Intelligen INS-500 User manual

Manual #5403645 - A
6/17
St. Louis, MO
800-325-3936
www.pottersignal.com
INS-500/1000
Nitrogen Generators
Installation, Operation, and
Instruction Manual

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
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-500 & INS-1000 • 5403645 • REV A • 6/17
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-500/1000 Exterior View .......................................................................................................................................................7
INS-500/1000 Interior View ........................................................................................................................................................8
IntelliGen™Display ....................................................................................................................................................................9
Installation of the Nitrogen Generator .........................................................................................................................................10
Wiring of the Nitrogen Generator ................................................................................................................................................12
Nitrogen Generator Operation .....................................................................................................................................................14
Nitrogen Functionality Test ........................................................................................................................................................16
Filling the Sprinkler System and Purging....................................................................................................................................17
Purging with IntelliPurge®Nitrogen Purge Valve (INS-PV).......................................................................................................18
Purging with Potter Nitrogen Purge Valve (NGP-SPV) ..............................................................................................................19
IntelliView™Dashboard Connectivity.........................................................................................................................................20
IntelliPurge®Wiring and Networking.......................................................................................................................................... 21
Maintenance and Part Replacements ...........................................................................................................................................22
Standard Maintenance (Every 1,000 Compressor Operating Hours) ..........................................................................................23
Compressor Air Intake Filters.............................................................................................................................................24
Air Tank Blow-down Strainer.............................................................................................................................................24
Filter Elements....................................................................................................................................................................25
Resetting Maintenance Alert and Checking for Leaks .......................................................................................................27
Air Compressor Replacement......................................................................................................................................................28
Nitrogen Membrane Replacement ...............................................................................................................................................28
Maintenance Alerts and Actions ..................................................................................................................................................29
Trouble Alerts and Probable Causes ............................................................................................................................................30
Troubleshooting ........................................................................................................................................................................... 32
Leak on Sprinkler System or Nitrogen Generator ..............................................................................................................32
Nitrogen Flow Rate and Nitrogen Purity Test ....................................................................................................................32
Normal Operating Parameters of the INS-500 and the INS-1000 ...............................................................................................33
Nitrogen Generator Leak Detection System ................................................................................................................................34
To Change the Leak Rate Warning Set Point........................................................................................................................35
To Change Sprinkler System Size ........................................................................................................................................35
INS-500/1000 Dimensional Drawings.........................................................................................................................................36
INS-500/1000 Piping Instrumentation Diagram..........................................................................................................................37
Wiring Diagrams..........................................................................................................................................................................38
INS-500/1000 Single Phase 115-120VAC ..........................................................................................................................38
INS-500/1000 Single Phase 208-240VAC..........................................................................................................................39
INS-500/1000 Three Phase 208-240VAC...........................................................................................................................40
INS-500/1000 Three Phase 460-480VAC...........................................................................................................................41
Menu Trees................................................................................................................................................................................... 42
Menu Tree 1 ........................................................................................................................................................................42
Menu Tree 2 ........................................................................................................................................................................43
Menu Tree 3 ........................................................................................................................................................................44
Menu Tree 4 ........................................................................................................................................................................45
Menu Tree 5 ........................................................................................................................................................................46
Menu Tree 6 ........................................................................................................................................................................47
Menu Tree 7 ........................................................................................................................................................................48

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
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.
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-500 & INS-1000 • 5403645 • REV A • 6/17
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-500 & INS-1000 • 5403645 • REV A • 6/17
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 42 for more information on programming.
The INS-500 and the INS-1000 are FM approved per FM 1035 "Nitrogen Generators".
• The INS-500 has a Bypass Fill Capacity of 500 gallons at 40 PSI and a Total System Capacity of 1,850 gallons
• The INS-1000 has a Bypass Fill Capacity of 1,000 gallons at 40 PSI and a Total System Capacity of 3,400 gallons
Part Number Model Description
1119606 INS-500, 115-120VAC 1PH 60 HZ (QUIET) IntelliGen™Nitrogen System-500, 115-120VAC Single Phase (Quiet)
1119607 INS-500, 115-120VAC 1PH 60 HZ IntelliGen™Nitrogen System-500, 115-120VAC Single Phase
1119608 INS-500, 208-240VAC 1PH 60 HZ IntelliGen™Nitrogen System-500, 208-240VAC Single Phase
1119609 INS-500, 208-240VAC 3PH 60 HZ IntelliGen™Nitrogen System-500, 208-240VAC Three Phase
1119610 INS-500, 460-480VAC 3PH 60 HZ IntelliGen™Nitrogen System-500, 460-480VAC Three Phase
1119611 INS-1000, 208-240VAC 1PH 60 HZ IntelliGen™Nitrogen System-1000, 208-240VAC Single Phase
1119612 INS-1000, 208-240VAC 3PH 60 HZ IntelliGen™Nitrogen System-1000, 208-240VAC Three Phase
1119613 INS-1000, 460-480VAC 3PH 60 HZ IntelliGen™Nitrogen System-1000, 460-480VAC Three Phase

