Nitrogen Generator System Manual
2nd Generation
Nitrogen Generator System Manual
GENERAL DESCRIPTION
The N2 Nitrogen Generator is designed for use on tap changers, breakers, main tanks or any other
electrical device requiring a gas-blanketed enclosure. The unit produces nitrogen by separating
oxygen from compressed air by means of hollow fiberglass separation membranes. The
compressed air is supplied by an on-board compressor and the generated nitrogen (N2) is fed to
internal storage vessels. The output concentration of the air separator (nitrogen purity) is factory
pre-set. The final regulator system maintains the gas-blanketed tank pressure between 0.5 and 5.0
psi at all times. If the tank pressure reaches a minimum of 0.5 psi, nitrogen is sent from the storage
vessels through the regulator assembly to the tank. Should tank pressure rise above 5.5 psi, a
relief valve will open to bleed off excess pressure to atmosphere.
IMPORTANT: Changing the output concentration may only be performed by trained and
authorized service technicians.
technicians
SYSTEM PRINCIPLE OF OPERATION
Refer to figure 1. The nitrogen generator system is contained within a climate-controlled cabinet that
closely controls the temperature range that the compressor system and nitrogen membrane are
required to operate within. When the on-board nitrogen storage tank drains to a preset level
(100psi), a compressor run cycle is initiated to refill the storage tank. Cool filtered air is drawn into
the compressor and compressed to a nominal output of 150 psi. The hot compressed air is then
directed through a heat exchanger that cools the compressed air below dew point for easier
moisture removal. As the hot air travels through the coalescing filter, the condensed moisture
collects in the filter bowl for draining at the end of the compressor cycle. The final filter removes all
particulates in the compressed air stream before entering into the membrane assembly. As the air
travels through the membrane, the outgoing nitrogen is regulated to a specific flow rate and
pressure that defines nitrogen purity at the given membrane operating temperature. The output
nitrogen of the membrane is diverted to atmosphere for a preset time, ensuring all contaminate
gases are purged before diverting to the storage tank. The generator storage tank stores 3 gallons
of Nitrogen at 100–120 psi to supply the final regulator system controlling the external gas space.
INLET AIR
FILTER
FILTER
WITH PURGE
FLOW
REGULATOR
COMPRESSOR
(2 STAGE)
NITROGEN
MEMBRANE
ONE WAY
VALVE
02
02
HEAT
EXCHANGER
TIMER
SOLENOID
STORAGE
TANK
COELESCING
PRE FILTER
WITH PURGE
FLOW
REGULATOR
FINAL
REGULATOR
SYSTEM
N2
02
Figure 1 – Nitrogen Generator Module Functional Operation
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
NITROGEN MEMBRANE PRINCIPLE OF OPERATION
Refer to Figure 2 below. Compressed air flows into the hollow fiber membrane. The various air
components, such as oxygen, nitrogen, carbon dioxide and water vapor pass through the membrane
wall but the rate at which this occurs differs for the various gasses.
wall,
gasses Oxygen and water vapor have a
high diffusion rate and diffuse rapidly through the membrane wall. Nitrogen has a low diffusion rate
and penetrates the membrane wall slowly; mainly at the end of the of the hollow fibers. The purity of
the nitrogen at the end of the fibers depends on the velocity of the gas flow. The nitrogen capacity of
the membrane depends on the flow rate, operating temperature and operating pressure of the
compressor.
Figure 2 – Membrane and Gas Flow
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
2 of 20
2nd Generation
Nitrogen Generator System Manual
SAFETY INFORMATION
Correct use of this equipment is important for your personal safety and for trouble-free functioning of
the unit. Incorrect control or attempts to perform adjustments could cause damage or lead to
incorrect gas supply.
supply Be sure to read and understand all instructions before attempting to operate
the unit. The unit is designed to produce nitrogen. The nitrogen is supplied by an internal generator
that produces nitrogen from ambient air through a process of separating oxygen from normal air.
You must not use the unit for any other purpose than what is specified. Do not operate the unit
beyond its limits (see Specifications). In addition to the warnings and cautions in this manual, use
the following safety guidelines for safe operation of the unit.
