NANO GEN2 i4.0 Manual

Maintenance & Service Manual
GEN2 i4.0 nitrogen gas generator
revision: REV;2022-045 document: 17-100-0660
© 2021 Air & Gas Solutions LLC.
www.n-psi.co.uk

2
about us
Experience. Customer. Service.
Experience.
Customer.
Service.
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
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.
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.

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nitrogen gas generator
GEN2i4.0
table of contents
section description page
1
1.0 general information
4
1.1 document information
1.2 support and manufacture details
1.3 general safety
2recommended tools
5
3maintenance guidelines
4shut down procedure before maintenance
5start up procedure after maintenance 6
6service intervals 7
7
7.0 procedure assemblies - 130 8
7.1 procedure assemblies - 110 9
7.2 panel conguration - 130 10
7.3 panel conguration - 110 11
7.4 process diagram 12
8service “A” instructions; external exhaust silencer / mufer(s) 13
99.0 service “B” instructions; piston valve seals - inlet / outlet block 14
9.1 service “B” instructions; exhaust block 15
10 10.0 service “C” instructions - 02 sensor solenoid valve(s) 16
10.1 service “C” instructions; control valve 17/18
11 service “D” instructions; percentage / PPM oxygen zirconia sensor 18/19
12 GEN2 service reset 20/21
13 trouble shooting 22
14 notes 23

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nitrogen gas generator
GEN2i4.0
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 system without prior consent from nano purication.
©2021 Air & Gas Solutions LLC.
range: GEN2 i4.0 nitrogen gas generators
models: GEN2 i4.0 -1110/2110/3110 & GEN2 2130/3130/4130/6130/8130/10130/12130
doc no: 17-100-0660
issue: 003
1.1 document introduction
This manual provides factory prescribed maintenance procedures for a nano purication solutions GEN2i4.0 Nitrogen Generator. The procedures
illustrated in this document are only to be performed by authorised personnel. For further information regarding the procedures outlined in this document
contact nano purication solutions before proceeding. Read this document carefully before attempting to install, service or operate the generator.
1.2 support and manufacture details
nano-purification solutions Ltd. (Manufacturer)
address: Dukesway
Team Valley Trading Estate
Gateshead
NE11 0PZ
United Kingdom
telephone: [phone]
internet: www.n-psi.co.uk
e-mail: [email protected]
nano-purification solutions
address: 5509 David Cox Road
Charlotte, NC 28269
USA
telephone: [phone]
internet: www.n-psi.com
e-mail: [email protected]
canada - nano-purification solutions inc.
address: 7 Petrie Street
St. Catharines,
Ontario
L2P 3J6
Canada
telephone: [phone]
internet: www.n-psi.com
e-mail: [email protected]
germany - nano-purication solutions inc.
address: Mommenpesch, 46
D-47839 Krefeld
Germany
telephone: [phone]
internet: www.n-psi.de
e-mail: [email protected]
1.3 general safety
For your own safety, when carrying out maintenance work on
the generator, all relevant national safety regulations must be
complied with relating to pressurised and electrical systems.
Only authorised, competent and trained personnel should
maintain the generator, this service 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.
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

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nitrogen gas generator
GEN2i4.0
2. recommended tools
The following tools will be required to service the generator
• Terminal screw driver
• 3mm at screwdriver
• Various metric allen keys/sockets
• Various metric spanners
• Torque wrench (0-40nm)
• Food grade lubricating grease
3. maintenance guidelines
• Maintenance operations only to be conducted when the system has been shut down and
fully depressurised.
• All connections must be undone with care, paying particular attention to the areas that
become pressurised.
• Do not modify or adjust the control settings.
• Only certied nano-purication solutions approved replacement parts to be used.
• Always check all connections for leakage and secure seating before operation.
• Ensure all loose parts removed during maintenance are retted correctly before operation.
4. shut down procedure before maintenance
If only Service A is to be carried out, only step 1 to 7 is required.
1. Isolate the buffer tank inlet and outlet.
2. Isolate the inlet air supply
3. Isolate the Nitrogen outlet
4. Allow unit to shutdown on low inlet pressure, unit shutdown will
take approximately 2 minutes
to complete a full shutdown
5. Press the Start / Stop button on the controller
6. Remove mains power from the generator.
7. Open the generators door to gain access to the control panel
8. Open both service valves mounted on the inlet & outlet manifolds.
9. Allow the unit to stand until no venting sound is heard from both
valves before carrying out any service work on the generator.
The configuration and orientation may vary per model
Before performing any maintenance or service operations on
this product, ensure the product is isolated from the compressed
air supply and fully depressurised. Also, ensure the product is
switched off and isolated from the mains power.
Characteristics of the CMS, pressure can build up to 2 Barg
after being shut-down
Service Valve Bottom
Service Valve Top
HOLD

