Potter Nitrogen Generator - Complete Plumbing Source
Contents
1. 9 7 9 Tins tal At OM Dc asssss 10 WINDE E 11 220 Wiring 11 Start up 12 Start up 12 Filling PFOCeQUEG ore oe erret ee eere tp tee e aan taa AUR UTRUM xk Teatre ry SV 13 Filling Procedure 1 Air Filling Method i e a iden ER TREE EA EUREN 14 Operant O ty ashes E 15 16 Filer EE 17 NGP 220 Filter 17 Automatic Drain Cleaning 17 Desiccant Dryer 0 18 Nitrogen Analyzer 15 19 Automatic Calibration 19 Calibratino The N AIO VADE Si icis o aider a HG T E E A 19 Calibration Errors and Error Codes a aa m eene inrer entrent inneren rese nnne nnne 19 Changing the Batteries u nom nie E E a eU ER s aqa E Gn e E E ted bie u huq umu 20 Changing the Oxygen Sense eee eere e erm d Fe eek e Pre HR care UHR D Ped EXER Eae el eure YU 20 guum 22 23 Technical Specifications and 13 24 Technical Diagrams and Illustrations 2 entente tan2. PRESSURE VALVE STARTER SWITCHES 2 Psi Ps2 EXCESS AIR ASME T VEN RELIEVING SAFETY 4 PE VALVE ba is AMD i d AFTER TRAIN Em REFRIGERATED 3 VALVE STORAGE po S COOLER VALVE DRYER BYPASS FAM N2 UNIT COMPRESSOR Figure 2 Typical N Generator Unit Diagram BYPASS VALVE MEMBRANE check _QUTLET PRESSURE VALVE PRESSURE GAUGE FLOW GAUGE gt CONTROL L NITROGEN PRESSURE GAUGE m SHUT DUTLET 8 PRESSURE SANE REGULATOR INLET SHUT METERING FILTERS WITH VALVE VALVE DIFFERENTIAL NITROGEN MEMBRANE PRESSURE VENT AUTOMATIC GAUGE ES FLDAT DRAINS NITROGEN ANALYZER PERMEATE OUTLET CONDENSATE OUTLET Nitrogen generation is affected by four 4 variables Temperature Flow Rate Membrane Pressure and Vent Pressure POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 3 NGP 220 Unit Diagram PRESSURE GAUGE BLOCKING VALVE FLOW CONTROL VALVE ANALYZER CONNECTION PRESSURE RELIEVING VALVE ANALYZER OIL LESS COMPRESSOR j BLOCKING AFTER COOLER dere 6 T BYPASS COALESCING 6 VALVE COALESCING FILTER PRESSURE FILTER MANUAL SWITCH DESICCANT DRYER ORIFICE CHECK PRESSURE VALVE SWITCH ps4 SAFETY RELIEF DX VALVE TO SYSTEM
3. DWG 585 1 NITROGEN RECEIVER POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Section 3 Installation Instructions Initial Inspection Arrival Check all packages andcrates in shipment for damage If damage is found contact the carrier immediately and file a shipping damage claim with the carrier Make sure that all ordered parts were received If there are any missing parts call the shipping carrier immediately If there are any questions concerning the shipment contact Potter Electric Signal at 800 325 3936 Receiving compressor is inspected at the factory and packaged to protect against shipping damage When the Potter Nitrogen Generator is unpacked inspect for damage or missing parts Contact the shipping carrier to settle all claims Do not operate the Potter Nitrogen Generator if damaged during shipment handling or use Damage may result in bursting and cause injury or property damage Rigging amp Moving Only move the supplied equipment with the correct material handling equipment Always follow safety guidelines when moving the equipment Make sure they are secured correctly before moving Location amp Installation There are up to 4 items to be installed with each Potter Nitrogen Generator system depending on model Determine the best location for each item and install each as shown on the system layout diagram Figure 4 Typical System Layout NITROGEN STORAGE TANK
4. 2 2 7 COMPRESSOR 9 ELECTRICAL X 7 PANEL NITROGEN GENERATOR DWG 0400 2 CABINET Air Compressor Package Except NGP 220 Install the air compressor package on a level surface close to the nitrogen generator and nitrogen storage tank The air compressor package includes a dryer The exact location to the nitrogen generator and nitrogen storage tank isn t critical however electrical power is required for the air compressor package and could be a factor in determining the ideal location A dedicated 115 volt 15 amp electrical circuit is required for the air dryer The air compressor package should be permanently installed following the General Air Products air compressor manual provided POTTER NITROGEN GENERATOR 5403585 REV D 8 11 NOTICE Do not install the AIR COMPRESSOR PACKAGE in an area where ammonia sulfur dioxide hydrogen sulfide mercaptans chlorides chlorine oxides of nitrogen acid fumes solvent vapors and ozone vapors or similar contaminants exist The equipment can be damaged by ammonia and other vapors shortening membrane life Locate the air compressor package to make sure no vapors are drawn into the intake Avoid locations such as a loading dock where large amounts of exhaust fumes and smoke may enter the air intake Nitrogen Generator Install the Potter Nitrogen Generator in a clean dry location with ambient temperatures above 50 F at all times The generator unit s
5. 3 CLOSE NITROGEN VR INLET OUTLET VALVES NT NITROGEN STORAGE TANK DWG 0400 2 ELECTRICAL PANEL 12 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 The factory installed nitrogen purity analyzer can be monitored by pressing the power button The nitrogen purity analyzer monitors the purity of the nitrogen in the nitrogen storage tank The air compressor will have to cycle ON and OFF several times before the purity level in the tank stabilizes Purging of the tank by cracking the drain valve open slightly may be necessary to make the air compressor cycle ON and OFF When the tank nitrogen purity stabilizes to the desired level the Potter Nitrogen Generator is operational and ready for the fire protection system to be filled Table 1 Pressure Switch Factory Settings Compressor Compressor Cut IN Cut OUT PSIG PSIG wm s w owes x xem ox wem ef wem fe x Note Actual settings may vary due to performance required Filling Procedure There are two different methods for filling the system initially Air Filling Method and Nitrogen Filling Method Use the proper filling method based on system commissioning requirements If a test is performed on air supply capability restore normal pressure within 30 minutes per NFPA requirements Re
