Aib NGP+

INSTRUCTION BOOK
PSA NITROGEN GENERATORS

NGP 240+, NGP 300+, NGP 360+, NGP 450+, NGP 550+, NGP 650+, NGP 800+,
NGP 1000+, NGP 1300+
Atlas Copco
PSA nitrogen generators
NGP 240+, NGP 300+, NGP 360+, NGP 450+, NGP 550+,
NGP 650+, NGP 800+, NGP 1000+, NGP 1300+
From following serial No. onwards: NLY 002 024
Instruction book
Original instructions
COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2018 - 03
No. 2920 7191 10
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS................................................................................................................................... 5
1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 5
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7
1.6 SPECIFIC SAFETY PRECAUTIONS FOR NITROGEN GENERATING EQUIPMENT...................................................... 8
1.7 SAFETY LABELLING ON NITROGEN GENERATORS........................................................................................9
2 Description.................................................................................................................... 11
2.1 GENERAL DESCRIPTION..................................................................................................................... 11
2.2 DETAILED DESCRIPTION..................................................................................................................... 12
2.3 FLOW DIAGRAM................................................................................................................................14
2.4 ELECTRIC DIAGRAM...........................................................................................................................16
3 Installation.....................................................................................................................17
3.1 DIMENSIONS....................................................................................................................................17
3.2 INSTALLATION.................................................................................................................................. 18
3.3 ELECTRICAL CONNECTIONS.................................................................................................................22
4 Elektronikon® Graphic controller............................................................................... 23
4.1 GENERAL........................................................................................................................................23
4.2 CONTROL PANEL.............................................................................................................................. 24
4.3 ICONS USED.................................................................................................................................... 25
4.4 MAIN SCREEN..................................................................................................................................27
4.5 CONTROL MODE SELECTION................................................................................................................30
4.6 OPERATION MODE SELECTION............................................................................................................. 31
4.7 CALLING UP MENUS.......................................................................................................................... 31
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4.8 INPUTS MENU...................................................................................................................................32
4.9 OUTPUTS MENU............................................................................................................................... 33
4.10 COUNTERS......................................................................................................................................34
4.11 EVENT HISTORY MENU.......................................................................................................................36
4.12 SERVICE MENU................................................................................................................................ 36
4.13 PROTECTIONS MENU......................................................................................................................... 40
4.14 WEEK TIMER MENU...........................................................................................................................40
4.15 INFO MENU......................................................................................................................................50
4.16 MODIFYING SETTINGS........................................................................................................................50
4.17 WEB SERVER.................................................................................................................................. 58
4.18 PROGRAMMABLE SETTINGS.................................................................................................................64
5 Operating instructions................................................................................................. 65
5.1 OPERATION.....................................................................................................................................65
5.2 CHECKING THE DISPLAY.....................................................................................................................68
5.3 TAKING OUT OF OPERATION................................................................................................................69
6 Maintenance.................................................................................................................. 70
6.1 GENERAL RECOMMENDATIONS AND PRECAUTIONS................................................................................... 70
6.2 MAINTENANCE SCHEDULE...................................................................................................................70
6.3 DISPOSAL OF USED MATERIAL............................................................................................................. 71
7 Adjustments and service............................................................................................. 72
7.1 CALIBRATION CHECK OF THE OXYGEN SENSOR....................................................................................... 72
7.2 REPLACEMENT OF THE O2 SENSOR..................................................................................................... 74
8 Optional equipment...................................................................................................... 77
8.1 OUTLET PRESSURE DEW POINT........................................................................................................... 77
8.2 EXTERNAL OXYGEN ANALYSER............................................................................................................ 78
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9 Trouble shooting.......................................................................................................... 81
10 Technical data...............................................................................................................85
10.1 REFERENCE CONDITIONS................................................................................................................... 85
10.2 LIMITATIONS FOR OPERATION.............................................................................................................. 85
10.3 PERFORMANCE DATA.........................................................................................................................85
10.4 CORRECTION FACTORS......................................................................................................................88
11 Pressure Equipment Directives...................................................................................91
12 Declaration of conformity............................................................................................ 93
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions

All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
1. The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
If any of the following statements does not comply with local legislation, the stricter of the
two shall apply.
2. Installation, operation, maintenance and repair work must only be performed by authorised,
trained, specialised personnel.
3. Before carrying out any maintenance, repair work, adjustment or any other non-routine
checks, stop the device. In addition, the power isolating switch must be opened and locked.
4. Never play with compressed air or gas. Do not apply an air or gas stream to your skin or
direct an air stream at people. Never use compressed air to clean dirt from your clothes.
When using the air to clean equipment, do so with extreme caution and wear eye protection.
5. Never operate the device below or in excess of its limit ratings.
6. No external force may be exerted on the air inlet and outlet valve. The connected pipe must
be free of strain.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the device or its components.
1.3 Safety precautions during installation

1. Install the equipment where the ambient air is cool and as clean as possible. Consult section
Reference conditions and limitations.
2. During installation or any other intervention on the equipment or one of the connected
machines, the machines must be stopped, de-energized and the isolating switch opened
and locked before any maintenance or repair. As a further safeguard, persons switching on
remotely controlled machines shall take adequate precautions to ensure that there is no one
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checking or working on the machine. To this end, a suitable notice shall be affixed to the
start equipment.
3. Install the equipment in an area free of flammable fumes, vapours and particles, e.g. paint
solvents, that can lead to internal fire or explosion.
4. The electrical connections must correspond to the applicable codes. The equipment must be
earthed and protected against short circuits by fuses in all phases. A lockable power
isolating switch must be installed near the equipment.
5. For machines controlled by a central control system, a sign stating "This machine may start
without warning" must be affixed near the instrument panel.
6. In multiple compressor systems, manual valves must be installed to isolate each
compressor. Non-return valves (check valves) must not be relied upon for isolating pressure
systems.
7. Never remove or tamper with the safety devices.
8. If the maximum pressure of the compressor is higher than the design pressure of the
connected equipment (e.g. a nitrogen generator or an oxygen generator), a full flow safety
valve must be installed between the compressor and the connected equipment, in order to
be able to blow off the excessive pressure.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance or repair.
These precautions apply to electrical devices.
For precautions applying to the connected equipment consult the relevant instruction
book.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your device.
1.4 Safety precautions during operation

non-observance of the normal caution and care required for installation, operation,
manufacturer.
1. Persons switching on remotely controlled machines shall take adequate precautions to

ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
2. Never operate the device in the presence of flammable or toxic fumes, vapours or particles.
3. Never operate the device below or in excess of its limit ratings.
4. Do not operate the device when there are flammable or toxic fumes, vapors or particles.
5. Keep all bodywork doors and panels closed during operation. The doors may be opened for
short periods only, e.g. to carry out routine checks.
6. People staying in environments or rooms where the sound pressure level reaches or
exceeds 90 dB(A) shall wear ear protectors.
7. Periodically check that:
• All guards and fasteners are in place and tight
• All hoses and/or pipes are in good condition, secure and not rubbing
• There are no leaks
• All electrical leads are secure and in good order
8. Never remove or tamper with the safety devices.
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Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance or repair.
book.
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair

non observance of the normal caution and care required for installation, operation,
manufacturer.
1. Use only the correct tools for maintenance and repair work.
2. Use only genuine spare parts.
3. A warning sign bearing a legend such as "Work in progress - do not start" shall be attached
to the starting equipment, including all remote start equipment.
4. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a clean cloth, paper or tape.
7. Never use a light source with open flame for inspecting the interior of the device.
8. All regulating and safety devices shall be maintained with due care to ensure that they
function properly. They may not be put out of action.
9. Before clearing the device for use after maintenance or repair, check that operating
pressures, temperatures and time settings are correct. Check that all control and shutdown
devices are fitted and that they function correctly.
10. Make sure that no tools, loose parts or rags are left in or on the device.
11. Never use caustic solvents which can damage materials of the device.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
book.
some statements may not apply to your machine.
Units and/or used parts must be disposed of in an environmentally friendly and safe
manner and in line with the local recommendations and legislation.
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1.6 Specific safety precautions for nitrogen generating

equipment
The nitrogen generator can be installed in the vicinity of the nitrogen consuming application
without the requirement for classification of the surrounding area as hazardous, provided that all
necessary measures have been taken to guarantee the maximum safety.
The nitrogen generating unit must be installed and used in observance of the instructions in this
booklet. Failure to observe these instructions will render the guarantee null and void and release
the manufacturer from all liability for direct or indirect damage or physical injury.
Hoses, pipes and connections used must be of the correct size and must be suitable for the
working pressure and purity. Never use frayed, damaged or worn hoses. Fixed piping is
recommended, especially for high purities. Connections made to the equipment must be free of
strain.
Nitrogen is not a toxic gas, but when the percentage of nitrogen in the air exceeds a specific
value, there is a risk of asphyxia. You should therefore never directly inhale the produced gas,
and avoid working in the immediate vicinity of the flowing nitrogen. Given the low quantities
produced, it is sufficient that the flow of nitrogen occurs in a normally ventilated environment to
avoid the risk of accumulation. Consult your supplier if in doubt.
Normal oxygen concentration in air is approximately 21% by volume. In general, air containing
less than 19.5% or more than 23.5% oxygen constitutes a hazardous working environment.
Typical symptoms of oxygen deficient atmospheres are listed in the table below. (ref. ANSI
Z88.2)
% oxygen at sea level (atmospheric pressure) Effects

>23.5 Increased fire hazard
20.9 Normal
19.0 Some adverse physiological effects occur, but they
are unnoticeable.
16.0 Increased pulse and breathing rate. Impaired
thinking and attention. Reduced coordination.
14.0 Abnormal fatigue upon exertion. Emotional upset.
Faulty coordination. Poor judgment.
12.5 Very poor judgment and coordination. Impaired
respiration that may cause permanent heart
damage. Nausea and vomiting.
<10 Inability to perform various movements. Loss of
consciousness. Convulsions. Death.
Oxygen concentrations higher than 23.5% create greater fire hazards than normal air. Oxygen is
not combustible, but it promotes very rapid combustion of flammable materials and some
materials that are normally regarded as being relatively non flammable.
When working on or around the generator, always wear a portable oxygen sensor to indicate safe
working conditions.
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Although a source of ignition energy is always necessary in combination with flammable

materials and oxygen, control or elimination of flammables is a precautionary step.
More details about the characteristics of nitrogen or oxygen can be found in the safety data sheet
for nitrogen and oxygen, both available as a separate publication (consult your supplier).
1.7 Safety labelling on nitrogen generators
The following safety label is attached to the nitrogen generator:

Translation of the text on the label
Nitrogen is a colorless, odorless and tasteless gas that does not support respiration.
Nitrogen can cause suffocation.
Oxygen enriched air is released as waste. Oxygen enriched air leads to an increased
risk of fire in the event of contact with inflammable products. Make sure that there is
adequate ventilation at all times.
Information on safety labels:
ISO 7000 - symbol 0419 Read the instruction manual
ISO 7000 - symbol 0434b General safety alert symbol
- Warning: Risk of asphyxiation
ISO 7010 - symbol P003 Fire hazard:

• No open flame near the generator
• Fire, open ignition source and smoking prohibited
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1079 9903 48 Warning:

• Generator can start automatically
• Read the manual before service or repair
• Turn off the power and disconnect the power
supply before service or repair
• Depressurize before service or repair
1079 9906 29 Warning: dangerous blow off
ISO 7010 - symbol M003 Wear ear protection
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2 Description
2.1 General description
Working principle
NGP 240+ up to NGP 1300+ nitrogen generators are intended to produce nitrogen (N2) for
industrial purposes. They use Pressure Swing Adsorption (PSA) technology to produce nitrogen
by passing compressed air through a tank containing adsorbent material.
The adsorbents are chosen on the basis of their adsorption characteristics: the adsorbent has
much more affinity for non-product molecules than for the product gas (N2). This characteristic
results in most of the desired molecules (N2) passing through the bed and remaining in the
product stream, while undesired components (product impurities) are captured by the adsorbent.
The PSA process is inherently a batch process, as the adsorbent bed requires periodic
desorption. Consequently, PSA systems usually contain two adsorbent tanks (adsorbers) to
provide operational continuity. At any time, one of the adsorbers will be delivering product (N2) by
adsorbing undesired components of the air, while the other adsorber is being regenerated by
depressurization to atmospheric pressure. When the adsorbing adsorber approaches saturation,
a set of valves quickly switches the functions. A nitrogen receiver downstream of the nitrogen
generator ensures that the delivery of nitrogen is continuous.
During the adsorption phase, compressed air flows through the sieve and oxygen molecules are
caught while nitrogen molecules pass on due to the different molecular size. The sieve continues
to adsorb oxygen until a saturation point is reached. During desorption, the entering air stream is
cut off and the oxygen is able to leave the tank at low pressure.
Operating principle of the nitrogen generator
Nitrogen PSA adsorbers contain Carbon Molecular Sieve (CMS) material to remove oxygen.
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The generator produces nitrogen at a purity level between 95 % and 99.999 % according to the
user requirements and the required nitrogen flow and pressure.
The nitrogen flow rate depends on the model size and the required purity.
The nitrogen pressure depends on the pressure of the compressed air at the inlet.
Variant Nitrogen purity Residual oxygen concentration

95 % 5%
96 % 4%
97 % 3%
% 98 % 2%
99 % 1%
99.5 % 0.5 %
99.9 % 0.1 %
99.95 % 500 ppm
ppm 99.99 % 100 ppm
99.999 % 10 ppm
2.2 Detailed description

The nitrogen generator is controlled by an Elektronikon® Graphic controller.
The controller is integrated in a cubicle at the front.
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ER Elektronikon controller V1 Inlet transfer valve, adsorber A

PI01 Inlet pressure gauge V2 Inlet transfer valve, adsorber B
PI02 Adsorber A pressure gauge V3 Bottom equalisation valve
PI03 Adsorber B pressure gauge V6 Top equalisation valve
PI04 Outlet pressure gauge V7 Outlet transfer, adsorber A
PI05 Consumer pressure gauge V8 Outlet transfer, adsorber B
PT01 Inlet pressure transmitter V9 Minimum pressure valve
PT02 Adsorber A pressure transmitter V10 Consumer valve
PT03 Adsorber B pressure transmitter V11 Inlet flushing valve
PT04 Outlet pressure transmitter BA01 Pilot air ball valve
OR01 Regeneration purge nozzle BA02 Inlet pressure ball valve
OR02 Bottom equalisation nozzle BA03 Adsorber A presure ball valve
OR03 Top equalisation nozzle BA04 Adsorber B pressure ball valve
OR04 Startup nozzle BA05 Pre-mix purity ball valve
PDP01 Inlet pressure dewpoint BA06 Outlet pressure ball valve
PDP02 Outlet pressure dewpoint (Optional) BA07 Nitrogen purity analysis ball valve
TT01 Inlet temperature sensor BA08 Outlet sample ball valve
FT01 Nitrogen flow transmitter FIL1 Pilot air filter
Y13 Inlet PDP sensor 2/2 spool valve HV1 Manual flow regulating valve
Y14 Purity sensor 2/2 spool valve NRV1 Non return valve
Y15 Outlet PDP sensor 2/2 spool valve OT01 Oxygen analyser
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SIL01 Blow off silencer V4 Blow off valve, adsorber A

SAV1 Adsorber A, safety valve V5 Blow off valve, adsorber B
SAV2 Adsorber B, safety valve V12 Outlet flushing valve
OR5 Inlet flushing nozzle ORO7 Exhaust nozzle
OR6 Outlet flushing nozzle
2.3 Flow diagram
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Flow diagram 9827 2995 10
Text on image
(1) Pre-mix sample (5) Nitrogen receiver

(2) Off spec gas (6) Optional outlet PDP sensor
(3) Pilot air (7) N2 sample connection
(4) Out of product scope
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Legend
A Adsorber A BA08 Ball valve, outlet sample

B Adsorber B SAV1 Safety valve, adsorber A
SIL1 Blow off silencer SAV2 Safety valve, adsorber B
V1 Inlet transfer valve, adsorber A PR01 Pressure regulator, pilot air
V2 Inlet transfer valve, adsorber B PR02 Pressure regulator, nitrogen purity
V3 Bottom equalization valve PR03 Pressure regulator, consumer
V4 Blow off valve, adsorber A HV1 Manual flow regulating valve
V5 Blow off valve, adsorber B NRV1 Non return valve
V6 Top equalization valve OR01 Regeneration purge nozzle
V7 Outlet transfer valve, adsorber A OR02 Bottom equalization nozzle
V8 Outlet transfer valve, adsorber B OR03 Top equalization nozzle
V9 Minimum pressure valve OR04 Startup nozzle
V10 Consumer valve OR05 Inlet flushing nozzle
V11 Inlet flushing valve OR06 Outlet flushing nozzle
V12 Outlet flushing valve OR07 Exhaust nozzle
Y1A–Y10A Spool valves (5/2 — monostable) PT01 Pressure transmitter, inlet
Y11–Y12 Spool valves (3/2 — monostable) PT02 Pressure transmitter, adsorber A
Y13 2/2 spool valve, inlet PDP sensor PT03 Pressure transmitter, adsorber B
Y14 2/2 spool valve, purity sensor PT04 Pressure transmitter, outlet
Y15 2/2 spool valve, outlet PDP sensor PDP01 Pressure dewpoint, inlet
BA01 Ball valve, pilot air PDP02 Pressure dewpoint, outlet (Optional)
BA02 Ball valve, inlet pressure TT01 Temperature transmitter, inlet
BA03 Ball valve, inlet pressure adsorber A FT01 Flow transmitter, nitrogen (optional)
BA04 Ball valve, inlet pressure adsorber B OT01 Oxygen analyser
BA05 Ball valve, pre-mix purity FIL1 Pilot air filter
BA06 Ball valve, outlet pressure PDp PDp filter
BA07 Ball valve, nitrogen purity analysis
2.4 Electric diagram

The electric diagram (9827 2995 00) can be found on the CD-ROM, DVD or USB, supplied with
the unit.
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3 Installation
3.1 Dimensions
The dimension drawing can be found on the CD-ROM, DVD or USB, supplied with the unit.
Drawing Size Purity variant

9828 5420 03 NGP 240+ PCT
9828 5420 04 NGP 300+ PCT
9828 5420 05 NGP 360+ PCT
9828 5420 06 NGP 450+ PCT
9828 5420 07 NGP 550+ PCT
9828 5420 08 NGP 650+ PCT
9828 5420 09 NGP 800+ PCT
9828 5420 10 NGP 1000+ PCT
9828 5420 11 NGP 1300+ PCT
9828 5420 53 NGP 240+ PPM
9828 5420 54 NGP 300+ PPM
9828 5420 55 NGP 360+ PPM
9828 5420 56 NGP 450+ PPM
9828 5420 57 NGP 550+ PPM
9828 5420 58 NGP 650+ PPM
9828 5420 59 NGP 800+ PPM
9828 5420 60 NGP 1000+ PPM
9828 5420 61 NGP 1300+ PPM
References used on the dimension drawings
Text on drawing Explanation

AIR in Air inlet
To N2 receiver To nitrogen receiver
From N2 receiver From nitrogen receiver
N2 Outlet Nitrogen outlet
Waste gas Exhaust connection
COG Center of gravity
Dimension drawings are subject to change. Please consult your supplier to get the latest
versions of the dimension drawings.
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3.2 Installation
For a good functionality of the gas generator it is paramount that the installation does not deviate
from the prescribed installation proposal. Therefore, consult the latest edition of the installation
proposal and its addendum on the Business Portal.
Outdoor operation
• The generator is not intended for outdoor use. Working temperature range is 5°C to 50°C.
• Humidity and dust: to avoid risk of damage to electronic components, install the generator in
an environment subject to limited relative humidity and low concentration of dust. The
generator must also be protected against water droplets, rain and wind. According to the
Low Voltage requirements (EN61010), indoor use is recommended for this unit.
Installation area requirements

