PRESSCON N-Gen Manuale utente

N-Gen nitrogen generator, High

Performance and Single tube

User manual

Type

User manual

Date

March 2021

Version / Revision

Version 2.0, Revision 00

Status

Approved

Company

PRESSCON

Location

Honselersdijk

Page 2 of 19

 
 Page 3 of 19 
Table of content 
INTRODUCTION .................................................................................................................................................. 4 
1PRECAUTIONS AND SAFETY INSTRUCTIONS ................................................................................................. 5 
1.1 GENERAL SAFETY STANDARDS .................................................................................................................... 5 
1.1.1 Working with the N-Gen nitrogen generator........................................................................................5 
1.1.2 Working with the compressor...............................................................................................................5 
1.2 DESCRIPTION OF GENERAL HAZARD SYMBOLS ................................................................................................ 6 
2SYSTEM COMPONENTS................................................................................................................................ 7 
2.1 N-GEN NITROGEN GENERATOR HIGH PERFORMANCE (H.P.) MULTI-F................................................................. 7 
2.2 N-GEN NITROGEN GENERATOR HIGH PERFORMANCE (H.P.) N-GEN CONTROLLER ................................................. 8 
3GENERAL OPERATION ................................................................................................................................ 11 
3.1 OPERATION OF THE N-GEN NITROGEN GENERATOR ...................................................................................... 11 
3.1.1 Compressed air supply ........................................................................................................................11 
3.1.2 Nitrogen production............................................................................................................................11 
3.2 SCHEMATIC OVERVIEW OF THE N-GEN NITROGEN GENERATOR ........................................................................ 12 
4CONTROLLER ............................................................................................................................................. 13 
4.1 MULTI-F CONTROLLER........................................................................................................................... 13 
4.2 N-GEN CONTROLLER ............................................................................................................................. 13 
4.2.1 Display 1085 ........................................................................................................................................13 
5ALARM AND ERROR HANDLING ................................................................................................................. 14 
5.1 MULTI-F............................................................................................................................................. 14 
5.1.1 Alarm button .......................................................................................................................................14 
5.1.2 Faults and alarms ................................................................................................................................14 
5.1.3 Alarm messages...................................................................................................................................14 
5.1.4 Resetting alarms..................................................................................................................................15 
5.2 N-GEN CONTROL.................................................................................................................................. 15 
5.2.1 Faults and alarms ................................................................................................................................15 
6MAINTENANCE AND SERVICE..................................................................................................................... 16 
6.1 MAINTENANCE OF THE N-GEN NITROGEN GENERATOR .................................................................................. 16 
6.2 COMPRESSOR MAINTENANCE .................................................................................................................. 16 
7WARRANTY................................................................................................................................................ 17 
8APPENDIX .................................................................................................................................................. 18 
9DOCUMENT HISTORY................................................................................................................................. 18 
10 TO CONCLUDE............................................................................................................................................ 19 
 
 

Page 4 of 19

Introduction

The N-Gen nitrogen generator is a system that provides a supply of nitrogen in a pressure vessel. It is applicable for various

purposes and in various industries where it is desired to generate nitrogen on site. The N-Gen nitrogen generator is a system that

consists only of a nitrogen generator unit. However, to be fully functional the N-Gen nitrogen generator needs a compressed air

supply and a start/stop signal.

The N-Gen nitrogen generator works on the basis of a start / stop signal that is supplied externally. This can be in the form of a

pressure switch or a digital output signal from another PLC. As soon as the N-Gen receives the signal, it immediately starts

producing nitrogen. As soon as the signal drops out, the N-Gen will first complete the production cycle, after which the generator

will stop. The nitrogen supplied by the N-Gen nitrogen generator is in fact an air mixture with a nitrogen concentration that

deviates from 95.0 vol.%N2 to 99.9999 vol.%N2. Nitrogen is an inert gas and at a high concentration it has the property of

preventing corrosion in a steel tank or pipe. It can also be used for fire and explosion prevention and for research in hospitals.

Furthermore, there are many other possible applications for nitrogen.

Important to know

The N-Gen nitrogen generator can be delivered in a range of capacities and in 2 versions. The N-Gen nitrogen generator can be built

as a High Performance (H.P.) generator or as a Single Tube generator. The difference is in the number of PSA tubes that are used to

make nitrogen. The High Performance version uses 2 PSA tubes and the Single tube version uses only 1 PSA tube. The Single Tube

generator is a simplified version of the High Performance generator, but the function of both systems remains the same. However,

for the Single Tube version it is always necessary to use a nitrogen pressure vessel. It is important to know that the Single Tube

version of the N-Gen has a maximum capacity of 2.5 m³/h with a maximum purity of 99%.

