PSA Nitrogen Generator Owner`s Manual All “N” Models

PSA Nitrogen Generator Owner`s Manual All “N” Models
PSA Nitrogen Generator
Owner’s Manual
All “N” Models
166 Keystone Drive
Montgomeryville, PA 18936
Telephone: 215-641-2700
Fax: 215-641-2714
PROPRIETARY NOTICE: All information herein is the property of MATHESON TRI-GAS and
must be kept confidential and not be disclosed without MATHESON TRI-GAS’s agreement nor
used, in whole or in part, in manufacturing or selling gas separation equipment without the
express written permission of MATHESON TRI-GAS. MATHESON TRI-GAS authorizes the
necessary and reasonable use of this document, and information herein, solely for the evaluation,
installation, operation, and maintenance of MATHESON TRI-GAS’s Nitrogen Generators. No
other use is authorized.
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Table of Contents
1
2
3
4
5
6
7
8
9
INTRODUCTION ............................................................................................................ 3
1.1
Company Presentation ................................................................................................... 3
1.2
Safety Information ......................................................................................................... 4
1.3
Warranty ........................................................................................................................ 5
1.4
Service Return Policy..................................................................................................... 7
UNPACKING AND INSPECTING................................................................................ 8
SITE AND UTILITY REQUIREMENTS...................................................................... 8
3.1
Air Supply ...................................................................................................................... 8
3.2
Additional Piping and Hoses.......................................................................................... 8
3.3
Electrical Supply ............................................................................................................ 8
3.4
Site Specifications.......................................................................................................... 9
SYSTEM ASSEMBLY................................................................................................... 10
SYSTEM OVERVIEW .................................................................................................. 11
5.1
Controls and Instrumentation Overview ...................................................................... 11
5.1.1
Main Power Switch ............................................................................................. 11
5.1.2
Power Light ......................................................................................................... 11
5.1.3
Hour Meter .......................................................................................................... 11
5.1.4
Pressure Switch ................................................................................................... 11
5.1.5
Standby Light ...................................................................................................... 11
5.1.6
Air Supply Pressure Gauge ................................................................................. 12
5.1.7
Peak Pressure Gauge ........................................................................................... 12
5.1.8
Tank Pressure Gauge........................................................................................... 12
5.1.9
Inlet Air Pressure Regulator ................................................................................ 12
5.1.10
Product Regulator................................................................................................ 12
5.1.11
Product Oxygen Analyzer ................................................................................... 12
5.2
Control Timer............................................................................................................... 12
PRINCIPLES OF OPERATION .................................................................................. 13
GENERATOR OPERATION ....................................................................................... 14
7.1
Start-Up........................................................................................................................ 14
7.1.1
Initial Start-Up..................................................................................................... 14
7.1.2
Normal Start-Up .................................................................................................. 15
7.2
Shutdown ..................................................................................................................... 16
7.2.1
Emergency Shutdown ......................................................................................... 16
7.2.2
Normal Shutdown ............................................................................................... 16
MAINTENANCE ........................................................................................................... 17
8.1.1
Nitrogen Generator.............................................................................................. 17
8.2
Filter Removal Procedure ............................................................................................ 19
TROUBLE SHOOTING................................................................................................ 20
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INTRODUCTION
Congratulations on your purchase of a MATHESON TRI-GAS, Inc. Pressure Swing
Adsorption (PSA) type Nitrogen Generator. This simple, turnkey machine provides a
cost-effective means for on-site generation of nitrogen. The Nitrogen Generator is based on
using the latest PSA technology and utilizes Carbon Molecular Sieve (CMS) to separate the
nitrogen from the other gases contained in air. The Nitrogen Generator uses two beds of
CMS to separate compressed air into a high-pressure nitrogen product stream and lowpressure oxygen enriched waste stream. Particulate and activated carbon filters are included
to remove impurities from the feed air. Each Nitrogen Generator comes pre-tested and fine
tuned to meet the customer specified nitrogen flow rate and purity.
Since the system contains very few moving parts, maintenance and repairs are minimal.
