NANO GEN2-1110 User manual

GEN2
NITROGEN GENERATOR
USER GUIDE

1. General information 3
1.1. Document introduction 3
1.2. Support and Manufacturers details 3
1.3. Warranty Guidelines 3
Contents Page
2. General safety 4
2.1. Intended Use 4
2.2. Personnel 4
2.3. Safe Handling 4
3. Product Description 5
  3.1. TechnicalSpecication        5
4. Product Contents 6
4.1. Packaging 6
4.2. Unpackaging The Equipment 7
5. Product Dimensions 8
6. Equipment Overview 9
7. System Layout 10
7.1. Site Location 11
7.2. Mechanical Installation 11
8. Electrical Control Panel 12
8.1. Remote Alarms 13
8.2. Remote Start/Stop 13
8.3. Start-up Procedure 13
  8.4. HMIInterface        14/15
9. Oxygen Analyzer Calibration 16
9.1. GEN2 - 1110, 2110, 3110 16
9.2. GEN2 - 2130, 3130, 4130,6130, 8130, 10130, 12130 17
9.3. Sensor Calibration 18
10. Maintenance 19
10.1. Daily Checks 19
10.2. Cleaning 19
10.3. Service Schedule 20
11. Troubleshooting 21
12. Warranty 22
13. Service Record 22
14. Electrical Schematic 23 / 24
15. Process & Instrumentation diagram 25

Page 317-110-0143
1. General Information
This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied,
photocopied, reproduced, translated, or reduced to any electronic medium or machine
readable form without prior consent in writing from nano-puricationsolutions. It may not
be distributed through the internet or computer bulletin board systems without prior consent
from nano-purication solutions.
1.1 Document Introduction
This manual provides factory prescribed installation and maintenance procedures for a
nano-puricationsolutionsGEN2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 your supplier before proceeding.
Read this document carefully before attempting to install or operate the nitrogen generator.
This document should be permanently available at the nitrogen generator installation site
and be kept in an easily accessible place.
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:
1.2 Support and Manufacturers details
nano-purication solutions inc.
5509DavidCoxRoad
Charlotte
NC 28269
USA
Telephone: [phone]
Fax:  +1(704)897-2183
Internet: www.n-psi.com
E-mail: [email protected]
nano-purication solutions ltd.
Dukesway,
Team Valley Trading Estate,
Gateshead,
NE11 0PZ
United Kingdom
Telephone: [phone]
Fax:  +44(0)1914977709
Internet: www.n-psi.co.uk
E-mail: [email protected]
1.3 Warranty Guidelines
All products are supplied with a 2 year manufacturer’s warranty from the date of purchase
and must be installed and maintained in accordance with the manufacturer’s guidelines.
Onlygenuineservicepartsshouldbeusedandnomodicationsmade.Forfurther
information please contact your supplier.
© 2016 nano-purication solutions.
Products: GEN2 - 1110, 2110, 3110, 2130, 3130, 4130, 6130, 8130, 10130, 12130
Doc No: 17-110-0143
Issue: 009

Page 4 17-110 -0143
2. General safety
2.1 Intended use of the Product
ThegeneratorisexclusivelyintendedfortheproductionofNitrogengasfromcompressedair,whichisfree
from bulk water, oil and solid matter constituents.
The product should be sited within a building (see section 7.1 Site selection). The generator must be operated
only in accordance with the data on the rating label and in accordance with the contractual conditions. Any
operations that do not comply with those stated on the product rating label will render the warranty void.
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, potentially resulting 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.
This product is only designed to operate at pressures of between 87 - 145 (6 - 10barg) or
232 psig (16 barg) dependant on the generator model.
2.2 Personnel
Only authorized, competent and trained personnel are permitted to work on the 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 Safe handling
Please ensure that relevant safe engineering practices and handling procedures are employed when handling,
installing and operating the product. Ensure that the equipment is depressurized and electrically isolated, prior
tocarryingoutanyofthescheduledmaintenanceinstructionsspeciedwithinthisuserguide.
A suitable lifting aid must be used to minimize the risk of physical injury or damage to the
product.

