TDI NITRO-GEN® Nitrogen Generator - Operating Instructions

Quick Start Guide

• Read and keep the supplied user guide in a convenient location for future use (a hard copy user guide is provided with every NITRO-GEN purchase).  Make this user guide available to all operators of the nitrogen generator.
• If any statement or specification in this user guide (especially with regard to safety) does not agree with legislation or standard industry practices, the more demanding directive shall apply.
• Direct any nitrogen vented from the generator to the outside of your facility so that it does not displace the air in the room and cause suffocation.
• You must employ federal, state, local and your plant's safe working practices and rules when operating this generator.
• The owner is responsible for maintaining the generator in a safe operating condition.
• Materials that you use to maintain, assemble, and connect the generator to supporting equipment should be rated and approved for use at the pressures generated by the generator.
• The generator remains pressurized after shutdown.  Before performing maintenance, filter changes, or opening piping, you must depressurize the system.  Depressurizing the system prevents the uncontrolled escape of high-pressure gas and possible injury.  You must wear eye and hearing protection during the depressurizing process to avoid possible injury.
• Follow your plant's lockout program before performing maintenance on the generator.
• Only trained maintenance technicians who are familiar with high-pressure air systems and who have read this user guide should perform maintenance on the generator.
• Wear personal protective equipment when in the proximity of the system.
• Never allow high-pressure gas to exhaust from an unsecured hose.  An unsecured hose my whip around and cause serious injury.  If a hose should burst during use, immediately close all isolation valves.
• Never disable or bypass any pressure or safety valve on the generator.

1. Inspect the container for damage. If "Tip-N-Tells" are on the container, verify tat they have not been triggered.  If triggered, notify the carrier immediately.

2. Open the container and inspect it for damage that may have occurred during transit.  If you observe damage, notify the carrier immediately.

3. Check the components against the packaging list.  If components are missing, contact TDI International, Inc. and provide the model number and the serial number of your unit.

4. Remove all packaging materials prior to operating the generator

• Remove any shrink and bubble wrap from the piping, valves, control panel, lock out / tag out electrical box, etc.
• Be sure that no loose parts are in the cabinet.  Secure the cabinet doors.

5. Save all packing supplies in case the equipment needs to be returned during warranty period.

Standard Equipment

• TDI NITRO-GEN® Membrane Nitrogen Generator
• (2) AA Batteries (packed in documentation folder)

Documentation

• Nitrogen generator quick start guide
• Nitrogen generator user guide

You should locate the nitrogen generator indoors and maintain an ambient air temperature around the unit of above 33ºF (0.5ºC) at all times.  The humidity of the location can range from 0-95% humidity, non-condensing.  Allow sufficient space around the generator to: a) install vent piping and access pipe connections, and b) perform maintenance.

The ground area you select as a location should be flat and stable.

Compressed Air Supply Requirements

Virtually any commercial air compressor is compatible with the NITRO-GEN® as long as it meets the compressed air supply requirements.

The compressed air entering the generator should be a approximately 70ºF (21ºC) to meet the output specification.  The generator can, however, function between 50 and 130ºF (10-55ºC) if required, though the output will vary accordingly.  The dew point of compressed air supplied to the generator must be 40ºF (5ºC) or lower.

Compressed air not meeting this dew point requirement can damage the generator and will void the warranty.  Air at temperatures higher or lower than this may cause damage not covered by the warranty.  The use of a correctly sized air dryer can ensure that the compressed air supply meets the dew point requirements.

NOTE - A compressed air receiving tank may be necessary to provide a reserve of compressed air to meet the fluctuating demands of the nitrogen generator.

NOTE - The use of a correctly sized air dryer can ensure that the compressed air supply meets the dew point requirements.