6. be construed as an admission by the Company that any product was not as warranted PROMPT DISPOSITION The Company will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within the warranty period Before returning any product write or call the distributor agent or authorized company from which the product was purchased describing defect and giving date and number of original invoice a well as proof of Factory supplied consumables and proof of scheduled maintenance Title and risk of loss pass to buyer upon delivery to the common carrier PRODUCT SUITABILITY Many States Localities and Countries have codes and regulations governing sales construction installation and or use of products for certain purposes which may vary from those in neighboring areas While General Air Products Inc attempts to assure that its products comply with such codes it cannot guarantee compliance and cannot be responsible for how the product is installed or used Before purchase and use of a product please review the product application and national and local codes and regulations and be sure that the product installation and use will comply with them 35
7. i A CONDENSATE DRAIN PIPE TO OIL 1 2 FNPT OXYGEN WATER SEPARATOR ENRICHED PERMEATE OUTLET PIPE TOA SAFE LOCATION 1 T G 2 0 6 1 DWG 0400 5 s AIR VENT L D ALL DIMENSIONS ARE 0 5 Fre noras 4o 2 5010 meme 20 se no 24 ss 20 72 24 19 40 1 4 c T5 Ce e ss 29 3 25 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 12 Compressor Refrigerated Dryer and Tank for NGP 200 weight 294 Ibs REFRIGERATED DRYER ELECTRICAL e gt x OUTLET ASME ELECTICAL SAFETY RELIEF CONNECTION VALVE NITROGEN 1 2 FNPT AIR OUTLET STORAGE TANK PIPE 2 GENERATOR AIR INLET COMPRESSOR PUMP 1 2 FPT INLET FROM GENERATOR OUTLET E COMPRESSOR MOTOR 33 0 1 0 TYP 360 1 2 DIA MOUNTING 1 2 MOUNTING HOLES HOLES DWG 0400 6 26 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 13 NGP 750 SOLO Packaged System weight 327 Ibs 3 4 MNPT NITROGEN QUTLET CONNECTION AIR COMPRESSOR PUMP 33 8 ELECTRICAL PANEL SEPARATOR CONDENSATE DRAIN Connection to riser shown for illustration purposes only Other system compon
8. recommends calibration on a weekly basis To serve as a reminder a one week timer is started with each new calibration At the end of one week a reminder icon appears on the bottom of the LCD Calibration is recommended if the user is unsure when the last calibration procedure was performed or if the measurement value is in question With compressed air 79 1 N new calibration is required when The measured percentage in 79 196 N is above 80 1 The measured N percentage in 79 1 N is below 78 1 The CAL reminder icon is blinking at the bottom of the LCD A simple calibration may be made with the sensor open to static ambient air Calibration Errors and Error Codes The nitrogen purity analyzer has a self test feature built into the software to detect faulty calibrations oxygen sensor failures and low operating voltage Refer to the following table for an explanation of error codes and possible actions to take 19 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Table 5 Error Codes Open the hand held nitrogen purity analyzer and disconnect and reconnect sensor Unit should perform an auto calibration and should read 79 1 If not contact Customer Service for possible sensor replacement No sensor attached Make sure unit has reached thermal equilibrium Press and No valid calibration data available hold the Calibration Button for three seconds to manually force a new calibration Battery bel
9. 5 SOLO 750 1150 2500 2500H 3100 N Purity Adjustable 95 99 Factory set at 95 nitrogen purity N Flow SCFM 0 5 0 3 1 4 1 4 2 0 3 5 6 8 10 1 13 6 Factory Set Output Pressure PSIG 100 125 125 125 110 110 125 100 125 Fill Capacity 95 2 at 40 PSI Gallons 41 27 125 125 190 325 600 850 1 200 Air Fill Capacity 0 40 PSI Gallons 220 200 415 750 750 1 150 2 500 2 500 3 100 Air Consumption SCFM 1 7 0 7 2 97 2 97 4 95 7 63 14 5 22 4 29 1 Dew Point of N P Delivered SOT Cae Ambient Temperature 50 F to 110 F 10 C to 43 Variable Description Air Purity ISO Class1 4 1 or better Free of water 38 F 3 C Dew Point compressor oil 0 008 PPM or 01 mg m3 hydrocarbons and particles 0 01 um microns Temperature Range 50 F 10 C to 110 F 60 C Recommended Inlet Temperature 95 100 F 35 38 C Pressure Maximum air pressure entering generator should not exceed 170 PSIG 24 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 10 Technical Diagrams and Illustration Figure 11 Nitrogen Generator Cabinet LIFTING EYE 2PLCS MODEL NGP 2500 INLET PRESSURE GAUGE AND LARGER ONLY AIR VENT MEMBRANE PRESSURE GAUGE 85 OUTLET PRESSURE GAUGE NITROGEN OUTLET PIPE TO N2 STORAGE TANK 1 ISOLATION VALVE BYPASS VALVE AIR INLET FROM COMPRESSOR PACKAGE 1 FILTER DIFFERENTIAL PRESSURE ISOLATION VALVE GAUGES 1
10. Potter Nitrogen Generator Installation Operation amp Service Manual Nitrogen Generator P POTTER cete Potter Electric Signal Company LLC St Louis MO Customer Service 866 240 1870 Technical Support 866 956 1211 Fax 314 595 6999 www pottersignal com Manual 5403585 D 08 11 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Table of Contents 10 4 Safety Guidelines iiss e Up pet eM UE E 4 portant to USErS u REI m 4 4 System D eSCTIDEI n au sssssssssssssesasssssssssssssesstssssssssssssvssssssesssessassssosssssssssssssssssssssssssssssessssssssessssssessssesssssssssssssssssos 6 8 Initial Inspection Arrival a a A aiaosa 8 hing epe EE 8 IPIE 8 Location amp Installation sor ob ero RO Ro rre o EIER CERE a egos ona ERR ERE Ee iini esee etd 8 0 8 Nitrogen Generator iiss ia cor aeo cp e yo REX ee ACER RE HERR URNA 9 Niro genra dotes tus aska 9 Refrigerated Dryer Separate for NGP 3 100 ONLY eene 9 NGP SPV Self Purging Valve
11. al of oxygen during the purge process The purge valve maintains system pressure during the purge process and prevents a system trip due to pressure loss The air vent in the NGP SPV automatically closes 1f water reaches the vent in the event of a alarm condition A plug is supplied to keep purge orifice free of debris when not in use A ball valve allows isolation of assembly when not surging to allow maintenance of strainer screen replacement of air vent or maintenance of purge orifice in the event it becomes clogged NGP 220 The NGP 220 includes a nitrogen storage tank oil less air compressor Nitrogen generator all mounted as one unit Install the NGP 220 by bolting the tank firmly to a level surface in a convenient location close to the fire sprinkler system connections Support the pipe to and from the tank independently POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Installation NOTICE Use back up wrenches when making connections or piping damage may occur piping connections must be independently supported and not impart stress on the components 1 For models NGP 415 750 1150 2500 and 2500H install piping from the air compressor package air outlet to the nitrogen generator air inlet For model NGP 3100 install piping from the air dryer outlet to the nitrogen generator air inlet Use 2 NPT pipe or larger If the compressor package was not ordered with the Potter Nitrogen Generator connect the nitrogen ge