• Temperature: the ambient temperature in the generator installation area must be between 5
˚C (41 ˚F) and 50 ˚C (122 ˚F). Install the generator away from heat sources. Therefore, also
avoid direct exposure to sunlight.
• Positioning: when selecting the installation area for the generator, take into account
minimum clearances required for operation and maintenance. A minimal free space of 1000
mm around the generator is recommended. Consult the Installation proposal drawings
further in this chapter. Install the generator on a level floor, suitable for taking its weight.
Handling and positioning of the nitrogen generator

The generator must be handled using suitable equipment such as a crane or a forklift truck.
Remove all packing material, taking care not to damage the generator.
Safety valves
Installation of full flow safety valves on the inlet and outlet receivers is obligatory.
The full flow of an installation is the maximum flow that the compressor can deliver.
Inlet air quality
The properties of the compressed air at the inlet of the nitrogen generator, as well as
the minimum pressure and flow rate requirements, play an important role with regard to
its performance and lifetime.
The compressed air used should be of a quality that meets ISO 8573-1:2010; class
2-4-1 . Using a lower quality of compressed air will cause irreversible damage to
the generator. In such case, the manufacturer denies all liability for damages and
any costs for repairs will be charged to the client.
The purity of the nitrogen produced is reduced when the air pressure at the inlet
decreases. Therefore the installation of an accordingly sized compressed air receiver is
mandatory. In case of any doubt with regard to the above, contact your supplier for
advice on the most suitable compressed air system (compressor, dryer, filters, receiver)
for the specific application.
The inlet dew point should be kept at 3 °C and should not exceed 5 °C (at reference conditions).
This dew point can be established by a correctly sized refrigerant dryer. In case of high ambient
temperatures, an oversized external refrigerant dryer should be selected.
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The nitrogen generators can be used with oil injected compressors as well as with oil free
compressors.
Please note however that it is of utmost importance to prevent any dust, water or oil from
entering the nitrogen generator, because this will damage the carbon molecular sieve
material.
• If an oil injected compressor is used, the coalescing filter and the activated carbon
filter have to be installed upstream the compressed air receiver, just after the
compressor outlet. (See installation proposal) On coalescing filters, a drain tube must be
installed. The drain pipes to the drain collector must not dip into the water. For draining of
pure water when oil injected compressors are used, install an oil/water separator (consult
your supplier).
• If an oil free compressor is used, principally no activated carbon filter is required upstream
the compressed air receiver. Install a dust filter downstream the nitrogen receiver to protect
the application from eventual dust contamination.
• If the compressor is not equipped with an automatic water separator, install an automatic
water separator upstream the inlet filters.
Piping connections
The installation proposals illustrate the components used in a typical nitrogen generator system.
Avoid distances exceeding 5 m (16.4 ft) between the various components.
Fixed piping is recommended, especially for high purities. As otherwise, O2 molecules might
permeate into the system, affecting the purity.
To facilitate the installation, AIRnet piping is recommended.

All piping must be connected free of stress.
Attention:
Always do a complete leaktest before finalising the installation. To be able to produce
high purity nitrogen, the installation has to be entirely leak free. The best way of finding
leaks is to isolate the installation under pressure (shut down the generator and close
ball valves before air receiver and after nitrogen receiver). Wait for one hour and monitor
the drop in pressure. If the drop in pressure is higher than 50 mbar (or 0.72 psi), leaks
are present and must be fixed.
• Connection of the inlet:

The compressed air inlet connection is located at the lower left.
• Connect the pipe.
• Connect the other end of the pipe to the compressed air receiver (upper connection
point).
• Connection of the nitrogen receiver:
• To the nitrogen receiver:
This connection (marked TO BUFFER) is located at the upper right side.
Connect the pipe at the other end to the lower coupling of the nitrogen receiver.
• From the nitrogen receiver:
This connection is located at the right side in the middle.
Connect the pipe at the other end to the upper coupling of the nitrogen receiver.
• Connection of the nitrogen outlet:
This connection is located at the left side in the middle.
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From this point on, nitrogen can be consumed. For peak consumption applications it is
recommended to install a second nitrogen receiver to the nitrogen outlet connection.
• Exhaust
In case there is no sufficient ventilation in the room, it is recommended to lead the exhaust
of the generator out of the room, since the exhausted air has an increased oxygen
concentration.
To keep the back pressure as low as possible and to guarantee the performance of the
generator, the piping to the exhaust has to be sufficiently large. See the table with minimum
pipe diameters in section Performance data.
The back pressure during regeneration (after exhaust) must be kept as low as possible. It
should not exceed 100 mbar.
Connections
TP1 Air in
TP2 To N2 receiver
TP3 From N2 receiver
TP4 N2 outlet
TP5 Waste gas
VA Vessel A
VB Vessel B
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• Do not direct the exhaust air towards hot surfaces or heat sources. Increased
oxygen levels can increase the risk for fire and explosion hazard.
• Keep the exhaust open at all times. Do not block or make the exhaust pipe
opening smaller. This might cause decreased performance of the generator or
even cause the muffler to explode.
Installation guidelines
- It is recommended that the connection of the compressor air outlet pipe is made on top of the main
air net pipe in order to minimize carry-over of possible condensate residue.
Make sure that no dirt particles (e.g. coming from corrosion in the compressed air network can enter
the generator. These particles may be harmful to the generator components).
- Ventilation: depending on how exhaust air will be vented, appropriate measures have to be taken to
make sure that oxygen concentration in the room never exceeds 22.5 % or drops below 19.5 %.
• In many cases, natural ventilation can be sufficient, for example rooms or halls provided with
ventilation openings. General guideline is that ventilation openings should at least have a flow
area of 1/100 of the floor area; openings should be diagonally opposite to each other and shall
ensure a free air circulation without obstacles. When natural ventilation is not possible, a
ventilation unit should be foreseen with a capacity of approximately 6 air changes per hour (with
a minimum of 4 air changes per hour). There shall be a safety warning in case ventilation fails.
• Note that each installation may require specific measures to ensure that oxygen concentration
in the room never exceeds the mentioned limits. It is the responsibility of the installer to make
sure that adequate measures are taken.
• Special consideration to the ventilation of underground rooms, pits, trenches, etc. is to be given:
Since oxygen is heavier than air, oxygen gas tends to accumulate in low lying areas.
- Room oxygen level detection system: When operators are working in the vicinity of gas generating
equipment and the oxygen content can rise or drop to a dangerous level, a continuous measurement
system is necessary. A system with a visual/audible alarm is advisable. The oxygen level detection
systems needs to be put in the working area and near the operator.
- Filter drain connections should be connected to a drain collector but must not dip into the water of
the drain collector.
- Use the main cable entry to connect the power supply cable to the unit.
- Make sure that the hose length is as short as possible if it is required to measure nitrogen at a
customer defined sample point in the network (for example the nitrogen receiver).
Warnings
• If a failure in gas supply (e.g. due to a power failure, the activation of an electrical
safety device, or a generator fault) is - even temporarily - not admissible, it can be
advisable to foresee a backup nitrogen source to enable provisional supply of gas
(totally or partially automatic).
• To ensure compliance with the standards imposed by the Machinery Directive, the
restart of the generator after the electrical power supply is restored cannot be
automatic. It must be activated manually by the operator.
• If the generator is connected to an existing pressure net, it is recommended to
install a pressure regulator and a check valve before the air receiver in order to
maintain constant pressure.
• When the generator is used to fill a large vessel or when its used to fill a vessel
which will experience large pressure fluctuations (larger than 2 bar), it is advised to
install a separate nitrogen buffer vessel.
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3.3 Electrical connections
Electric power supply
For safety reasons, the following instructions must be observed strictly.

The electrical installation must comply with current standards, in particular regarding the
earthing line.
Recommendations:
• Always connect the earthing line.
• The main socket must be located in an easily accessible position.
• Low voltage fuses on the unit and fuse installation at customer location is specified
on the service diagram included in the documentation.
Before any service intervention on the unit please make sure that the electrical
power is totally disconnected. Therefore, please unplug the unit from the main
power supply.
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4 Elektronikon® Graphic controller
4.1 General
Controller
General description
The Elektronikon® controller automatically controls and protects the generator, i.e.:
•
In order to control the generator and to read and modify programmable parameters, the
controller has a control panel provided with:
• LEDs, indicating the status of the generator
• A display indicating the operating conditions or a fault
• Keys to control the generator and to access the data collected by the controller
• Buttons to manually start and stop the generator
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4.2 Control panel
Elektronikon® controller
Parts and functions
Reference Designation Function

1 Display Shows the generator operating condition and a number
of icons to navigate through the menu.
2 Pictograph Automatic operation
3 Pictograph General alarm
4 General alarm LED Flashes if a shut-down warning condition exists.
5 Pictograph Service
6 Service LED Lights up if service is needed
7 Running signal LED Indicates that the generator is running.
8 Voltage on LED Indicates that the voltage is switched on.
9 Pictograph Voltage on
10 Enter key Key to activate the selected menu or to modify the
selected parameter.
11 Escape key To go to previous screen or to end the current action
12 Scroll keys Keys to scroll through the menu.
13 Stop button Button to stop the generator. LED (7) goes out.
14 Start button Button to start the generator. LED (7) lights up indicating
that the controller is operative.
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4.3 Icons used
Status icons
Name Icon Description

Stopped/Running When the generator is stopped, the icon stands still.
When the generator is running, the icon is rotating.
Machine control mode Local start/stop
Remote start/stop
Network control
Automatic restart after voltage Automatic restart after voltage failure is active
failure
Week timer Week timer is active
Active protection functions Shutdown
Warning
Service Service required
Main screen Change main screen
Main chart
Operation mode Automatic
Manual
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System icons
Icon Description
Generator
Filter
Failure expansion module
Network problem
General alarm
Menu icons
Icon Description
Inputs
Outputs
Alarms (Warnings, shutdowns)
Counters
Test
Settings
Service
Event history (saved data)
Access key/User password
Network
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Set point
Info
General settings
Valves
Navigation arrows
Icon Description
Up
Down
4.4 Main screen
Control panel
(1) Scroll keys

