Intelligen INS-1500 User manual

Manual #5403646 - F
04/19
St. Louis, MO
800-325-3936
www.pottersignal.com
INS-1500/2000
Nitrogen Generators
Installation, Operation, and
Instruction Manual

2
INS-1500 & INS-2000 • 5403646 • REV F • 04/19
Potter Electric Signal Company, LLC
St. Louis, MO • [phone]
WARRANTY INFORMATION
GENERAL PROVISIONS & LIMITATIONS
Potter Electric Signal Company, LLC (the “Company”) warrants to each original purchaser (“Purchaser”) of its new products from the
Company or its Authorized Distributor that such products are, at the time of delivery to the Purchaser, made with good materials and
workmanship. No warranty is made with respect to:
1. Any product, which has been repaired or altered in such a way, in the Companies judgment, as to affect the product adversely.
2. Any product, which has, in the Companies judgment been subjected to negligence, accident, improper storage, improper installation
or application.
3. Any product, which has not been operated or maintained in accordance with the recommendations of the Company.
4. Components or accessories manufactured, warranted and serviced by others.
5. Any reconditioned or prior owned product.
Claims for items described in 4 above should be submitted directly to the manufacturer.
WARRANTY PERIOD
The Company’s obligation under this Warranty is limited to repair or, at its option, replacing during normal business hours at the designated
facility of the Company, any part that in its judgment proved not to be as warranted within the applicable Warranty Period as follows.
COMPONENTS
All non-consumable components are warranted for 12 months from the date of purchase. Consumable are not covered under warranty. The
unit must have been installed by either a factory authorized distributor or agent in accordance with the factory recommendations taking into
account all other local site conditions not originally noted to the factory. The unit must be operated and maintained in accordance with the
Factory recommendations and original design conditions. Failure to provide such proof of the above may void warranty.
LABOR TRANSPORTATION & INSPECTION
The Company will repair or replace any product or part thereof which in the Companies judgment is proved to be not as warranted. Labor
costs are not covered under warranty.
All costs of transportation of product, labor or parts claimed not to be as warranted and, of repaired or replaced parts to or from factory
shall be borne by purchaser. The Company may require the return of any part claimed not to be as warranted to one of its facilities as
designated by the Company, transportation prepaid by Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon
which installed to the same extent as if such parts were original components.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE
COMPANY MAKES NO OTHER WARRANTIES, EXPRESSED OR IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED
WARRANTY OR MERCHANTABILITY.
THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE
TO THE PURCHASER AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR
LIABILITIES. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER CAUSED.
No statement, representation, agreement, or understanding, oral or written, made by any agent, distributor, representative or employee of
the Company which is not contained in this Warranty will be binding upon the company unless made in writing and executed by an ofcer
of the Company.
This warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed
not to have been as warranted. Any action for breach of this warranty must be commenced within one year after the date upon which the
cause of action occurred.
Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company that any product was not as
warranted.
PROMPT DISPOSITION
The Company will make a good faith effort for prompt correction or other adjustment with respect to any product, which proves to
be defective within the warranty period. Before returning any product, write or call the distributor, agent or authorized company from
which the product was purchased, describing defect and giving date and number of original invoice, as well as proof of Factory supplied
consumable and proof of scheduled maintenance. Title and risk of loss pass to buyer upon delivery to the common carrier.
PRODUCT SUITABILITY
Many States, Localities and Countries have codes and regulations governing sales, construction, installation, and/or use of products for
certain purposes, which may vary from those in neighboring areas. While Potter attempts to assure that its products comply with such
codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a
product, please review the product application, and national and local codes and regulations, and be sure that the product, installation, and
use will comply with them.