12. dels NGP 1150 and NGP 2500 tank weight 198 16 1 4 COMPRESSION FITTING 9 9 CONNECTION i FROM COMPRESSOR 2 FPT CONNECTION 1 2 FPT INLET FROM N2 14 FPTVENT GENERATOR OUTLET 68 8 55 2 49 2 13 2 2 8 REF NOTE ALL DIMENSIONS ARE 0 5 31 3 4 FPT CONNECTION TO AIR MAINTENANCE DEVICE 2 FPT ALTERNATE CONNECTION 1 9 16 X 7 8 SLOTS 6 0 LOCATED 90 APART 17 DIAMETER CIRCLE 1 4 FPT DRAIN CONNECTION DWG 0400 11 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 20 120 Gallon 2 Tank Model NGP 2500H tank weight 325 165 1 2 FPT INLET FROM N2 GENERATOR OUTLET ASME SAFETY RELIEF VALVE 4 4 VENT PRESSURE GAUGE 1 4 COMPRESSION FITTING CONNECTION FROM COMPRESSOR 750 77 0 61 0 1 4 DRAIN CONNECTION 21 0 1 Y NOTE DIMENSIONS ARE 0 5 32 p 2 CONNECTION 3 4 FPT CONNECTION TO AIR MAINTENANCE DEVICE 1 4 FPT AUXILIARY CONNECTION 1 2 FPT AUXILIARY CONNECTION 2 FPT ALTERNATE CONNECTION 48 0 34 0 1 ALTERNATE CONNECTION 9 16 X 7 8 SLOTS LOCATED 90 APART ON A 21 DIAMETER CIRCLE 24 0 DWG 0400 12 POTTER NITROGEN GENERATOR 5403585 REV 8 11 ion 11 F r in 5400277 REV B Potter Nitrogen Generator Factory Settings NGP _ Date Code Order _ f _Oriice Size Purity M
13. ed Nitrogen Purity Sensor Replace Battery and Sensor Element annually Desiccant amp filters Replace annually Table 3 List of Service Parts Part Number Description 1119784 NGP SPV Nitrogen Self Purge Valve 1119785 NGP MK Nitrogen Maintenance Kit includes P N s 5130098 amp 5330157 5130098 Battery for NGP Nitrogen Sensor 2 batteries 5330157 NGP FLT Nitrogen Filter Cartridges 1 each of 4 amp 10 cartridges 5330014 Sensor Element for NGP 1119797 NGP DMK Nitrogen Maintenance Kit with Desiccant for the NGP 220 ONLY The nitrogen membrane has an estimated 10 year service free life provided the quality of input air listed under the Technical Specifications section of this manual are always met The hollow fiber membrane doesn t require any maintenance When the desired nitrogen purity cannot be obtained the membrane should be replaced 16 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Filter Replacement To replace the filters in the generator cabinet 1 N Loosen and remove copper tubing running from bottom of bowls to automatic float drains Unscrew the bowl from the filter body Remove the element by unscrewing the retainer at the bottom of the filter Be sure that the 10C10 050 filter in on the inlet left side and the 4C10 050 is to the right Clean filter body and bowl with a clean rag Reinstall filters and bowls be carefu
14. ee screws from the back of the device A 1 phillips screwdriver is required to remove these screws Once the screws are removed gently separate the two halves of the device The batteries can now be replaced from the back half of the case Be sure to orient the new batteries as indicated in the embossed polarity on the back case NOTE If the batteries are installed incorrectly the batteries will not make contact and the device will not operate Carefully bring the two halves of the case together while positioning the wires so they are not pinched between the two case halves The gasket separating the halves will be captured on the back case half Reinsert the three screws and tighten until the screws are snug Figure 4 The device will automatically perform a calibration and begin displaying of oxygen HELPFUL HINT If unit does not function verify that the screws are tight to allow proper electrical connection Changing the Oxygen Sensor Should the oxygen sensor require changing the device will indicate this by presenting Err lo on the display after initiating a calibration To change the oxygen sensor begin by removing the three screws from the back of the device A 1 Phillips screwdriver 15 required to remove these screws Once the screws are removed gently separate the two halves of the device Disconnect the oxygen sensor from the printed circuit board by pressing the unlock lever first and then pulliing the c
15. embrane Pressure TT 2 T 3 T 2 5 Riser Capacity L For 1609 Park 370 Place Hazelwood MO 63042 33 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 12 Maintenance and Purge L Table 9 Maintenance Log Initial Fill Post Purge N N Level N N Level Riser Location Date Time Level at at Purge Data Time Levelat at Purge Generator Valve Generator Valve Work Completed POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Section 13 Warranty Policy GENERAL PROVISIONS amp LIMITATIONS Potter Electric Signal Company LLC the Company warrants to each original purchaser Purchaser of its new products from the Company or its Authorized Distributor that such products are at the time of delivery to the Purchaser made with good materials and workmanship No warranty is made with respect to 1 Any product which has been repaired or altered in such way in the Companies judgment as to affect the product adversely 2 Any product which has in the Companies judgment been subjected to negligence accident improper storage improper installation or application 3 Any product which has not been operated or maintained in accordance with the recommendations of the Company 4 Components or acc essories manufactured warranted and serviced by others 5 Any reconditioned or prior owned product Claims for items described in 4 above should be
16. ents may be required 27 AMD 2 AIR MAINTENANCE DEVICE NITROGEN GENERATOR CABINET 1 2 FNPT PERMEATE OUTLET CONNECTION DWG 0400 7 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 14 NGP 220 Packaged System tank weight 175 Ibs NITROGEN CABINET OIL LESS COMPRESSOR NITROGEN STORAGE TANK DESSICANT AIR FILTER 47 9 16 diu B oo aie Wy CL TL 1 2 NPT OUTLET TYP 9 3 16 16 1 2 DWG 585 3 35 11 16 18 28 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 15 Compressor and Refrigerated Dryer all models except NGP 200 NGP 220 NGP 750 SOLO amp NGP 3100 A REFRIGERATED DRYER ELECTRICAL PANEL amp S CONDENSATE OUTLET ELECTRICAL CONNECTION 1 2 AIR OUTLET PIPE TO NITROGEN GENERATOR AIR INLET COMPRESSOR PUMP 1 4 O D COMPRESSION FITTING CONNECT TO N2 STORAGE TANK ASME SAFETY RELIEF VALVE 1 0 B 1 2 DIA MOUNTING HOLES 1 2 DIA MOUNTING HOLES DWG 0400 8 ALL DIMENSIONS ARE 20 5 38 2 36 0 gt s NGP 1150 NCP 1150 305 Ibs NGP 2500 NCP 2500 440 165 NGP 2500H NCP 2500 440 165 5 E 33 4 2 29 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 16 Compressor for NGP 3100 only Weigh