WARNING - This unit is an electrical appliance. Make sure that the main power supply is
disconnected before you perform installation,
installation maintenance or repair work.
work
WARNING - If you must work on the equipment with the main power supply on, be aware of
electrical hazards.
DANGER - When working on the equipment, do not wear loose clothes, jewelry or hair. They could
become en-tangled in the fan blades.
WARNING - The compressor becomes very hot when operating. Be careful when you open the
cabinet after the unit has been operating for any length of time.
time Do not touch the compressor.
compressor Allow
it to cool down before you start to perform any service on the unit. If you must work on the unit
while it is hot, be sure to wear protective gloves to protect yourself from the heat.
CAUTION - Do not block the ventilation inlets and outlets as this could cause overheating and
damage to the unit.
WARNING - In order to prevent injury or damage caused by the sudden release of compressed
air, make sure that the unit and connected systems
y
are fullyy de-pressurized
p
before yyou start
uncoupling parts of the system. Make sure no one tampers with the pressure-relief valve.
DANGER - This unit produces nitrogen and oxygen-enriched air. Nitrogen can cause suffocation.
Oxygen-enriched air can lead to increased risk of fire in the event of contact with flammable
products. Ensure adequate ventilation at all times.
IMPORTANT: The following words and symbols appear throughout this manual and designate
important safety instructions:
DANGER - Indicates information important to the proper operation of the equipment. Failure to
observe will result in damage to the equipment and/or severe bodily injury or death.
WARNING - Indicates information important to the proper operation of the equipment. Failure to
observe may result in damage to the equipment and/or severe bodily injury or death.
CAUTION - Indicates information important to the proper operation of the equipment. Failure to
observe may result in damage to the equipment.
Read all safety instructions to avoid personal injury or death, and to avoid damage to the unit or
property.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
SPECIFICATIONS
Nominal Performance
Nitrogen (N2 ) *
Purity of N2
delivered *
Flow rate*
Dew point of N 2
delivered *
Electrical
125psi
Voltage/Frequency
120Vac, 60 Hz
Power consumption *
1–19A
depending on
ambient
conditions
Potential free alarm
Normally open,
1A
99.5%
~3.0 SLPM
<–50°C
Average performance from –40° to 50°C
Purity of N 2
>99.0%
delivered
Dew point of N 2
–40°C
delivered
1.0 SLPM Continuous
Flow rate
5.0 SLPM Purge
Maximum Oil
Volume to
30,000 gallons
Blanket
Final Output Pressure
Maintained between 0.2 and 5.5 psi
* Nitrogen Delivery properties at
nominal temperature of 25°C.
Ambient Conditions
Temperature Range
–40° to +40°C
Air quality
Normally clean
ambient air
Relative humidity
< 90%
Altitude
0–6000 ft
Environment
Noise level
Less than 65
db(A)
Location
Outdoors, wall
t d
mounted
Safety standards
CE; applicable
standards
* Typical operation:
Fan only — 1A
Heaters (low ambients) — 10A
AC (high ambients) — 5A
Compressor Run (5 min) — 9A
Table 1 – Nitrogen Generator Specifications
CAUTION – The nitrogen generator is designed to provide the equivalent volume of nitrogen as a
standard nitrogen system consuming the standard 225 cuft bottle every 4 days or more. If the
application requires more nitrogen volume, consult the factory for a specialized unit. Operating the
equipment beyond the rated 1 lpm continuous will result in damage to the unit and void the
manufacturer’s
manufacturer
s warranty.
warranty
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
INSTALLATION — SINGLE TRANSFORMER
CAUTION - The unit must be mounted in an upright position. Do not mount unit on its side
or back.
WARNING - A crane or similar lifting device is required to lift and secure unit to wall
mounting surface.
CAUTION - Do not block the ventilation inlets and outlets, this could cause overheating and
damage to the unit.
WARNING – Support structure and mounting hardware must be capable of supporting the
generator weight of 380 lbs minimum. Cabinet is designed to be mounted using 1/2”
hardware.
