Nano Eco gen2 User manual

User guide

ECO GEN

2nitrogen generator

revision: 2022-018 document: 17-100-0693

www.n-psi.co.uk

Experience. Customer. Service.

about us

Experience.

Our team is comprised of and supported by individuals spanning

all disciplines from research & development, engineering &

manufacturing, marketing & sales and service & support. Our

backgrounds are in air and gas purication and our experience

in this eld spans a wide range of industries. We combine this

knowledge and experience to ensure our products and services are

designed and provided to meet the objectives and expectations

of you - our Customer.

Service.

At nano we recognise that world-class customer service is the

most important component to any successful business. Your

business needs to exceed your customers’ expectations to

stand out from your competitors and our service must positively

impact your business so you can be successful in doing so. Our

commitment is simple… we will stand behind our products and

ensure that our customer service is unrivaled in the industry.

Customer.

We recognise that our Customers are not only our valuable

distribution partners who sell and support our products or the

machine builders who depend on them as protection for their

equipment. They are the contractors who install them, the

manufacturers who use them in their processes and the service

people who maintain them. At nano we have developed our

products, packaging and support materials to ensure they exceed

all of our Customers’ expectations.

3

section description page

1. support details 4

2. general information

5

2.1 document introduction

2.2 warranty guidelines

2.3 general safety

2.4 intended use of the product

3. technical specications

6

3.1 ow rates

3.2 correction factors

3.3 product dimensions 7

4. product overview 8

4.1 typical system layout 9

4.2 remote start/stop control 10

4.3 start-up procedure 11

4.4 shutdown procedure

4.5 control panel displays 12

5. maintenance

13

5.1 cleaning

5.2 daily checks

5.3 service guidelines

5.4 service schedule and breakdown 14

5.5 service kits and spares 15

6trouble shooting 16

7process and instrumentation diagram 17

7.1 wiring diagram 18

notes 19

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1. manufacturers detials and support

nano-purication solutions ltd. (Manufacturer)

address: Dukesway

Team Valley Trading Estate Gateshead

NE11 0PZ

United Kingdom

telephone: +44 (0) 191 497 7700

internet: www.n-psi.co.uk

email [email protected]

usa - nano-purication solutions inc.

address: 5509 David Cox Road

Charlotte, NC 28269

USA

telephone: +1 (704) 897-2182

internet: www.n-psi.com

email: [email protected]

canada - nano-purication solutions inc.

address: 7 Petrie Street

St. Catharines,

Ontario L2P 3J6

Canada

telephone: +1 (905) 684-626

internet: www.n-psi.com

email: [email protected]

germany - nano-purication solutions inc.

address: Mommenpesch, 46

D-47839

Erkelenz

Germany

telephone: +49 2151 4828 418

internet: www.n-psi.de

email [email protected]

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5

2. general information

to any electronic medium or machine readable form without prior consent in writing. It may not be distributed through the internet or

computer bulletin board systems without prior consent.

2.1 document introduction

This manual provides factory prescribed maintenance procedures for the nitrogen generator. The procedures illustrated in this document

are only to be performed by authorized personnel. For further information regarding the procedures outlined in this document contact the

manufacturer before proceeding.

2.2 general safety

No modications must be made to the product. Any modications may reduce the operational safety of the product and invalidate the

manufacturer’s warranty. This could potentially result in damage to the product and serious personal injury.

For your own safety, when carrying out work on this product, all relevant national safety regulations must be complied with relating to

pressurized and electrical systems.

Only authorized, competent and trained personnel are permitted to work on this product. This user guide is intended solely for such

personnel and is to be used only as a reference; it should not be used to replace conventional training.

2.3 packaging

All products are securely packaged in a specically designed wooden packing box. The dryer will be held in a horizontal position by

wooden struts; using straps to secure the product to the box base. The box top cover can be removed by removing the 4 xing screws

and lifting off in one piece.

2.4 intended use of the product

The nitrogen generator is exclusively intended for the treatment of compressed air, which is free from bulk water, oil and solid matter

constituents.

The product should be located within a building and protected from extreme conditions and weather. The nitrogen generator must be

operated only in accordance with the data on the rating plate. Any operations that do not comply with those stated on the product

rating label will render the warranty void

NOTES: highlight important sections of

information where particular care and

attention should be paid.