17. fer to Table 7 Potter Nitrogen Generator Performance Specifications for more information of using nitrogen or air 13 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Filling Procedure 1 Air Filling Method The Air Fill filling procedure for the Potter Nitrogen System no pressure in sprinkler piping or nitrogen storage tank can be used to test air supply capability to restore normal air pressure to the system within 30 minutes per NFPA requirements 1 2 3 4 5 6 7 Start refrigerated air dryer dryer should run 2 minutes before starting compressor Open the generator bypass valve Close the generator inlet and outlet valves Open all appropriate air maintenance device valves necessary to fill the sprinkler system Start air compressor Allow the sprinkler system to reach the desired pressure As soon as sprinkler system pressure is reached put the sprinkler system back into service by placing the air maintenance device in maintenance position refer to the air maintenance device manual for proper operation Returning the Generator Back into Service or Supervisory Pressure Only Installations Note It is recommended to use the nitrogen filling method to efficiently replace oxygen enriched air in the system with nitrogen Refer to the nitrogen filling method procedure in this manual To return the nitrogen generator to service 1 2 3 4 5 Close generator bypass valve Slowly open the genera
18. g p g 0 Symbol normal operation The calibration symbol is located at the bottom of the display and is timed to activate when a calibration 15 ON OFF ON OFF Key This This key is used to turn the device on or off ss is used to turn the device on or off Calibration K This key is used to calibrate the device Holding the key for more than three seconds will force the device to enter a calibration mode Calibration The device will assume a percent oxygen concentration when calibrating Be sure to apply 100 oxygen or ambient air concentration to the device during calibration or the device will not calibrate correctly Automatic Calibration After the unit is turned on it will automatically calibrate to room air The display should be stable and reading 79 1 To check the nitrogen concentration of a sample gas after the unit has been calibrated 1 Connect the Tygon tubing to the bottom of the analyzer by threading the barbed adapter onto the oxygen sensor 2 Attach the other end of the sample hose to the sample gas source and initiate flow of the sample to the unit at a rate of 1 10 liters per minute 2 liters per minute is recommended 3 Using the ON OFF key make sure the unit is in the power ON mode 4 Allow the nitrogen reading to stabilize This will take about 30 seconds or more Calibrating the N Analyzer Calibrate the analyzer upon initial power up Thereafter Maxtec
19. hould be leveled and anchored to the floor or wall with appropriate fasteners If the location 15 below freezing at any time the generator unit must be enclosed in a separate heated enclosure to keep the temperature above 50 F The nitrogen generator must be accessible at the front for servicing all major components inside the cabinet NOTICE Unless factory authorized no more than five 5 riser systems are to be connected to a single Potter Nitrogen Generator Exceeding the fill capacities can result in compressor run times that can shorten the compressor life Nitrogen Storage Tank Bolt tank firmly to a level surface in a convenient location close to the fire sprinkler system connections Support the piping to and from the tank independently Refrigerated Air Dryer Separate for NGP 3100 ONLY Install the refrigerated air dryer assembly on a level surface close to the air compressor assembly and nitrogen generator The intake port of the air dryer should be below the exhaust port of the air compressor after cooler Do not over elevate the dryer The distance between the air dryer and the air compressor isn t critical however a dedicated 115 volt 15 amp electrical circuit is required for the air dryer The air dryer should be permanently installed to the floor using appropriate fasteners NGP SPV Self Purging Valve Kit Install a purge valve assembly kit on each system in a tee prior to the inspector test valve to aid in remov
20. isassemble the nitrogen membrane separator Equipment damage may occur and cause the system to function incorrectly POTTER NITROGEN GENERATOR 5403585 REV D 8 11 The Potter Nitrogen Generator operates using membrane technology The smaller oxygen and water vapor molecules can pass through permeate the membrane quickly The larger nitrogen molecules are less likely to diffuse through the separator tubes therefore they continue downstream to the separator outlet The permeate molecules are discharged to atmosphere through a vent in the separator casing The Potter Nitrogen Generator is specifically designed to provide clean dry pure nitrogen for use in fire protection sprinkler systems The generator is a fully assembled package ready to be connected to a new or existing fire sprinkler system using either a factory pre engineered air compressor or an existing air source capable of providing the required air flow and air quality for the installation These turn key systems include all air filtration required to keep the generator operating at peak efficiency and most models come standard with pressure gauges and a nitrogen purity analyzer except NGP 220 Figure 1 Typical Complete System Diagram RELIEF
21. it must be read thoroughly and completely understood before installation and operation of the Potter Nitrogen Generator All appropriate safety standards for handling of gases as determined by local or national laws and regulations should be followed at all times Unpacking After unpacking unit carefully inspect all parts and equipment for any damage that may have occurred during transit Make sure to tighten fittings bolts etc before putting unit into service Do not operate unit 11 damaged occured during shipping handling or use Contact Potter immediately General Safety Information Important Read all of the safety information in this manual before operating this equipment Use of the equipment in a manner not specified within this manual may impair the protection provided by the generator and could result in an unplanned release of pressure which may cause serious injury or damage Only competent personnel who have been trained qualified and approved by Potter Electric Signal Company should perform commissioning servicing and repair procedures When handling installing or operating this equipment personnel must employ safe engineering practices and observe all related local regulations health and safety procedures and legal requirements for safety Ensure that the equipment is depressurized and electrically isolated before carrying out any of the scheduled maintenance instructions specified in this manual The warni