Maintenance is simple yet necessary. Air compressor and filter maintenance procedures are
especially important and should be followed carefully. If the recommended maintenance
procedures are followed, your nitrogen generator will provide you with many years of
reliable service.
1.1 Company Presentation
MATHESON TRI-GAS is established as a world leader in the supply of systems for
generation hydrogen and Nitrogen. We have been supplying Hydrogen and Nitrogen
generators since 1987. Information about our products and our company can be found at
our web site: www.mathesontrigas.com
MATHESON TRI-GAS activities frequently include full responsibility for conceptual and
detail engineering design, procurement, fabrication, supply and installation of packages for
various industries worldwide.
MATHESON TRI-GAS’ Nitrogen Generator offers operators the benefits of this advanced,
but simple technology. The principle advantages of PSA systems are:
-
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Compact
Low weight
Safe, reliable operation
Simple maintenance
Ease of operation
Rapid start-up
3
1.2 Safety Information
The following section outlines the basic safety considerations regarding use of your
Nitrogen Generator. Please refer to the technical references for additional information.
Read carefully and act accordingly before installing, operating or repairing the unit.
· The operator must employ safe working practices and rules when operating the
nitrogen generator.
· The owner is responsible for maintaining the unit in a safe operating condition.
· Always use approved parts when performing maintenance and repairs. Make sure
that replacement parts meet or exceed the pressure requirements.
· Only authorized, trained and competent individuals must perform installation,
operation, maintenance and repair.
· Completely depressurize the generator, tanks, and lines prior to performing any
mechanical work, including changing the filters. The nitrogen must be vented to the
outside or to a large, well-ventilated room to avoid suffocation due to lack of oxygen.
· Safety glasses should be worn if the cabinet door is open while the machine is
operating.
WARNING
Pressurized gases are contained within the generator and the receiver and product
tanks. High-pressure gases are dangerous and may cause injury or death if handled
or used inappropriately.
· Never allow high-pressure gas to exhaust from an unsecured hose. An unsecured
hose may exhibit a whipping action, which can cause serious injury. If a hose
should burst during use, immediately close all isolation valves.
· Never disable or bypass any safety relief valves on the air receiver or product tanks.
· Always make certain that the nitrogen generator is unplugged prior to
performing any electrical work.
NOTE
If any statement or specification within this booklet, especially with regard to safety,
does not agree with legislation or standard industry practices, the more demanding
shall apply.
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1.3 Warranty
LIMITED WARRANTY
This equipment is sold by Matheson Gas Products (Matheson) under the warranties set forth in
the following paragraphs. Such warranties are extended only with respect to the purchase of this
equipment directly from Matheson or Matheson's Authorized Agent as new merchandise and are
extended to the first Buyer thereof other for than the purpose of resale.
For a period of one year from date of original delivery (ninety days in corrosive service) to Buyer
or to Buyer's order, this equipment, is warranted to be free from functional defects in materials
and workmanship and to conform to the description of this equipment contained in this manual
and any accompanying labels and/or inserts, provided that this equipment is properly operated
under the conditions of normal use and that regular and periodic maintenance and service is
performed or replacements are made in accordance with the instructions provided. Expendable
parts of this equipment are similarly warranted to be free from functional defects in materials and
workmanship and to conform to the description of this equipment contained in this manual and
any accompanying labels and/or inserts. The foregoing warranties shall not apply if the
equipment has been repaired other than by Matheson or a service facility designated by
Matheson, or if this equipment has not been operated and maintained in accordance with written
instructions provided by Matheson, or has been altered by anyone other than Matheson, or if the
equipment has been subject to abuse, misuse, negligence or accident.
Matheson's sole and exclusive obligation and the Buyer's sole and exclusive remedy under the
above warranties is limited to repairing or replacing, free of charge, at Matheson's sole discretion,
the equipment or part which is telephonically reported to be a problem to the local Matheson
Branch Location, and which if so advised, is returned with a written statement of the observed
deficiency, not later than seven days after the expiration of the applicable warranty, to the
Matheson Gas Equipment Technology Center during normal business hours, transportation
charges prepaid, and which, upon examination, is found to comply with the above warranties.