Page517-110-0143
3. Product Description
3.1 Technical Specication
The nitrogen generator operates on the Pressure Swing Adsorption (PSA) principle to produce a continuous
stream of nitrogen gas from clean dry compressed air.
Pairsofdualchamberextrudedaluminiumcolumns,lledwithCarbonMolecularSieve(CMS),arejoinedvia
an upper and lower manifold to produce a two bed system. Compressed air enters the bottom of the ‘online’
bedandowsupthroughtheCMS.OxygenispreferentiallyadsorbedbytheCMS,allowingnitrogentopass
through.
After a pre-set time the control system automatically switches the bed to equalization mode where the online
bed pressure is equalized with the second regenerated bed. Once equalized the online bed is switched to
regenerativemodeandoxygenisventedfromtheCMS.Asmallportionoftheoutletnitrogengasisexpanded
into the bed to accelerate the regeneration. At the same instant the second bed comes on-line and takes over
the separation process.
The CMS beds alternate between online equalization and regeneration modes to ensure continuous and
uninterrupted nitrogen production.
Whenageneratorisspeciedwithaninternaldryer,eachCMScolumnhasauniqueadsorptionmediatube
technologydryerttedintothebottomofeachcolumn.
The unique intergrated dryer does not require servicing and the life is aligned to the CMS material.
Theintergrateddryerreducesenergyrunningcostsbyeliminatingtheadditionalexternaldryerpurge(typically
20% of the dryer inlet air consumption) and the associated pressure loss across an external dryer. The
compressed air requirement is also reduced accordingly.
Theoxygen concentrationin thenitrogen streamis monitoredcontinuously onmodels ttedwith anoxygen
analyzer.Iftheoutletconcentrationexceedstherequiredproductionlevel,thenitrogenoutletisclosedandthe
gas is vented to atmosphere. Normal operation will resume when the purity recovers.
Parameter Units
Inlet Air Quality ISO8573.1:2010 Class1.2.1/Class1.5.1(whenttedwithAMTintegraldryer)
Minimum Inlet Pressure Barg (psig) 6 (88)
MaximumInletPressure Barg (psig) 10(145)or16(232)
Rated Inlet Temperature °C (°F) 20-25(68-77)
Minimum Inlet Temperature °C (°F) 5(41)-Subjecttocorrectionfactor.
MaximumInletTemperature °C (°F) 40 (104) - Subject to correction factor.
Supply Voltage VAC(50/60Hz) 88-264 VAC
Input Current Amps (VAC) 1.3 / 0.8 (110-230)
IP Rating IP11 / NEMA 2
Noise dB (A) <90

Page 6 17-110 -0143
4. Product Contents
1. GEN2 Series Nitrogen Generator
2. Documentation
• 1xUserGuide
• 1xDeclarationofConformity
3. Packaging
• 1xGeneratorsupportbaseandboxcover
4.1 Packaging
Allproductsaresecurelypackagedinaspecicallydesignedwoodenpackingbox.The
nitrogen generator will be held in a horizontal position by wooden struts used to secure the
producttotheboxbase.Theboxtopcovercanberemovedbyremovingthescrewsand
lifted off in multiple pieces.
Damage to Packaging
Checkimmediatelytoestablishwhetherdamagehasoccurredtotheexternalpackaging
andifthedamageextendstotheproductinside.Ifthereisdamagetoaproduct,contact
the relevant supplier immediately.
The support packing box permits longitudinal stacking; however the central
section of the packing box should not be considered load bearing.
In no circumstances must a damaged product be used in operation. Using
damaged products can lead to irreparable functional faults or cause serious
physical harm.