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
Contents
Safety Guidelines...............................................................................................................................................................................................4
Important Notice to Users........................................................................................................................................................................4
Unpacking................................................................................................................................................................................................ 4
General Safety Information...................................................................................................................................................................... 4
System Overview............................................................................................................................................................................................... 6
Key Terms ................................................................................................................................................................................................ 6
IntelliGen™Controller.............................................................................................................................................................................. 6
INS-1500/2000 Exterior View ........................................................................................................................................................................... 7
INS-1500/2000 Interior View ............................................................................................................................................................................ 8
INS-1500/2000 Nitrogen Tank View .................................................................................................................................................................9
INS-1500/2000 Air Compressor View...............................................................................................................................................................10
IntelliGen™Display ...........................................................................................................................................................................................11
Installation of the Nitrogen Generator ............................................................................................................................................................... 12
Wiring of the Nitrogen Generator ......................................................................................................................................................................16
Air Compressor (208V, 230V or 460V Three Phase) ..............................................................................................................................16
Compressor Sensor Wire..........................................................................................................................................................................17
Air Tank Blow-Down Located on the Bottom of the Tank Mounted Air Compressor (120V) ...............................................................18
Nitrogen Cabinet (120V) .........................................................................................................................................................................18
Internet Connectivity, PLINK, and BMS (Optional) ...............................................................................................................................19
Nitrogen Generator Operation ........................................................................................................................................................................... 20
Nitrogen Functionality Test ..............................................................................................................................................................................22
Filling the Sprinkler System and Purging..........................................................................................................................................................23
Purging with IntelliPurge®Nitrogen Purge Valve (INS-PV) .............................................................................................................................24
Purging with Potter Nitrogen Purge Valve (NGP-SPV) ....................................................................................................................................25
IntelliView™Dashboard Internet Connectivity..................................................................................................................................................26
IntelliPurge®Wiring and Networking ................................................................................................................................................................27
Maintenance and Part Replacements .................................................................................................................................................................29
Standard Maintenance (Every 1,000 Compressor Operating Hours) ................................................................................................................ 30
Compressor Air Intake Filters..................................................................................................................................................................31
Air Tank Blow-down Strainer..................................................................................................................................................................32
Lubricated Air Compressor Oil................................................................................................................................................................32
Filter Elements......................................................................................................................................................................................... 33
Resetting Maintenance Alert and Checking for Leaks ............................................................................................................................35
Air Compressor Replacement............................................................................................................................................................................35
Nitrogen Membrane Replacement ..................................................................................................................................................................... 36
Maintenance Alerts and Actions ........................................................................................................................................................................37
Trouble Alerts and Probable Causes .................................................................................................................................................................. 38
Troubleshooting .................................................................................................................................................................................................40
Leak on Sprinkler System or Nitrogen Generator ................................................................................................................................... 40
Nitrogen Flow Rate and Nitrogen Purity Test .........................................................................................................................................40
Normal Operating Parameters of the INS-1500/2000 .......................................................................................................................................41
Nitrogen Generator Leak Detection System ......................................................................................................................................................42
To Change the Leak Rate Warning Set Point............................................................................................................................................. 43
To Change Sprinkler System Size.............................................................................................................................................................. 43
INS-1500/2000 Cabinet Dimensional Drawings ...............................................................................................................................................44
INS-1500/2000 Compressor Dimensional Drawings ........................................................................................................................................45
INS-1500/2000 Air Tank Dimensional Drawings.............................................................................................................................................. 46
INS-1500/2000 Piping Instrumentation Diagram..............................................................................................................................................47
Wiring Diagrams................................................................................................................................................................................................ 48
INS-1500/2000 200-208VAC Three Phase.............................................................................................................................................. 48
INS-1500/2000 230-240VAC Three Phase.............................................................................................................................................. 49
INS-1500/2000 460-480VAC Three Phase.............................................................................................................................................. 50
Menu Trees.........................................................................................................................................................................................................51
Menu Tree 1 .............................................................................................................................................................................................51
Menu Tree 2 .............................................................................................................................................................................................52
Menu Tree 3 .............................................................................................................................................................................................53
Menu Tree 4 .............................................................................................................................................................................................54
Menu Tree 5 .............................................................................................................................................................................................55
Menu Tree 6 .............................................................................................................................................................................................56
Menu Tree 7 .............................................................................................................................................................................................57

