Parker Nitrogen Generator NGC-0001 / NGC-0002 / NGC-0005

Transcription

1 Parker Nitrogen Generator NGC-0001 / NGC-0002 / NGC-0005 Installation, Operation and Maintenance Manual Bulletin TI-NGC

2 Retain this user guide for future reference.

3 CONTENTS 1 Safety Information Markings and symbols Description Technical Specification Dimensions Unpacking the equipment Overview of the equipment Installation & Commissioning Recommended System Layout Locating the equipment Wall mounting the generator Storage Tank Installation Electrical Installation Operating the equipment Starting the equipment Shutting down the equipment Maintenance Annual Filter Service Requirement Filter Replacement Troubleshooting Process & Instrumentation Diagram / Electrical Parker Hannifin Corporation

4 1 Safety Information Important: Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all personnel concerned. Use of the equipment in a manner not specified within this user guide may impair the protection provided by the generator and could result in an unplanned release of pressure, which may cause serious personal injury or damage. Only competent personnel trained, qualified, and approved by Parker Hannifin should perform commissioning, service and repair procedures. When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related local regulations, health & safety procedures, and legal requirements for safety. Ensure that the equipment is depressurized and electrically isolated, prior to carrying out any of the scheduled maintenance instructions specified within this user guide. Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures. Accidents can be avoided by recognizing that any machinery is potentially hazardous. Parker Hannifin can not anticipate every possible circumstance which may represent a potential hazard. The warnings in this manual cover the most known potential hazards, but by definition can not be all-inclusive. If the user employs an operating procedure, item of equipment or a method of working which is not specifically recommended by Parker Hannifin the user must ensure that the equipment will not be damaged or become hazardous to persons or property. Nitrogen is not a poisonous gas but, in a concentrated form, there is a risk of asphyxiation. The generator produces a flow of nitrogen and 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. Any fire should be fought by means appropriate to the material causing the fire with the exception being the use of water. Note: Any interference with the calibration warning labels will invalidate the gas generator s warranty and may incur costs for the re-calibration of the gas generator. This equipment is for indoor use only. Do not operate outdoors. 1.1 Markings and symbols The following markings and international symbols are used on the equipment and within this user guide: Caution, Read the User Guide. Highlights actions or procedures which, if not performed correctly, may lead to personal injury or death. Highlights actions or procedures which, if not performed correctly, may lead to damage to this product. Highlights actions or procedures which, if not performed correctly, could lead to electric shock. When disposing of old parts always follow local waste disposal regulations. Highlights information relevant to an operating procedure or process. DANGER Disconnect the mains supply before removing this cover. NITROGEN (N 2 ) NITROX DO NOT BREATHE Asphyxiant in high concentrations. No odor. Slightly lighter than air. Ensure adequate ventilation. Breathing 100% nitrogen will produce immediate unconsciousness and death due to lack of oxygen. NON-FLAMMABLE COMPRESSED GAS MAX PRESSURE 10barg (145 psi) Use only with equipment compatible with this pressure. 4 Parker Hannifin Corporation

