Donaldson Ultrafilter Nitropac N01 Series User manual

IOM_DO_NITROPAC_GB_2017_07_03.docx
Operation Manual GB
Nitrogen Generators
Nitropac N01x – N06x

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Operation Manual Nitropac N01x – N06x

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Operation Manual Nitropac N01x – N06x
Contents
How to use this manual 4
Introduction 5
Technical Description 5
Basic concept 5
General construction 6
Nitropac model number breakdown 6
Warranties and Liabilities 7
Safety Notices 8
Symbols 8
Safety Notice to Users 8
Product Overview 9
Pressure Switch Overview 10
10
Electrical Panel Layout 11
Technical Specification 12
Environment 12
Compressed Air Supply 12
Electrical Requirements 12
General 13
Installation 14
Generator Environment 15
Unit Controls 16
Inlet / Outlet Connections 16
Compressed Air Quality 17
Electrical Connection 18
Recommended Piping Layout 18
Commissioning / Safe Start-Up Procedure 19
Normal Operation 21
Cleaning 21
Service Requirements 22
Safe Isolation Process 22
Service Schedule 22
Service Counter Reset 23
PLC Settings 24
Troubleshooting 25
Pneumatic Schematic - Rev 2A 26
Electrical Schematic – Rev 3 27

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Operation Manual Nitropac N01x – N06x
How to use this manual
This manual is intended for end users and has been written so that it can either be read as a step
by step guide to installation and usage; or as a reference document where you can skip to the
relevant information. However, please note that this manual includes important safety information
for how to install and operate the system properly.
Please review each of the following sections carefully.
Thank you for selecting Donaldson to meet your Gas Generation needs, should you require any
further assistance or support please do not hesitate to contact Donaldson.

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Operation Manual Nitropac N01x – N06x
Introduction
The Donaldson Nitropac Generator is designed to cater for a wide variety of industrial and
scientific applications. Your generator will have been carefully selected to meet your specific
pressure, flow, and purity requirements, if you have any questions regarding the sizing of your
system please do not hesitate to contact Donaldson.
Technical Description
Basic concept
A modular range of Carbon Molecular Sieve (CMS) nitrogen gas generators. The generators
operate using Pressure Swing Adsorption (PSA). This is where the product contains two separate
containers or “beds” of granular carbon pellets.
The unit requires a compressed air supply to operate, ultimately it is akin to many standard air
filtration / drying products. The inlet compressed air is passed into the first “bed”, as the air
passes across the carbon bed the oxygen is adsorbed, allowing the nitrogen in the compressed
air to carry on through the bed for collection and further use. After a certain time the online bed of
carbon will become saturated with oxygen. At this point in time, the control system will operate
various valves to bring the second bed of carbon on line. As the second bed comes on line the
first bed is vented to atmosphere to release the adsorbed oxygen and regenerate the bed ready
to be re-used again. This cycle will continue to repeat until the user stops consuming nitrogen.
Should the demand for Nitrogen be less than the rated output flow, or indeed should the demand
stop the generator will automatically go into ECO Mode and the front panel LED will illuminate. In
ECO mode the changeover of the columns is suspended which will stop the consumption of inlet
compressed air. The control system will automatically detect when the demand for Nitrogen
resumes and the generator will start to produce Nitrogen again.

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Operation Manual Nitropac N01x – N06x
General construction
The range will consist of 6 different sizes of the product. A 3D Cad image can be seen below:
The front end cabinet, control system and valves are consistent across the range. To increase the
outlet capacity as you go up the range of generators additional banks of CMS beds will be added.
(Note: for 5 to 6 column sets additional vent valves and silencers are required and are fitted to the
rear of the CMS columns)
Nitropac model number breakdown
3 BASIC UNIT
4 NITROPAC WITH % O2 ANALYSER
5 NITROPAC WITH PPM O2 ANALYSER
User Interface
BASE MODEL 6
th
SIZE IN RANGE
Front End
CMS “Beds” ranging
from 1 to 6 sets
depending on model
DONALDSON RANGE
N

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Operation Manual Nitropac N01x – N06x
Warranties and Liabilities
Claims for warranty and liability concerning personal injury or material damage become void if
caused by one or more of the following reasons:
Inappropriate use or application of the unit.
Incorrect installation, start-up, operation and maintenance of the unit.
Operation of a noticeably defective unit
Failure to follow operation manual procedures regarding concerning transport, storage,
installation start-up and maintenance of the unit.
Implementing constructional modifications to the unit.
Inadequate monitoring of parts on the unit that are subject to wear
Improper repairs
Use of non-original parts
Please also note the general warranty conditions for products of the manufacturer.