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nitrogen gas generator
GEN2i4.0
5. start up procedure after maintenance
Test and ensure no leaks with in the unit and system after every step after step 5
1. Ensure all serviced parts and assemblies are secured
(excluding the electronic panel on 110 units)
2. Connect mains power supply
3. Close the 2 service valves
4. Press and hold the ‘Start-up’ button on the front screen
5. Slowly open the compressed air inlet valve, allow to cycle
for 2 minutes
6. Slowly open the buffer tank inlet and outlet valves
7. Slowly open the Nitrogen Outlet Valve
8. Allow the unit to cycle to set purity.
Note; A high purity alarm may occur
9. Final internal leak check
10. Secure the electronic panel (on 110 units)
11. Close door
The configuration and orientation may vary per model
Service Valve Top Service Valve Bottom
HOLD

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nitrogen gas generator
GEN2i4.0
6. service intervals
The following table details the recommended service intervals for this product and the service kits to be used.
Service
Recommended Service Intervals
1 Year (or 8,000
running hours)
2 Year (or 16,000
running hours)
3 Year (or 24,000
running hours)
4 Year (or 32,000
running hours)
5 Year (or 40,000
running hours)
A
B 
C
D
Oxygen Analyser Recommended Service Intervals
F (Zirconia) 
Nitrogen
Generator
Model
Service Code
A
B C D
6 - 12 Barg 6 - 16 Barg
(87 - 174 psig) (87 - 232 psig)
GEN2- 01110
A-BSP-110
A-NPT-110
A-BSP-130HP
A-NPT-130HP B-PVSK-130 C-SSVK-130
C-CVK-130 D-GCR-PPM
GEN2 - 02110
GEN2- 03110
GEN2- 02130
A-BSP-130
A-NPT-130
GEN2- 03130
GEN2- 04130
GEN2- 06130
GEN2- 08130
GEN2- 10130
GEN2- 12130
Service A - (A-XXX-1X0) 1” external exhaust silencer/mufer
Service A - (A-XXX-130HP) 2” external exhaust silencer/mufer
Service B - (B-PVSK-130) All piston valve seals are to be replaced
Service C - (C-SSVK-130) O2Sensor solenoid valves
Service C - (C-CVK-130) All control valves are to be replaced
Service D - (D-GCR-PPM) Percentage/ppm oxygen zirconia sensor
The serial/part number of the nitrogen generator must be supplied when requesting any of the services listed above,
this is to ensure the correct service parts are selected.

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nitrogen gas generator
GEN2i4.0
7. product assemblies - 130
130 Range
GEN2 - 2130
GEN2 - 3130
GEN2 - 4130
GEN2 - 6130
GEN2 - 8130
GEN2 - 10130
GEN2 - 12130
Service D
Service B
Service C
Service C
Service B
Service B
Service A

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nitrogen gas generator
GEN2i4.0
7.1 product assemblies - 110
110 Range
GEN2 - 1110
GEN2 - 2110
GEN2 - 3110
Service A
Service B
Service B
Service C
Service C Service D
Service B

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nitrogen gas generator
GEN2i4.0
Control Valve
assembly
Nitrogen
Outlet
Manifold
Electronic
Panel
02
Analyser
Control tubing and wiring is not shown
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)
7.2 panel conguration - 130
BASE ENCLOSURE
WITH NEEDLE VALVE
(46-XXX-XX-XXXXX-XXXX-XNV-XXX)
BASE ENCLOSURE
WITH SINGLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM2-XXX)
BASE ENCLOSURE
WITH DOUBLE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM3-XXX)
BASE ENCLOSURE
WITH LARGE MASS FLOW
(46-XXX-XX-XXXXX-XXXX-XM4-XXX)

11
nitrogen gas generator
GEN2i4.0
Control tubing and wiring is not shown
7.3 panel conguration - 110
Control Valve
Assembly
O2
Analyser
Electronic
Panel
Nitrogen
Outlet
Manifold