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
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 Potter
Nitrogen Generator as well as equipment. To help recognize this information, observe the
following symbols.
Safety Guidelines
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.
CAUTION
D
Important Notice to Users
The Installation, Operation, and Instruction Manual supplied with each unit must be read thoroughly and completely understood
before installation and operation of the Potter IntelliGen™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.
Unpacking
After unpacking unit, carefully inspect all parts and equipment for any damage that may have occurred during transit. Make sure
to tighten ttings, bolts, etc. before putting unit into service.
Do not operate if damage occurred during shipping, handling, or
use. Contact Potter immediately.
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 specied 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, qualied, and approved
by Potter Electric Signal Company 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 specied in this manual.

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
The warnings in this manual cover most known potential hazards, but by denition cannot be all-inclusive. If the user employs an
operating procedure, item of equipment, or a method of working that is not specically recommended by Potter Electric Signal
Company, 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 ow
of nitrogen and oxygen enriched air which quickly disperses in the atmosphere. However, do not directly inhale the output gas
from the outlet pipe.
The generator is classied as non-hazardous for transportation purposes and as non-ammable for re regulations. This equipment
is for indoor use only. Do not operate outdoors.
Specic procedure must be developed for maintenance of the equipment on which the membrane separator is located. Appropriate
labels must be continuously displayed in all areas where personnel might be exposed to a nitrogen atmosphere under normal or
upset condition.
Do not attempt to disassemble the nitrogen membrane sepa-
rator. Equipment damage may occur and cause the system to
function incorrectly.
Operation of the nitrogen membrane 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.

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
System Overview
Key Terms
Potter IntelliGen™ Nitrogen Generators are specically designed to provide clean, dry, high purity nitrogen for use in re
protection sprinkler systems. The generator is a fully assembled package ready to be connected to a new or existing re sprinkler
system using a factory pre-engineered air compressor. These easy-to-use systems include all air ltration equipment and controls
required to keep the generator operating at peak efciency.
The Potter IntelliGen™Nitrogen Series operates using membrane technology. The smaller oxygen and water vapor molecules
can pass through (permeate) the membrane quickly. The larger nitrogen molecules are less likely to diffuse through the separator
tubes; therefore, they continue downstream to the separator outlet. The permeated molecules are discharged to the atmosphere
through a vent in the separator housing.
Bypass Mode – Most nitrogen generators cannot produce enough nitrogen to completely ll the sprinkler system in 30 minutes
required by NFPA 13. Therefore, they contain valves that allow the nitrogen membrane to be bypassed so the system can be lled
with compressed air. The valve setting that bypasses the nitrogen membrane is called Bypass Mode.
Nitrogen Generating Mode – The valve setting that allows the air to ow through the nitrogen membrane and create nitrogen is
called Nitrogen Generating Mode.
Purging – Purging is dened as the removal of oxygen from the sprinkler system via a purge valve. The purge valve allows some
gas to escape from the system which requires the nitrogen generator to supply nitrogen to maintain system pressure. This process
therefore increases the nitrogen concentration within the system piping over time.
IntelliGen™Controller
The IntelliGen™ Nitrogen Generator Series is the only line of intelligent nitrogen generators for re sprinkler systems. At the heart
of the IntelliGen™units, is the IntelliGen™Controller. The IntelliGen™Controller monitors every aspect of the nitrogen generator
to ensure the unit is performing optimally. The IntelliGen™Controller monitors pressure, runtime, power, connectivity and
operational mode. Using this information and proprietary algorithms, the IntelliGen™Controller can determine if the unit needs
to be in Bypass Mode or Nitrogen Generating Mode. No need to manually change ball valve congurations or worry if the unit
is producing nitrogen. Also, by monitoring the generator activity the controller can indicate the development of sprinkler system
leaks, user interaction, and even if maintenance to the generator is required. Combined with the IntelliPurge®Nitrogen Purge
Valve, the IntelliGen™Nitrogen Generator is the only system that can truly monitor and protect a sprinkler system.
See Menu Tree Diagram on page 51 for more information on programming.
The INS-1500 and the INS-2000 are FM approved per FM 1035 "Nitrogen Generators".
• The INS-1500 has a Bypass Fill Capacity of 2,000 gallons at 40 PSI and a Total System Capacity of 6,200 gallons
• The INS-2000 has a Bypass Fill Capacity of 2,400 gallons at 40 PSI and a Total System Capacity of 12,000 gallons
Part Number Model Description
1119614 INS-1500, 200-208VAC 3PH 60 HZ IntelliGen™Nitrogen System-1500, 200-208VAC Three Phase
1119615 INS-1500, 230-240VAC 3PH 60 HZ IntelliGen™Nitrogen System-1500, 230-240VAC Three Phase
1119616 INS-1500, 460-480VAC 3PH 60 HZ IntelliGen™Nitrogen System-1500, 460-480VAC Three Phase
1119617 INS-2000, 200-208VAC 3PH 60 HZ IntelliGen™Nitrogen System-2000, 200-208VAC Three Phase
1119618 INS-2000, 230-240VAC 3PH 60 HZ IntelliGen™Nitrogen System-2000, 230-240VAC Three Phase
1119620 INS-2000, 460-480VAC 3PH 60 HZ IntelliGen™Nitrogen System-2000, 460-480VAC Three Phase