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Operation Manual Nitropac N01x – N06x
Safety Notices
Symbols
This manual uses the following symbols to highlight specific areas important to the safe and
proper use of the Generator.
Table 1 - Safety Symbols
Safety Notice to Users
These instructions must be read thoroughly and understood before installation and operation of
your Donaldson Nitropac. Use of the Generator in a manner not specified by Donaldson MAY
impair the SAFETY provided by the equipment.
When handling, operating or carrying out any maintenance, personnel must employ safe
engineering practices and observe all relevant local health and safety requirements and
regulations.
Nitrogen is not a poisonous gas, but if the concentration in the inhaled air
becomes too high there will be a risk of asphyxiation.
Ensure that adequate ventilation is provided for the surrounding area,
(depending on the operating specification and model selected the
generator can produce up to a maximum flow of 2,556 L/min)
A WARNING notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
personal injury or in the worst case death. Do not proceed beyond a WARNING
notice until the indicated conditions are fully understood or met.
A CAUTION notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
damage to the Generator or the Application. Do not proceed beyond a CAUTION
notice until the indicated conditions are fully understood or met.
Caution, risk of electric shock. Ensure power to the Generator has been removed
before proceeding.

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Operation Manual Nitropac N01x – N06x
Product Overview
Pressure Gauges 4x
PLC
Interface
Power Switch
Equalization Valve
Inlet Pressure Regulator
Equalization Valve
Changeover Valves 2x
Electrical Panel
Exhaust silencers
2x
Exhaust Valves
2x
Outlet Flow
Controller
Outlet Pressure
Regulator
DF Afterfilter DF Prefilter

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Operation Manual Nitropac N01x – N06x
Pressure Switch Overview
There are two possible versions of pressure switch, pre-2016 units will have Black
FESTO pressure switches as below:
The pressure switch has two channels:
Channel A is used to trigger ECO mode
Channel B is used to trigger low pressure alarm
Setting Channel A (ECO mode)
Press edit once
Press up arrow to select channel A
Press edit
Press edit again to show SP
Using up or down arrows adjust to 0.05bar less than inlet pressure.
Press edit again to show HY (hysteresis)
Using up or down arrows adjust to 0.2bar
Press edit
Using up and down arrows set to NO (Normally open)
Press edit to save and exit
NOTE: The pressure switch is for indication only. Calibration is not required.
Pressure switch is pre-set at the factory, no adjustment should be required. The above is
for information only.
Output A indicator
Pressure display
Edit button
Output B indicator
Bar graph display

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Operation Manual Nitropac N01x – N06x
Post 2016 units will have the new White SMC Pressure switch, both perform the same
function and are fully interchangeable, setup instructions for SMC are as follows:
Again, the pressure switch has two channels:
Channel F1 is used to trigger ECO mode
Channel F2 is used to trigger low pressure alarm
F0 is used to set the switch pressure unit.

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Operation Manual Nitropac N01x – N06x
Electrical Panel Layout
Percentage
Oxygen Sensor
% Variant PPM Variant
Circuit
Breaker
Power
Supply
Triple Deck
PLC
Expansion
Module
Pressure
Switch
Valve
Manifold
O2
Analyser
O2 Analyser
PPM Oxygen
Sensor
Control
Relays

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Operation Manual Nitropac N01x – N06x
Technical Specification
Environment
Minimum Operating Ambient Temperature +5°C (41°F)
Maximum Operating Ambient Temperature* +50°C (122°F)
Maximum Relative Humidity 80% (non-condensing)
Maximum Altitude 2000m
When taken out of storage, the Generator should be allowed to acclimatize at room temperature for a
minimum of 3 hours before operation.
Compressed Air Supply
Depending on your specific application, the pressure and flow required from the compressed air supply to
the generator will vary. For your specific requirements please refer to your quotation documents, or contact
Donaldson for further information. However all installations must meet the following conditions:
If you are in any doubt over the quality of your inlet compressed air DO NOT CONNECT to the generator,
and contact Donaldson. Donaldson can offer a full range of compressors and air preparation equipment if
required, which can be backed up by our global service support network.
It is the User / Installer’s responsibility to ensure the generator is connected
to a suitably rated air supply, the air supply must also provide suitable
protection to prevent over pressurization of the Nitrogen Gas Generator.
Electrical Requirements
Voltage 100 - 240 VAC ±10%
Frequenc
y
50/60 H
z
Curren
t
2.0 – 1.0
A
Input connection C20 Plu
g
Power cord (Supplied) C19 socket to local connection
Pollution degree 2
Installation categor
y
Class I Protection
T
ransient Overvoltage Category II
Minimum Air Quality IS0 8573-1:2010 class 2.2.1
Minimum Inlet Air Pressure 6 barg (87 psig)
Maximum Inlet Air Pressure 10 barg (145 psig)
Minimum Inlet Air Temperature +5oC (41°F)
Maximum Inlet Air Temperature +35oC (95°F)