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nitrogen gas generator
GEN2i4.0
CMS Column CMS Column CMS Column
CMS Column
CMS Column
CMS Column CMS Column CMS Column
PDES (IF FITTED)
ISO CLASS
1.3.2
OR BETTER
Note:
Letters surrounded by a red ring are reference to the
required service kit for that component.
Service A: Replace exhaust silencer(s)/ mufer(s)
Service B: Replace piston valve seals
Service C: Replace all pilot valves, diaphragm
valves and solenoid coils and oxygen
anaylser control valve(s)
Service D: Replace oxygen analyser(s)
For more information about service kits see page 7.
For more information about service schedules and
prices please contact your service provider.
7.4 process diagram

13
nitrogen gas generator
GEN2i4.0
8. service ‘A’ instructions - external exhaust silencer/mufer(s)
(A-XXX-1X0)
(A-XXX-1X0HP)
Recommended tools;
• 35mm Spanner (1inch silencer)
• 70mm Spanner (2inch silencer)
• Strap wrench if available
• Thread sealing material
1. Carry out step 1-7 of the ‘Shut Down Procedure Before Maintenance’ (page 5)
2. Remove Exhaust Silencer/Mufer(s) from the unit
3. Clean the thread and remove any sealing material debris from exhaust block
4. Apply new thread sealing material to new Exhaust Silencer/ Mufer(s)
5. Attach Exhaust Silencer/Mufer(s), ensuring they are tight.
There are two 1inch silencer variants, please consult customer service
Do Not Over Tighten
Standard Pressure
6 - 12 Barg
GEN2130 build
2 x 1 inch silencer/mufer
High Pressure
6 - 16 Barg
GEN2HP 130 build
1 x 2 inch silencer/mufer
Standard & High Pressure
6 - 12 & 6 - 16 Barg
GEN2110 build
1 x 1 inch silencer/mufer

14
nitrogen gas generator
GEN2i4.0
Pressure will build due to the CMS, expect
loud releases of low pressure, high volume gas
PISTONS
INLET / OUTLET
BLOCK
PLATE
M6 SCREWS
9. service ‘B’ instructions; piston valve seals - inlet / outlet block
(B-PVSK-130)
Recommended tools;
• 5mm, 8mm, Allen Key Attachments
• Torque Wrench (7-40Nm)
• Piston Removal Tool
1. Carry out all steps of the ‘Shut Down Procedure Before
Maintenance’ (page 5)
2. Remove the front plates (12x M6 screws)
3. Screw the Piston Removal Tool into the rear of the piston and pull
- Take note of the piston positioning
4. Discard the O-rings, wear rings and sealing disc.
5. Clean the piston
6. Grease the new O-rings and apply to the piston
7. Clean and lightly regrease piston bore
8. Ret the pistons into the manifold
- The small piston is located in the center hole
9. Re-attach the front plates. The 6mm bolts torqued setting; 7Nm
10. Carry out all the start up procedure steps on page 6
Piston
Removal
Tool
O-Ring
Wear Ring
O-Ring
Inlet / Outlet Block
Plate
Sealing
Disc
Recommend
Grip Region
(if Required)
M6 Screws
Pistons

15
nitrogen gas generator
GEN2i4.0
9.1 service ‘B’ instructions - exhaust block
Piston Servicing
Recommended tools;
• 5mm, 8mm, Allen Key Attachments
• Torque Wrench (7-40Nm)
• Piston Removal Tool
1. Carry out all steps of the ‘Shut Down Procedure Before
Maintenance’ (page 5)
2. Remove the end plates (4x M10 screws)
3. Screw the Piston Removal Tool into the rear of the piston and pull
- Take note of the piston positioning
4. Discard the O-rings, wear rings and sealing disc.
5. Clean the piston
6. Grease the new O-rings and apply to the piston
7. Clean and lightly regrease piston bore
8. Ret the pistons into the manifold
- The small piston is located in the center hole
9. Re-attach the front plates. The 10mm bolts torque setting; 40Nm
10. Carry out all the start up procedure steps on page 6
Pressure will build due to the CMS, expect
loud releases of low pressure, high volume gas
Use a food grade grease
for bearings and sealing
Sealing
Disc
Recommend
Grip Region
(If Required)
Piston
Removal
Tool
O-Ring
Wear Ring
O-Ring

16
nitrogen gas generator
GEN2i4.0
10. service ‘C’ instructions - O2 sensor solenoid valve(s)
(C-SSVK-130)
Recommended tools;
• Various spanners
• Thread sealing material
• Terminal Screw Driver
It is recommended that the analyser is not left open to atmospheric oxygen for prolonged time periods, it is advised to complete the service in a timely
manner.
1. Carry out all steps of the ‘Shut Down Procedure Before Maintenance’ (page 5)
2. Identify the type and location of the O2analyser
3. Take note of the positioning of the electronic connections, and remove
4. Release the clip retaining the sensor and carefully angle away the assembly from the unit.
5. Loosen the ttings highlighted to release the sensor
6. Discard the solenoid valve(s)
7. Clean the threads and reapply sealing material
8. Fit the new solenoid valve(s)
9. Replace the assembly in place
10. Carry out all the start up procedures on page 6.