The N-Gen nitrogen generator has a capacity that varies from systems that supply 2.0 m³/h nitrogen to systems that can supply

16.0 m³/h of nitrogen at 8 bar compressed air and 99% purity. In addition, by combining several N-Gen generators, a capacity of

over 3,000.0 m³/h can be reached, depending on the customer's requirements.

The N-Gen nitrogen generator is designed on flow and the corresponding purity. The higher the purity the lower the flow that

comes from the generator. An N-Gen 16.0 for example has a capacity of 16.0 m³/h nitrogen at a purity of 99% and 8 bar

compressed air. However, if the purity is increased to 99.99%, the generator only has a capacity of 4.0 m³/h nitrogen, if the purity is

decreased to 95% the capacity becomes 27.0 m³/h nitrogen. The pressure of the compressed air is also important. In the example

above, the flow of 16.0 m³/h of nitrogen is achieved with an air pressure of 8 bar. If the air pressure is lowered to 6 bar, the

generator will no longer deliver 16.0 m³/h nitrogen. The flow will be lower. When the capacity of the N-Gen nitrogen generator

increases, the dimensions of the system also increases, however, the rest of the appearance remains the same.

Page 5 of 19

1Precautions and safety instructions

1.1 General safety standards

When working with the N-Gen nitrogen generator, there are a number of safety risks that have to be considered. These risks

include topics such as dangerous voltages, high pressure and danger of suffocation when breathing in a high concentration of

nitrogen. These are further explained in this chapter. It is highly recommended to observe the safety risks before carrying out any

work on the system. The safety risks in this chapter are divided among the different components of the system. For more

information on the composition of the components, see chapter 2.

1.1.1 Working with the N-Gen nitrogen generator

The N-Gen nitrogen generator is commonly located in the technical room of the facility. When operating or when working on the

nitrogen generator, the following hazards should be considered.

Symbol

Description

Applies to

HIGH PRESSURE, Relief pressure from

components before work is conducted.

The external components of the nitrogen generator which are:

•Valves;

•Hoses;

•PSA vessels.

DANGEROUS VOLTAGE,

Forbidden to work on the system if the

power is on.

All components that are connected to the control cabinet. Applied

voltages are:

•24V AC;

•25V DC;

•230V AC;

DANGER OF INHALATION,

danger of asphyxiation if breathing

high concentration of nitrogen.

Avoid the specified area to avoid health

hazards.

The nitrogen output connection. The mixture produced by the

nitrogen generator consists of 95% or more nitrogen. Inhalation

directly from the output connection may cause intoxication. The

nitrogen quickly mixes with the ambient air so that at a distance of

>0.5m from the nitrogen output connection it no longer poses a

health risk.

1.1.2 Working with the compressor

In order to work safely and responsibly with the compressor, it is recommended to read the maintenance manual of the respective

device carefully. Please also observe the hazard symbols and safety precautions. In addition to the symbols described in this

manual, the manufacturer may have used different symbols. When working on the compressor, the following hazards, which

generally apply to the compressors, must be taken into account.

Symbol

Description

Applies to

HIGH PRESSURE, Relief pressure from

components before work is conducted.

The external and internal components of the compressor which

are:

•Compressed air HP vessel;

•Tubing, filters, oil barrel;

•Compressor block.

OVERPRESSURE VALVE,

Be aware of the sudden relief of

overpressure.

The compressed air HP vessel which has an overpressure valve of

10 Bar. The overpressure valve can relief its pressure suddenly.

DANGEROUS VOLTAGE,

Forbidden to work on the system if the

power is on.

All internal components of the compressor. Applied voltages are:

•230V AC;

•380V AC.

MOVING PARTS AND ROTAGING FAN,

Risk of getting stuck or injuries to

limbs. Turn the machine off completely

before working on it.

All internal components of the compressor which consist out of

some rotating and moving parts.

For the precautions and safety instructions of the compressor, PRESSCON also refers to the enclosed

instructions of the compressor manufacturer. These can be found with the compressor or in the control panel

of the nitrogen generator.

Page 6 of 19

1.2 Description of general hazard symbols

In addition to the identified risks for the nitrogen generator and the compressor, the following symbols can also be applied. When a

hazard symbol is encountered, please observe its meaning carefully before further commencing the work.

Symbol

Description

Symbol

Description

1. OVERPRESSURE VALVE,

Be aware of the sudden relief of

overpressure.

7. HIGH PRESSURE,

Relief pressure from components before

work is conducted.