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Operation Manual Nitropac N01x – N06x
General
Model N01* N02* N03* N04* N05*
Width mm(in) 500 (19.68)
Height mm(in) 1738 (68.42)
Depth mm(in) 760(29.92) 920(36.22) 1080(42.52) 1240(48.82) 1400(55.12)
Weight kg(lbs) 197(433) 282(620) 367(807) 452(994) 537(1181)
Shipping weight kg(lbs) 277(609) 364(801) 451(992) 538(1184) 625(1375)
Noise level 59 dBA @ 1m
Model N06*
Width mm(in) 500 (19.68)
Height mm(in) 1738 (68.42)
Depth mm(in) 1560(61.42)
Weight kg(lbs) 622(1368)
Shipping weight kg(lbs) 712(1566)
Noise level 59 dBA @ 1m

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Operation Manual Nitropac N01x – N06x
Installation
It is the user/installer’s responsibility to ensure that the generator is located and
protected against any external influences such as vibration, shock, wind, snow
loading, earthquake or fire. The installation should conform to all local regulations
and should be leak tight and completed by technically competent personnel.
Final Location of the generator should be carefully considered, the largest model in the range will
weight 622 kg / 1368 lbs. Equipment is only to be installed on floor with a weight rating of min
1000kg/m2or 200 lbs per Sq.ft.
Once in position the foot plate of the generator should be secured to the floor with fixings suitable
to the materials of construction of the floor. 13mm diameter holes are provided adjacent to the
levelling bolts to allow the unit to be fixed to the floor. Depending on the generator model you will
have 4 or 8 fixing positions. Typically 10mm or 3/8” floor fixings approx. 75mm or 3” in length will
be suitable on most concrete floors.

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Operation Manual Nitropac N01x – N06x
Generator Environment
The Generator is designed for indoor use only. It should be installed adjacent to the
application it is supplying. If this is not convenient then the unit can be sited
elsewhere, however, consideration should be made of the lengths of pipe runs as
pressure drops can result from extended runs of pipe.
Consideration should be given to the location of the generator to ensure it is
protected from extreme fluctuations in ambient temperature. Ensure that adequate
ventilation is provided for the surrounding area, (depending on the operating
specification and model selected the generator can produce up to a maximum flow
of 2,556 L/min). Installation in a confined space or poorly ventilated space is not
recommended, however if you choose to do so ambient oxygen monitoring
equipment is recommended.
Please refer to the drawing below for the general dimensions of the unit.
Maximum Ambient Conditions: +50°C (dry bulb) 80%RH (Max) Non-Condensing
General Dimensions
The Generator must always be placed on a level surface. Failure to do so
will affect the stability of the Generator.
1738
500 760
1560
Note: Each additional tank
assembly = 160mm

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Operation Manual Nitropac N01x – N06x
Unit Controls
Inlet / Outlet Connections
Power Switch
Air Inlet
1” BSP Female
Eco Mode
LED
Service
LED
Tank Pressure
Gauge
Outlet Pressure
Gauge
Column 1
Pressure Gauge
Column 2
Pressure Gauge
Control
Screen
Power Inlet Nitrogen Output
¾” BSP Female
Tank Supply
¾” BSP Female
Tank Return
¾” BSP Female