Return trip transportation charges for the equipment or part shall be paid by the Buyer.
MATHESON SHALL NOT BE OTHERWISE LIABLE FOR ANY DAMAGES
INCLUDING BUT NOT LIMITED TO INCIDENTAL DAMAGES, CONSEQUENTIAL
DAMAGES, OR SPECIAL DAMAGES, WHETHER SUCH DAMAGES RESULT FROM
NEGLIGENCE, BREACH OF WARRANTY OR OTHERWISE.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND
THE WARRANTIES HEREINABOVE SET FORTH. MATHESON MAKES NO
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE WITH RESPECT TO THE EQUIPMENT OR PARTS THEREOF.
ACCEPTANCE OF THE EQUIPMENT BY THE FINAL BUYER INDICATES THE
FINAL BUYER'S ACCEPTANCE OF ALL WARRANTIES AND LIMITATIONS SET
FORTH ABOVE
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USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual
and accompanying labels and/or inserts when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must be checked periodically, with
the frequency of such inspections depending upon the scope of use. Damaged, worn or
contaminated equipment should not be used. Parts that are broken, missing, plainly worn,
distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, Matheson Gas Products recommends that a telephonic or written request for
service advice be made to the Matheson Equipment Engineering Group in Montgomeryville
Pennsylvania or to the nearest Matheson Gas Products Branch location.
This equipment or any of its parts should not be altered without the prior written approval of
Matheson Equipment Engineering Group. The user of this equipment shall have the sole
responsibility for any malfunction, which results from improper use, faulty maintenance, damage,
improper repair or alteration by anyone other than Matheson Gas Products or a service facility
designated by Matheson Gas Products. Further, the ultimate user of the equipment is responsible
for the training and safe operation of the equipment by personnel in his/her employ.
The Nitrogen Generator, excluding air supply system, is warranted against defects in materials
and workmanship, under normal use and operation, as applicable on the warranty listed below.
All compressors and dryers are covered by the original equipment manufacturer's warranty.
These warranties shall be null, void, inoperative, and not binding upon MATHESON TRI-GAS,
Inc. if a defect or malfunction occurs in the product or any part thereof from any feed air
malfunction, or improper filter element maintenance, or repair, attempted repair, adjustment
or servicing by anyone other than an authorized representative of MATHESON TRI-GAS, or
external causes. Said warranty shall extend and apply to the Nitrogen Generator only while said
system is owned and used exclusively by the original purchaser.
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1.4 Service Return Policy
General Service
A unit which is not functioning in a normal manner should be removed from service until such
time that repairs or replacement can be made. Upon completion of repair, full testing should be
performed to assure the user that the regulator has been returned to its original operating
parameters. Matheson offers a repair service to its customers for all products that Matheson sells.
To arrange for repair service, call 1-800-828-4313 and ask for the Warranty Administrator. NO
PRODUCT WILL BE RECEIVED BY MATHESON WITHOUT INDICATION OF GAS
SERVICE AND WITHOUT PROPER RETURN MATERIAL AUTHORIZATION
PROVIDED BY THE WARRANTY ADMINISTRATOR. (All repairs must be made by
Matheson or an assigned and approved facility to maintain any warranties or guarantees)
If the unit is under an applicable warranty, return the unit to Matheson for repair or replacement.
To arrange for warranty service, call 1-800-828-4313 and ask for the Warranty Administrator.
NO PRODUCT WILL BE RECEIVED BY MATHESON WITHOUT INDICATION OF
GAS SERVICE AND WITHOUT PROPER RETURN MATERIAL AUTHORIZATION
PROVIDED BY THE WARRANTY ADMINISTRATOR.