Inlet Air Pressure and Volume Requirements

The inlet air pressure requirement is 100 PSI for all NITRO-GEN® models.  If your inlet air pressure is not equal to the requirement, the nitrogen output may be above or below the system's design capability.  Inlet air pressures higher than the maximum allowable working pressure (MAWP) will damage the nitrogen generating system and void the warranty.  In addition, a given model will consume more or less compressed air depending on the desired nitrogen purity and flow rate. 

Adjustment for Altitude

Add 1% tot he feed air consumption requirement for every 300 feet above sea level.

Adjustment for Length of Air Supply Piping

The air supply piping must supply the required volume of feed air at the required pressure as measured at the generator inlet connection.  If the supply piping from the compressed air receiving tank to the generator is greater than 50 fee, increase the air supply line with one standard NPT size larger than the generator inlet size (Table 1).

Table 1. Standard NPT Pipe Sizes:

Nitrogen Output Piping Requirements

Nitrogen output piping should be the same size as the nitrogen discharge piping on the generator.  If the length of the output piping connecting the generator to your process is greater than 50 feet, use piping one standard NPT size larger than the generator output line (Table 1).

2. Install batteries for the oxygen analyzer.

3. Install any supporting equipment (including air compressor, booster, air dryer or receiving tanks) according to the manufacturer's recommendations.

4. Have a qualified pipefitter install suitable piping from:

• The compressed air supply to the inlet of the nitrogen generator.
• The nitrogen generator outlet to your process.
• NOTE - use of piping sizes smaller than the recommended size will significantly decrease system performance and void the warranty.

5. Any tanks that you use in conjunction with the generator should be fitted with applicable pressure safety valves.

Start the air compressor per the manufacturer's instructions before starting the nitrogen generator.  Be sure that all valves from the air compressor to the generator inlet are open.

A - Set Valves to Pre-Start Positions

• Be sure the main shutoff (compressed air inlet) valve is closed.
• Turn the start-up purge control valve to the start-up purge position.
• Turn the calibration control valve to the normal operation position.

B - Begin Flow Through the Generator

• Slowly open the main shutoff (compressed air inlet) valve.
• Turn the inlet control valve to the on position.
• Be sure the inlet pressure regulator is set to the specification.  (The pressure is read at the gauge above it.)

C - Monitor the System Purity and Flow

• Adjust the outlet flowmeter to the design specification.  Turn clockwise to reduce flow (counter-clockwise to increase).
• After 3 minutes, turn the start-up purge control valve to the normal operation position
• Press the power button ( ) on the oxygen analyzer.  Watch for the display to stabilize.
• NOTE: If this is your first time starting the unit (or if it has come out of storage or been moved from a different elevation) calibrate the analyzer as follows:
• Turn the calibration control valve to the calibrate position.
• After 3 minutes, press the analyzer calibration button ( ).  It will display 20.9%.
• Turn the calibration control valve to the normal operation position.
• Monitor the purity of the nitrogen at the oxygen sensor display.  Subtract the value from 100 to determine purity of the nitrogen output.
• Adjust the outlet flowmeter to the desired output.  Nitrogen purity will increase as flow in reduced.
• Turn clockwise to reduce flow and oxygen content (counter-clockwise to increase flow and oxygen content.)

NOTE - When power is restored after a power failure, the generator automatically resumes operation.

2. Turn the inlet control valve to the off position.

3. Turn the start-up purge control valve to the off position.

4. Turn the calibration control valve to the off position.

5. Press the power button ( ) on the oxygen analyzer.

6. Stop the compressor.

1. Wear eye and hearing personal protection equipment.

2. Close the main shutoff (compressed air inlet) valve.

3. Turn the inlet control valve to the on position.

4. Turn the start-up purge control valve to the start-up purge position.

5. Be sure the inlet pressure gauge reads zero.

6. Turn the inlet control valve to the off position.

7. Turn the start-up purge control valve to the normal operation position.

Phone: (520) 799-8000 | Email: sales@tdiinternational.com  © Copyright 2000-2012 TDI International, Inc.

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