(2) Enter key
(3) Escape key
Function
The Main screen shows the status of the generator operation and is the gateway to all functions
implemented in the controller.
The Main screen is shown automatically when the voltage is switched on and one of the keys is
pushed. It is switched off automatically after a few minutes when no keys are pushed.
Typically, 6 different main screen views can be chosen:
1. Generator animation
2. Two value lines
3. Four value lines
4. Chart (High resolution)
5. Chart (Medium resolution)
6. Chart (Low resolution)
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Generator animation
This type of Main screen shows the operating of the generator as an animation.
Two and four value lines views

This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu).
• Section A shows information regarding the generator operation.
• Section B shows Status icons. Following icon types are shown in this field:
• Fixed icons
These icons are always shown in the main screen (e.g. generator stopped or running,
generator status).
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer,
automatic restart after voltage failure , etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To call up more information about the icons shown, select the icon concerned using the
scroll keys and press the enter key.
For more information on these icons, see Icons used.
• Section C is called the Status bar.
This bar shows the text that corresponds to the selected icon.
• Section D shows the Action buttons. These buttons are used:
• To call up or program settings
• For service message or emergency stop
• To have access to all data collected by the controller
The function of the buttons depends on the displayed menu. The most common functions
are:
Designation Function
Menu To go to the menu
Modify To modify programmable settings
Reset To reset a timer or message
To activate an action button, highlight the button by using the Scroll keys and press the
Enter key.
To go back to the previous menu, press the Escape key.
Chart views
To change the plotted input signal, go to the input menu and select the desired input signal.
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When Chart (High Resolution) is selected, a chart showing the value of a parameter selected in
the Inputs menu per minute is shown on the Main screen. Each point in the chart is 1 second.
The screen shows the last 4 minutes.
The switch button icon for selecting other screens is changed into a small Chart and is
highlighted (active).
When Chart (Medium Resolution) is selected, a chart showing the parameter per hour is shown
on the Main screen. Each point is the average of 1 minute. The screen shows the last 4 hours.
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When Chart (Low Resolution) is selected, a chart showing the parameter per day is shown on the
Main screen. Each point is the average of 1 hour. The screen shows the evolution over the last
10 days.
4.5 Control mode selection
Function
To select the regulation mode, i.e. whether the generator is in local control, remote control or
controlled via a local area network (LAN).
Procedure
Starting from the main screen, use the scroll buttons to go to the Local start/stop icon (1) and
press the Enter button:
There are 3 possibilities:

• Local control
• Remote control
• LAN (network) control
After selecting the required regulation mode, press the Enter button on the controller to confirm
your selection. The new setting is now visible on the Main screen. See section Icons used for the
meaning of the icons.
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4.6 Operation mode selection
Function
To select the operation mode, i.e. whether the generator is in automatic mode or manual mode.
Procedure
Starting from the Main screen, use the Scroll keys to go the Operation icon and press the Enter
button.
The following screen appears:

Text on figure
(1) Operation Mode

(2) Manual
(3) Automatic
There are two modes:

• Manual mode: The generator operates independently of the nitrogen consumption. After
selecting this mode, the operation mode will switch automatically to automatic operation
after 24 hours of operation.
• Automatic mode: in automatic mode, the generator will take into account the consumed
nitrogen flow. Depending of the flow, the generator will apply capacity control to minimize
energy consumption or enter standby if no nitrogen is consumed.
After selecting the required operation mode, press the Enter button to confirm your selection. The
new setting is now visible on the Main screen. For information on the icons, see Icons used.
4.7 Calling up menus
Description
When the voltage is switched on, the Main screen is shown automatically (see section Main
screen):
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Text on figure
(1) A: Production
(2) B: Regenerating
(3) Menu
• To go to the Menu screen, highlight the Menu button (3), using the Scroll keys.
• Press the Enter key to select the menu. Following screen appears:
• The screen shows a number of icons. Each icon indicates a menu item. By default, the
Inputs icon is selected. The status bar shows the name of the menu that corresponds with
the selected icon.
• Use the Scroll keys to select an icon.
• Press the Enter key (2) to open the menu or press the Escape key (3) to return to the Main
screen.
4.8 Inputs menu
Menu icon, Inputs
Function
To call up information regarding the actually measured data and the status of some inputs such
as the vessel pressure.
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Procedure
Starting from the main screen (see section Main screen):
• Move the cursor to the Menu button and press the Enter key.
• Using the Scroll keys, move the cursor to the Inputs icon.
• Press the Enter key. Following screen appears:
4.9 Outputs menu
Menu icon, Outputs
Function
To call up information regarding the actual status of some outputs such as the generator standby,
purity alarm, general shutdown, etc.
Procedure
Starting from the Main screen (see section Main screen):
• Move the cursor to the Outputs icon using the Scroll keys.
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Text on figure
(1) Outputs
(2) Pressure Dewpoint
(3) Purity
(4) Outlet Flow
(5) Running
The screen shows a list of data.
4.10 Counters
Menu icon, Counters
Function
To call up:
• The running hours
• The number of hours that the controller has been powered
• The operational state timers
Procedure
Starting from the Main screen (see Main screen),
• Using the Scroll keys, move the cursor to the Counters icon. Following screen appears:
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Text on figure
(1) Counters
(2) Running Hours
(3) Module Hours
(4) Loaded Hours
(5) Actual state time
The screen shows a list of all counters with their actual readings. A number of counters keep
track of the state of the generator:
• Running hours: counts the operation hours of the generator.
• Loaded hours: the same as running hours, but shows to which time interval the energy
counters refer; this counter is also reset when the energy counters are reset.
• Actual state time: shows how long the current state has been active.
• Programmed state time: shows how long (at most) the current state should be active.
• Actual half cycle time: shows how long the adsorbing vessel has been adsorbing
(since last vessel shift).
• Programmed half cycle time: shows how long the half cycle should take.
• Regeneration cycles vessel A: integer that counts how many cycles vessel A has
performed.
• Regeneration cycles vessel B: integer that counts how many cycles vessel B has
performed.
• Module hours: shows how long the Elektronikon controller has been active. This timer
can not be reset, not even when downloading new Elektronikon software.
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4.11 Event history menu
Menu icon, Event History
Function
To call up the last shutdown and last emergency stop data.
Procedure
• Using the Scroll keys, move the cursor to the Event History icon.
• The list of last shutdown and emergency stop cases is shown.
• Scroll through the items to select the desired shutdown or emergency stop event.
• Press the Enter key to find the date, time and other data reflecting the status of the
generator when that shutdown or emergency stop occurred.
4.12 Service menu
Menu icon, Service
Function
• To reset the service plans which are carried out.
• To check when the next service plans are to be carried out.
• To find out which service plans were carried out in the past.
• To modify the programmed service intervals.
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Procedure
Starting from the Main screen (see Main screen):
• Using the Scroll keys, move the cursor to the Service icon. Following screen appears:
Text on figure
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the items to select the desired item and press the Enter key to see the details
as explained below.
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Overview
Text on figure
(1) Overview
(2) Running Hours (green)
(3) Real Time hours (blue)
Example for service level (A):

The figures at the left are the programmed service intervals. For Service interval A, the
programmed number of running hours is 4000 hours (upper row, green) and the programmed
number of real time hours is 4380 hours, which corresponds to six months (second row, blue).
This means that the controller will launch a service warning when either 4000 running hours or
4380 real hours are reached, whichever comes first. Note that the real time hours counter keeps
counting, also when the controller is not powered.
The figures within the bars are the number of hours to go till the next service intervention. In the
example above, the generator was just started up, which means it still has 4000 running hours or
4337 hours to go before the next Service intervention.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands
for a number of service actions to be carried out at the time intervals programmed in the
Elektronikon controller.
When a service plan interval is reached, a message will appear on the screen.
After carrying out the service actions related to the indicated levels, the timers must be reset.
From the Service menu above, select Service plan (3) and press Enter. Following screen
appears:
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Text on figure
(1) Service plan

(2) Level
(3) Running hours
(4) Real time
Next Service
Text on figure
(1) Next service

(2) Level
(3) Running hours
(4) Actual
In the example above, the A Service level is programmed at 4000 running hours, of which 8
hours have passed.
History
The History screen shows a list of all service actions done in the past, sorted by date. The date at
the top is the most recent service action. To see the details of a completed service action (e.g.
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Service level, Running hours or Real time hours), use the Scroll keys to select the desired action
and press the Enter key.
4.13 Protections menu
Menu icon, Protections
Function
To call-up the protections.
Before resetting a warning or shut down message, always remedy the problem.
Frequently resetting these messages without remedying may damage the generator.
Procedure
• Move the cursor to the Menu button and press the Enter key (2).
• Using the Scroll keys, move the cursor to the Protections icon. Following screen appears:
• Press the Enter key (2). Following screen appears:

• Use the Scroll keys to select a protection.
• Press the Enter key (2) to modify the warning/shutdown level.
• If a protection is a warning or shutdown, the warning or shutdown icon blinks below the
protection icon.
4.14 Week timer menu
Menu icon, Week timer
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Function
• To program time based start/stop commands for the generator.