CAUTIONS: indicate any situation or

operation that may result in potential

damage to the product, injury to the user,

or render the product unsafe.

annotations

WARNING: This product can expose you to chemicals including lead, which is known to the

State of California to cause cancer and/or birth defects or other reproductive harm. For more

information, go to www.P65Warning.ca.gov.

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3. technical specication

specications standard options

minimum operating pressure 6 barg (87 psig)

maximum operating pressure 10 barg (145 psig)

recommended operating temperature range 20 to 25°C (68 to 77°F)

design operating temperature range 5 to 50°C (41 to 122°F)

inlet air quality -40°C pdp (-40°F pdp) 3°C pdp (37°F pdp)

power supply requirements 100 to 240V AC @ 50 or 60 Hz 24V DC

All generators should be proceeded by a coalescing ﬁlter regardless of oil or oil free applications, a 0.01mg/m1 grade

coalescing ﬁlter must be installed on the inlet to the generator.

3.1 ow rates

model

rated outlet ow for nitrogen purity outlet (maximum oxygen content)

99.9%

(0.1%)

99.5%

(0.5%)

99%

(1%)

98%

(2%)

97%

(3%)

96%

(4%)

95%

(5%)

Nm3/hr scfh Nm3/hr scfh Nm3/hr scfh Nm3/hr scfh Nm3/hr scfh Nm3/hr scfh Nm3/hr scfh

ECO-GEN2090 1.4 49.4 2.2 77.7 2.7 95.3 3.7 130.6 4.6 162.4 5.3 187.1 5.9 208.3

ECO-GEN2110 2.4 87.7 3.4 120.0 4.3 151.8 5.8 204.8 7.2 254.2 8.4 296.6 9.4 331.9

ECO-GEN2130 4.0 141.2 5.6 17.7 7.1 250.7 9.6 339.0 12.0 423.7 13.9 490.8 15.5 547.3

Inlet Temperature Correction Factors

°C 5 10 15 20 25 30 35 40 45 50

°F 41 50 59 68 77 86 95 104 113 122

correction factor 0.8 0.9 0.94 1 1 0.98 0.95 0.9 0.85 0.72

Inlet Pressure Correction Factors

barg 6 7 8 9 10

psig 87 101 116 130 145

correction factor 0.88 11.10 1.20 1.20

3.2 correction factors

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3.3 product dimensions

model

dimension

A B C D E F G

mm inches mm inches mm inches mm inches mm inches mm inches mm inches

ECO-GEN2090 1064 42 440 17 366 14 225 7¾ 110 4 60 2¼ 125 5

ECO-GEN2110 1391 55 440 17 366 14 225 7¾ 110 4 110 2¼ 125 5

ECO-GEN2130 1991 78 440 17 366 14 225 7¾ 110 74.25 110 2¼ 125 5

DIMENSION ‘A’

DIMENSION ‘C’

DIMENSION ‘D’

DIMENSION ‘G’

DIMENSION ‘F’

DIMENSION ‘E’

DIMENSION ‘B’

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4. product overview

number description number description

1compressed air inlet (1/2” BSPP) 8regulated outlet pressure gauge

2to buffer (1” BSPP or NPT) 9online column pressure gauge

3from buffer (1/2” BSPP) 10 compressed air inlet pressure gauge

4nitrogen outlet (1/2” BSPP) 11 purge ow control

5mains inlet (electrical supply) 12 generator column

6remote start/stop 13 exhaust silencer

7control panel display 14 alarm output

1

3

4

10

9

8

7

11

13

5

6

14

12

2

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4.1 typical system layout

IMPORTANT: It is essential that the system into which the generator is installed is tted with a pressure limiting/

relief device. This device should be installed between the compressor and the product.

nitrogen

outlet

pressure relief valve pressure relief valve

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4.2 remote start/stop control

To gain access to the remote start/stop feature:

• Remove the two M6 screws from each side of the enclosure.

• Open the front cover and locate the ying lead on the bottom of the control plate and remove the insulating sheath.

• There are six wires;

1. Red Wire - Remote Stop

2. Black Wire - Remote Start/Stop

3. Blue Wire - Alarm Output (Zero volt contact)

4. White Wire - Alarm Input (Zero volt contact)

5. Green Wire - 24V DC Output

6. Yellow Wire - 24V DC Output

• To set up the Remote Start/Stop control, remove/break the connection between the Black wires and green wires connect

externally to a remote switch or relay.