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Operation Manual Nitropac N01x – N06x
All of the Generator output ports are located on the output panel on the Left hand side of the
Generator. See below for recommended piping layout
Compressed Air Quality
The Nitropac Generator is an air purification system; it does not generate any gas pressure. Gas
pressure is created and supplied to the generator by the user’s compressed air system. It is the
user / installer’s responsibility to ensure that all components connected to the gas
generator comply with local health and safety regulations and that the compressed
air system is suitably protected from over pressure, including appropriately sized
safety relief devices for both the compressed air and nitrogen process tanks.
No pressure greater than 10 barg should be applied to the inlet of the Nitropac product.
The Nitropac Generator will typically be the last stage in a complete air compression and filtration
system, the inlet air quality must meet a minimum of IS0 8573-1:2010 class 2.2.1. Class 2.2.1. is
further defined as:
Class 2– Particulate
Per cubic meter of air the particulate count should not exceed 400,000 particles in the 0.1 to 0.5
micron range, 6000 particles in the 0.5 to 1 micron range and 100particles in the 1 to 5 micron
range.
Class 2 – Water
A minimum pressure dewpoint (PDP) of -40odegC (-40odegF) is required, no liquid water is
permitted.
Class 1 – Oil
Per cubic meter of air the maximum permissible oil content is 0.01mg, total level for liquid,
aerosol and vapor.
A typical installation will consist of the following items:
Air Compressor (Oil-Free or Oil Lubricated)
Compressed Air Storage Tank (with automatic condensate drain)
Oil/Water Separator
Pre-filter
Active Carbon Filter
Line Air Regulator
Desiccant Air Dryer
Dust Filter
Active Carbon Tower
Dust Filter
Nitropac Nitrogen Generator
Nitrogen Process Gas Tank
Sizing of all components in this line will have a critical effect on the performance of the Nitrogen
Gas Generator, in particular the Nitrogen process Gas Tank. Please refer to your quotation
documents for details of the items we have recommended to meet your specific requirements.

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Operation Manual Nitropac N01x – N06x
Should you require any further assistance or support please do not hesitate to contact
Donaldson. A full installation and commissioning service can be provided through the Donaldson.
Electrical Connection
Connect the Generator to a single-phase AC voltage supply using the power cord
provided. The generator is fitted with an internal transformer that can accept any supply
from 100 to 240 volts AC. If the appropriate power cord is not supplied; a new plug,
rated to at least 5 amps, can be fitted by a qualified electrician.
DO NOT USE inadequately rated detachable Mains cords.
This unit is classified as SAFETY CLASS 1. THIS UNIT MUST BE EARTHED. Before
connecting the unit to the mains supply, please check the information on the serial plate.
The mains supply must be of the stated AC voltage and frequency.
EARTH/GROUND (E):- Green & Yellow or Green
LIVE (L):- Brown or Black
Neutral (N):- Blue or White
Recommended Piping Layout
To allow proper operation and commissioning of the generator it is important to include bypass
valves at the generator inlet / nitrogen outlet of the system. It is also recommended that a Non-
return valve be fitted on the exit of the system to prevent downstream pressure from returning to
the system and damaging the generator. Please see below for recommended piping layout.

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Operation Manual Nitropac N01x – N06x
Commissioning / Safe Start-Up Procedure
With reference to the diagram above in “Recommended Piping Layout” section.
Once the generator has been installed, DO NOT Switch on the power immediately. It is
recommended that the inlet compressed air supply valve (1) remains closed, and that the inlet
bypass valve (2) is opened slightly to sufficiently allow the inlet compressed air to vent and purge
any remaining moisture from the newly installed pipework (if this is the first operation of the
compressed air supply, it is recommended that the air be vented for a minimum of 2hrs to allow
the air filtration and dryer to stabilise). Once the inlet pipework has been purged, the inlet bypass
valve (2) can then be closed and the pressure gradually introduced to the generator by slowly
opening the compressed air inlet (1) valve. The outlet bypass valve (3) should now be open to
atmosphere, and the delivery valve (4) to the customer application should be closed. Ensure that
both Process Tank Isolation valves (5) are both fully open. The power can then be turned on. On
first start up air will be introduced to Column 1 and the front panel gauge will slowly start to rise.
The front panel display will show a message “COLUMN 1” and a timer counting up. After approx.
30 to 80 seconds (timing will vary depending on your specific performance requirements) the front
panel display will briefly show an “EQUALIZING” message and the pressure on Column 1 and 2
gauges should level out. Column1 will then vent rapidly to zero and column 2 will continue to rise
slowly. During this process the TANK pressure gauge should continue to slowly rise. Allow the
Nitrogen Process Gas Tank to reach pressure, then continue to vent the outlet gas through the
bypass valve (3) for a minimum of 4 hours (ideally this should be done overnight to fully purge all
the remaining oxygen/moisture in the system). The Generator has been pre-set in the factory to
give the specified output flow-rate and pressure. Failure to achieve the factory specification after
maintenance may be as a result of an incorrect service procedure, please review any
maintenance carried out. If unable to achieve specification contact Donaldson for further
assistance. After this time the outlet bypass valve (3) can be closed, and the delivery valve (4) to
the customer application should be slowly opened to pressurise the line.