5 2 Description The Parker Nitrogen Generator is designed to provide a constant supply of nitrogen gas, at a pre-selected purity, flow, and pressure, as specified in section 2.1 below. The system uses proven Pressure Swing Adsorption (PSA) technology with a Carbon Molecular Sieve (CMS) to separate N 2 from the atmosphere and store it at a high purity level. This user guide contains all of the information necessary for the correct use of the Parker Nitrogen Generator range. Should you have any queries regarding the safe and correct installation, operation or maintenance of the generator, contact the supplier before proceeding. 2.1 Technical Specification This specification is valid when the equipment is located, installed, operated, and maintained as specified within this user guide. High Purity Nitrogen (N 2 ) Outlet flow Maximum outlet pressure Units NGC-0001 NGC-0002 NGC-0005 cfm (l/min) barg (psi g) Purity % Mechanical connections Nitrogen Outlet (1) 7 (101.5) 0.07 (2) 7 (101.5) >99.8 (<0.1% O 2 ) 1/4 NPT (5) 9.5 (137.8) Electrical data 115v Connection Type IEC320 Supply Voltage Range * V ac 115v 1 phase + PE 50/60Hz Supply Voltage Fluctuation ± 10% Current A A Fuse Anti Surge (T), 250v, 5 x 20mm Breaking Capacity 10 UL Listed) 230v Connection Type - - IEC320 Supply Voltage Range * V ac v 1 phase + PE 50/60Hz Supply Voltage Fluctuation - - ± 10% Current A Fuse A Anti Surge (T), 250v, 5 x 20mm Breaking Capacity UL Listed) Environmental data F Temperature ( o C) (2 35) 40 o C Humidity (80% MAX 31 o C) IP Rating IP20 / NEMA 1 Pollution Degree 2 Installation Category II m < 2000 Altitude (ft) (6562) Noise db(a) <65 5 Parker Hannifin Corporation

6 2.1.1 Dimensions 2.2 Unpacking the equipment This generator is heavy and must not be manually lifted. Remove the equipment from its packaging, check that it has not been damaged in transit and verify that the following items have been included with your equipment: Description Qty Wall bracket assembly 1 Power supply cable 1 If any items are missing or damaged please contact your Parker representative. 2.3 Overview of the equipment 6 Parker Hannifin Corporation

7 3 Installation & Commissioning Do not install this equipment until the following instructions have been read and understood by all personnel concerned. Before continuing with the installation and commissioning of this equipment ensure that it is correctly sized for the inlet pressure and application and that the electrical supply voltage and frequency meet the requirements detailed within this specification and on the equipment rating plate. 3.1 Recommended System Layout 3.2 Locating the equipment The generator should be located indoors, either on a flat surface or mounted to a wall, and be protected from direct sunlight, moisture, and dust (Refer to section 2.1 of this user guide for the generator s environmental specification). When considering the final location of the generator ensure that: The generator is positioned within easy access of the electrical supply. There is adequate space available around the generator for maintenance access and lifting equipment. Consideration has been made of the noise generated by the generator when in use. DO NOT Position the generator so that it is difficult to operate or disconnect from the electrical supply. Position the generator directly above electrical equipment as condensate may collect at the base of the generator. Use noxious chemicals or machinery that produces fumes, a 20 ft. radius of the generator. Due to the nature of operation there is a possibility of oxygen enrichment surrounding the generator. Ensure that the area is adequately ventilated. Where the risk of oxygen enrichment is high, such as a confined space or poorly ventilated room, the use of oxygen monitoring equipment is advisable. The NGC-0005 is capable of delivering nitrogen at a flow rate of 5L/min. We consider these levels to be of no concern. Nitrogen is not a poisonous gas but, in a concentrated form, there is a risk of asphyxiation. If the generator is operated within a confined space ensure that adequate ventilation and oxygen monitoring equipment is fitted. 7 Parker Hannifin Corporation

8 3.2.1 Wall mounting the generator Ensure that the wall is capable of supporting the entire weight of the generator. Refer to section for weights and dimensions. The generator should be attached to the wall using the mounting bracket supplied. Mark a horizontal line on the wall at a height along which the upper mounting holes of the generator will be located. Mark two points on the line at a distance of 16 inches apart, and drill two holes to accommodate wall anchors. Secure the hanging brackets provided to the wall. Remove the top cover from the generator and secure the hanging bar to the rear panel using the M8 screws and nuts provided. Lift the generator up to the wall and locate the hanging bar into the hanging brackets. Secure the bar to the brackets using the M6 x 12 bolts provided. 3.3 Storage Tank Installation A minimum 12 gallon storage tank is required for the correct operation of the NGC system (Parker Number: XXXXX). Connect the Nitrogen Out port of the generator to the inlet port on the storage tank using 1/4 I.D. tubing. The N 2 storage tank should be fitted with an isolation valve on both the inlet and outlet ports, however, the installation of an additional isolation valve at the generator outlet port is recommended. If a regulated back-up N 2 cylinder is to be used within the system, it can be connected in-line using a barbed tee connection. The gas supply valve for this cylinder should be turned off. Ensure that all piping materials are suitable for the application, clean and debris free. When routing the pipes ensure that they are adequately supported to prevent damage and leaks in the system. All components used within the system must be rated to at least the maximum operating pressure of the equipment. It is recommended that the system be protected with suitably rated pressure relief valves. 3.4 Electrical Installation Attach the mains supply cable provided to the IEC 320 socket and connect to the electrical supply. If a cordset, other than the one provided, is used to connect the equipment to the electrical supply ensure that it is suitably rated for the application and in accordance with local and national code regulations. The equipment must be bonded to earth (grounded) through the cordset. 8 Parker Hannifin Corporation