• A 24V DC Output must be connected to the Black wire to enable the dryer to operate, if the connection is broken or if there is no

voltage the generator will switch off and revert to shutdown mode, displaying “REMOTE STOP ACTIVE” on the controller display.

IMPORTANT: Under no circumstances should an external voltage or current be applied to any of these wires, as

damage to the control system will occur, negating the warranty.

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4.3 start-up procedure

• Ensure the inlet air temperature is between 5°C and 50°C (41°F and 122°F).

• Ensure that all compressed air isolation valves are fully closed before operating.

• Power up the generator, this will automatically start the generator and the display will illuminate.

• Slowly open the air inlet valve (see page 10/11) and check for any leaks. Continue to open the air inlet valve until fully open.

• Allow the generator to cycle at least two times.

• Slowly open the ‘To buffer tank’ isolation valve (see page 10/11) until the buffer tank is at full pressure (this will take a few cycles)

• Slowly open the ‘From buffer tank’ isolation valve (see page 10/11). At this point the generator control system will be able to

operate fully.

4.4 shutdown procedure

Please ensure this procedure is followed when shutting down the generator.

• Do not turn off the power to the generator

• Isolate all compressed air connections to the Nitrogen Generator and buffer vessel.

• Allow the generator to continue to operate until the display indicates low pressure

• Once low pressure is indicated the generator will depressurise itself through the exhaust valves.

• Once the generator is fully depressurised the power can be switched off and the mains power isolated.

Beware it can take up to two hours to clean the buffer tank, and hit required purity

CAUTION: The generator may still retain trapped pressure!

Do not switch off or isolate the power to the generator before the generator is isolated from the

compressed air source and fully depressurised.

Pease ensure the correct shut down procedure is followed to shut the generator down.

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4.5 control panel displays

1. Power-up Display (only visable on power start-up for 10 seconds)

During power-up the screen will display:

• Program number followed by the revision.

• Total hours dryer has operated.

2. Power-up Display Continued

During power-up the screen will display:

• Remote stop active will only appear if the remote start connection has been broken or the

external relay/switch is not active

• Low inlet pressure will only appear if the inlet pressure is below the desired set-point

• Hours the generator has run between services

• Hours the generator has run in Economy mode

3. Start-up Sequence

During the start-up sequence the screen will display:

• Start-up will be displayed until the half cycle count has met the de-sired set point

• Column ‘A’ status and Column ‘B’ status, this will be shown as online

• Hours the generator has run between services

• Hours the generator has run in Economy mode

NOTE: Purity only shown if option is tted

4. Normal Operation Display

During normal operation, if the generator enters economy mode the screen will display:

• economy mode indicator to let you know it has shutdown, this will only occur when the

desired outlet pressure reaches the set-point

• Hours the generator has run between services

• Hours the generator has run in Economy mode

Speak to the manufacturer about your requirements.

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3. maintenance

• maintenance operation should only be conducted when the system has been shut down and fully depressurized.

• all connections must be isolated and removed with care, paying particular attention to the areas that become pressurized.

• do not modify or adjust the control settings.

• only certied and approved replacement parts should be used.

• always check all connections for leakage and secure seating.

• ensure all loose parts are removed or secured to the dryer before operation.

3.1 cleaning

Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical connections. If required a mild detergant

may be used, however do not use abrasives or solvents as these may cause damage.

3.2 daily checks

• check the generator for any external damage assess and eliminate any defects found.

• if the red service light appears, the generator must be serviced to ensure the best quality possible. contact the service provider

and request a service kit for the product.

• remove any loose dust or dirt from the generator, clean all surfaces that appear to have attracted unwanted contaminants.

• always check all connections for leakage and secure seating.

• ensure all loose parts are removed or secured to the generator before operation.

3.3 servicing guidelines

• maintenance operation should only be conducted when the system has been shut down and fully depressurized.

• isolate the generator from the compressed air and electrical supply ensuring the system is in a safe condition for maintenance

to be carried out on.

• all connections must be removed with care, paying particular attention to the areas that become pressurized.

• all gasket seals removed during maintenance operations must be replaced with new gaskets.

• only certied and approved replacement parts should be used.

• do not modify or adjust the control settings.

• always check all connections and sealing faces for cleanliness and secure seating prior to assembly.

• ensure all components are re-tted to the product before operation.

• always check all connection and sealing faces for any leakage, if any found resolve and check again.