If advised by the Warranty Administrator to return the product to Matheson, prepare the product
for shipment and write, in large lettering the RMA Number assigned by the Warranty
Administrator on the outside of the box. Also, if required by the Warranty Administrator, supply
the completed RMA form with the product. Make sure that the product is adequately packaged,
in the original shipping container if possible, and shipped prepaid (Matheson will not accept COD
freight) with a description of the observed deficiency to the attention of the:
Warranty Administrator
Matheson Gas Products
166 Keystone Drive
Montgomeryville, PA 18936
The user is expected to periodically inspect the product for leaks, loose or worn parts, broken or
non-functioning components and to address those situations immediately. If the user would
require verbal assistance in ascertaining the potential of a problem with any Matheson product,
contact the local Matheson branch for assistance or your Matheson Sales Representative.
The MATHESON TRI-GAS Warranty includes the following:
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2
UNPACKING AND INSPECTING
The Nitrogen Generator is shipped in a single crate, including the accessory kit. If you
ordered optional air receiver or product receiver tanks, these would be shipped in a separate
crate. The contents of the crate(s) should be inspected upon delivery to assure that no
damage has taken place during transit. Save the carton and wrapping, as it may be
necessary to return the generator in event of shipping damage. If any components are
found to be damaged, the carrier should be notified immediately. The individual pieces
should be checked against the packing list. If any discrepancy is found, contact your local
distributor or MATHESON TRI-GAS Inc. at (215) 641-2700. Please include the model
number and the serial number with all correspondence.
3
SITE AND UTILITY REQUIREMENTS
The following requirements must be met to enable the nitrogen generator to perform at its
rated capacity. Deviation from these requirements may result in poor performance, injury to
persons or machinery, and voiding of warranty.
3.1 Air Supply
Air supplied to the generator must be between 100 °F / 38 °C and 33° F / 0.5 °C, with a
water dew point of 40°F / 5°C or below. Air at temperatures higher or lower than this may
cause damage not covered by warranty. Likewise, moisture content higher than that
specified may damage the adsorbent material and void the warranty. Air pressure, air
receiver and nitrogen receiver vessels must be compatible with the generator. Use of a
correctly sized refrigerant dryer will ensure that air meets specified standards.
The performance of our PSA type Nitrogen Generators is based on minimum 100 psig / 6.9
bar g operating pressure. Operation at higher or lower pressure will result in a nitrogen
production above or below design. Air consumption for each Nitrogen Generator depends
on nitrogen product purity and flow rate. Please consult MATHESON TRI-GAS for
details.
3.2 Additional Piping and Hoses
The air supply piping components must be capable of supplying the required amount of
feed air at the required pressure measured at the generator inlet connection. If the length of
piping from the air receiver is greater than 50 feet, an air supply line one size larger than
the Nitrogen Generator inlet air nozzle size should be used.
3.3 Electrical Supply
Power supply must be 110 V or 220 V / 1 ph / 50 - 60 Hz as labeled on the unit. Power
consumption is less than 0.1 kW.
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3.4 Site Specifications
Select a non-hazardous area indoors for installation which remains above 33 °F / 0.5°C and
below 100 °F / 38 °C. Adequate space should be provided around the generator for access
and routine maintenance. Ensure that there is enough space for the air receiver and product
receiver skid next to the unit.
The exhaust piping from the nitrogen generator may be vented outside, but any additional
piping used should be the same size as the exhaust piping supplied with the generator or
larger depending on the length of the pipe. Exhaust piping should not have any restrictions
or valves, and should be as short as possible.
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4
SYSTEM ASSEMBLY
This section provides a step-by-step procedure for easy assembly of the Nitrogen Generator
with optional air supply system and tanks.
1. Position the nitrogen generator in an area as described in Section 3.4. Lift the
nitrogen generator carefully to avoid damaging piping or control system.
2. Carefully lift the air receiver and nitrogen receiver (if supplied) and position next to
the nitrogen generator skid. The tanks should be located as close as possible to the
unit.
NOTE
Carefully attach lifting devices and any rigging to ensure that piping and valves are
not damaged.
3. Install the air compressor and refrigerant dryer (if supplied) in accordance with the
manufacturer’s instructions. Attach air supply connections to the Nitrogen
Generator. Install suitable piping or hoses from the compressor to the dryer, from the
dryer to the air receiver, and from the air receiver to the Nitrogen Generator. The
connections may be "hard plumbed" by the user, if desired.