9 4.0 Operating the equipment 4.1 Starting the equipment 1. Open the valves on the Nitrogen outlet port and the N 2 storage tank inlet port. 2. Close the valve on the N 2 storage tank outlet port. 3. Switch the Main Switch to the ON position and ensure that the green switch illuminates. The cooling fan motor will start immediately and after approximately 120 seconds the on-board compressor will start. The nitrogen generation process will consist of a compressor run sequence followed immediately by an exhaust sequence. These cycle times vary depending upon the model of generator as shown below. An audible pressure release will indicate that the unit is producing N2 Model Compressor Run Time Exhaust Time (Seconds) (Seconds) NGC NGC NGC The generator may take up to 7 hours to fully pressurize an empty storage tank. To reduce this time it is recommended that the storage tank be pre-pressurized to psig using a regulated supply of N 2 from a high pressure cylinder. 4. When the system is fully pressurized open the valve on the N 2 storage tank outlet port to allow gas flow to the application downstream. The generator is designed to run continuously and requires no further intervention. Economy Mode In the event of low or zero flow requirement the cycle will continue until the N2 storage vessel is fully pressurized where upon the unit will cease cycling and shutdown. This energy saving mode is shown via the green Economy indicator on the front panel. When the pressure falls the unit will re-enter normal operation. 4.2 Shutting down the equipment 1. Switch the power switch to the OFF position and ensure that the green switch extinguishes. 2. Close the valves on the Nitrogen outlet port, the N 2 storage tank inlet port, and the N 2 storage tank outlet port. 3. To de-pressurize the generator switch the power switch to the ON position for 20 seconds to allow the generator to exhaust. Once exhausted switch the Main Switch to the OFF position. If the storage system is fully pressurized the internal tubing will need to be depressurized. Carefully turn out the drain tube retaining nut, attached to the elbow on the base of the coalescing filter bowl, and wait until the pressure gauge on the generator reads 0 psi. 9 Parker Hannifin Corporation

10 5.0 Maintenance It is essential that the generator is powered down and fully depressurized before carrying out any servicing procedures (Refer to section 4.2) The quality and reliability of the generator is maintained through preventive maintenance performed on a scheduled, regular basis. Although the frequency of this maintenance is determined by particular use conditions, it is recommended that filter elements are changed at least every twelve months. 5.1 Cleaning Clean the generator with a damp cloth only and avoid excessive moisture around any electrical sockets. If required you may use a mild detergent, however do not use abrasives or solvents as they may damage the warning labels on the equipment Service Intervals Description Of Maintenance Required Typical Recommended Service Interval Component Operation Daily Weekly 6 Months 4000 Hrs 12 Months 8000 Hrs 36 Months Hrs Generator Check that the power switch is illuminated. Generator Check that the exhaust valve is discharging on a regular basis. Generator Check for leaks. Generator Check the pressure gauge during operation. Generator Ensure there is adequate ventilation clearance around the generator. Generator Check the condition of the electrical supply cables. Generator Generator Generator Filter overhaul Recommended Service A Compressor replacement (Option 1 only) Recommended Service B Valve replacement Recommended Service C KEY: Check Essential Procedure 10 Parker Hannifin Corporation