• To program time based changeover commands for the net pressure band.
• Four different week schemes can be programmed.
• A week cycle can be programmed; a week cycle is a sequence of 10 weeks. For each week
in the cycle, one of the four programmed week schemes can be chosen.
Procedure
• Move the cursor to the Menu action button and press the Enter key. Use the Scroll buttons
to select the Week timer icon.
Text on figure
(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week 1
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(6) Remaining Running Time
The first item in this list is highlighted. Select the item requested and press the Enter key on
the controller to modify.
Programming week schemes

• Select Week Action Schemes and press Enter. A new window opens. The first item in the
list is highlighted. Press the Enter key on the controller to modify Week Action Scheme 1.
Text on figure

(2) Week Action Scheme 1
• A weekly list is shown. Monday is automatically selected and highlighted. Press the Enter
key on the controller to set an action for this day.
Text on figure

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
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(6) Friday
(7) Saturday
(8) Sunday
• A new window opens. The Modify action button is selected. Press the Enter button on the
controller to create an action.
Text on figure
(1) Monday
(2) Modify
• A new pop-up window opens. Select an action from this list by using the Scroll keys on the
controller. When ready press the Enter key to confirm.
Text on figure
(1) Monday
(2) Actions
(3) Remove
(4) Start
(5) Stop
(6) Pressure Set point 1
(7) Modify
• A new window opens. The action is now visible in the first day of the week.
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Text on figure
(1) Monday
(2) Start
(3) Save
(4) Modify
• To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm.
Text on figure
(1) Monday
(2) Start
(3) Save
(4) Modify
• A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours.
Use the ← or → Scroll keys to modify the minutes.
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Text on figure
(1) Monday
(2) Time
(3) Save
(4) Modify
• Press the Escape key on the controller. The action button Modify (4) is selected. Use the
Scroll keys to select the action Save.
Text on figure
(1) Monday
(2) Start
(3) Save
(4) Modify
• A new pop-up window opens. Use the Scroll keys on the controller to select the correct
actions. Press the Enter key to confirm.
Text on figure
(1) Monday
(3) Are you sure?
(4) No
(5) Yes
(6) Save
(7) Modify
Press the Escape key to leave this window.
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• The action is shown below the day the action is planned.
Text on figure

(2) Monday - Start
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
Press the Escape key on the controller to leave this screen.
Programming the week cycle

A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four
programmed week schemes can be chosen.
• Select Week Cycle from the main Week Timer menu list.
Text on figure
(1) Week Timer

(3) Week Cycle
(4) Status
(5) Week Timer Inactive
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• A list of 10 weeks is shown.
Text on figure
(1) Week Cycle

(2) Week 1
(3) Week 2
(4) Week 3
(5) Week 4
(6) Modify
Press the Enter key on the controller twice, to modify the first week.
• A new window opens. Select the action, example: Week Action Scheme 1
Text on figure
(1) Week Cycle

(2) Week 1
(6) Modify
• Check the status of the Week Timer

Use the Escape key on the controller to go back to the main Week Timer menu. Select the
status of the Week Timer.
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Text on figure
(1) Week Timer

(3) Week Cycle
(4) Status
• A new window opens. Select Week 1 to set the Week Timer active.
Text on figure
(1) Week Timer

(2) Week
(4) Week 1
• Press the Escape key on the controller to leave this window. The status shows that week 1
is active.
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Text on figure
(1) Week Timer

(3) Week Cycle
(4) Status
• Press the Escape key on the controller to go to the main Week Timer menu. Select
Remaining Running Time from the list and press the Enter key on the controller to Modify.
Text on figure
(1) Week Timer

(3) Week Cycle
(4) Status
• This timer is used when the week timer is set and for certain reasons the generator must
continue working. The remaining running time, for example 1 hour, can be set in this screen.
This timer is prior to the Week Timer action.
Text on figure
(1) Week Timer

(2) Week action schemes
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4.15 Info menu
Menu icon, Info
Function
To show the MAC address.
Procedure
• Using the Scroll keys, move the cursor to the Info icon. Following screen appears:
• Press the Enter key. The Atlas Copco internet address appears on the screen.
4.16 Modifying settings
Menu icon, Settings
Function
To display and modify a number of settings (e.g. Time, Date, Date format, Language, units ...).
Procedure
Starting from the Main screen (see Main screen), move the cursor to the Menu button and press
the Enter key.
A screen, similar to following screen appears:
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Using the Scroll keys, move the cursor to the Settings icon and press the Enter key. Following
screen appears:
Text on figure
(1) Settings
(2) Automatic Restart (text is linked to the selected icon)
The screen shows a number of icons. Move the cursor to the icon of the function to be modified
and press the Enter key.
Icon Function
Network settings
General settings
Automatic Restart
Main chart
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Icon Function
Generator settings
Access key
Network settings
Select the network settings icon as described above and press the Enter button (2). Following
screen appears:
Text on figure
(1) Network
(2) CAN
(3) Ethernet
By default, the first item (CAN) is selected. Press the Enter key. Following screen appears:
CAN settings menu
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Text on figure
(1) CAN
(2) CAN Address
(3) PC Tools Channel
(4) ES Channel
(5) Modify
Use the Scroll keys to select the setting to be modified, press Enter and follow the indications on
the screen.
Ethernet settings menu
Text on figure
(1) Ethernet
(2) IP Address
(3) Subnet mask
(4) Gateway IP
(5) Modify
Using the Scroll keys, move the cursor to the setting to be modified (e.g. Ethernet) and press the
Enter button (2).
A pop-up screen appears. Use the ↑ or ↓ key to select the required parameter and press the
Enter key to confirm.
General settings
Select the General settings icon as described above and press the Enter button (2). Following
screen appears:
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Text on figure
(1) General
(2) Language in use
(3) Time
(4) Date
(5) Date format
The screen shows the first items of a list of all settings. Use the scroll button to see the other
items in the list.
Press the Enter button (2). By default, the first item (Language in use) is selected.
Use the ↓ key of the Scroll keys to select the setting to be modified and press the Enter key.
A pop-up screen appears. Use the ↑ or ↓ key to select the required parameter and press the
Enter key to confirm.
Automatic Restart
The controller has a built-in function to automatically restart the generator if the voltage is
restored after voltage failure, called Automatic Restart.
Provided the automatic restart function is activated and the controller was in the
automatic operation mode, the generator will automatically restart if the supply voltage
to the module is restored within a programmed time period.
The power recovery time (the period within which the voltage must be restored to have
an automatic restart) can be set between 15 and 3600 seconds or to 'Infinite'. If the
power recovery time is set to 'Infinite', the generator will always restart after a voltage
failure, no matter how long it takes to restore the voltage.
A restart delay can also be programmed allowing for example the generator and the
compressors to be restarted one after the other. This is strongly recommended in case
the function is activated.
To deactivate/activate the restart function, use password 4735. If the function is activated, this is
visible in the Main screen.
By default, "Automatic Restart" is deactivated.
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To modify the Automatic Restart settings:

• Select the Automatic Restart icon as described and press the Enter button (2). Following
screen appears:
Text on figure
(1) Automatic Restart

(2) Automatic Restart
(3) Maximum Power Down Time
(4) Restart Delay
(5) Modify
• The screen shows a list of settings. By default, the first item is highlighted.
Using the Scroll keys, move the cursor to the setting to be modified and press the Enter
button (2). A pop-up screen appears. Use the ↑ or ↓ key to select the required value and
press the Enter button (2) to confirm.
Main chart settings
Chart ranges and bands can be modified. This can cause the current value to be out of
range and can thus cause the absence of a visible curve in the graph.
The main chart settings menu allows to adjust the scale and curves on the graph. To modify
these settings, proceed as follows:
• Select the Main chart settings icon as described above and push the Enter button (2). A
screen similar to the one below appears:
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Text on figure
(1) Main chart

(2) Main chart signal
(3) Chart range
(4) Minimum
(5) Maximum
(6) Chart band
(7) Low
(8) High
(9) Off
The screen shows the main chart signal, the current chart range and band settings. To modify
these settings, proceed as follows:
Push the Enter button, select Chart Range or Chart Band as desired and confirm.
Modifying the Chart Band
Select Chart Band as described above and proceed as follows:
• Push the Enter button: the low band setting becomes highlighted. Push the Enter button to
modify the on/off setting or use the arrow down key to modify the low setting.
• Push the Enter button to confirm the modification.
• Proceed to modify the high band setting.
Generator settings
To be able to modify the settings, you need a password. Otherwise, you can only
consult the active settings.
Select the Generator settings icon as described above and press the Enter button (2). Following screen appears:
The screen shows a list of settings. By default, the first item (Time Settings) is highlighted.
Press the Enter button (2). The following screen appears:
• Time settings
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Time Settings (only for service)
Text on figure
(1) Time Settings

(2) Equalization Time
(3) Production Time
These settings are password protected!
If the service password is entered, the cycle timings can be adjusted between the limits
which are displayed in small characters.
• Regulation
If the service password is entered the regulation settings can be modified.
• Using the scroll keys, move the cursor to the setting to be modified and press the Enter
button (2).
• A popup screen appears. Use the ↑ or ↓ key to select the required value and press the
Enter button (2).
Access key
Different security levels are programmed in the controller (e.g. user, service technician, etc). This
menu item is used to change the security level. Scroll to the correct icon using the scroll key.
Press the Enter button. Press the Enter button again to modify the security level. Press the Enter
button again, a pop-up menu appears. Use the scroll keys to enter the password of the new
security level. Press the Enter button to confirm the change.
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4.17 Web server

All Elektronikon controllers have a built-in web server that allows direct connection to the
company network or to a dedicated PC via a local area network (LAN). This allows to consult
certain data and settings via a PC instead of via the display of the controller.
Getting started
Make sure you are logged in as administrator.
• Use the internal network card from your computer or a USB to LAN adapter (see picture
below).
USB to LAN adapter (for Windows XP)
USB to LAN adapter (for Windows 7)
• Use a UTP cable (CAT 5e) to connect to the controller.
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Configuration of the network card

To configure the network card:
• Open Network and Sharing Center, via Control Panel, by clicking View network status and
tasks.
• Click on Change adapter settings.
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• Select the Local Area connection, which is connected to the controller.
• Click with the right button and select Properties.
• Use the checkbox Internet Protocol (TCP/IP). To avoid conflicts, de-select other properties if
they are selected. After selecting TCP/IP, click on the Properties button to change the
settings.
• Use the following settings:

• IP Address 192.168.100.200
• Subnetmask 255.255.255.0
• Click OK and close Network and Sharing Center.
Configuration of the web server

Configure the web interface
The internal web server is designed and tested for Microsoft® Internet Explorer 6, 7 and
8. Other web browsers like Opera and Firefox do not support this internal web server.
When using Opera or Firefox, a redirect page opens. Click on the hyperlink to connect
to the download server from Microsoft® to download the latest version of Internet
Explorer, and install this software.
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• When using Internet Explorer:

Open Internet Explorer and click on Tools - Internet options (2).
• Click on the Connections tab and then click on the LAN settings button.
• In the Proxy server Group box, click on the Advanced button.
• In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses
can be given but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and
192.168.100.2). Now you add 192.168.100.100 and separate the 3 IP addresses by putting
semicolons.
Click OK to close the window.
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Viewing the controller data

• Open your browser and type the IP address of the controller you want to view in your
browser (in this example http://192.168.100.100). The interface opens:
Controller screen (typical).