• The unit must be mounted above grade level.
• Install unit away from heat sources.
• Do not install in an enclosed cabinet; proper ventilation is required.
Figure 3 – Generator mounting dimensions
1. Measure and mark the mounting holes or studs as shown by the center-to-center distances on
figure 3. IMPORTANT: Make sure the bolt holes are level and high enough to support cabinet
above grade.
2. Lift the unit into position with crane and top hook.
3. Secure hardware. NOTE: Cabinet is designed to be installed using 1/2” hardware.
4. Plumb to transformer using copper or stainless steel 1/4” or larger tubing.
NOTE: Inlet and outlet ports of generator are female 1/4” NPT.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
5 of 20
2nd Generation
Nitrogen Generator System Manual
INSTALLATION — MULTIPLE TRANSFORMER
CAUTION - The unit must be mounted in an upright position. Do not mount unit on its side
or back.
WARNING - A crane or similar lifting device is required to lift and secure unit to wall
mounting surface.
CAUTION - Do not block the ventilation inlets and outlets, as this could cause overheating
and damage to the unit.
WARNING – Support structure and mounting hardware must be capable of supporting the
generator weight of 380 lbs minimum. Cabinet is designed to be mounted using 1/2”
hardware.
WARNING – Use of the Nitrogen Generator for multiple transformers requires evaluation of
several to maintain the health of each transformer. Do not proceed unless all conditions
are met.
1. Calculate the required usage for each transformer to be connected to the generator. The total
sum of usage cannot exceed 1 slpm. For example, 1 slpm continuous usage equates to using
a single standard 225 cuft nitrogen bottle every 4 days.
2 IMPORTANT: Each transformer must have a final nitrogen pressure regulation system with
2.
tank alarms.
3. IMPORTANT: Piping for each transformer must contain a one-way valve to prevent airspace
backflow to the supply line.
4. IMPORTANT: Piping for each transformer must contain a separate isolation valve.
5. IMPORTANT: Each transformer must be protected by an appropriate pressure/vacuum device.
Figure 4 – Multiple Transformer Installation Flow
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
6 of 20
2nd Generation
Nitrogen Generator System Manual
HVS Part Number:
MN2-0A0133
7.5 psi
One Way
Valve
Isolation
Valve
Regulator
Bypass
Valve set
to “Bypass”
0.5 psi
Mini N2 shown.
Standard N2
System can be
used with addition
of one-way and
isolation valves.
Nitrogen
Generator
Figure 5 – Typical Example of Multiple Transformer Installation
CAUTION – The recommended maximum volume of oil to be blanketed is 30,000
30 000 gallons based upon
a 12% nitrogen-to-oil blanket ratio. For larger oil volume requirements, consult the factory for a
specialized unit. Use of the nitrogen generator for larger oil volumes will void the manufacturer’s
warranty.
N2-Gen-Manual
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
Rev. 2.4, 10/13/2009
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
7 of 20
2nd Generation
Nitrogen Generator System Manual
ELECTRICAL CONNECTIONS
WARNING - Electrical shock hazard. Failure to follow these instructions could result in
serious injury or death.
• Electrical ground is required on this appliance.
• Do not use an extension cord with this appliance.
• The unit should be grounded according to local electrical codes to prevent the possibility
of electrical shock. It requires a grounded receptacle with separate electrical lines,
protected by fuses or circuit breaker of the proper rating.
• Check with a qualified electrician if you are in doubt as to whether the appliance is
properly grounded.
Figure
g
6 – Alarm and Power Connections
1. Conduit entry points are located on both sides of the cabinet. Install conduit with sealed
connectors to prevent water entry to the generator system.
2. After pulling wire, seal conduit entry with expanding foam or similar. The generator compressor
must not be allowed to draw air from conduit.
3. Locate the terminal block on the regulator module. Loosen the two thumb screws and swing
terminal panel cover out of the way to expose terminal connections.
4 Connect the wiring to the terminals as shown in Figure 6 above
4.
above.