11 5.3 Service Kits 115v Variant Service Kit Interval Description Kit No NGC-0001 NGC-0002 NGC-0005 A 12 months (8000 Hrs) Filter overhaul B 12 months (8000 Hrs) Compressor replacement C 36 months (24000 Hrs) Valve replacement v Variant Service Kit Interval Description Kit No NGC-0001 NGC-0002 NGC-0005 A 12 months (8000 Hrs) Filter overhaul B 12 months (8000 Hrs) Compressor replacement C 36 months (24000 Hrs) Valve replacement Parker Hannifin Corporation

12 5.1 Annual Filter Service Requirement Filter Replacement Air Intake Filter (NGC-0001 and NGC-0002 only) 1. Unscrew the filter assembly from the compressor and discard. 2. Fit the replacement filter assembly to the compressor turning it clockwise by hand until secure. Air Intake Filter (NGC-0005 only) 1. Unclip the filter cap and remove the sponge from the filter housing. 2. Fit the replacement sponge to the housing and replace the filter cap. Figure 1 Coalescing Filter Replacement 1. Ensure that the internal pressure is completely relieved by slowly unscrewing the tube nut at the bottom of the filter bowl. Once depressurized remove the valve assembly from the bowl. 2. Unscrew the bowl from the head and remove the element from the bowl. 3. Carefully remove the replacement element from its packaging and insert it into the bowl. Ensure that the element fits correctly into the guides provided in the bowl. 4. Refit the bowl to the head ensuring that the locking detail on the head and bowl are lined up when hand tight. 5. Refit the valve assembly to the filter housing bowl. Figure 2 Silencer Assembly Replacement 1. Unscrew the silencer (counter clockwise) from the valve body. Notice that the silencer is comprised of an outer, blue porous plastic housing with a brass insert. Discard both pieces. 2. Screw the replacement silencer onto valve body fitting until it is hand tight. Figure 3 12 Parker Hannifin Corporation

13 5.1.2 Valve Replacement 1. Disconnect the DIN plug from the solenoid coil and unscrew the four fixings that hold the valve bonnet to the body. 2. Discard the bonnet and the o-ring and fit the replacement. 3. Fit the DIN plug on to the solenoid valve and secure it into position using the screw provided. 4. On completion check that the wiring is secure. Figure Compressor Replacement 1. Disconnect the outlet tube at the tube nut and disconnect the compressor wiring at the in-line Molex connector. 2. Unscrew the vibration mount fixings located on the underside of the chassis and carefully remove the compressor. 3. Screw the four vibration mounts supplied into the threaded holes on the replacement compressor. 4. Mount the compressor onto the chassis and secure it into place using the replacement vibration mount fixings. 5. Reconnect the wiring and outlet tube. Figure 5 13 Parker Hannifin Corporation

14 6 Troubleshooting Indication Possible Cause Corrective Action Green power switch not Illuminated Poor power cord connection / blown power fuse Incorrect input voltage External fuse blown or circuit breaker tripped Be sure the power cord is securely connected to the power supply outlet and to the unit. Check / replace 10A fuse located in power socket Check the incoming voltage and rating number plate for voltage spec Check fuse; replace if necessary. Reset circuit breaker; check for overload On/Off switch failure Verify power to unit. Replace switch. Green power switch illuminated but no operation Unit is in economy mode until storage pressure to 94 psi Check green economy light N2 storage (tank) pressure drops during period of no use. Compressor motor runs excessively; unable to reach maximum N2 storage pressure Internal leak in the generator Leak in N2 storage or supply line Close N2 outlet to storage valve, run unit to max pressure, check and correct compressed air and N2 pressure circuit / fitting leaks Leak-check line fittings and connections. Correct leak(s) 14 Parker Hannifin Corporation

15 7.0 Schematics 15 Parker Hannifin Corporation

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