General Air Products NGPSA-1000 User manual
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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
1-800-345-8207
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
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Section 3 Before Installation Begins
•Find a location for the nitrogen generator to be installed meeting these requirements:
Dimensions are within the above noted General Arrangement
drawing under Section 2
Dry, clean, and well-ventilated
Ambient temperatures above 50° F at all times
Access to front for service
Conveniently located near fire sprinkler system connections
Conveniently located near drain
•Run a dedicated electrical circuit with an electrical disconnect switch to the install location.
NOTE: The NGPSA Nitrogen Generators may operate on numerous voltages and at different amperages as noted in the
following table.
Model
Phase
Amperage
Voltage/Hz.
Circuit Breaker Size (Amps)
NGPSA-1000-2A
SINGLE
12.3
208/60
20
NGPSA-1000-3A
SINGLE
10.6
230/60
20
NGPSA-1000-2B
THREE
10.2
208/60
20
NGPSA-1000-3B
THREE
10.2
230/60
20
NGPSA-1000-4B
THREE
5.1
460/60
15
NGPSA-1700-2B
THREE
13.2
208/60
20
NGPSA-1700-3B
THREE
13.2
230/60
20
NGPSA-1700-4B
THREE
6.6
460/60
15
NGPSA-2200-2B
THREE
20.3
208/60
30
NGPSA-2200-3B
THREE
20.3
230/60
30
NGPSA-2200-4B
THREE
10.2
460/60
20
The Nitrogen Generator creates a 30% to 40% oxygen stream which may pose a flammability problem in an oxygen-sensitive
environment. Pipe per installation requirements and ensure the area surrounding the nitrogen generator is adequately ventilated.
The Nitrogen Generator should always be installed in an adequately ventilated room. Nitrogen is nontoxic and largely inert.
Rapid release of nitrogen gas into an enclosed space displaces the oxygen and can cause an asphyxiation hazard. Inhalation of
nitrogen in excessive concentrations can result in unconsciousness without any warning symptoms.
WARNING
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Section 4 Uncrating and Inspection
On arrival, do a full inspection by checking all packages and crates in the shipment for damage.
If damage is found, sign for the damage or refuse the shipment. Contact the carrier immediately
and file a shipping damage claim with the carrier.
Check to ensure all components are contained and no visible damage has occurred during shipping.
Crate Checklist:
N2 Analyzer
Important: Read all of the safety information in this manual before installing or operating this equipment.
CAUTION
Item
Nitrogen storage tank
Air storage tank
Nitrogen generator
Air Compressor
Manual
10 ft. ¼” condensation drain tube
Nitrogen Analyzer
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Section 5 Installation of Nitrogen Generator
•Anchor the unit to a level surface using the ½” diameter holes on the Nitrogen Generator base.
•The NGPSA-1700 and NGPSA-2200 air tank and compressor must be mounted separate from the base.
Use the feet on the air tanks to anchor them to a level surface close to the Nitrogen Generator base.
Floor mounting the NGPSA-1000
Floor mounting the generator
(NGPSA-1700 & NGPSA-2200)
Floor mounting the air tank
(NGPSA-1700 & NGPSA-2200)
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•Close the ½” nitrogen outlet shutoff valve on the nitrogen storage tank. See Section 2.2 General
Arrangement Views for reference.
•Use the supplied 10’ of ¼” OD tube to run the drain line from the base of the generator. See Section 2.2
General Arrangement Views for reference. NOTE: Tubing will need to be restrained as air pressure from
the drain valve may cause the tubing to be displaced from the drain.
•Install ½” NPT pipe (or larger) from the ½” FNPT nitrogen tank outlet valve to the fire sprinkler system air
maintenance device.
•Install ½” NPT pipe from the Air Maintenance Device to the sprinkler system using standard accepted
installation practices. Additional system components may be required.
Additional Installation For NGPSA-1700 & 2200 Only
The NGPSA-1700 & 2200 are shipped in two separate pieces; the nitrogen storage tank and the air
compressor portion. Because they are separate, they must be plumbed and wired together.
•Using the supplied ½” tubing, connect the air compressor tank outlet connection to the N2 generator inlet
valve as shown below. Simply push the tube into the fitting until snug. Pull on the tube slightly to ensure that
it is properly connected.
•Connect the two separate supplied ¼” tubes to the air tank drain and the water separator connections as
shown above.
N2 generator
inlet valve
tube
connection
Air tank
outlet tube
connection
Water
separator drain
connection
Air tank drain
connection
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5.1 Wiring
All wiring should be performed by a licensed electrician and conform to NEC and all applicable local
standards. For wiring instructions refer to the Wiring Diagrams below.
