Nitrogen Generator System Manual

2 nd 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

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 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

02

TIMER

SOLENOID

02

ONE WAY

VALVE

HEAT

EXCHANGER

STORAGE

TANK

COELESCING

PRE FILTER

WITH PURGE

FLOW

REGULATOR

FINAL

REGULATOR

SYSTEM

N2 02

Figure 1 – Nitrogen Generator Module Functional Operation

The patented 2 nd 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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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 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


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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 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

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 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 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.


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SPECIFICATIONS

Nominal Performance

Purity of N2 delivered *

Flow rate*

Dew point of N 2 delivered *

99.5%

~3.0 SLPM

<–50°C

Average performance from –40° to 50°C

delivered

Dew point of N 2 delivered

>99.0%

–40°C

Flow rate

1.0 SLPM Continuous

5.0 SLPM Purge

Maximum Oil

Volume to

Blanket

30,000 gallons

Final Output Pressure

Maintained between 0.2 and 5.5 psi

* Nitrogen Delivery properties at nominal temperature of 25°C.

Electrical

Power consumption *

Potential free alarm

Ambient Conditions

Temperature Range

Air quality

Altitude

Environment

Noise level

1–19A depending on ambient conditions

Normally open,

1A

–40° to +40°C

Normally clean ambient air

0–6000 ft

Less than 65 db(A)

Outdoors, wall

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


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INSTALLATION — SINGLE TRANSFORMER

CAUTION - The unit must be mounted in an upright position. Do not mount unit on its side or back.

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.


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INSTALLATION — MULTIPLE TRANSFORMER

CAUTION - The unit must be mounted in an upright position. Do not mount unit on its side or back.

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 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


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HVS Part Number:

MN2-0A0133

7.5 psi

Regulator

Bypass

Valve set to “Bypass”

One Way

Valve

Isolation

Valve

0.5 psi

Nitrogen

Generator

Mini N2 shown.

Standard N2

System can be used with addition of one-way and isolation valves.

Figure 5 – Typical Example of Multiple Transformer Installation

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.


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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.

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.

5. Alarm connections are not required for generator operation but are highly recommended.

6. Reposition the terminal panel cover and tighten thumb screws.


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Nitrogen

Regulator

Module

Climate

Control

Interface

Control

Module

Climate

Control

Filter

Nitrogen

Module

Cabinet

Air Inlet

Filter

Oil Sump

Regulator Module 3 rd

Stage Regulation

Bypass Valve

Coalescing Filter

Assembly

Air Compressor

Filter

Figure 7 – Nitrogen System Component Identification


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Heat Exchanger

Assembly

Nitrogen Membrane

Assembly (No Filters)

Particle Filter

Storage Tank Pressure

Switch Assembly

Nitrogen Purge Solenoid and

Membrane Pressure Gauge

Nitrogen Storage Tank

Air Compressor

Enclosure Heater

(1 of 3)

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START UP

IMPORTANT: Make sure the unit has been properly installed according to the Installation

Instructions included in this manual.

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

Figure 8 – Generator Inlet and Outlet Valves

Gas Space

Return Valve

(Open during Purge

Operation

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.

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.


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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 5 to 6 – CLOSED

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 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).


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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.

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

2. Heating system on temperature

3. High enclosure temperature alarm

4. Low enclosure temperature alarm

5. Audible and Visual alarm

6. Digital display in degrees

80° F

63° F

105° F

40° F

“ON”

Fahrenheit

8. High condenser temperature alarm 170° F

Figure 9 – Climate Control Interface


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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 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.

than 8º F (4ºC) below the set temperature “LO” set point to –20°F (or –29°C).


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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 Adjust-

down” 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” 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”.

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.


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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

Alarm

Low Gas Space

Pressure

Condition

Gas space pressure has gone lower than 0.2 psi

High Gas Space

Pressure

Gas Space pressure has exceeded 5.5 psi

Terminal Condition

Contact closes between terminals 1 and 2


Electrical Rating

1A, 120VAC or 2A, 30VDC

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


NOTE: All ratings listed are resistive.

Table 2 – External Alarms

40A, 125VAC


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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


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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

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:

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.

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.


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MAINTENANCE (continued)

COALESCING & PARTICLE FILTER ASSEMBLIES — installation instructions (continued)

6. Tighten housings securely but do not over-tighten. 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

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. Disconnect power to the generator.

2. Remove pressure switch cover.

3. Loosen the lock nut with 3/4” open end wrench.

4. Using a 5/8” open-end wrench, turn the adjuster clockwise to increase the setpoint and t l k i t d th 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.


6,581,694; 6,568,287; 6,062,821; 5,902,381 and 5,744,764.

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2 nd Generation


TROUBLESHOOTING

Compressor does not operate

 Power source is off

 Unit is in “Standby” status

 Temperature is too high or low

 Inlet filter is contaminated

 Leaks in the hoses or connections

Membrane pressure or delivery pressure too low

(continuous run)

 Excessive consumption

Desired nitrogen flow not achieved

 Pressure switch misadjusted

 Coalescing filter(s) dirty or bowls are leaking

 One way valve leaking

 Leaks in hoses or connections

 Climate control not working

* To check for leaks, use soap solution of leak-tracing spray.

 Turn main power source on

 Wait until pressure in storage vessel is reduced

 Ambient temperature is too high (above 40°C)

 Climate control is not should be checked

 Call Waukesha

 Replace the carbon filter and compressor inlet filter

 Seal any leaks*

 Contact Waukesha to confirm appropriate application

 Set pressure switch

 Replace filters and check bowls for leaks*

 Replace the one-way valve

 Seal any leaks*

 Call Waukesha


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

19 of 20

2 nd Generation


NOTES


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

Nitrogen Generator System Manual

GENERAL DESCRIPTION

SAFETY INFORMATION

SPECIFICATIONS

Nominal Performance

Final Output Pressure

Electrical

INSTALLATION — SINGLE TRANSFORMER

INSTALLATION — MULTIPLE TRANSFORMER

ELECTRICAL CONNECTIONS

START UP

STARTUP (continued)

PROPER SYSTEM OPERATION CHECKS

CLIMATE CONTROL

NOTE:

.

CLIMATE CONTROL (continued)

CLIMATE CONTROL (continued)

ALARMS

SHUT DOWN

MAINTENANCE

MAINTENANCE (continued)

OTHER MAINTENANCE

TROUBLESHOOTING

NOTES

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