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
INS-500/1000 Exterior View
Fig. 1
12
3
4
56
7
8
9
10
11
13
12
14
15
1. Upper Cabinet Latches (Qty. 2)
2. IntelliGen™Display
3. Air Compressor Power Switch
4. Nitrogen Tank
5. Nitrogen Tank Gauge
6. 12" Flex Hose to Fire Sprinkler System (1/2"
MNPT)
7. N2 Tank Outlet Valve (V03)
8. N2 Tank Inlet Valve (V02)
9. Air Tank
10. Air Tank Gauge
11. Air Tank Outlet Valve (V01)
12. Blow-Down Solenoid (AD01)
13. Valve With Strainer
14. 3/8" Drain Tube (10' Supplied)
15. Ø9/16" Mounting Hole (Qty. 4)

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
INS-500/1000 Interior View
Fig. 2
1
18
19
20
21
22
2
3
4 5 6
7
8
9
10
11
12
13
14
15
16
17
1. Nitrogen Membrane (M01)
2. Flow Control Valve (FCV01)
3. Back Pressure Regulator (PRV02)
4. Instrument Air Solenoids
5. Membrane Outlet N2Solenoid (XV02)
6. IntelliGen™Controller
7. Owner Supplied Power Connection
8. PLINK Connection
9. BMS Connection
10. Pressure Transducer (PI01)
11. Nitrogen Sample Port (SP)
12. N2Bleed Valve (V04)
13. Bypass Solenoid Valve (XV03)
14. Coalescing Filter 5µm (F01)
15. Coalescing Filter 1µm (F02)
16. Coalescing Filter .01µm (F03)
17. Activated Carbon Filter with Drain Valve (F04)
18. Cooling Fan (CF01)
19. Excess Air Regulator (PRV01)
20. Membrane Inlet Air Solenoid (XV01)
21. Instrument Air Filter (F05)
22. Instrument Air Regulator (PRV03)

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
POWER
SILENCED
SILENCE CLEAR
1 2 3
4 5 6
7 8 9
0
MAINT PURGE ENTER ESC
MAINTENANCE
BYPASS TROUBLE
PURGING
IntelliGen™Display:
IntelliGen™Display LED Light Indications:
IntelliGen™Display Button Indications:
The IntelliGen™Display is the interface to the IntelliGen™Nitrogen Generator. This display shows the generator’s history,
parameters, and troubles; as well as devices networked to the unit.
POWER – The green POWER LED indicates if the IntelliGen™Nitrogen Generator has power.
SILENCED – The amber SILENCED LED indicates the Trouble Horn on the IntelliGen™Nitrogen Generator is silenced.
BYPASS – The amber BYPASS LED indicates if the IntelliGen™Nitrogen Generator is in Bypass Mode. If the Bypass LED
indicator is off, the unit is in Nitrogen Generating Mode.
PURGING – The amber PURGING LED indicates the IntelliGen™Nitrogen Generator detects that a networked INS-PV is in a
purge process.
MAINTENANCE – The amber MAINTENANCE LED indicates the IntelliGen™Nitrogen Generator needs maintenance.
TROUBLE – The red TROUBLE LED indicates the IntelliGen™Nitrogen Generator has a trouble condition.
SILENCE – The "SILENCE" button will silence the Trouble Horn on the IntelliGen™Nitrogen Generator.
CLEAR – The "CLEAR" button will clear all Troubles.
MAINT – The "MAINT" button will display the Maintenance Menu.
PURGE – The "PURGE" button will bring up the Purge Menu on the IntelliGen™Display.
Fig. 3