NOTE
Use of piping sizes smaller than the recommended size will significantly decrease
system performance.
WARNING
Use only materials with compatible pressure rating on components on the product
pipe lines.
4. Install relief valve on the air receiver and nitrogen receiver.
5. Check all fittings for leaks using a leak detecting solution.
6. A qualified electrician should install all electrical connections and the electrical
power supply. Plug in the nitrogen generator into an approved outlet of the correct
voltage and frequency. Connect the optional compressor(s) and dryer to an
appropriate power supply (according to the requirements stated on the motor
nameplate).
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5
SYSTEM OVERVIEW
5.1 Controls and Instrumentation Overview
This section describes the function of each control on the PSA Nitrogen Generator. The
location and purpose of all instrumentation is also listed. An electro- mechanical timer
located inside the control enclosure automatically controls your Nitrogen Generator. Do not
attempt to alter the timer; any changes made will void the performance specifications.
Controls for supporting equipment, such as the compressor and dryer, are not included in
this section. Please consult the original manufacturer’s instructions, located in the
appendices, for further information.
5.1.1
Main Power Switch
This switch supplies power to the nitrogen generator. The green “Power Light” is
lit when the switch is “ON”. The “Main Power” switch is located on the front of
the control panel.
The “Main Power” switch allows the operator to disconnect power from the
generator. PSA cycling will stop immediately whenever the switch is turned
“OFF”. Nitrogen production will stop; airflow from optional air receiver must be
stopped manually using the isolation valve. The isolation valve must be opened
and the switch must be returned to the “ON” position before the unit can be
restarted.
5.1.2
Power Light
This green indicator is lit when the “Main Power” switch is “ON”. This light
uses a 110 or 220 volt bulb.
5.1.3
Hour Meter
This meter shows number of hours the generator has produced nitrogen and
excludes standby time.
5.1.4
Pressure Switch
The nitrogen product pressure switch controls the on and off pressure range of
the Nitrogen Generator. The pressure switch is installed in the nitrogen product
line inside the cabinet.
The pressure switch can be set to turn the unit off and on at desired product
pressure levels. The factory settings call for the generator to switch “OFF” when
product pressure exceeds 75 psig and to switch “ON” when product pressure falls
about 10 psi. The setting may very with different models and applications.
5.1.5
Standby Light
This amber indicator is lit when the nitrogen product receiver pressure is above
the high set point of the pressure switch. This light uses a 110 or 220 volt bulb.
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5.1.6
Air Supply Pressure Gauge
This gauge monitors the feed air pressure. The inlet air pressure gauge is located
on the optional air supply receiver.
5.1.7
Peak Pressure Gauge
This gauge monitors the pressure changes in the adsorber beds throughout the
cycle. The “Peak Pressure” gauge is located on the front of the control panel.
The pressure variations throughout the cycle should be recorded for one complete
cycle.
5.1.8
Tank Pressure Gauge
The “Tank Pressure” gauge monitors the pressure of the nitrogen product. The
gauge is located on the front of the control panel.
5.1.9
Inlet Air Pressure Regulator
The regulator allows the operator to adjust the pressure of the feed air to the
pressure range desired. The inlet air pressure regulator is located inside the
cabinet.
The regulator is set at the factory but may require minor adjustment in the field.
Note that the output pressure of the compressor limits the maximum pressure.
5.1.10 Product Regulator
The regulator sets the delivery pressure of the nitrogen product. The regulator is
located on the optional product receiver tank. Please refer to Section 1.2 for
safety information regarding high-pressure nitrogen.
5.1.11 Product Oxygen Analyzer
The oxygen analyzer (optional) receives a small sample flow from the product
receiver tank to continuously monitor the product nitrogen purity. Most of the
oxygen analyzers are equipped with alarms that will be activated when the
oxygen content gets too high. The oxygen analyzer display is located on the
front of the control panel. The sensor is installed inside the panel. The sample
must be connected to the 5/32” tube located at the side of the control panel. It
should be supplied from the product receiver tank through 5/32” tubing.