5. Alarm connections are not required for generator operation but are highly recommended.
6. Reposition the terminal panel cover and tighten thumb screws.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
Nitrogen
Regulator
Module
Climate
Control
Interface
Nitrogen
Generator
Module
Climate
Control
Module
Climate
Control
Filter
Heat Exchanger
Assembly
Cabinet
Air Inlet
Filter
Nitrogen Membrane
Assembly (No Filters)
Oil Sump
Particle Filter
Regulator Module 3rd
Stage Regulation
Bypass Valve
Storage Tank Pressure
Switch Assembly
Coalescing Filter
Assembly
Nitrogen Purge Solenoid and
Membrane Pressure Gauge
Nitrogen Storage Tank
Air Compressor
Air Compressor
Filter
Enclosure Heater
(1 of 3)
Figure 7 – Nitrogen System Component Identification
2nd Generation
The patented
Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
9 of 20
2nd Generation
Nitrogen Generator System Manual
START UP
IMPORTANT: Make sure the unit has been properly installed according to the Installation
Instructions included in this manual.
CAUTION - When the compressor starts,
starts the cooling fan on the heat exchanger should
rotate. If fan is not rotating, turn unit off or damage to the unit could occur.
The generator system is factory set for optimum purity and no adjustments are necessary. The
design of the system is such that the operating temperatures of all components must be
controlled to optimize nitrogen purity. Because of this, it is necessary for the climate control
system be energized for a period of 8 hours prior to releasing nitrogen from the generation
system.
The climate control system is preset to cool when the enclosure air temperatures exceed 80°F and
heat when the enclosure air temperature declines below 63°F. The enclosure air is continually
cycled through the system to avoid temperature gradients anywhere in the system.
After all components have been brought within temperature specifications, the generator is ready
for use and the gas space purge operation can begin.
Generator Storage
Tank Pressure
From Gas Space
To Gas Space
Generator Outlet
Valve (Shown in
Open Position)
Gas Space
Pressure
Gauge and
Alarm Point
Settings
Gas Space
Return Valve
(Open
during Purge
Operation
ONLY)
Figure 8 – Generator Inlet and Outlet Valves
1. Before operating, the gas space pressure switch contacts must be set to allow the needle to
move (alarm points protect the needle during transport.
2. Loosen the clamp around the needle alarm knobs. There is a small screw on the bottom of the clamp.
3. Adjust the low pressure contact (left knob) to 0.2 psi. Adjust the high pressure contact (right knob) to
5.5 psi.
4 Tighten the clamp
4.
clamp.
5. Turn on the main power feed to the generator with appropriate fuse or breaker disconnect.
6. Verify that the climate control internal fan is operating and climate control interface is energized.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
10 of 20
2nd Generation
Nitrogen Generator System Manual
STARTUP (continued)
7. Verify storage tank pressure. If tank is empty or below 100psi AND if ambient temperature is
between 105°F and 40°F, the air compressor should immediately start and run for approximately
5–7 minutes. NOTE: A strong hissing sound will be heard for the first 2–3 minutes as the nitrogen
is diverted to atmosphere before being brought to full purity.
8. If compressor does not run due to ambient temperatures, close generator door and wait for
enclosure temperature to be brought within specifications.
9. After compressor charges the storage tank and shuts off, perform a continuity check on the
following alarms contacts:
Terminals 1 to 2 – OPEN
Terminals 2 to 3 – OPEN
Terminals 4 to 5 – OPEN
Terminals 5 to 6 – CLOSED
Terminals 7 to 8 – OPEN
10. Open the outlet valve.
11. Compressor will cycle as storage tank drains to 100 psi. Compressor shut-off is 110–125 psi.
Typical runtime is 5–10 minutes, depending upon altitude.
12. Rotate the regulator panel bypass valve from full regulation to bypass operation.
13. Open the return valve.
14. Close the generator door and latch.
15. Purge for the calculated amount of time based upon 5 liters per minute flow rate.
16. Close return valve.
17. Change regulator panel bypass valve from bypass mode to full regulation mode. This will
maintain the gas space from 0.5 psi to 5 psi.
IMPORTANT: Check all pipes and connection for leaks using soap or leak-tracing spray.