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
1. On arrival, do a full inspection by checking all packages and crates in the shipment for damage.
2. If damage is found, sign for the damage or refuse the shipment. Contact the carrier immediately and le a shipping damage
claim with the carrier.
3. Check to ensure all components are contained and no visible damage has occurred during shipping.
• Nitrogen Cabinet
• IntelliGen™Display
• Air Tank
• Nitrogen Tank
• Air Compressor
4. Each nitrogen generator requires a minimum of one Air Maintenance Device (AMD) and one Nitrogen Purge Valve per
sprinkler system. Check to see these components have arrived.
• Air Maintenance Device (one per riser) (NGP-AMD-1 #1119621)
• Nitrogen Purge Valve (NGP-SPV #1119784) or (INS-PV #1119478)
• Portable Nitrogen Analyzer (one per job) (PNA #1119504)
5. Find a location for the nitrogen generator to be installed meeting these requirements:
• Dry, clean and well-ventilated
• Dimensions 54” X 42” X 32” (H x W x D)
• Ambient temperatures above 50º F at all times
• Access to front for service
• Conveniently located near re sprinkler system connections
• Conveniently located near a drain
• Near a dedicated electrical circuit with an electrical disconnect switch
6. Mount the skid base to the oor using (4) 3/8” bolts. See Fig. 4.
7. To plumb the nitrogen generator to the re sprinkler system rst, install the supplied 12" exible hose to the N2Tank Outlet
Valve (V03). Plumb the 1/2" NPT piping to the sprinkler system Air Maintenance Device using standard accepted installation
practices. See Fig. 5.
Fig. 5
Installation of the Nitrogen Generator
Fig. 4
1/2" MNPT to Fire
Sprinkler System
Supplied Flexible Hose

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
8. Pipe the provided 10' of the 3/8” drain tubing to the oor drain in the sprinkler room. Do not pipe the drain tubing upward.
Ensure drain tubing is restrained. See Fig. 6.
9. Each riser requires a minimum of ONE Nitrogen Purge Valve to be installed prior to implementing the Nitrogen Purging
Procedure. For installation instructions, refer to Model NGP-SPV Bulletin (#5401520) or Model INS-PV Manual
(#5401532) supplied with each purge valve. See Fig. 7 for NGP-SPV installation diagram. See Fig. 8 for INS-PV installation
diagram.
Installing the purge valve upside down will not allow the system to purge. Also, ensure that there is NO water in
the pipe to the purge valve.
Fig. 6
111 /4"
7"
1/2" NPT TEE CONNECTION AND CLOSE NIPPLE
(SUPPLIED BY SPRINKLER CONTRACTOR)
PIPE FROM SPRINKLER SYSTEM
INSPECTOR'S TEST VALVE
PURGE ORIFICE (N 2 SAMPLING PORT
)
NGP-SPV
PIPE PLUG (INSTALL AFTER
PURGE COMPLETE)
REMOVE PLUG WHEN SAMPLING
N 2 LEVELS AND PURGING
PURGE BALL VALVE
SHOWN IN NORMAL (NON - PURGE) POSITION
UNION - POSITION VENT / ORIFICE
APPROPRIATELY
DWG. #0400-13
71 /4"
Fig. 7
Pipe to Floor Drain
7 1/4"
20 1/2"
7 1/8"
INSPECTORS TEST VALVE
PIPE FROM SPRINKLER SYSTEM
1/2" NPT TEE CONNECTION AND CLOSE NIPPLE
(SUPPLIED BY SPRINKLER CONTRACTOR)
PURGE BALL VALVE, SHOWN
IN NORMALLY CLOSED (NON-PURGE) POSITION
VENT
UNION - POSITION VENT/ORIFICE/INS-PV
APPROPRIATELY
INS-PV
INTELLIPURGE
UNION
ORIFICE
Fig. 8