22. l not to switch bowls or filters and check for leaks NGP 220 Filter Replacement 1 do Unscrew bowl from filter body Remove the element by unscrewing the retainer at the bottom of the filter Replace filter elements with like sized elements from maintenance kit Clean filter body and bowl with a clean rag Reinstall filters and bowls be careful not to switch bowls or filters and check for leaks Automatic Drain Cleaning l px Remove drain piping and clamp securing automatic drains Remove and disassemble the drain Carefully clean the inside of the drain with a clean rag Reinstall drains Reinstall piping and pressure test the filters and piping for leaks Figure 9 Drain Assembly Details body cover orifice seal floating manuali drain discharge plastic data plate 542 7 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Desiccant Dryer Maintenance The only service required for silica gel units is when the desiccant color moisture indicator has changed from bright orange meaning dry to white meaning wet Should this color change occur 1 Turn off and depressurize the line containing the dryer unit 2 Loosen the clamp ring and remove the bowl from the top housing 3 Proceed to step 2 or 3 as desired Desiccant Replacement 1 Pour out used desiccant 2 Open new container and refill bowl 3 Shake or tap bowl to settle desicca
23. n concentration at Potter Nitrogen Generator Measure and record time date and nitrogen concentration at the purge valve assembly 18 If nitrogen level 15 9590 or greater at purge valve close purge valve to normal non purging position Normal Operation Nitrogen is generated by the Potter Nitrogen Generator from compressed air The generator 15 controlled by pressure controls that monitor the nitrogen pressure and automatically starts and stops the air compressor based on the control settings Occasional start and stop operation of the Potter Nitrogen Generator is normal Frequent start and stop operation more than 4 times per hour is not normal operation indicating service is required When the air compressor is not running the Inlet and Membrane pressure gauges will read 0 when the air compressor 15 not running Only the Outlet pressure gauge indicates pressure while the compressor is not running When the air compressor is running all three pressure gauges read pressure and typically show different pressure readings this is normal Note For the NGP 220 model only membrane and outlet pressure gauges are provided 15 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Section 5 Maintenance pressure must be relieved from the entire nitrogen generator system BEFORE servicing To avoid system damage and or personal injury the nitrogen generator should be isolated from the compressed air supply and the gene
24. nerator inlet air connection to a source of compressed air The air should be a minimum of 40 F pressure dew point and should be free of liquid oil and water see specification chart For Model NGP 220 follow steps 5 6 and 8 ONLY 2 Install piping minimum pipe from the nitrogen generator outlet to the nitrogen storage tank 3 Install piping from refrigerated air dryer and nitrogen generator condensate outlet connections to an appropriate drain location Follow local regulations when disposing of condensate Some local regulations may require an oil water separator Pipe the discharged air and water to a position where the it will not be a hazard to personnel 4 Install 4 copper tubing or equivalent from the PS 2 pressure switch compression fitting located on the air compressor assembly to the nitrogen storage tank 4 compression fitting Does not apply to NGP 220 amp NGP 750 SOLO model 5 Install gt NPT pipe or larger from the nitrogen storage tank outlet connection to the sprinkler system air maintenance device using standard accepted installation practices Use gt NPT pipe or larger 6 Install gt NPT pipe or larger from the air maintenance device to the sprinkler system using standard accepted installation practices Additional system components may be required 7 Install piping to membrane permeate outlet if required by local jurisdiction due to inadequate ventilation Adequate or outdo
25. ngs in this manual cover the most known potential hazards but by definition cannot be all inclusive If the user employs an operating procedure item of equipment or a method of working that is not specifically recommended by Potter Electric Signal Company the user must ensure that the equipment will not be damaged or become hazardous to persons or property POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Nitrogen is not a poisonous gas However in a concentrated form there 1s a risk of asphyxiation The generator produces a flow of nitrogen and oxygen enriched air which quickly disperses in the atmosphere However do not directly inhale the output gas from the outlet pipe The generator is classified as non hazardous for transportation purposes and as non flammable for fire regulations This equipment 15 for indoor use only Do not operate outdoors Operation of the nitrogen membrane separator above the rated design pressure may be hazardous Do not connect it to compressed air sources that can exceed its maximum rated pressure without installing appropriate pressure controls and safety relief devices in the compressed air supply line Specific procedures must be developed for maintenance of the equipment on which the membrane separator is located Appropriate labels must be continuously displayed in all areas where personnel might be exposed to a nitrogen atmosphere under normal or upset conditions NOTICE Do not attempt to d