Any leakage will reduce capacity considerably.
PROPER SYSTEM OPERATION CHECKS
1. During air compressor run and with outlet valve shut, check membrane outlet gauge (on top of
storage tank) and verify that the pressure rises above 130 psi. If not, there are leaks between
the compressor and storage tanks or the inlet carbon filter and compressor filter may be clogged.
2. Verify that compressor should turn on at 90–100 psi and turn off at 110–125 psi. If not, readjust.
NOTE: In higher altitude locations, the pressures may need to be adjusted to the low side of
specifications.
3. Verify that the nitrogen storage system is not leaking. With generator outlet valve shut and the air
compressor off, verify that there is no decrease in pressure on the nitrogen regulator module
gauge. If a decrease is present, the one-way valve, storage tank or nitrogen regulator module may
be leaking.
4. Verify during compressor run that the coalescing filter purges the collected water and reseals
during the next compressor run. The oil sump drain can be used to speed the cycling of the air
compressor.
5. At each compressor start, verify that the solenoid valve diverts to atmosphere. At each start, there
will be a strong hissing sound for two minutes
minutes. If not
not, the solenoid valve may have failed
failed. If the
hissing sound is heard for something other than two minutes, the solenoid timer is misadjusted.
Push the corresponding buttons on timer to display 110 (seconds).
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
CLIMATE CONTROL
As soon as electrical power is supplied to the Generator system, the cool air stream blower will
start to operate. The blower will run continuously so that the controller can monitor the enclosure’s
internal temperature. The enclosure temperature will be displayed on the face of the controller.
If the enclosure temperature is greater than the factory cooling set point of 80°F, the “Cool” status
LED will flash. This indicates that the coolant compressor’s automatic off cycle timer is working.
The off cycle timer is factory set at 3-1/2 minutes. At the end of 3-1/2 minutes, the coolant
compressor and the condenser air blower will begin to operate. This signifies that the cooling
system has begun operation to remove heat and humidity from the enclosure. This procedure may
take 20 to 30 minutes before it reaches full capacity.
When the temperature inside the enclosure decreases 7
7°F
F below the “Cooling
Cooling on
on” set point,
point the
coolant compressor and the condenser blower will cycle off. The cool air blower will continue to
operate, circulating air within the enclosure. The controller has a factory programmed temperature
differential of 7°F. Example: “Cooling on” @ 80°F; “Cooling off” @ 73°F.
The climate control system also provides power to three external heaters which are mounted in
various places within the equipment enclosure. If the enclosure temperature is below the factory
heating set point of 63º F, the heat status LED will be ‘”on”. This indicates the heat relay has been
energized and is providing power to the three 400 watt heaters (there is no time delay before
heating begins). When the temperature of the enclosure rises 7°F above the set point, the
controller will de-energize the heat relay and cycle the heater “off”.
NOTE: There is a dead band programmed into the controller that prevents heating and
cooling from operating simultaneously.
PROGRAMMING THE CONTROLLER
The controller has been programmed at the factory with typical default settings for immediate system
operation. Please review the following default settings:
1. Cooling system on temperature
80° F
2. Heating system on temperature
63° F
3. High enclosure temperature alarm
105° F
4. Low enclosure temperature alarm
40° F
5. Audible and Visual alarm
“ON”
6. Digital display in degrees
Fahrenheit
7 Filter maintenance alarm
7.
0 days – Disabled
8. High condenser temperature alarm
170° F
Figure 9 – Climate Control Interface
2nd Generation
The patented
Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
12 of 20
2nd Generation
Nitrogen Generator System Manual
CLIMATE CONTROL (continued)
The temperature alarm settings have been preset to protect the generator system before known
failure values. Changing these values is generally not recommended; however, if the above factory
values have been inadvertently changed, the following programming information is provided for
reference.
To change the factory default settings, enter the programming code sequence:
“1 Adjust-up” arrow
“2 Adjust-down” arrow
“3 Select”
“4 Exit”
After pressing the above sequence, the program LED should illuminate along with three alternating
flashing boxes on the display face, indicating the code was accepted. If no selection is made within
one minute, the system returns to the normal operating mode.
