Economy over-ride facility (optional on generators fitted with an O2analyser) can be used to maintain the beds when the generator is in
economy mode. If the over-ride is enabled, a clean up cycle will be performed once every 20 minutes. This allows the generator to go straight
on-line when the outlet pressure falls below the regulated outlet pressure.
*The Economy Period is factory set to 5 minutes, however this can be adjusted during commissioning.
Rapid Cycle – this cycle is used for lower purity generators (250ppm – 5.0%). The chambers are filled and
exhausted alternately on a fixed cycle time. The Rapid Cycle takes 160 seconds to complete.
Pure Start - The higher purity generators (10 - 100ppm) require a two stage cleaning process (A + B):
A The chambers are filled and exhausted alternately.
B The chambers are then filled and exhausted on a reduced cycle.
The pure start cycle times are dependant upon the production purity of the generator. Refer to the table below for
guidance.
PRODUCTION PURITY
PURE START CYCLE (Secs)
A B
10 ppm 4 x 120 120/90
100 ppm 4 x 90 90/70
The Start clean up cycle can be disabled within the customer settings menu (applies only to generators fitted with an O2analyser),
however Compair strongly recommend that the start up cycles remain enabled.
The economy mode can be disabled within the customer settings menu(applies only to generators fitted with an O2analyser), however
Compair strongly recommend that this option remains enabled.
O2 = 5.00 %
Rapid Cycle
O2 = 100 ppm
Pure Start A

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4.6 Menu Interface
The default menu displays the current operating status of the generator and, when running, indicates the purity of the gas delivered at the
“Nitrogen Outlet” port.
Note. The purity reading is for indication purposes only.
The menu driven interface provides access to the essential operational parameters of the generator. From the default menu use the and
keys to scroll through to the desired menu and press .
The interface will automatically default back to the main operating menu if no key activity has been detected for one minute. After an additional
two minutes of inactivity the display will shutdown. To bring the display back on-line press .
4.6.1 Menu Map
3.1 O2 Alarm
Over-ride = 0
3.2 O2 Calibration
= 5.00%
3.3 O2 Alarm Level
= 5.05%
3.4 O2 Alarm Delay
= 60s
3.5 Start Clean Up
Enable = 1
3.6 Economy Enable
= 1
3.7 Fault Relay
On Stop = 0
3.8 O2 Analogue FSD
= 6.00%
3.9 O2 PPM Offset
= [---]
3.10 Modbus Address
= 1
3.11 Remote Control
= 1
1. Hour Meters
2. Fault Log 2.1 Fault 1: Active
C1 at 5234h
2.1 Fault 10:
[---]
1.1 Hours Run
5234h
1.2 Service Due At
8000h
1.3 Hours Economy
25h
O2 = 5.00 %
Running
3. Customer
Settings

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4.6.2 Password Protected Menus
The customer settings sub-menus contain the parameters that may be customised by the end user. To prevent unauthorised changes being
made these menus are password protected and cannot be accessed until the password has been entered correctly.
4.6.3 Hour Meters
4.6.4 Fault Log
The following codes are used within the system:
Note. Any faults that are active when the power is switched off, and remain active when the power is re-applied, will cause a new entry to be
added into the fault log.
To enter the password from the main operating menu press and hold both the and keys for approximately 5
seconds until the menu changes to the password prompt as shown
The flashing cursor will be positioned over the first digit.
Using the key change the first digit of the code and press . The cursor will move to the next digit.
Repeat the process and enter the following password 1 2 1 _ _.
When the password has been entered correctly the Hour Meters menu will be displayed.
Use the key to navigate to page 3 “Customer Settings”.
The time in hours that the generator has been producing gas.
The time in operating hours that the generator can produce gas before a service is required.
The time in hours that the generator has been operating in Economy mode.
The fault log contains details of the ten most recent faults that have occurred on the generator. Each fault is
represented by a code which is displayed along with the time (hours run) at which the fault occurred and the
status of the fault.
Fault Codes Notes
C1 Pressure Start Inhibit Low inlet pressure. Inhibits start.
P1 Inlet Pressure Fault Low inlet pressure during cycling.
P2 Pressure Sensor Fault Pressure sensor communication error.
E1 Power Failure
Y1 O2Alarm
Y2 O2Communication failure Communication fault between O2analyser and control board
Y3 Incorrect cell selected
Y4 O2high (out of range) Occurs when O2> 25% (% generators) / O2> 1.05% (ppm generators)
Y5 O2zero drift error Contact Compair
S1 Service due