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
1. Run a dedicated electrical circuit with an electrical disconnect switch to sprinkler room.
2. To wire the INS-500 or INS-1000, open the front panel at the top of the nitrogen cabinet to access wiring terminal blocks. Use
the 1/2" or 3/4" knockouts on back of cabinet for electrical conduit. See Fig. 9.
3. Depending on the voltage of the model (120V, 208V, 230V, 460V-Single or Three phase) follow the wiring diagram in this
manual on page 38, or use the wiring diagram on the inside of the nitrogen generator cabinet door.
4. For internet connectivity (see the IntelliView™section on page 20 for more details), wire a CAT-5 Ethernet cable using a 1/2"
knockout on the back of the cabinet to the Ethernet Port on the IntelliGen™Controller. See Fig. 10.
Wiring of the Nitrogen Generator
All wiring should be performed by a licensed electrician and conform to NEC and all applicable local standards.
Fig. 9
Fig. 10
Wiring Terminal
Block
(120V shown)
Knockouts
(Bottom knockout is
hidden in drawing)
For Three Phase motors, ensure the air compressor turns in the correct direction labeled on the air compressor.
Ethernet Port

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
5. Using the other 1/2" knockout on the back of the cabinet, wire the IntelliPurge®Nitrogen Purge Valve to the IntelliGen™
Controller using 3 wire cable (22 AWG recommended). See the IntelliPurge®Section on page 21 for more details. Connect
the PLINK to the terminal blocks next to the controller. See Fig. 11.
Fig. 12
BMS-NO
BMS-NC
BMS-C
Fig. 11
6. Using the same 1/2" knockout on the back of the cabinet, a form C relay is available to wire any BMS (Building Management
System) to the BMS terminal blocks. See Fig. 12.
PL-G
PL-B
PL-A

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
Nitrogen Generator Operation
Initial Set Up:
1. Before beginning, make sure the water supply to the sprinkler system is turned off.
2. Make sure all piping connections have been made in accordance with the installation instructions.
3. Ensure the Air Compressor Power Switch located on the right side of the cabinet is in the "OFF" position.
4. Close the Air Maintenance Device. If multiple Air Maintenance Devices are used, ensure all valves are in closed position.
5. Close the N2Tank Outlet Valve (V03) on the nitrogen tank. See Fig. 13.
6. Turn power ON to the nitrogen generator using the contractor installed "Electrical Disconnect" switch.
7. The IntelliGen™Display will turn on, indicating power with a green LED labeled "POWER".
Note: There will be a short delay as the IntelliGen™Display turns on and the system boots up.
8. The amber LED labeled "BYPASS" will activate if the pressure is less than 55 PSI in the nitrogen tank.
Fig. 13
To Fire Sprinkler System
V03

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
9. Turn power ON to the air compressor using the switch labeled “Air Compressor Power” on the right side of the cabinet. See
Fig. 14.
10. The air compressor will begin running and the pressure in the air tank and nitrogen tank will begin to rise. Start recording the
time it takes until the compressor turns off.
11. When the nitrogen tank pressure reaches approximately 80 PSI the valves inside the cabinet will close.
12. When the air tank pressure reaches approximately 105 PSI the air compressor will turn off.
13. If the nitrogen generator is isolated from the sprinkler system:
• The air compressor of the INS-500 should take no longer than 8 minutes to pressurize both tanks and turn off.
• The air compressor of the INS-1000 should take no longer than 6 minutes to pressurize both tanks and turn off.
If the air compressor is not turning off, or it is taking longer than expected, go to the Troubleshooting section in this manual
on page 32.
14. When the two tanks are pressurized, the amber LED labeled "BYPASS" on the IntelliGen™Display will turn off and "Mode"
on the IntelliGen™Display will change to "N2 Mode". This indicates that the unit is now in Nitrogen Generating Mode.
15. Check all piping connections for leaks as pre-plumbed ttings may have loosened during shipment. Any pressure drop on the
tanks during this time could indicate a leak.
Fig. 14