NOTE: Pressing the “4 Exit” button at any time while in the programming mode returns the
controller to the normal operating mode.
Press the “3 Select” button to continue programming. The set temperature “HI” LED illuminates with
the display indicating the ‘cooling on’ setpoint. The coolant compressor will begin operation at this
temperature and will remain operating until the enclosure temperature decreases approximately
seven degrees Fahrenheit (four degrees Celsius). Press the “1 Adjust-up” or “2 Adjust-down”
arrow until the desired set point is displayed. The range for this adjustment is 70°F to 126°F, (21°C
to 52°C). When the adjustment is complete, press the “3 Select” button to continue.
The set temperature “LO” LED is on with the display indicating the ‘heating on’ set point. The
heating system will begin operation at this temperature and remain operating until the enclosure
temperature increases approximately seven degrees Fahrenheit (four degrees Celsius). Press the
“1 Adjust-up” or “2 Adjust-down” arrow until the desired set point is displayed within a range of
0°F to 63°F (–17.8°C to +17°C).
NOTE: Review alarm settings if the ‘cool on’ or ‘heat on’ set points have been changed.
Press the “3 Select” button to continue. The set alarm “HI” LED is on with the display indicating
the high temperature alarm setpoint. The alarm will activate at this temperature and will
automatically reset at two degrees Fahrenheit (one degree Celsius) below this temperature. Press
the “1 Adjust-up” or “2 Adjust-down” arrow to change the alarm setpoint to a point greater than
8ºF (or 4ºC) above the set temperature “HI” set point, to 135°F (or 57°C).
Press the “3 Select” button to continue. The set alarm “LO” LED is on with the display indicating
the low temperature alarm set point. The alarm will activate at this temperature and will
automatically reset at two degrees Fahrenheit (or one degree Celsius) above this temperature.
Press the “1
1 Adjust-up
Adjust-up” or “2
2 Adjust-down
Adjust-down” arrow to change the alarm setpoint to a point no less
than 8º F (4ºC) below the set temperature “LO” set point to –20°F (or –29°C).
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
CLIMATE CONTROL (continued)
Press the “3 Select” button to continue. The alarm LED will flash and the display will show “ALL”,
indicating the “ALL” alarm on/off status. Press “3 Select” and the display will show either “ON” or
“OFF”, indicating current alarm status. Press “1 Adjust-up” or “2 Adjust-down” to toggle the mode
as desired. If the “OFF” mode is selected, no alarms will activate and the audible on/off select
function is skipped.
Press the “3 Select” button to continue. The audible LED will flash and the display will show “AUD”,
indicating the audible alarm on/off status. Press “3 Select” and the display shows “ON” or “OFF”
indicating the current audible alarm status. Press “1 Adjust-up” or “2 Adjust-down” arrow to toggle
the mode desired.
Press the “3 Select” button to continue. The “C” LED flashes and the display shows either “F” for
degrees Fahrenheit or “C” for degrees Celsius. Press the “1 Adjust-up” arrow or “2 Adjustdown” arrow to toggle the mode as desired.
Press the “3 Select” button to continue. The code LED is on and the display shows “PIN”. To set a
new user PIN code, press the “1 Adjust-up” button. The display will flash “4”, prompting an entry
of a four button sequence using the “1 Adjust-up”, “2 Adjust-down”, “3 Select” and/or “4 Exit”
buttons Any sequence of the four buttons may be programmed as the code.
buttons.
code As the buttons are
pressed, the display will show the number of buttons that were pressed.
NOTE: After pressing a button, there will only be 5 seconds to press the next button. If the
next button is not pressed within the allotted time, the system will default to no PIN code,
indicated by “0” on the display. Once the sequence is entered the display will no longer
flash, and will show “4”.
CAUTION - Always record the selection sequence (PIN code) and store in a secure place
place.
Press the “3 Select” button to continue. The filter LED flashes and the display will show “FIL”,
indicating the filter alarm days selection. Press the “3 Select” button and the display will show the
number of days that the alarm is set in one-half day increments. Example: 10.5 indicates the alarm
will activate every ten and one-half days.