Page 717-110-0143
4.2 Unpacking the Equipment
The generator is supplied in a wooden crate. It is recommended that the crate be moved into position using a
forklift truck or pallet truck. Remove the generator from the wooden crate using an overhead crane. Use the
following illustrations for correct guidance on safe handling and lifting techniques.
12
3 4
56
7 8

Page 8 17-110 -0143
5. Product Dimensions
MODEL
INLET
PORT SIZE
A B C D E F G
Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches mm
GEN2-1110 1”
22.95 583 8.42 214 47.83 1215 6.37 162 9.92 252 15.43 392 44.58 1132.5
GEN2-2110 1”
29.56 751 15.03 382 47.83 1215 6.37 162 9.92 252 15.43 392 44.58 1132.5
GEN2-3110 1”
36.18 919 21.65 550 47.83 1215 6.37 162 9.92 252 15.43 392 44.58 1132.5
GEN2-2130 1”
29.56 751 15.03 382 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-3130 1”
36.18 919 21.65 550 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-4130 1”
42.79 1087 28.26 718 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-6130 1”
55.90 1420 41.49 1054 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-8130 1”
69.25 1759 54.72 1390 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-10130 1”
82.42 2095 67.95 1726 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
GEN2-12130 1”
95.59 2428 81.18 2062 71.33 1812 6.37 162 12.48 317 31.57 802 68.20 1732.5
(A)
(B)
(C)
(D)
(E)
(G)
(F)
14.17 [360]
15.74[400]

Page 917-110-0143
6. Equipment Overview
All connection points are clearly marked on the generator and are represented in the diagram below.
(GEN2 1110, 2110, 3110, 2130, 3130, 4130, 6130, 8130, 10130, 12130)
Air Inlet
‘Dimension F’
(1” Port)
1
N2 To Buffer Tank
‘Dimension I’
(1” Port)
2
N2 From Buffer Tank
‘Dimension H’
(1/2” Port)
3
N2 Outlet
‘Dimension G’
(1/2” Port)
4
Main Power
Inlet
5
HMI Screen
Display
6
10
11
12
N2 Outlet pressure
Gauge
Sample Point
(1/8” Port)
Top Cover
13 Silencers/Mufers
Air inlet pressure
Gauge
9
7
8
Column A pressure
Gauge
Column B pressure
Gauge
13
1
2
3
4
5
6
7
8
9
10
11
14 Purge adjustment
14
12
ExternalSamplePointOnlyAvailableon
GEN2 2130-12130 Nitrogen Generators.
Internal Sample Point Available on
GEN2 1110-3110 Nitrogen Generators.

Page 10 17-110 -0143
7. System Layout
Only personnel trained, qualied and approved by the supplier should perform
installation, commissioning, service and repair procedures.
1Compressor (Not Supplied)
With External Desiccant Dryer
With Integrated Dryer
7
28
Buffer Vessel
3
Wet Air Receiver (Not Supplied)
9
Pressure Relief Valve*
4 10
N2 Generator
5
Pre-ltration(1 micron & 0.01 micron)
11
Dust Filter (1 micron)
6
Desiccant Air Dryer Nitrogen Outlet
Pre-ltration(Water Seperator)
Dust Filter (1 micron)
Ref Description Ref Description
(1) It is the customers responsibility to ensure pressure relief valves are tted to the compressed air system. All vessels supplied by nano
come with a pressure relief valves and pressure gauge as standard.
(2) Buffer vessel is used for mixing nitrogen gas, this is not to be used as downdtream storage.
(3) Reference ‘1’ & ‘2’ are supplied separately.
N2 Storage (Optional)
*Note: For service details please see page 20.
1
2
8
34
7
8
9
10
11
1
2
8
34
7
8
9
10
11
6
5
It is essential that the system into which the product is installed is tted with a pressure
limiting/relief device. This device should be between the compressor and the generator.
The device must be set to prevent the maximum working pressure of 145psig (10 barg) or
232 psig (16 barg) from being exceeded.