Navigation and options
• The banner shows the generator type and the language selector (depending on the
languages that are installed on the controller).
• On the left side of the interface, you can find the navigation menu.
If a license for ESi is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• Es: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.
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Generator settings
All settings can be hidden or shown. Put a mark for each setting. Only the machine status is fixed
and can not be removed from the main screen.
Counters
Counters give an overview of all actual counters from the controller and the generator.
Info status
Machine status is always shown on the web interface.
Digital inputs
Gives an overview of all digital inputs and their status.
Digital outputs
Shows a list of all digital outputs and their status.
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Special protections
Give an overview of all special protections of the generator.
ES screen controller
If an ESi license is provided, the ES button is shown in the Navigation menu. At the left side, all
machines in the ES are shown and at the right side, the ES status are shown.
A possible ESi screen
4.18 Programmable settings
Description
The regulation and safety devices are factory-adjusted to obtain optimum performance of the
generator. No adjustments are required.
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5 Operating instructions
5.1 Operation
Start-up procedure
For the designation of the components, see section Air flow diagram.
Step Description
1 Check the supply voltage. If 230V is available, continue to step 2. Adjust the transformer
connections in case 115V is available (see service diagram)
2 Make sure all ball valves between the generator and the receivers are opened and the
ball valve after the refrigerant dryer is closed.
3 Make sure the following ball valves inside the generator are closed: BA05 and BA08.
4 Make sure the following ball valves inside the generator are opened: BA01, BA02,
BA03, BA04, BA06, BA07.
5 Make sure the refrigerant dryer (ID or FD) is not running in energy efficient mode. This
mode can cause an increase of outlet dew point and a shutdown of the generator as a
consequence.
6 Switch on the refrigerant dryer 10 minutes in advance of the compressor (if applicable).
7 Start the compressor.
8 Slowly open the valve after the compressor so the compressor can slowly fill the air
receiver in order to fill the air receiver with compressed air dried down to a dew point of
3 °C .
9 Enter the required nitrogen purity in the controller by navigating to Menu - Settings -
Generator - Regulation - Purity. The controller will use this setting to tune its capacity to
the consumed nitrogen flow (capacity control energy saving feature).
10 Enter the minimum required nitrogen purity in the controller by navigating to Menu -
Settings - Generator - Regulation - Min Purity. The controller will use this setting to start
flushing the nitrogen receiver when the minimum purity is reached.
Note: during flushing, the consumer valve V10 is closed and no nitrogen is available at
the outlet.
11 Make sure the pilot air pressure regulator PR01 is set to a pressure between 6 and 9
bar (85 – 130 psi).
12 Check the inlet dew point on the controller display. If this value exceeds 5 °C, the air
receiver needs to be flushed until a value below 5 °C is reached. The flushing of the
inlet receiver will be done automatically by valve V11. During this time, the generator is
in standby until a dewpoint of 5°C has been achieved at the inlet.
13 Start the generator by pushing the start button on the controller. The generator will now
start automatically. During "startup" the nitrogen receiver is filled through restriction
orifice OR04 until the pressure difference between the air receiver and nitrogen receiver
is less than the delta pressure setting (found in Menu - Settings - Generator - Regulation
- Delta Pressure). During "flushing" the nitrogen receiver is flushed through orifice OR06
until the purity in the vessel is equal to the Min Purity setting as entered in step 7.
Flushing can take up to 2 hours for “PCT” generators and up to 6 hours for "PPM"
generators. After flushing, the generator is ready for nitrogen production.
14 Regulate the outlet nitrogen pressure with pressure regulator PR03 to the requested
nitrogen pressure.
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Step Description
15 Make sure the outlet flow measured by FT01 does not exceed the nominal flow of the
nitrogen generator. Regulate the flow by controlling HV1. Exceeding the nominal flow
will cause the purity to drop. If the purity drops below the Min Purity setting, the outlet
flow is cut off to enable flushing of the nitrogen receiver.
The nominal flow is continuously calculated by the generator and can be found as
follows:
• go to Menu;
• go to Settings;
• go to Generator;
• go to Capacity control.
More flow means lower nitrogen purity, less flow means higher nitrogen purity. The
purity in the nitrogen receiver can be read on the main screen.
16 Set the time and date in the settings menu: . Menu - Settings - General Settings - Time.
Format: dd/mm/yy and hh:mm:ss.
17 Set the required warning and shutdown levels in the Protections menu.
18 Set the generator in automatic operation mode on the main screen. This enables
standby and capacity control modes.
Manual operation mode

In manual mode, the generator runs at normal timer based operation, independently from the
detected flow rate.
Automatic operation mode

In automatic mode, the generator will apply capacity control in 5 stages:
Nitrogen consumption level compared to Capacity control

nominal generator capacity
100 % Normal operation
Less than 80 % Cycle time modulation stage 1
Less than 1 % Standby
Inlet PDP protection

As standard, the NGP+ is equipped with an inlet PDP protection feature. When the inlet air PDP
exceeds 5°C, the PSA cycle is automatically shut down and an inlet flushing cycle is started. The
inlet flushing valve V11 allows a small flow of air through OR05 to the silencer, which will reduce
the load of the refrigerant dryer and allows the inlet air receiver to be dried until the required
dewpoint is achieved.
Capacity control
NGP+ generators are equipped with a capacity control feature. This feature enables the controller
to modulate the capacity (and thus the required amount of compressed air) depending on the
consumed nitrogen flow.
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The capacity is controlled by varying the cycle times (e.g. cycle time modulation). A lower
capacity means longer cycle times, a higher capacity means shorter cycle times. By doing this,
the outlet purity can be maintained constant and as a consequence less compressed air will be
used (energy saving up to 50%).
The feature also enables a generator which has been sized for high temperature to use less
energy when it is colder than the temperature for which the generator is sized.
Overflow protection
To protect the generator from being overloaded, the adsorbers are protected by the minimum
pressure valve V9 (see section Air flow diagram).
During normal operation, i.e. when the pressure difference between the air receiver and nitrogen
receiver is less than theDelta Pressure setting, see section Modifying settings (Menu - Settings -
Generator - RegulationDelta Pressure), the minimum pressure valve is open.
If the nitrogen demand would become too high,, the pressure difference will increase and when it
is higher than the Delta Pressure setting, minimum pressure valve V9 will close. At this stage, the
flow is restricted by startup nozzle OR04 as long as the pressure difference between the air
receiver and the nitrogen receiver is larger than the Delta Pressure setting. To recover from this
state, the outlet flow must be restricted to the nominal flow of the generator or less. When the
pressure difference becomes smaller than the Delta Pressure setting, the generator will wait 10
minutes before opening minimum pressure valve V9.
Guaranteed purity
To protect the installation from low purity that could harm its process, the NGP+ is equipped with
a guaranteed purity control. The minimum purity that is allowed in the installation can be set in
the controller. See section Modifying settings (Menu - Settings - Generator - Regulation - Min
Purity).
If the purity in the nitrogen receiver becomes lower than the Min Purity setting, the flow to the
installation is cut off by closing consumer valve V10. At the same time, outlet flushing valve V12
is opened to flush the nitrogen receiver with a flow, controlled by flushing nozzle OR06. This way,
the purity in the nitrogen receiver is recovered as fast as possible. Once the measured purity is
better than the Min Purity setting, flushing valve V12 will close and consumer valve V10 will open.
Changing the purity

Before changing the purity level of the generator, make sure which variant of nitrogen generator
has been installed:

95 % 5%
96 % 4%
97 % 3%
% 98 % 2%
99 % 1%
99.5 % 0.5 %
99.9 % 0.1 %
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99.95 % 500 ppm
ppm 99.99 % 100 ppm
99.999 % 10 ppm
The % variant has an oxygen sensor with a measurement range from 0 % to 10% oxygen level,
corresponding with 4-20 mA.
The ppm variant has an oxygen sensor with a measurement range from 0 ppm to 1000 ppm
oxygen level, corresponding with 4-20 mA.
Both variants are optimized in cycle times, purge flow and nozzle sizes to deliver maximum
performance at the desired purity.
To change the desired outlet purity, navigate to Menu - Settings - Generator - Regulation - Purity.
Based on this setting, the generator will adapt its capacity control and apply cycle time
modulation when necessary. When changing the purity setting, the Min Purity setting also needs
to be changed (navigate to Menu - Settings – Generator – Regulation – Min Purity). Based on
this setting, the generator will only allow nitrogen with a better purity than the Min Purity setting to
be sent to the installation.
Stopping procedure
To stop the generator, press the stop button on the controller. The generator will finish its current
cycle and vent both adsorber vessels.
If the installation is to be started up afterwards, it is advised not to use this function. Instead, stop
the consumption of nitrogen which will turn the generator in stand-by mode automatically. This
enables a start-up time of less than one minute, compared to up to one hour if the unit is
completely stopped.
5.2 Checking the display

Check the display regularly for readings and messages.
The main screen shows the generator inlet dew point, outlet purity, outlet flow and outlet
pressure.
Always check the display and remedy the trouble if the alarm LED (see section Control panel) is
alight or blinking.
The display will show a service message if a service plan interval has been exceeded or if a
service level for a monitored component has been exceeded. Carry out the service actions of the
indicated plans or replace the component and reset the relevant timer, see section Service menu.
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5.3 Taking out of operation
Procedure
Step Action
1 Stop the generator and close the air inlet and nitrogen outlet valve.
2 Depressurize the generator as described in section Test settings.
Switch off the voltage and disconnect the generator from the mains.
3 Close the ball valves towards the generator and depressurize the air and nitrogen
connections.
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6 Maintenance
6.1 General recommendations and precautions
Safety
Before carrying out any maintenance or corrective activity read the following recommendations
and safety precautions and act accordingly.
• To depressurize the adsorbers, navigate to Menu - Test - Depressurize vessels.

