General Air Products NGPSA-1000 User manual

NGPSA
Installation, Operation
and Maintenance Manual
NGPSA OIM
REV: 0
(09/23)
Call 1-800-345-8207
or visit our web site for our complete product listing
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Table of Contents
Section 1 Safety & Warnings...............................................................................................................4
1.1 Important Notice to Users ........................................................................................................................4
1.2 Unpacking ...............................................................................................................................................4
1.3 General Safety Information ......................................................................................................................4
Section 2 System Overview.................................................................................................................6
2.1 Piping and Instrumentation Diagram........................................................................................................7
2.2 General Arrangement Views....................................................................................................................8
Section 3 Before Installation Begins ................................................................................................11
Section 4 Uncrating and Inspection..................................................................................................12
Section 5 Installation of Nitrogen Generator ...................................................................................13
5.1 Wiring ....................................................................................................................................................15
5.2 Wiring Diagrams ....................................................................................................................................15
5.3 Initial Air Fill ...........................................................................................................................................17
5.4 Nitrogen Startup ....................................................................................................................................19
Section 6 Nitrogen Control Module ..................................................................................................20
6.1 Main Display ..........................................................................................................................................20
Section 7 Nitrogen Generator Alarms/Troubleshooting..................................................................22
Section 8 Process Piping System Leak Check................................................................................24
Section 9 Maintenance.......................................................................................................................24
9.1 Filter Replacement.................................................................................................................................25
9.2 Air Compressor Replacement................................................................................................................26
Section 10 Normal Operating Parameters..........................................................................................27
Section 11 Nitrogen Analyzer Instructions ........................................................................................28
11.1 Automatic Calibration.............................................................................................................................28
11.2 Calibrating the N2 Analyzer ...................................................................................................................28
11.3 Calibration Errors and Error Codes........................................................................................................29
11.4 Changing the Batteries ..........................................................................................................................29
11.5 Changing the Oxygen Sensor................................................................................................................30
Section 12 Warranty Policy .................................................................................................................31
If there are any questions regarding installation, operation, or maintenance of this system, please call
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IMPORTANT: ALL INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
Consult factory for the most up to date version of this manual - 1-800-345-8207.

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Section 1 Safety & Warnings
This manual contains safety information that is important to know and understand. This information is provided for the
safety of installers, operators, and users of the Nitrogen Generator. To help recognize this information, observe the
following symbols.
Danger indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
Caution indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
Notice indicates important information, that if not followed may cause damage to equipment or property.
1.1 Important Notice to Users
The Installation and Owner’s Manual supplied with each unit must be read thoroughly and completely understood before
installation and operation of the Nitrogen Generator. All appropriate safety standards for handling of gases as determined by
local or national laws and regulations should be followed at all times.
1.2 Unpacking
After unpacking unit, carefully inspect all parts and equipment for any damage that may have occurred during transit.
Make sure to tighten fittings, bolts, etc. before putting unit into service.
1.3 General Safety Information
Important: Read all of the safety information in this manual before operating this equipment. Use of the equipment in a
manner not specified within this manual may impair the protection provided by the generator and could result in an
unplanned release of pressure, which may cause serious injury or damage. Only competent personnel, who have been
trained, qualified, and approved by General Air Products should perform commissioning, servicing, and repair procedures.
When handling, installing, or operating this equipment, personnel must employ safe engineering practices and observe all
related local regulations, health, and safety procedures, and legal requirements for safety.
Ensure that the equipment is depressurized and electrically isolated, before carrying out any of the scheduled maintenance
instructions specified in this manual.
WARNING
DANGER
WARNING
CAUTION
NOTICE
Do not operate if damage occurred during shipping, handling,
or use. Contact General Air Products immediately.

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The warnings in this manual cover the most known potential hazards, but by definition cannot be all-inclusive. If the user
employs an operating procedure, item of equipment, or a method of working that is not specifically recommended by General
Air Products, the user must ensure that the equipment will not be damaged or become hazardous to persons or property.
Nitrogen is not a poisonous gas. However, in a concentrated form, there is a risk of asphyxiation. The generator produces
a flow of nitrogen and oxygen enriched air which quickly disperses in the atmosphere. However, do not directly inhale the
output gas from the generator outlet pipe.
The 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 procedures must be developed for maintenance of the equipment in which the nitrogen separator is located.
Appropriate labels must be continuously displayed in all areas where personnel might be exposed to a nitrogen
atmosphere under any condition.
WARNING
NOTICE
Operation of the nitrogen separator above the rated design
pressure may be hazardous. Do not connect it to
compressed air sources that can exceed its maximum
rated pressure without installing appropriate pressure
controls and safety relief devices in the compressed air
supply line.
Do not attempt to disassemble the nitrogen generator.
Equipment damage may occur and cause the system to
function incorrectly.

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Section 2 System Overview
The NGPSA Nitrogen Generator operates using Pressure Swing Adsorption (PSA) gas separation technology, which utilizes
2 towers of Carbon Molecular Sieve (CMS) to separate nitrogen from the other gases contained in the air. Smaller oxygen
and water vapor molecules latch onto the molecular sieve bed and the larger nitrogen molecules continue downstream to
the separator outlet. While tower 1 is generating an enriched high-pressure stream of nitrogen, tower 2 is purging away all the
waste oxygen and water vapor molecules to the atmosphere. This process occurs for a set duration and eventually the towers
will switch their role; tower 2 generates an enriched nitrogen stream and tower 1 purges away all the waste air to atmosphere.
The Nitrogen Generator is specifically designed to provide clean, dry, high purity nitrogen for use in various process systems.
The generator is a fully assembled package using factory pre-engineered air compressors and controls. These turn-key
systems include all air filtration equipment required to keep the generator operating at peak efficiency.
Product
Designation
Outlet Pipe
Connection,
(FNPT)
Sprinkler System
Capacity (GAL.)
Bypass
Capacity
(GAL.)
Weight
(lbs.)
Outlet N2
Pressure
(PSI)
Air Tank
Pressure
(PSI)
NGPSA-1000 1/2 16880 1100 525 60-75 85-105
NGPSA-1700 1/2 24390 1700 775 60-75 85-105
NGPSA-2200 1/2 24390 2200 915 60-75 85-105

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2.1 Piping and Instrumentation Diagram

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2.2 General Arrangement Views
NGPSA-1000 General Arrangement

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NGPSA-1700 General Arrangement

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NGPSA-2200 General Arrangement