2. DANGEROUS VOLTAGE,

Forbidden to work on the system if the

power is on.

8. HOT PARTS,

Do not touch parts with bare hands. Use

heat-resistant clothing.

3. DANGEROUS TO INHALE GAS,

Avoid the specified area or wear appropriate

breathing equipment.

9. MOVING PARTS,

Risk of getting stuck or injuries to limbs. Turn

the machine off completely before working

on it.

4. NOISE,

Wear ear protection to prevent hearing

damage.

10. ROTATING FAN,

Risk of getting stuck or injuries to limbs. Turn

the machine off completely before working

on it.

5.MACHINE WITH AUTOMATIC START,

Machine stops and starts automatically when

it is operating normally. Turn off the machine

completely before working on it.

11. ATTENTION,

Special situation occurs, follow additional

instructions.

6. READ THE OPERATING AND MAINTENANCE

INSTRUCTIONS,

It is advised that the maintenance

instructions are read before continuing work.

Page 7 of 19

2System components

The N-Gen nitrogen generator consists of a nitrogen generator and a compressor. This chapter describes these components by

providing an illustration and numbering the most important parts. The compressor is not described because different brands can be

used that come with their own manual.

2.1 N-Gen nitrogen generator High Performance (H.P.) multi-f

Reset

2. 2.

10.

Figure 1. schematic illustration of the N-Gen High Performance nitrogen generator

Page 8 of 19

2.2 N-Gen nitrogen generator High Performance (H.P.) N-gen controller

14.

FX Prevent

12.

3. 3.

13.

11.

Figure 2. Schematic illustration of the N-Gen High Performance nitrogen generator

Page 9 of 19

14.

FX Prevent

12.

3. 3.

13.

11.

15.

16.

Figure 3. Schematic illustration of the N-Gen High Performance nitrogen generator

Page 10 of 19

Legend

Legend for the N-Gen nitrogen generator.

Ref. No.

Description

Function

Nitrogen output tube

Tube which puts out the nitrogen mixture that is produced by the nitrogen

generator. This outlet will be connected to the piping that runs to the pressure

vessel.

PSA vessels

High pressure vessels with active carbon inside. The Pressure Swing Adsorption

process takes place within these vessels.

PSA pressure gauges

0 –10 bar (0,0 –1,0 MPa) pressure gauges that indicate the pressure within the

PSA vessels. The left pressure gauge is for the left PSA vessel and the right

pressure gauge is for the right pressure vessel.

Digital nitrogen HP vessel

pressure regulator

Digital pressure switch with a start and stop steting. At default, the pressure

regulator will generate a start signal below 4.0 Bar. At 6.5 Bar, the signal will turn

off and the text on the display will turn green. If the pressure then drops below

4.0 Bar, the text on the display will turn red and a new start signal is generated.

Control cabinet

Control cabinet containing all the electronic components needed to manage the

nitrogen generator.

Compressed air regulator and

pressure switch

Composition of pressure control valve and pressure switch. The maximum air

pressure for the nitrogen generator is manually setup by adjusting the pressure

control valve. The pressure switch notifies the system if there is a pressure drop.

Compressed air inlet

Push-in connection that is used for connecting the compressor to the nitrogen

generator. This is commonly done with a 16mm nylon air hose.

PSA control manifold

A pneumatically controlled manifold block that regulates the flow of air and

nitrogen during the Pressure Swing Adsorption process.

Compressed air filters

2 filters that filter out dirt and moisture that comes with the compressed air.

10.

Reset button

Red button that lights up when the Multi-F controller receives a signal on its

External alarm input. By pressing the button an attempt can be made to reset the

alarm.

11.

Spring safety

Mechanical valve that releases the excess pressure from the nitrogen storage

tank. This protects the nitrogen storage tank against the creation of a pressure

higher than the design pressure of the tank.

12.

Nitrogen high-pressure vessel

connection

Pipe that blows out the nitrogen mixture produced by the nitrogen generator. This

connection is specially made for a high pressure storage tank.

13.

Touchscreen

The touchscreen is the main control device for reading the statuses and values of

the system. The touch screen is used for navigating and adjusting the settings.

14.

Oxysensor

Oxygen sensor that takes a sample of the nitrogen produced by the generator. By

measuring the sample, the Oxy sensor verifies that the generator is working

properly.

15.

PSA control valves

Electric valves controlled by the generator's controller. The valves provide

pneumatic control of the valves on the PSA control manifolds.

16.

Bekoguard

Switch that detects if humidity is present in the supplied compressed air.

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