5.2 Control Timer
An electro mechanical cam timer automatically controls the nitrogen generator. The cams
are adjusted to the optimum time settings at factory. Do not attempt to change the time
settings since this will affect the system performance and void the performance
specifications.
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6
PRINCIPLES OF OPERATION
The Matheson Tri-Gas Nitrogen Generator uses state of the art technology to provide the
end user with a reliable source of nitrogen. An overview of the operation of the generator is
given below.
The Nitrogen Generator is a two-bed adsorber system. The Nitrogen Generator consists of
two adsorber vessels filled with CMS, a valve assembly, air filters, main pressure regulator,
and a product receiver tank. Dry, compressed air (78%nitrogen, 21% oxygen, <1% argon)
at about 100 psig / 6.9 bar g and normally 68 °F / 20 °C is passed through the air filters,
which remove particles and oil vapor, and then through the air inlet regulator (if supplied),
which reduces the air to the final operating pressure. It is important to maintain the inlet air
at the correct pressure; otherwise, generator performance may deviate from design. Clean
and dry air is directed to one of the adsorber beds where oxygen and water vapor is
adsorbed faster than nitrogen in the pore structure of the CMS, thus increasing the nitrogen
purity of the product gas stream to the desired level (95 – 99.999% as required by
customer). This product flows out of the top of the adsorber bed, through the pureflo valve,
and into the product receiver at a pressure slightly below the feed air pressure.
A portion of the intermediate product produced is directed through the purge orifice. This
nitrogen is allowed to flow back through the other adsorber sieve bed and out through the
exhaust line at atmospheric pressure. This action purges the CMS of oxygen, and prepares
the bed for the next cycle. The pressure in the adsorber vessels is equalized after about one
minute before the next cycle starts. The beds switch roles; the first bed is purged while the
second bed produces nitrogen product. The active bed will remain on-line until just prior to
becoming saturated with oxygen. When the cycle is completed, the controller will exhaust
the saturated bed, and pressurize the fresh adsorber bed. This allows a continuous flow of
nitrogen gas from the unit for as long as the unit is in operation.
Oxygen enriched waste gas is piped to the atmosphere through a silencer.
Dry nitrogen product stream, with the specified max O2 content, exits the adsorber vessels
and is stored in a common product receiver tank (optional). Nitrogen purity and flow rate
can be checked before the nitrogen is supplied to the consumer.
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7
GENERATOR OPERATION
This section describes the procedure for starting, running, and stopping the nitrogen
generator. The operator should notify personnel in the area that the generator will be
started and make sure the start-up will not interfere with any other operations.
7.1 Start-Up
This section describes the necessary steps of both the initial start-up and a normal routine
start-up. If this is the first time the unit has been started, follow the Initial Startup
procedure.
7.1.1
Initial Start-Up
1. Verify that power supply is 110 V or 220 V / 1 ph / 50 - 60 Hz as labeled on
the unit.
2. Turn on the compressed air supply. Follow air compressor manufacturer's
start-up instructions (see your manufacturer's manual). Check that air
pressure is in the range of 90-175 psig / 6.2 – 12.1 barg [620-1210 kPa].
Open the air supply valve.
WARNING
Shut off the main air supply valve and depressurize the generator before
repairing any leaks.
NOTE
During the start up sequence, check for leaks in all pipe fittings and valves.
Remember, even a small leak on the product nitrogen piping can
severely reduce production capacity!
3. Turn the Main Power switch to the “OFF” position.
4. The Nitrogen Generator may have a time delay relay. This is only applicable
at initial start up to maximize purity.
5. Plug the power cord into a properly fused and grounded electrical outlet of
the correct voltage as marked on the unit.
6. Turn Main Power switch to “ON”. Observe that the power indicator light is
on. If light is off, check fuse or light bulb.
7. Observe pressure gauges for one or more cycles. There should be pressure at
the “Peak Pressure” gauge. (Product pressure will vary with certain models.)