Press the “1 Adjust-up” or the “2 Adjust-down” arrow to vary the desired number of days.
Programming 0 days will disable the alarm.
NOTE: The required number of days to set this alarm will be determined by the ambient air
conditions.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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ALARMS
The nitrogen generator system features non-powered alarm contacts that can be used to monitor
the condition of the system externally. The following table lists each alarm and its corresponding
cause terminal condition and the maximum rating for the monitoring system.
cause,
system
Alarm
Condition
Terminal Condition
Electrical Rating
Low Gas Space
Pressure
Gas space pressure has gone
lower than 0.2 psi
Contact closes between
terminals 1 and 2
1A, 120VAC or 2A, 30VDC
High Gas Space
Pressure
Gas Space pressure has
exceeded 5.5 psi
Contact closes between
terminals 2 and 3
1A, 120VAC or 2A, 30VDC
Low Nitrogen
Storage Tank
Nitrogen Storage tank has
fallen lower than 50 psi.
Contact close between
terminals 4 and 5 AND contact
opens between terminals 5 and 6
5A, 250VAC or 5A, 30VDC
or 0.8A 125VDC
Generator Temp
Alarm
Internal air space has risen
above 105°F OR fallen below
40°F
Contact closes between
terminals 7 and 8
40A, 125VAC
NOTE: All ratings listed are resistive.
Table 2 – External Alarms
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
SHUT DOWN
Under normal operation, the unit can be left on. The compressor will switch on/off automatically
according to the storage vessel pressure (100 psi on, 125 psi off). The unit should only be switched
off for maintenance work using the following procedure:
1. Disconnect the main power feed to the generator.
2. The compressor side of generator will automatically (but gradually) decompress for
approximately 1 minute.
3. Nitrogen storage tank will continue to maintain pressure to regulation module unless manually
drained. If necessary, close the output valve to the air space and drain storage tank with
regulation panel sump drain.
Pressure Vacuum
Gauge and Alarm
Settings
Nitrogen Storage
Tank Pressure
Gauge
Sump Drain
Figure 10 – Regulation Module Assembly
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
MAINTENANCE
NOTE: COMPLETE FILTER REPLACEMENT KIT IS AVAILABLE, PART NO. 1030-1727K.
CARBON FILTER MUST BE CHANGED BI-ANNUALLY
Install a new carbon absorber/dust filter, Part No. 1030-1231:
1. Open the door to the generator unit.
2. Slide the carbon filter out of the retaining brackets.
3. Install a new filter, making note of the airflow direction.
4. Close the door to the generator unit.
AIR COMPRESSOR INLET FILTER — REPLACE BI-ANNUALLY OR EVERY 400 HOURS
Install a new filter
filter, Part No
No. 1030-1301:
1030 1301:
1. Disconnect power to the generator unit.
2. Open the door to the generator unit and unscrew the air compressor filter assembly.
3. Inspect for contamination on air compressor inlet side of the filter. If contaminated, the system
has pumped contaminates through the system and the coalescing/final filter elements must be
replaced.
4. Install the new air compressor filter assembly.
5. Release pressure from nitrogen storage tank using the sump valve (see figure 10 on page 16)
until 95 psi remains.
6. Close the generator door and reconnect power.
7. Verify that compressor successfully charges the storage tank — this process should take approx.
10 minutes.
OIL SUMP — CLEAN BI-ANNUALLY OR EVERY 400 HOURS
The oil sump must be checked and cleaned periodically:
1 Disconnect power to the generator system
1.
system.
2. Close the outlet valve to isolate the gas space from generator system.
3. Make sure unit is de-pressurized by opening the sump valve (see figure 10 on page 16).
4. If necessary, clean the oil sump with soap and warm water. The housing can be unscrewed
from the mounting base for cleaning. Tighten housing securely but do not overtighten.
5. Reconnect power and verify that the compressor successfully charges the storage tank — this
process should take approx. 10 minutes.
CAUTION - Use only mild soap and water for cleaning
cleaning. Do not use degreaser or other
incompatible chemicals.