• ensure the product is left operating in a safe working condition after completion of maintenance.

Maintenance operations should only be carried out by authorized, suitably trained personnel.

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5.4 service schedule and breakdown

service year 1

(12 mths)

year 2

(24 mths)

year 3

(36 mths)

year 4

(48 mths)

year 5

(60 mths)

A

B 

C

D

When contacting your service provider be sure to provide the part number and serial number of your generator,

this can be found on the rating plate located top right hand side of the generator.

• Service A - Every 1 Year 12 Months)

Replace External Exhaust Silencers

• Service B - Every 2 Year (24 Months)

Replace Exhaust Valves

Replace Inlet Valves

Replace Nitrogen Outlet Valve

Replace Solenoid Coils

• Service C - Every 4 Year (48 Months) Replace:

Oxygen analyzer solenoid valve

• Service D - Every 5 Year (60 Months) Replace:

Oxygen analyzer sensor (if tted).

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5.5 service kits and spares

model service A service B service C sevice D

ECO-GEN2-090 31-100-5009 31-100-5150

31-100-5160

31-100-5200 [x2]

31-100-1525

31-100-5260 31-100-1530ECO-GEN2-110 31-100-5011

ECO-GEN2-130 31-100-5013

kit number description kit contents

31-100-5009 Replacement Exhaust Silencers (x2) Exhaust Silencers

31-100-5011 Replacement Exhaust Silencers (x2) Exhaust Silencers

31-100-5013 Replacement Exhaust Silencers (x2) Exhaust Silencers

31-100-5150 Replacement Exhaust Valves (x2) Exhaust Valves

31-100-5160 Replacement Normally Closed Inlet Valves (x2) N/C Inlet Valves

31-100-5260 Replacement Nitrogen Outlet Valve (x1) Outlet Valve & Coil 24v

31-100-5200 Replacement Solenoid Coils (x2) 24v DC Coils

31-100-1525 Oxygen analyzer solenoid valve (x1) N2 Solenoid Valve

31-100-1530 Oxygen analyzer sensor (x1) N2 Analyzer

31-100-???? Replacement solenoid coil (x1) Coil 24v

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6. trouble shooting

problem problem caused solution

poor

performance

Insufcient inlet pressure Inlet pressure should be a minimum of 6barg (87psig) if not then

adjust inlet pressure settings.

Electrical fault Ensure the power is on and the generator front panel is illuminated;

check the generator is cycling correctly

Excessive inlet

air temperature Check against the technical specication

Insufcient purge air Purge incorrectly adjusted, consult the service personnel to adjust

settings (factory pre-set).

Exhaust silencer blocked Replace exhaust silencer/mufer element.

failure

to cycle

Controller not functioning correctly Ensure the controller is powered up, check the on screen column

status to ensure it is powering the solenoid valves during operation

Insufcient inlet pressure Inlet pressure should be a minimum of 6barg (87psig) if not then

adjust inlet pressure settings.

Controller not illuminated Check power supply to the dryer, check fuse and replace.

Failure to de-pressurize

when cycling

Solenoid valve not functioning correctly; if there is power to the coil,

replace valve.

Outlet ow stops Check inlet air supply

Failure to initialize

Ensure that all isolation valves are fully closed, power up the

generator, slowly open the air inlet valve and allow the generator

to cycle.

Erratic air ow from exhaust Faulty or damaged valves, carry out service

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7. process and instrumentation diagram

TO BUFFER

FROM BUFFER

PRESSURE

REGULTOR

FLOW

CONTROLLER

PURGE

VALVES

N2 OUTLET

VALVE

OUTLET

PRESSURE SENSOR

REGULATED OUTLET

PRESSURE GAUGE

ONLINE COLUMN

PRESSURE GAUGE

INLET ‘B’

SOLENOID

VALVE

EXHAUST EXHAUST

INLET ‘A’

SOLENOID

VALVE

INLET

PRESSURE GAUGE

INLET

PRESSURE

SENSOR

COMPRESSED

AIR INLET

FLOW

CONTROLLER

O2 analyzer (if fitted)

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7.1 wiring diagram

Controller

Box Earth Pin

Enclosure

Front Plate

Earth Pin

O2 Analyser

options only

Resistor

500Ω

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notes

.......................................................................................................................................................................................................

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notes

.......................................................................................................................................................................................................

20

NANO ECO GEN2 User manual

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