For NGPSA-1700 & 2200 Only
Use the supplied wiring cable from the electrical enclosure to connect to the motor. Follow the wiring
instruction inside the motor wire cover. Take note of the voltage, the NGPSA-1700 & 2200 are dual voltage
motors, ensure that the correct wiring instruction is followed.
5.2 Wiring Diagrams
Figure 1. NGPSA-1000 wiring diagram
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Figure 2. NGPSA-1700 & 2200 wiring diagram
Wiring location is inside the generator electrical enclosure.
If you are installing a 3-phase unit, rotation direction will need to be checked for the air compressors. Flywheel
rotation is counter-clockwise when looking at the fan end of the compressor as shown below. If rotation is not
correct, then switch any two of the 3 wires (L1, L2, or L3) on the terminal blocks inside the electrical enclosure.
Flywheel end
of Compressor
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5.3 Initial Air Fill
•Before beginning, make sure the water supply to the sprinkler system is turned off and sprinkler piping has
been completely drained.
•Make sure all piping connections have been made according to installation instructions.
•Close all Air Maintenance Device (AMD) valves. If multiple AMDs are used, ensure all valves are in the
closed position.
•Turn the Nitrogen/Air Fill handle to the Air Fill position.
•Ensure that the nitrogen tank outlet ball valve is in the closed position.
•Turn on the nitrogen generator. The power on LED will turn on.
•The compressor will run until it reaches its off pressure of 105psig.
•Check all piping connections for leaks as pre-plumbed piping may have loosened during shipping.
•The nitrogen generator is now ready to fill the sprinkler system to the required supervisory pressure.
•Open the ball valve at the nitrogen storage tank outlet.
•Open the AMD bypass valve to begin filling the sprinkler system.
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•Allow the sprinkler system to reach the required pressure. NOTE: This should finish in 30 minutes per the
required NFPA guidelines.
•As soon as the sprinkler system supervisory pressure is reached, put the sprinkler system back into service
by placing the AMD in the maintenance position (refer to the AMD manual for proper operation).
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5.4 Nitrogen Startup
1. Having completed Section 5.3 Initial Air Fill, the system is now ready to begin generating nitrogen. Turn the
Nitrogen/Air Fill handle to the Nitrogen position.
2. The generator will only enter Nitrogen Mode if the nitrogen tank air pressure is below 60 psig. Open the ball
valve on the nitrogen tank drain until the pressure drops to 60 psig.
3. The left or right tower gauge on the control panel should now display a pressure between 85 and 100 psig.
The time it will take for each NGPSA model to go from 60-75psig in Nitrogen Mode is shown in the table
below.
4. Repeat steps 2 & 3 to ensure that the nitrogen fill times from 60-75psig are consistent.
5. On the second cycle, open the Nitrogen Test Port Valve located on the outlet of the Nitrogen Generator.
6. Turn on the Nitrogen Analyzer. For more information on the Nitrogen Analyzer see Section 11.
7. Attach the Nitrogen Analyzer to the Nitrogen Test Port.
8. The nitrogen purity level reading should measure 98%+. If not go to the troubleshooting section.
9. Close the Nitrogen Test Port Valve and disconnect the Nitrogen Analyzer. Make sure to power off the
Nitrogen Analyzer.
10. Do not leave the Nitrogen Test Port Valve open.
11. The system is now in operation. For purging instructions, see the Purge Valve Manual.
Model
NGPSA-1000
NGPSA-1700
NGPSA-2200
Time from 60-75psig @
98% N2
2 minutes 45 seconds 1 minute 45 seconds 5 minutes
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Section 6 Nitrogen Control Module
The Nitrogen Control Module is an embedded processor with an LCD display used to control the nitrogen
generator and provide useful information on alarm, compressor operating hours and cycles, and nitrogen
operation.
6.1 Main Display
When cycling power to the controller, the initial display will provide the user with the most useful information.
This can be seen below in Figure 1.
Figure 3. Main Display
Table 1. Main Display details
1
The “STATUS” of the generator is shown here. This consists of the following:
•N2 ON – The system is generating nitrogen until the nitrogen tank reaches 75psig.
•BYPASS ON – The air fill valve is in the bypass position and no nitrogen is being
generated.
•PURGING – The nitrogen generator has reached its maximum pressure of 75psig
and will enter “N2 ON” when pressure in the nitrogen tank drops to 60psig.
•N2 PURGE – The nitrogen tank has just reached its cutout pressure of 75psig, but
must complete its purge cycle before entering “PURGING” mode.
2
The up and down arrows shown here indicate that by pressing the UP and DOWN arrow
buttons on the controller will scroll through the other displays.
3
“AIR PRES:” displays the pressure in the air tank in psig
1
2
3
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