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
Nitrogen Functionality Test:
1. To ensure the nitrogen generator is operating correctly and that the correct nitrogen purity is being produced, a functional test
must be performed.
2. On the inside of the nitrogen cabinet locate the blue N2Bleed Valve (V04). See Fig 15.
3. Slightly open the blue N2Bleed Valve and begin relieving the pressure from the nitrogen tank.
4. Quickly close the blue N2Bleed Valve when you see the red instrument air solenoid lights turn on. This will happen at
approximately 60 PSI as shown on the IntelliGen™ display. See Fig 16.
Note: If the pressure in the nitrogen tank drops below 55 PSI, the IntelliGen™Nitrogen Generator will return to
Bypass Mode. Close the valve and wait for the nitrogen generator to rell the tanks and the unit to return to Nitrogen
Generating Mode before trying again.
5. Immediately begin timing to see how long it takes to reach approximately 80 PSI in the nitrogen tank while the nitrogen
generator is in Nitrogen Generating Mode.
6. If the nitrogen generator is isolated from the sprinkler system:
a. The INS-500 should take no longer than 8 minutes to pressurize the nitrogen tank to 80 PSI.
b. The INS-1000 should take no longer than 4 minutes to pressurize the nitrogen tank to 80 PSI.
7. During this time, connect the Portable Nitrogen Analyzer to the Nitrogen Sample Port (SP) to measure the purity of the
exiting gas. The analyzer should read 98.0% or greater. This may take a few minutes.
8. When the nitrogen generator reaches approximately 80 PSI in the nitrogen tank, the red instrument air solenoid lights will
turn off. The air compressor will continue to run until the air tank pressure reaches approximately 105 PSI.
Fig. 15
Fig. 16
V04

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INS-500 & INS-1000 • 5403645 • REV A • 6/17
Filling the Sprinkler System and Purging:
1. To ll the sprinkler system, open the N2Tank Outlet Valve (V03) on the nitrogen tank and open the bypass valve on the Air
Maintenance Device. See Fig. 17.
2. The pressure in the nitrogen tank and the air tank will decrease rapidly, causing the nitrogen generator to switch to Bypass
Mode.
3. The amber LED labeled "BYPASS" will turn on and the "Mode" on the IntelliGen™Display will turn to "Bypass Mode". This
indicates that the nitrogen generator is lling the system with air to meet the NFPA required 30 minute ll time.
4. The air compressor will also turn on.
5. Allow the re sprinkler system to reach the desired pressure. This should take 30 minutes or less.
6. As soon as sprinkler system supervisory pressure is reached, put the sprinkler system back into service by placing the Air
Maintenance Device in the maintenance position (refer to the Air Maintenance Device manual for proper operation).
7. When the sprinkler system(s) are completely lled, the nitrogen generator will repressurize the air tank and nitrogen tank to
capacity. The air compressor will turn off and the unit will automatically return to Nitrogen Generating Mode.
Note: The amber LED labeled "BYPASS" should be off and the "Mode" on the IntelliGen™Display will display "N2 Mode".
8. Reset the Leak Rate by pressing the "MAINT" button on the IntelliGen™Display Keypad. Enter "0000" for passcode.
9. Move the cursor to "Excess N2 Demand" and press "ENTER".
10. Press "ENTER" on the keypad to clear maintenance alert and reset Leak Rate (LR).
11. You will receive conrmation that the alert has been cleared.
12. Press "ESC" to return to the main screen.
Fill only one re sprinkler system at time. Doing multiple systems at once could lead to longer compressor
runtimes and possible damage to equipment. Allow air compressor to cool before beginning again.
Fig. 17 V03