Make sure the pressure in the adsorbers drops to 0 bar and maintain this
depressurizing state for at least two minutes.
• Switch off the generator.
The release of oxygen molecules from the CMS is a very slow process. This might
cause a pressure buildup in the adsorbers, even after they were depressurized.
Before maintenance, make sure the generator is fully depressurized.
To manually depressurize the adsorbers, navigate to Menu - Test - Depressurize.
Warranty - Product liability

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts
is not covered by Warranty or Product Liability.
Service kits
For overhauling and for preventive maintenance, a wide range of service kits is available. Service
kits comprise all parts required for servicing the component and offer the benefits of genuine
spare parts while keeping the maintenance budget low.
Consult your Atlas Copco Customer Centre.
Service contracts
Atlas Copco offers several types of service contracts, relieving you of all preventive maintenance
work. Consult your Atlas Copco Customer Centre.
6.2 Maintenance schedule
General
To maintain the generator efficiency and to reduce the risks of faults, strictly observe the
recommended maintenance schedule.
On the Main screen, the remaining number of hours before service is displayed. This is a counter
that counts down from 4000 hours. For more information, see Service menu.
The following table specifies the frequency of the recommended maintenance operations,
expressed in operating hours of the generator:
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Programmed service interventions
Frequency Service plan Activity

Daily Check the controller for information on the purity,
alarms and service messages.
Every 4000 hours of operation A • Check fitted connections in and around the unit
or every 6 months (1) for potential leaks.
• Check for damaged wiring or loose connections.
• Replace the in- and outlet filter cartridges.
• Replace the activated carbon filter.
Every 8000 hours of operation B • Replace the inlet dew point sensor and outlet
or every year (1) dew point sensor (optional).
• Replace the pneumatic valves V3 and V6.
Every 16000 hours of operation C • Replace the pneumatic valves V1, V2, V4, V5,
or every 2 years (1) V7 and V8.
• Replace the built-in pilot air filter cartridge.
Every 40000 hours of operation D • Replace the oxygen sensor and analyser
or every 5 years • Replace the bellows on NGP 800 – 1300+
(1): whichever comes first

After maintenance activities, the service counter needs to be reset. Contact your supplier.
All spare parts required for scheduled maintenance are included in a specific Service kit. Part
numbers of the Service kits can be found in the spare parts list.
Proper and timely maintenance is extremely important to safeguard the lifetime of the
molecular sieves bed. The manufacturer cannot take any responsibility for improper
functioning of the generator if maintenance is not done as prescribed. In this respect,
regular maintenance of all equipment upstream of the generator, including but not
limited to the compressor and the filter package used is of extreme importance. For
maintenance instructions of this equipment, please be referred to the instruction manual
of the equipment involved.
6.3 Disposal of used material
Used filters or any other used material (e.g. adsorbent, lubricants, cleaning rags, machine parts,
etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the
local recommendations and environmental legislation.
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7 Adjustments and service
7.1 Calibration check of the oxygen sensor
General information
The zirconium type sensor does not need to be calibrated periodically because the outlet signal
and the deviation are guaranteed to be stable during the 5 year lifetime of the sensor.
Before commencing the calibration check, make sure the oxygen analyser sample flow is set at
the correct pressure and flow. Please refer to the table below for the correct settings.
Maintenance interval Service

At replacement (every 5 years) Replace sensor (see section Sensor replacement).
Oxygen sensor
1 Pressure regulator (PR02), adjusted to 2 bar (29 psi)

2 Zirconium sensor (OT01)
3 Purity sensor valve (Y14)
Location of the oxygen analyzer

The oxygen analyzer is located in the electrical cabinet:
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Location and detail of the oxygen analyser
Oxygen analyzer display
The keypad has the following functionality:
Button Function
A Menu Open/Close
B Enter button
C Next (increment) button
D Previous (decrement) button
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Sensor range
Sensor type O2 measurement range O2 concentration of

calibration gas
Nitrogen generator with % sensor 0–10 % 5000 ppm / 0.50 %
Nitrogen generator with ppm sensor 0-1000 ppm 100 ppm / 0.01 %
Calibration check
1. Put the generator in manual operation mode (see section Operating mode selection).
2. Close the ball valve (BA06) of the purity measurement (sample) line.
3. Apply calibration gas (see the table above) at a pressure of 2 bar(g) (29 psi(g)).
Allow time (approx. 15 min.) for the sensor to respond. To know if a stable value is reached,
it should be shown during 5 minutes without changing.
Note:
The concentration of the calibration check gas can vary depending on the application. The
values in the table are guide values.
4. Confirm that the value which reads from the display corresponds to the value on the
calibration gas certificate. If the value does correspond, continue to step 5 of this procedure.
If not, replace the sensor and analyser. These components are shipped as a complete kit
which is calibrated at the factory.
5. Disconnect the calibration check gas and reconnect the feedback line to the pressure
regulator.
6. Open the purity measurement line ball valve (BA07).
7. Set the generator back to Automatic mode.
7.2 Replacement of the O2 sensor
General information
Oxygen sensors have to be disposed of according to the applicable regulations.
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Electrical connections
1 Oxygen analyzer
2 Oxygen sensor
Oxygen sensor replacement procedure
The zirconium oxygen sensor and the oxygen analyzer need to be replaced as a couple.
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1 Pressure regulator (PR02), adjusted to 2 bar (29 psi)

2 Zirconium sensor (OT01)
3 Purity sensor valve (Y14)
1. Shut down the generator

2. Close the ball valve (BA07) of the purity measurement line.
3. Switch off the voltage.
4. Open the electrical cabinet and disconnect the oxygen sensor wiring from the oxygen
analyzer. Also disconnect the wiring of the oxygen analyzer.
5. Remove the oxygen sensor and the oxygen analyzer from sampling system.
6. Fit the new oxygen sensor and analyzer, and connect them to the control box (see electrical
connections).
7. Open the purity measurement line ball valve (BA07).
8. Switch on the power and start the generator.
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8 Optional equipment
8.1 Outlet pressure dew point

An outlet pressure dew point sensor (PDP02) is available as an extra measure to monitor the
dew point of the consumed nitrogen. This feature is especially useful if the nitrogen dew point is a
critical parameter in the process where the nitrogen is used.
Note that the outlet dew point of a nitrogen generator is not stable and can make large variations
depending on operating conditions. The highest outlet dew point will be -40 °C PDP, but this can
drop down to -70 °C in some cases.
Reference Description
1 Housing
2 Solenoid
3 Outlet pipe
4 Needle valve
5 Sensor
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Electrical connections of PDP sensor
8.2 External oxygen analyser

An external oxygen analyser is available for the means of monitoring the oxygen level in the room
where the nitrogen generator is installed.
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General arrangement
Note that adequate ventilation of the machine room is always necessary and ducting the exhaust
of the generator outside is highly recommended.
See Specific safety precautions for nitrogen generating equipment for more information.
Electrical connections
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Reference Designation
1 Status indicator
2 Red
3 Green
4 Sounder
5 24VDC power in
6 Relay 3
7 RS 232
8 4-20mA out
9 % oxygen analyser
10 Top
11 Terminal marker strips fitted to rear of analyser
12 Bottom
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9 Trouble shooting
Low purity warning

When the nitrogen concentration in the nitrogen receiver becomes lower than the Minimum Purity
setting, the generator will start flushing the nitrogen receiver and show a low purity alarm. At this
point, no nitrogen is available at the outlet of the generator.
Check the following possible causes:
• Check that the nitrogen purity ball valve BA07 is in open position and nitrogen sample ball
valve BA05 is in closed position.
• Make sure the generator is in running mode.
• Variations in operating conditions, such as flow, pressure and temperature can have a large
impact on the outlet purity. To check whether the generator’s capacity at the current
operating conditions is exceeded or not, check the Consumption Level reading by navigating
to Menu – Settings – Generator – Capacity Control. When the consumption level is higher
than 100%, it means that the generator has less capacity than requested. In this case, the
nitrogen consumption is too high and the amount of nitrogen flow at the outlet needs to be
reduced. If this is not an option, increasing capacity on a particular nitrogen generator can
be done by:
• Decreasing the purity setting to a lower purity
• Increasing the inlet pressure
• Decreasing the ambient temperature if the current temperature is higher than 20 °C.
• Inlet pressure should remain constant at all times. This is a direct cause of compressor
sizing. If the compressor is running at full load over a complete cycle, the compressor is
sized too small. If this is the case, lower the pressure setpoint of the compressor. If the
compressor is oversized, then it would run in unload during one or more complete cycles. In
this case, increase the pressure setting of the compressor so it's capacity is matched to that
of the nitrogen generator. Alternatively, a pressure regulator should be installed before the
air receiver in order to have a constant inlet pressure during multiple cycles.
• Make sure the exhaust opening is not blocked.
• In case of a load/unload compressor, make sure that the load/unload period is shorter that
two minutes. Do this by lowering the pressure band of the compressor and oversizing of the
inlet air receiver.
• If the exhaust is connected to outdoors, make sure the exhaust line is sized correctly. Refer
to section Installation proposal for details.
• Check the reading of the pressure on sample pressure regulating valve PR02. This should
read 2 bar (29 psi).
• Check the reading of the oxygen sensor OT01 by applying a reference gas to the oxygen
sensor. See section Calibration of the oxygen sensor for a detailed procedure.
High dryer pressure dew point

The inlet pressure dew point of a nitrogen generator should be 3 °C and may not exceed 5 °C.
NGP+ nitrogen generators are equipped as standard with an inlet dew point monitoring sensor,
which monitors the dew point of the refrigerant dryer used.
Make sure that a dedicated FD dryer is used if ambient temperatures exceed 30°C.
A high dew point can be caused by an overload of the refrigerant dryer, which can occur during
startup. To prevent this from happening, the refrigerant dryer should be switched on before the
compressor. When the compressor is switched on, the outlet flow of the compressor should be
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reduced by means of choking with a ball valve. This causes the produced compressed air to have
enough time to pass the dryer and fill the air receiver with the correct quality of inlet air.
If the air receiver has been filled with air that has a higher dew point than 5° C, the air receiver
will be purged automatically by inlet flushing valve V11. As a consequence, the dewpoint of the
air receiver will drop to the required level for operation.
Failed To Pressurize
This alarm is triggered when adsorber A or B failed to build up pressure. In normal working
conditions, the pressure inside an adsorber vessel should rise to the inlet pressure during the
production state. If this does not happen, the process of producing nitrogen has to be halted.
• Make sure the inlet air pressure is higher than 5 bar (72 psi).
• Make sure the pilot air pressure regulator PR01 is regulated to 6 bar (87 psi).
• Check if the pilot air tubing has been correctly installed. Refer to the flow diagram for
detailed instructions. The flow diagram shows which solenoid valves connect to which
process valves. It also shows the tubing numbering.
• Check if the pneumatic valves are actuating.
Failed To Blow Off Vessel A (or Vessel B)