Record the results in the Operator’s Logbook.
8. Nitrogen will start to flow to the product tank.
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9. When Product Pressure reaches 70 to 90 psig / 4.8 to 6.7 bar g. (480 – 670
kPa), the amber light should go on and nitrogen production will stop. When
product is used and Product Pressure falls about 10 psi below the high set
point, the amber light will go off and nitrogen production will resume. The
pressure switch may be adjusted to other desired set pressures.
NOTE
When the nitrogen generator is turned on for the first time or after a
prolonged shutdown period, it is likely that the Product Receiver is full
of air. Product purity can be increased by purging the Product Receiver
to safe area / outside the building for approximately 15 minutes before
using the product.
7.1.2
Normal Start-Up
Follow this procedure to start the generator for normal operation. If this is the
first time the unit has been started, follow the Initial Startup procedure.
1. Open the air isolation valve.
2. Turn on the Main Power switch.
3. Open any shut off valves in the product nitrogen line to the user’s piping
system. Allow the system purity to rise before using product.
NOTE
If the generator or any part of the system has been opened to the atmosphere,
the system must be purged of any residual air.
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7.2 Shutdown
This section describes how to perform both an emergency shutdown and a normal
shutdown.
7.2.1
Emergency Shutdown
In case of an emergency, simply turn the Main Power Switch to OFF. This will
stop all generator functions immediately. Nitrogen supply can be shut off
manually closing the nitrogen product ball valve located on the optional product
receiver tank.
7.2.2
Normal Shutdown
This procedure allows the generator to be restarted more quickly than execution
of an emergency or abnormal shutdown procedure would.
1. Turn the Main Power switch to “OFF”. There is no need to close the
nitrogen product ball valve.
WARNING
The generator will remain pressurized after shut down. Before performing any
maintenance or opening any piping systems, always depressurize the system. Failure
to do so may result in injuries.
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8
MAINTENANCE
MATHESON TRI-GAS Generators will provide many years of trouble-free operation if the
recommended maintenance is performed thoroughly and regularly. In addition to the
procedures given below, the customer must also perform all maintenance recommended by
the manufacturers of the component items employed in the MATHESON TRI-GAS
Generators. Note that where any component manufacturer specifications are different from
those of MATHESON TRI-GAS, the more demanding schedule should be adopted.
WARNING
Read and follow all safety procedures given below and in Section 1.2, Safety
Information.
8.1.1
Nitrogen Generator
The nitrogen generator is a rugged unit and requires only minimal maintenance.
Failure to follow the maintenance schedule may result in damage to the unit and
voiding the warranty.
Every day:
1. Check for air and product leaks.
2. Check instrument air pressure.
3. Visually check control panel.
4. Record nitrogen concentration and flow rate; operating or ambient
temperature, feed air pressure, product tank pressure, and sieve bed pressures
throughout one cycle.
5. Verify that the automatic filter drain is working properly.
6. Manually operate air receiver drains.
Every month:
1. Clean filter bowls.
2. Calibrate optional oxygen analyzer as per attached manufacturer’s
instructions.
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Three months:
1. Change Particulate pre filter element.
2. Operate safety valves.
3. Operate manual valves.
4. Check for leaks and repair if necessary.
Six months:
1. Change Coalescing filter element
Annually:
1. Install valve repair kits on flow control valve and equalizer valves.
2. Disassemble and inspect all air-operated valves; install repair kits if required.
3. Test all air pilot valves.
4. Check for air and product leaks.
5. Change activated carbon tower and/or activated carbon filter element
upstream of the adsorber vessels. The steel activated carbon towers should
be returned to Matheson TriGas for refill. We recommend keeping a filled,
spare tower in stock to reduce downtime during replacement.
6. Check O2 analyzer sensor for proper operation as per manufacturer’s
instructions and order replacement.
Three years:
1. Install repair kits in all pneumatically operated valves.
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8.2 Filter Removal Procedure
Clean filter elements are vital to good system performance. The filters remove particulates
as well as liquid water and oil. The prefilter removes particles down to 5 microns in size.