26. nt Fill bowl to 1 8 below inner step 4 Dispose of desiccant according to local codes Desiccant Regeneration 1 Pour out used white desiccant onto flat pan Place desiccant in 350 F oven for approximately three hours or until the desiccant color has changed back to bright orange 2 Remove desiccant from oven and allow it to cool to ambient temperature 3 Pour desiccant back into unit bowl periodically shaking and tapping to settle the desiccant Replace bowl bowl guard and clamp onto unit Be sure clamp ring is securely locked in place before re pressurizing the unit Important Note Please replace color change label blue to pink currently on your dryer assembly with the new color change label orange to white included with kit 18 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 6 Nitrogen Analyzer Instruction Table 4 Nitrogen Analyzer Features The 3 digit liquid crystal display LCD provides direct readout of nitrogen concentrations in the range of 0 105 0 100 1 105 0 used for calibration determination purposes The digits also display error codes and calibration codes as necessary 3 Digit Display The low battery indicator is located at the top of the display and is only activated when the Low Battery Indicat voltage on batteries is below a normal operating level The sign is located to the right of the concentration number and is present durin g
27. on the AMD for the riser s being commissioned releasing nitrogen into the system pe c D ge p Allow the nitrogen generator to run for 30 minutes with the Inspectors Test Valve open pumping nitrogen into system and forcing air out The Potter Nitrogen Generator creates 30 to 40 oxygen stream which may pose 8 flammability problem in an oxygen sensitive environment Pipe per installation requirements and ensure the area surrounding the Nitrogen Generator 15 adequately ventilated The Potter Nitrogen Generator should always be installed in an adequately ventilated room Nitrogen 15 nontoxic and largely inert Rapid release of nitrogen gas into an enclosed space displaces the oxygen and can cause an asphyxiation hazard Inhalation of nitrogen in excessive concentrations can result in unconsciousness without any warning symptoms 10 After 30 minutes of nitrogen flush close the Inspectors Test Valve for the riser being commissioned 11 Place AMD into maintenance position and allow riser to fully pressurize 12 After riser has fully pressurized restore water supply to riser 13 Record time date and nitrogen concentration at Potter Nitrogen Generator 14 Record riser location time date and nitrogen concentration at the purge valve assembly 15 Flush and pressurize each additional riser repeating steps 7 15 16 Open the NGP SPV purge valves s 17 In 2 weeks Measure and record time date and nitroge
28. onnector out of the receptacle The oxygen sensor can now be replaced from the back half of the case HELPFUL HINT Be sure to orient the new sensor by aligning the red arrow on the sensor with the arrow in the back case A small tab is located on the back case that 1s designed to engage the sensor and prevent it from rotating within the case Figure 5 NOTE If the oxygen sensor is installed incorrectly the case will not come back together and the unit may be damaged when the 20 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 screws are reinstalled Reconnect the oxygen sensor to the connector on the printed circuit board Carefully bring the two halves of the case together while positioning the wires to ensure they are not pinched between the two case halves Make sure the sensor is fully inserted and in the proper orientation Reinsert the three screws and tighten until the screws are snug Verify the unit operates properly The device will automatically perform a calibration and begin displaying of oxygen 21 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 7 Tr leshootin Table 6 Troubleshooting Anaya Elo conte sins Open analyzer flow control valve 1 16 turn from closed Nitrogen Flow control open too far Close flow 4 MtG Pos increments to achieve desired purity level Nitrogen percentage too low Membrane Diesel Observe Membrane pressure while operating Consult factory for
29. ons An independent 115 volt 15 amp circuit is required for the air dryer Install electrical disconnect switches for both the compressor and the refrigerated air dryer All wiring should conform to NEC and applicable local standards NGP 220 Wiring Install electrical disconnect switch for the air compressor The sole electrical connection is to the pressure switch mounted closest to the nitrogen cabinet door This pressure switch is pre wired to the second pressure switch mounted on the tank All wiring should be performed by a licensed electrician and conform to NEC and all applicable local standards Figure 7 NGP 220 Wiring Diagram LINE MOTOR LINE MOTOR 6 o M COMPRESSOR MOTOR PS 2 PS 1 COMPRESSOR TANK PIPING LINE MOTOR 7 8 NEUTRAL p LINE MOTOR 5 2 PS 1 DWG 4585 2 GROUND 4 11 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 4 Start up an ration Start up Procedure Before beginning start up procedure make sure the water supply is turned off 1 10 11 12 Make sure all piping connections have been made according to installation instructions Before powering up Potter Nitrogen Generation compressor check all piping connections for leaks Close all air maintenance device valves Fully open the generator bypass valve Fully close the nitrogen generator inlet and outlet valves Power the ai
30. or ventilation may be required by local jurisdiction Figure 5 Typical System Layout REFRIGERATED RYER TORISER DWG 0400 3 1 NITROGEN GENERATOR CABINET NITROGEN STORAGE TANK ELECTRICAL PANEL 8 Install a NGP SPV on each riser in a tee prior to the inspector test valve The purge valve assembly requires a male 2 NPT connection at installed tee After installation close ball valve prior to initiating test or purging process The ball valve should only be opened when purging the system A 7 plug is installed in the orifice which requires removal during purge process Plug should be installed in orifice when purging process is not being performed to keep orifice free of debris and buildup POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 6 NGP SPV Installation Diagram ru 11 PIPE FROM SPRINKLER SYSTEM 1 2 TEE CONNECTION AND CLOSE NIPPLE SUPPLIED BY SPRINKLER CONTRACTOR PURGE ORIFICE N2 SAMPLING PORT PEL PLUG INSTALL AFTER NC PURGE COMPLETE REMOVE PLUG WHEN SAMPLING Nz LEVELS UNION POSITION VENT ORIFCE APPROPRIATELY PURGE BALL VALVE SHOWN IN NORMAL NON PURGE POSITION INSPECTOR S TEST DWG 0400 13 Wiring Refer to General Air Products air compressor manual and refrigerated air dryer manual for wiring instructi