17
nitrogen gas generator
GEN2i4.0
11. service ‘C’ instructions - control valves
(C-CVK-130)
Recommended tools;
• 3mm Flat screw driver
• 11mm spanner
• Food safe lubrication grease
• Thread sealing material
• Terminal Screw driver
Part 1 - Control valves
1. Carry out all steps of the ‘Shut Down Procedure Before
Maintenance’ (page 5)
2. Release the assembly by the four screws on the base of the control
valve assembly (circled)
3. We recommend to service a valve one by one
4. Disconnect the electronic connection on the valve
5. Remove retaining screws to release a control valve
6. Unscrew the ttings from valve, take note of removed connections
7. Discard the valve and O-ring from the control valve manifold
8. Lightly grease and t the new O-ring into the control valve manifold
9. Attach the new valve with the push-ts and electronic connection
10. Repeat until all valves have been serviced
11. Fit the Control valve manifold assembly back into the unit
Screws Screws
Retaining
Screws
Elbow Fitting
Elbow
Fitting Valve
Manifold
Elbow
Fittings
Pressure
Transducer
O-Rings
Blank
Valves

18
nitrogen gas generator
GEN2i4.0
11.1 service ‘C’ instructions - control valves
C-CVK-130
Part 2 - Nitrogen outlet manifold control valves
1. Disconnect the electrical connectors
2. Remove the solenoid coils
3. Evenly and slowly (1 full revolution per screw), loosen the 4
screws around the 2 valves. This will release any trapped gas
4. Allow gas to vent.
5. Once the venting has reduced, fully remove the screws
6. Take note of the positioning of the valve bonnet direction
and diaphragm
7. Discard the valves and solenoids
8. Place the new valve bonnet and diaphragm
9. Torque the 8 screws to 7Nm
10. Connect the solenoid coils and electrical connector to valves
11. Carry out all the start up procedure steps on page 6
Typical 130 Build

19
nitrogen gas generator
GEN2i4.0
12. service ‘D’ instructions - percentage/ppm oxygen zirconia sensor
(D-GCR-%) SEN ZTX %
(D-GCR-PPM) SEN-ZTX ppm
Recommended tools;
• 3mm Allen Key
It is recommended that the analyser is not left open to atmospheric oxygen for prolonged time periods, It is advised to complete the service in a
timely manner.
1. Carry out all steps of the ‘Shut Down Procedure Before
Maintenance’ (page 5)
2. Undo electrical connection
3. Unscrew Sensor Cell
4. Discard the expired sensor cell - On PPM sensors, take note of the
‘Offset’ located on the side of the new sensor cell.
5. Hand tighten the new sensor cell.
6. Reconnect electronic connection
7. For PPM sensors, reconnect the mains power, and follow calibration
instructions from the manufactures supplied manual.
8. Carry out all the start up procedure steps on page 6
The configuration and orientation may vary per model
Atmospheric Oxygen degrades the sensor

20
nitrogen gas generator
GEN2i4.0
13. GEN2i4.0 service reset
1 Home Screen
01/01/2021
09:30 NANO
7.0 barg 101 psig
0.48
%
2 Select your required access level
Select your required access level
01/01/2021
09:30 NANO
0.48
%
Factory
Distributor
Engineer
User
Restore
3 Press the password input section
01/01/2021
09:30 NANO
0.48
%
Factory
Distributor
User
Restore
# # # #
Press the password input section.
4 Enter the password then press the Enter button.
NANO
Restore
Esc
Clr
Enter
Min. 0 Max. 999999
+/-
7
6
4
3
0
5
9
12
.
8
Enter Password
5 Press the unlock key.
01/01/2021
09:30 NANO
0.48
%
Factory
Distributor
User
Restore
# # # #
Press the unlock key.
6 Press “Service Details”
01/01/2021
09:30 NANO
0.48
%
Settings
Service Details
Manual Control
Factory Restore
Build Details