It should be changed every 3 months.
The coalescing filter removes particles down to 0.01 microns in size. The life of the
coalescing filter is dependent on how well the prefilter performs its job; it will last for 6
months when the prefilter is regularly maintained.
The activated carbon tower and/or activated carbon filter element removes oil vapor down
to about 0.003 ppm. The life of the activated carbon tower and/or activated carbon filter
element is dependent on the oil content in the feed air. An activated carbon tower will
typically last for 12 months when the upstream filters are regularly maintained.
WARNING
Do not try to remove filter bowls unless both the Air Supply gauge and the Process
Pressure gauge clearly read zero psig.
1. Disconnect the tubes from the bottom of the bowls.
2. To remove the bowls, push the bowl latch down and rotate the bowl while pulling
down.
3. Inspect the bowls. If the drain system is working properly, the bowls should be empty.
4. Replace any filter element that looks damaged or excessively dirty.
NOTE
A plugged drain system will cause water and oil to carry over into the adsorber, which
will cause permanent damage to the adsorbent. Such damage is not covered by
the Manufacturer's Warranty. Use of filters other than those specified by
MATHESON TRI-GAS could result in damages not covered by the warranty.
5. Wash the bowls in soapy water and rinse thoroughly.
6. Reconnect the drain tubes. Make sure the bowl latches are securely locked in place.
Be careful to avoid cutting O-rings
7. Remove activated carbon tower and replace with new activated carbon.
8. Slowly open the air inlet valve to pressurize the bowls. Examine for leaks and tighten if
needed.
INT-0245 rev A1
19
9
TROUBLE SHOOTING
This section enables the operator to determine the cause of operation problems and suggests
remedies for the problems. If there are several likely causes, investigate the simpler
solutions first. Regardless of the type of malfunction, a person who is thoroughly familiar
with the system performs the troubleshooting best. If further assistance is required, contact
your local distributor or MATHESON TRI-GAS Inc.
Symptom
Nitrogen generator
Not cycling
Probable Cause
Low voltage or
low amperage
Corrective Action______
Check electrical source
Circuit breaker
tripped
Reset circuit breaker
Fuse blown
Replace fuses located inside
control enclosure.
Main power is OFF
Turn Nitrogen generator
power switch ON.
Low operator air
pressure
Increase air regulator
pressure
Defective wiring
Check wiring connections
____________________________________________________________
Nitrogen generator
N2 pressure switch
Reduce standby pressure
runs continuously;
set too high
Amber light OFF
Defective N2 pressure
Replace switch
switch
INT-0245 rev A1
Excessive product
usage
Reduce product
consumption
Product line leak
Repair leak
Cycle pressure too low
Increase air regulator
pressure
Defective wiring
Check wiring connections
20
Symptom
Low product flow
Probable Cause
Corrective Action______
Feed air flowrate
Adjust air supply pressure
is too low
and flow
____________________________________________________________
Low product purity
Product flow too high
Decrease product flow
O2 analyzer malfunction
Check operation and
calibration
Feed pressure too low
Increase operating
pressure or flow
Switching valve not
opening / closing
Dirty or defective valve;
clean or replace
No pilot signal; check pilot
valve using manual override;
replace coil or pilot valve
Tubing plugged or
pinched; replace tubing
Check-valves leak
Rebuild or replace check
valves
Muffler plugged
Clean muffler
Oil or water in unit
Contact Matheson Tri-Gas
____________________________________________________________
Filter drains remains
Drain valve dirty
Clean valve
open
____________________________________________________________
Filter drain does not
Drain valve plugged
Clean valve
open
Low operator air
Increase regulator
pressure
pressure
Tubing plugged or
Pinched
INT-0245 rev A1
21
Replace tubing
*****CAUTION*****
DO NOT DISCONNECT OR
TURN OFF AIR TO GENERATOR
UNLESS GENERATOR POWER SWITCH
IS TURNED OFF
INT-0245 rev A1
22
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