31. ow minimum operating voltage Replace batteries Wait for displayed nitrogen reading to stabilize when calibrating the device at 10096 oxygen Wait for unit to CAL Err St O2 Sensor reading not stable reach thermal equilibrium Please note that this can take up to one half hour if the device is stored in temperatures outside the specified operating temperature range Press and hold the Calibration Button for three seconds to manually force a new calibration If unit repeats this error more than three times contact Customer Service for possible sensor replacement CAL Err lo Sensor voltage too low Press and hold the Calibration Button for three seconds to manually force a new calibration If unit repeats this error more than three times contact Customer Service for possible sensor replacement CAL Err Bat Battery voltage too low to recalibrate Replace batteries Changing the Batteries CAL Err hi Sensor voltage too high When the batteries need to be changed the device will indicate this in one of two ways The battery icon on the bottom of the display will begin to flash This icon will continue to flash until the batteries are changed The unit will continue to function normally for approx 200 hours If the device detects a very low battery level an error code of E04 will be present on the display and the unit will not function until the batteries are changed To change the batteries begin by removing the thr
32. r compressor system ON and check all piping connections for leaks refer to Figure 6 Make sure the compressor has the proper amount of oil except NGP 220 DO NOT oil the NGP 220 Check that electrical connections to the air compressor and refrigerated air dryer 1f applicable have been made according to installation instructions Turn the refrigerated air dryer ON for at least 2 minutes before starting the compressor if applicable If filling the system with air follow Filling Procedure 1 If filling the system with nitrogen follow Filling Procedure 2 Turn the air compressor OFF and vent the entire nitrogen generator piping system by opening the nitrogen storage tank drain valve Close the nitrogen storage tank drain valve Fully open the generator inlet valve and outlet valve Close the bypass valve Power the air compressor system ON Monitor the inlet membrane and outlet pressure gauges Refer to Figure 6 Note for the NGP 220 unit monitor the membrane and outlet gauge only The outlet pressure builds until it reaches compressor cut off pressure and the compressor automatically turns off When the outlet pressure falls below the cut in pressure the air compressors automatically turn on Refer to Table 1 for Cut in Cut out pressures Figure 8 Leak Check Valve Location Diagram CHECK FOR LEAKS AIR MAINTENANCE EVICE CLOSE ALL VALVE REFRIGERATED RYER OPEN GENERATOR BYPASS VALVE FOR LEAKS
33. rator system fully depressurized before any maintenance or service is performed All maintenance and troubleshooting activities for the Potter Nitrogen Generator should be performed by qualified personnel using reasonable care Before servicing isolate all risers by closing all AMD valves and relieving all system pressure from the Potter Nitrogen Generator Failure to do so could result in serious injury or death The Potter Nitrogen Generator features durable components and construction for long lasting value reliable performance and require little maintenance The air filter and oil in the compressor require quarterly inspection replacement The filters in the generator enclosure and batteries for Nitrogen Purity Analyzer require yearly replacement Check the performance and operating conditions of the Potter Nitrogen Generator This includes e Verifying stable pressure readings on all pressure guages Confirming the filter differential pressure gauges read in the green zone when the air compressor is running Confirming that operating pressure settings are correct Refer to Table 7 The following table shows the scheduled maintenance required on the Potter Nitrogen Generator Table 2 Scheduled Maitenance Table Part Frequency Filters Replace annually or as differential pressure indicates Compressor Oil Repl rterl not applicable to the NGP 220 Automatic Drains Clean annually or as requir
34. rounding the Nitrogen Generator is adequately ventilated The Potter Nitrogen Generator should always be installed in an adequately ventilated room Nitrogen is nontoxic and largely inert Rapid release of nitrogen gas into an enclosed space displaces the oxygen and can cause an asphyxiation hazard Inhalation of nitrogen in excessive concentrations can result in unconsciousness without any warning symptoms 14 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Filling Procedure 2 Nitrogen Filling Method The Nitrogen Fill Filling Procedure for the Potter Nitrogen System no pressure in sprinkler piping or nitrogen storage tank Make sure that water supply to the sprinkler system is off before starting this procedure Note This filling method is NOT recommended for the NGP 220 Make sure water supply to the riser is off Make sure the NGP SPV purge valve assembly is in the closed non purging position Open the Inspectors Test Valve On all risers in the system that are being commissioned Make sure that AMD valves on all riserse to the system are closed in order to isolate nitrogen generator tank Start the refrigerated air dryer Run the refrigerated air dryer for 2 minutes before starting compressor Start the generator compressor if it is not already running Make sure the nitrogen generator is not bypassed Wait for nitrogen storage tank to reach full pressure and compressor to shut off Slowly open bypass valves
35. setting procedure Replace or dry Membrane by purging nitrogen tank purge manual drains on automatic drains clean drain if excessive water is released from manual drain pecia be normal nearing the end of a filling Nitrogen Flow control closed too far Open flow control until purity level 1s reached Nitrogen Percentage too high Defective check valve Replace check valve Filters clogged Replace filters Close bypass valve open nitrogen outlet and air Bypass valve open inlet valves Press reset button check for power and function Compressor not starting No Pressure Low pressure of pressure switches Open the nitrogen analyzer and disconnect and Analyzer Error E02 No sensor attached 8 y reconnect sensor Defective or wet Nitrogen Membrane 22 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 tion 8 Nitrogen Generator Parts Diagram Figure 10 Nitrogen Parts Diagram 23 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Section 9 Technical Specifications and Drawings Table 7 Potter Nitrogen Generator Performance Specifications Nitrogen flow and air consumption are based on factory pressure settings Refer to Section 11 Factory Settings for system specific settings Table 8 Requirement for Compressed Air Supplied to Generator Model NGP NGP NGP NGP 750 NGP NGP NGP NGP NGP ope 220 200 41