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
INS-1500/2000 Exterior Cabinet View
Fig. 1
12
3
4
5
6
7
1. Upper Cabinet Latches (Qty. 2)
2. IntelliGen™Display
3. Control Power Only Switch
4. Compressor Sensor Wire Cord Grip
5. Nitrogen Tank Connection (1/2" FNPT)
6. Air Tank Connection (1/2" FNPT)
7. 3/8" Drain Tube Connection (10 ft. Supplied)

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
INS-1500/2000 Interior View
Fig. 2
1. Nitrogen Membrane (M01)
2. Flow Control Valve (FCV01)
3. Back Pressure Regulator (PRV02)
4. Instrument Air Solenoids
5. Membrane Outlet N2Solenoid (XV02)
6. Owner Supplied Power Connection
7. IntelliGen™Controller
8. Compressor Sensor Wire Connection
9. PLINK Connection
10. BMS Connection
11. Pressure Transducer (PI01)
12. Nitrogen Sample Port (SP)
13. N2Bleed Valve (V04)
14. Bypass Solenoid Valve (XV03)
15. Water Separator (WS01)
16. Coalescing Filter 1µm (F01)
17. Coalescing Filter .01µm (F02)
18. Activated Carbon Filter with Drain Valve (F03)
19. 3/8" Drain
20. Excess Air Regulator (PRV01)
21. Membrane Inlet Air Solenoid (XV01)
22. Instrument Air Regulator (PRV03)
23. Instrument Air Filter (F04)
1
20
21
22
23
2
3
4 5 6
10
11
12
7
13
14
15
16
17
18
9
8
19

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
INS-1500/2000 Nitrogen Tank View
Fig. 3
1. 1/2" FNPT N2Tank Inlet Valve (V02)
2. Nitrogen Tank Pressure Gauge
3. Pressure Safety Valve (PSV01)
4. 1/2" FNPT N2Tank Outlet Valve (V03)
5. N2Tank Drain Ball Valve
1
2
4
3
5

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INS-1500 & INS-2000 • 5403646 • REV F • 04/19
INS-1500/2000 Air Compressor View
Fig. 4
1. Oil Level Switch
2. Air Compressor Air Filter
3. 1/2" FNPT Air Tank Outlet Valve (V01)
4. 1/2" MNPT Flexible Hose (12" Provided)
5. Electrical Panel
6. Compressor Sensor Wire (20 ft. Provided)
7. Blow-Down Solenoid With Controller (120V
Plug Connection)
8. 1/4" Drain Tubing (10' Provided)
9. Air Compressor Pressure Switch
10. Oil Sight Glass
11. Oil Drain Port
1
11
10
2
3
4
5
6
7
8
9