18
INS-500 & INS-1000 • 5403645 • REV A • 6/17
Purging with IntelliPurge®Nitrogen Purge Valve (INS-PV):
1. See Manual #5401532 for full details on installing, programming, purging and wiring of the INS-PV.
2. Go to the end of the sprinkler system(s) where the INS-PV(s) is installed. Each riser should have one INS-PV.
3. Check to ensure power is connected to the INS-PV. The green Power LED will be ON.
4. Open the ball valve on the INS-PV.
5. Ensure the INS-PV is installed properly. Installing the valve upside down will cause the unit to not purge. Any trapped water
in the piping will also cause the unit to not purge.
6. To check that the INS-PV is allowing air/nitrogen ow, toggle the “MANUAL PURGE” switch ON. This will open the
solenoid valves inside the unit.
7. If the sprinkler system is pressurized, listen for ow out of the Purge Exhaust Port on the bottom of the unit. You may also
use your ngers to feel for ow. If no ow is present, there is a blockage such as a shut ball valve, water in the pipe, or a
clogged orice upstream.
8. If the INS-PV unit is not connected to a nitrogen generator or an INS-RA, toggle the “START PURGE” switch to start the
Purge Process.
9. Once the Purge Process has started, the yellow Purge LED indicator will begin blinking.
10. The Purge Time Display will display the max number of purge days, which is the maximum amount of time the unit is
allowed to purge before indicating a trouble.
11. The N2 Level display will blink indicating that it is taking an initial nitrogen level reading. After ve minutes the N2 Level
display should read ambient nitrogen levels, between 78-81%.
12. The INS-PV is now purging. The oxygenated air is escaping out of the Purge Exhaust Port.
13. If an IntelliPurge®Nitrogen Purge Valve (INS-PV) is connected to a nitrogen generator or an INS-PV, the S1 toggle switch
will be DISABLED.
14. Return to the nitrogen generator.
15. If an INS-PV is connect to the nitrogen generator, press the “PURGE” button on the IntelliGen™Display keypad.
16. Follow all prompts.
17. Once the system reaches 98% the INS-PV automatically closes and your system is purged.
Fig. 18
Slotted Cam Latch
S2 Toggle Switch
S1 Toggle Switch
Purge Exhaust Port
Purge Time Display
Power LED
N2 Level % Display
Purge LED
Trouble LED

19
INS-500 & INS-1000 • 5403645 • REV A • 6/17
Purging with Potter Nitrogen Purge Valve (NGP-SPV):
1. See Bulletin #5401520 for full details on installing and purging of the NGP-SPV.
2. Go to the end of the sprinkler system(s) where the NGP-SPV(s) is installed. Each riser should have one NGP-SPV purge
valve.
3. Open the ball valve on the NGP-SPV.
4. Ensure the NGP-SPV is installed properly. Installing the valve upside down will cause the unit not to purge. Any trapped
water in the piping will also cause the unit not to purge.
5. Unscrew the 1/2" pipe plug located at the end of the NGP-SPV.
6. Check to ensure ow is coming out the purge valve.
7. If the sprinkler system is pressurized, listen for ow. You may also use your ngers to feel for ow. If no ow is present,
there is a blockage such as a shut ball valve, water in the pipe, or a clogged orice upstream.
8. Wait approximately 14 days before returning to the job site and checking the exiting gas with the Portable Nitrogen Analyzer.
9. Check the nitrogen purity to ensure the exiting gas is 98% or greater.
10. If the gas is 98% purity or greater close the ball valve and screw the plug back in. The system is purged.
11. If the nitrogen purity is 85% or greater, wait another 7 days before returning to the site and rechecking. Some larger systems
may have longer purge times.
12. If the nitrogen purity is around 80% it indicates that there is a blockage in the sprinkler system piping, the ball valve is closed
on the purge valve or that your nitrogen generator is in Bypass Mode.
Fig. 19

20
INS-500 & INS-1000 • 5403645 • REV A • 6/17
Potter's IntelliGen™Controller is designed to provide you with live status updates of your nitrogen generator. The IntelliGen™
Nitrogen Generator needs to be wired using a CAT-5 Ethernet cable. The Ethernet port is located on the bottom left of the
IntelliGen™Controller. When the unit is wired and powered on, data will be accessible at www.PotterIntelliView.com.
Register your nitrogen generator, visit www.PotterIntelliView.com.
1. Log In or Register New User.
2. If you are a new user you will be required to enter your name, company information, and a valid e-mail address.
3. You will receive an e-mail conrmation with an account verication link.
4. Once logged in, click the "Register Generator" button on the Dashboard Overview page.
5. Enter the unit’s MAC ID Number and the Serial Number which can be found on the IntelliGen™Controller inside the cabinet.
See Fig. 20.
IntelliView™Dashboard Internet Connectivity
6. Add a name for the generator and the building where the generator is located.
7. A window will appear indicating that you have successfully added the nitrogen generator. Click save.
8. The page will refresh with information on the new nitrogen generator.
9. For more information on the Potter IntelliView™Dashboard, watch a tutorial at www.potterintelliview.com.
Fig. 20
MAC ID
Serial Number