36. submitted directly to the manufacturer WARRANTY PERIOD The Company s obligation under this Warranty is limited to repair or at its option replacing during normal business hours at the designated facility of the Company any part that in its judgment proved not to be as warranted within the applicable Warranty Period as follows COMPONENTS non consumable components are warranted for 12 months from the date of purchase Consumables are not covered under warranty The unit must have been installed by either a factory authorized distributor or agent in accordance with the factory recommendations taking into account all other local site conditions not originally noted to the factory The unit must be operated and maintained in accordance with the Factory recommendations and original design conditions Failure to provide such proof of the above may void warranty LABOR TRANSPORTATION amp INSPECTION The Company will repair or replace any product or part thereof which in the Companies judgment is proved to be not as warranted Labor costs are not covered under warranty costs of transportation of product labor or parts claimed not to be as warranted and of repaired or replaced parts to or from factory shall be borne by purchaser The Company may require the return of any part claimed not to be as warranted to one of its facilities as designated by the Company transportation prepaid by Purchaser to establish a claim under this
37. ta atta sense tasa tasses seta seta sense sans eins ea s tasto senno 25 Factory Settings 33 Maintenance and Purge Log wscciccsssssscessssssescssassosssssnsascessessescsessssscasisnsssonds sovessesasasconstusessdeosesodsesseascedasoaea s eonseceessessssseas 34 Warranty Polley uay asqanuhaakawaasqasiiaqysqakyqwasqiayayaaasaasiysaqasasuypiayyaqyhuiuayakuayysnuistassy aqusysquwss 35 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Section 1 Safety Safety Guidelines This manual contains safety information that 15 important to know and understand This information is provided for for the safety of installers operators and users of the Potter Nitrogen Generator as well as equipment To help recognize this information observe the following symbols Danger indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury Warning indicates a potentially hazardous situation which 1f not avoided COULD result in death or serious injury Caution indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury NOTICE Notice indicates important information that if not followed may cause damage to equipment or property Important Notice to Users The Installation and Owner s Manual supplied with each un
38. tor inlet valve Slowly open generator outlet valve Open the Purge Ball Valve to place it in the purge position While the air compressor is running monitor the nitrogen generator Inlet and Membrane pressures Pressure readings should be similar The air compressor should automatically cycle OFF when the nitrogen storage tank pressure reaches the compressor cut out pressure After at least 10 air compressor cycles ON OFF check the nitrogen purity at the nitrogen purity analyzer by pressing the ON button To efficiently increase cycle times relieve pressure in storage tank by opening and closing the storage tank vent The purity level in the storage tank should be stabilized however it may be necessary to run the generator for more cycles to reach the factory set purity level Turn off analyzer after use Periodically check the nitrogen purity level of the sprinkler system at the NGP SPV purge valve assembly using a nitrogen analyzer or a portable oxygen analyzer Refer to Section 6 for nitrogen purity analyzer instructions Continue purging using the installed purge valve assembly until acceptable nitrogen levels are reached to achieve maximum corrosion protection Close the purge valve after desired nitrogen purity level is achieved The Potter Nitrogen Generator creates 3096 to 4090 oxygen stream which may pose a flammability problem in an oxygen sensitive environment Pipe per installation requirements and ensure the area sur
39. ts Model No NGP 3100 555 Ibs 91 Ibs 1 4 O D COMPRESSION FITTING CONNECT TO N2 STORAGE TANK COMPRESSOR ELECTRICAL PANEL 14 0 1 2 DIA MOUNTING HOLES 26 5 ASME SAFETY RELIEF 33 0 VALVE 10 HP MOTOR FLEX HOSE 1 2 MNPT CONNECT TO DRYER INLET 38 0 2 1 2 DIA MOUNTING HOLES 44 0 Figure 17 Dryer for NGP 3100 only ELECTRICAL INLET 20 9 C 20 0 244 AIR OUTLET 1 2 FNPT 1 AIR INLET 15 8 gt 1 2 CONDENSATE 0 3 DWG 0400 9 OUTLET NOTE ALL DIMENSIONS ARE 10 5 30 POTTER NITROGEN GENERATOR 5403585 REV D 8 11 Figure 18 30 Gallon N2 Tank Models NGP 415 and NGP 750 tank weight 85 Ibs ASME SAFETY RELIEF VALVE _ PRESSURE GAUGE 40 8 1 ry 2 8 REF 1 4 COMPRESSION FITTING CONNECTION FROM COMPRESSOR CONNECTION 4 4 VENT 1 2 FPT INLET FROM GENERATOR OUTLET 1 434 ALTERNATE 1 1 2 CONNECTION 1 25 1 1 4 DRAIN CONNECTION 12 6 NOTE ALL DIMENSIONS ARE 30 5 ALTERNATE 1 1 2 FPT 3 4 FPT CONNECTION TO AIR MAINTENANCE DEVICE 31 1 9 16 X 7 8 SLOTS LOCATED 90 APART ONA 15 DIAMETER CIRCLE DWG 40400 10 ASME SAFETY RELIEF VALVE PRESSURE GAUGE 63 0 Figure 19 80 Gallon Tank Mo
40. warranty Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components Rev 6 2011 DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED OR STATUORY INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE EXCLUSIVE AND ONLY REMEDY AVAILABLE TO THE PURCHASER AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIALDAMAGES EXPENSES LOSSES OR DELAYS HOWSOEVER CAUSED No statement representation agreement or understanding oral or written made by any agent distributor representative or employee of the Company which is not contained in this Warranty will be binding upon the company unless made in writing and executed by an officer of the Company This warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed not to have been as warranted Any action for breach of this warranty must be commenced within one year after the date upon which the cause of action occurred Any adjustment made pursuant to this warranty shall not
Download Pdf Manuals
Related Search