COALESCING & PARTICLE FILTER ASSEMBLIES — REPLACE BI-ANNUALLY OR EVERY 400 HOURS
Install new filters as a set, Part Nos. 1030-1300 (coalescing) and 1030-1303 (particle):
1. Disconnect power to the generator system (see Figure 7 on page 9).
2. Close the outlet valve to isolate the gas space from generator system.
3. Carefully unscrew the filter housings (retain housing O-rings for reuse) from the bodies.
4. If necessary, clean the filter housings with soap and warm water.
5. Replace coalescing and particle filters and O-rings.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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2nd Generation
Nitrogen Generator System Manual
MAINTENANCE (continued)
COALESCING & PARTICLE FILTER ASSEMBLIES — installation instructions (continued)
6. Tighten housings securely but do not over-tighten.
7 Release pressure from nitrogen storage tank using the sump valve (see figure 10 on page 16)
7.
until 95 psi remains.
8. Reconnect power and verify that the compressor successfully charges the storage tank — this
process should take approx. 10 minutes.
CLIMATE CONTROL FILTER — REPLACE BI-ANNUALLY
Install a new filter, Part No. 1030-1302:
1. Replacement of the climate control filter is dependent of outside conditions such as dust or
other debris.
2. Slide the climate control filter from the retaining brackets. Some units may require removal of
the brackets.
3. Replace filter.
OTHER MAINTENANCE
STORAGE TANK PRESSURE SWITCH
The pressure switch setting is factory set and normally should not change. If problems are
encountered during shipment or maintenance activity the following procedure is for reference.
1.
2.
3.
4.
Disconnect power to the generator.
Remove pressure switch cover.
Loosen the lock nut with 3/4” open end wrench.
Using a 5/8” open-end wrench, turn the adjuster clockwise to increase the setpoint and
counterclockwise
t l k i tto decrease
d
th
the setpoint.
t i t
5. Hold the adjuster with wrench and tighten lock nut.
6. If deadband adjustment is required, turn thumbwheel clockwise to increase deadband and
counterclockwise to decrease deadband.
7. Reinstall cover and reconnect power to generator to check adjustments.
DOOR GASKET
Inspect door gasket bi-annually for rips, tears or misalignment.
ADJUSTING THE PURITY
The purity of the nitrogen is factory preset. The purity of the nitrogen gas can be set between 97%
and 99.5%.
IMPORTANT: Adjusting the purity is a procedure that requires a skillful technician with a
knowledge of the process. If this procedure is to be done, we require service by Waukesha
Electric Systems to prevent voiding warranty.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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2nd Generation
Nitrogen Generator System Manual
TROUBLESHOOTING
 Power source is off
 Turn main power source
on
 Unit is in “Standby” status
 Wait until pressure in
storage vessel is reduced
 Temperature is too high or
low
 Ambient temperature is
too high (above 40°C)
 Climate control is not
functioning
gp
properly
p y and
should be checked
 Call Waukesha
 Inlet filter is contaminated
 Replace the carbon filter
and compressor inlet filter
 Leaks in the hoses or
connections
 Seal any leaks*
 Excessive consumption
 Contact Waukesha to
confirm appropriate
application
Compressor does not operate
Membrane pressure or
delivery pressure too low
(continuous run)
 Pressure switch misadjusted
 Coalescing filter(s) dirty or
bowls are leaking
Desired nitrogen flow not
achieved
 One way valve leaking
 Leaks in hoses or
connections
 Climate control not
working
 Set pressure switch
 Replace filters and check
bowls for leaks*
 Replace the one-way
valve
 Seal any leaks*
 Call Waukesha
* To check for leaks, use soap solution of leak-tracing spray.
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
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Rev. 2.4, 10/13/2009
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2nd Generation
Nitrogen Generator System Manual
NOTES
The patented 2nd Generation Nitrogen Generator system is manufactured and distributed
by High Voltage Supply, a division of Waukesha Electric Systems, Inc. U.S. Patent Nos.
6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.
N2-Gen-Manual
Rev. 2.4, 10/13/2009
20 of 20
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