This alarm is triggered when adsorber A (or B) failed to depressurize. In normal working
conditions, the pressure inside an adsorber vessel should lower to the atmospheric pressure
during the regeneration state. If this does not happen, the process of producing nitrogen has to
be halted.
• Make sure the pilot air pressure regulator PR01 is regulated to 6 bar (87 psi).
• Make sure the exhaust opening is not blocked.
• If the exhaust is connected to outdoors, make sure the exhaust line is sized correctly. Refer
to section Installation proposal for details.
• Check if the pilot air tubing is installed correctly. Refer to the flow diagram for details. The
flow diagram shows which solenoid valve connects to which process valve. It also shows the
tubing numbering.
• Check if the pneumatic valves are actuating. If not, disassemble the actuator from the body
and check that the valve is free moving and free of dust.
High Working Pressure

This alarm is activated when the inlet pressure exceeds 10 bar (145 psi). This Is the maximum
design pressure of the generator.
Reduce the inlet pressure.
Low Working Pressure

This alarm is activated when the inlet pressure drops below 5 bar (72 psi). This is the minimum
working pressure of the generator.
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High Inlet temperature

This alarm is activated when the inlet temperature exceeds 50 °C (122 °F). This is the maximum
inlet temperature of the generator.
No outlet pressure
The NGP+ nitrogen generator features protections against overflow and regulations for
guaranteed purity. Because of these features, it is able to shut off the pressure to the outlet by
control valves.
If no pressure is available at the outlet, check the protection conditions of the generator:
• Is the generator started up properly? This can be checked by comparing the pressure of the
air receiver to the pressure of the nitrogen receiver. The difference in pressure should be
less than 0.5 bar.
• Make sure the nitrogen receiver is able to build up pressure by checking that there are no
restrictions in the piping between the generator “to buffer” connection and the nitrogen
receiver. Double check that the connection diameter is corresponding to the installation
proposal.
• Check the purity of the nitrogen receiver. This parameter is displayed on the main screen.
This parameter should be higher than the Minimum Purity setting before pressure will be
available on the outlet.
The following description describes the conditions to actuate the control valves:
Minimum pressure valve V9:
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Opens when the Delta Pressure over the CMS bed is within operating limits. This Delta Pressure
is adjustable on the controller in Menu – Settings – Generator – Regulation – Delta Pressure.
Caution: changes to this setting can only be made if there is no alternative way to remedy the
problem. Changing this setting can cause overflow of the CMS bed. Increase the setting if the
pressure in the nitrogen receiver is stable, but not high enough to open the Minimum pressure
valve.
Consumer valve V10:

Opens when minimum pressure valve V9 is opened and the actual purity is higher than the
Minimum Puritysetting. The minimum purity setting is adjustable on the controller in Menu –
Settings – Generator – Regulation – Minimum Purity.
Inlet flushing valve V11:

Opens when the inlet PDP is higher than 5°C. During this period, the wet inlet receiver will be
flushed until it is dry at 3°C PDP.
Outlet flushing valve V12:
Opens when minimum pressure valve V9 is opened and the actual purity is lower than the
Minimum Purity setting or when minimum pressure valve V9 is opened and the nitrogen receiver
pressure is lower than 2 bar. The Minimum Purity setting is adjustable on the controller in Menu –
Settings – Generator – Regulation – Minimum Purity.
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10 Technical data
10.1 Reference conditions
Air pressure at generator inlet 7.0 bar 102 psi

Ambient temperature (air inlet temperature) 20 ˚C 68 ˚F
Air inlet quality Class [2-4-1] acc. ISO Class [2-4-1] acc. ISO
8573-1:2010 8573-1:2010
10.2 Limitations for operation

Inlet air quality Class [2-4-1] acc. ISO 8573-1:2010
Compressed air inlet pressure, maximal 10 bar 145 psi
Compressed air inlet pressure, minimal* 5.0 bar 72 psi
Compressed air temperature, maximal 50 ˚C 122 ˚F
Compressed air temperature, minimal 5 ˚C 41 ˚F
Ambient air temperature, maximal 50 ˚C 122 ˚F
Ambient air temperature, minimal 5 ˚C 41 ˚F
*When operating at this low pressure, make sure the pneumatic valves switch in time.
10.3 Performance data
Outlet flow rate at reference conditions (1)

If the feed air pressure deviates from reference pressure, the performance of the nitrogen
generator will have to be corrected.
Nitrogen flow (Nm3/h)
Purity NGP NGP NGP NGP NGP NGP NGP NGP NGP
240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
95.000% 518 669 820 970 1187 1421 1780 2258 2871
96.000% 468 605 741 876 1073 1284 1608 2040 2594
97.000% 420 543 665 787 963 1152 1444 1831 2329
98.000% 363 470 575 680 833 997 1249 1584 2014
99.000% 298 385 471 557 682 816 1023 1298 1650
99.500% 252 325 398 471 577 690 865 1097 1395
99.900% 180 232 284 337 412 493 618 784 996
99.950% 138 178 218 258 315 377 473 600 762
99.990% 105 136 167 197 242 289 362 459 584
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240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
99.999% 68 87 107 127 155 186 232 295 375
(1): The indicated flow (N2 flow) is the Free Nitrogen Delivery (FND), i.e. the nitrogen flow
referred to 20 °C, 1000 mbar and 0 % relative humidity. During testing of the units, the rejection
limit is + or – 5 % of the nominal nitrogen flow.
Inlet air flow at reference conditions (2)

Compressed air inlet (Nm3/h)
240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
95.000% 937 1211 1483 1755 2149 2571 3283 4164 5295
96.000% 891 1151 1410 1668 2042 2443 3120 3957 5032
97.000% 835 1078 1321 1563 1913 2289 2923 3707 4714
98.000% 775 1001 1226 1451 1776 2125 2713 3442 4377
99.000% 697 900 1102 1304 1597 1911 2440 3095 3935
99.500% 646 835 1023 1210 1482 1773 2264 2871 3651
99.900% 561 725 888 1050 1286 1538 1964 2492 3169
99.950% 455 588 720 852 1043 1248 1593 2020 2569
99.990% 419 541 663 784 960 1149 1465 1859 2364
99.999% 357 461 565 669 818 979 1249 1585 2015
(2): The indicated flow (FAD) is the average Free Air Delivery flow (FAD = Free Air Delivery, i.e.
referred to the inlet conditions). The air requested by the nitrogen generator is not constant
during the production cycle. Every time the vessels are pressurized there will be an air
consumption peak during a few seconds which can be 3 to 4 times the average consumption.
Therefore it is important to size the air receiver correctly. During testing of the units, the rejection
limit is + or – 5 % on the air demand.
Air factor at reference conditions

Air factor
240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
95.000% 1.81 1.81 1.81 1.81 1.81 1.81 1.84 1.84 1.84
96.000% 1.90 1.90 1.90 1.90 1.90 1.90 1.94 1.94 1.94
97.000% 1.99 1.99 1.99 1.99 1.99 1.99 2.02 2.02 2.02
98.000% 2.13 2.13 2.13 2.13 2.13 2.13 2.17 2.17 2.17
99.000% 2.34 2.34 2.34 2.34 2.34 2.34 2.39 2.39 2.39
99.500% 2.57 2.57 2.57 2.57 2.57 2.57 2.62 2.62 2.62
99.900% 3.12 3.12 3.12 3.12 3.12 3.12 3.18 3.18 3.18
99.950% 3.31 3.31 3.31 3.31 3.31 3.31 3.37 3.37 3.37
99.990% 3.98 3.98 3.98 3.98 3.98 3.98 4.05 4.05 4.05
86 2920 7191 10
Instruction book
240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
99.999% 5.28 5.28 5.28 5.28 5.28 5.28 5.38 5.38 5.38
Dimensions and weight
NGP NGP NGP NGP NGP NGP NGP NGP NGP

240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
Width mm 2230 2570 2650 2720 2850 2900 3460 3660 3860
Length mm 1800 1800 1800 2300 2300 2300 3120 3120 3120
Height mm 2610 2640 2625 3020 3050 3040 3970 4175 4405
Weight Ton 3.2 3.8 4.8 6.4 7 7.7 10.3 12 14.2
N2 & air l 3000 4000 5000 6000 8000 10000 12000 16000 20000
receiver
size
Air l 3000 3000 4000 5000 6000 8000 10000 12000 16000
reveiver
size
VSD
Mechanical connections
NGP NGP NGP NGP NGP NGP NGP NGP NGP

240+ 300+ 360+ 450+ 550+ 650+ 800+ 1000+ 1300+
Air inlet DN 80 100 150
inch 3 3 6
N2 to DN 80 100
buffer inch 3 4
N2 from DN 50 80 100
buffer inch 2 3 4
(PCT)
N2 from DN 40 50
buffer inch 1 1/2 2
(PPM)
N2 outlet DN 50 80 100
(PCT) inch 2 3 4
N2 outlet DN 50
(PPM) inch 2
Waste mm 315 400 600
gas
blow-off
2920 7191 10 87
Instruction book
10.4 Correction factors
Correction factors
If the inlet pressure and/or ambient temperature differ from the reference data, the nominal
performance figures need to be corrected with correction factors Kpc, Kpa, Ktc and Kta. The
value of the correction factors differs from generator type (ppm or %): % generators deliver
nitrogen with a purity from 95 % to 99.9 %, ppm generators deliver nitrogen with a purity from
99.95 % to 99.999 %.
Pressure correction factors
Capacity Air ratio

Kpc Kpa
Pressure (bar) % ppm % ppm
5 0.71 0.78 1.03 1.06
5.5 0.79 0.84 1.01 1.03
6 0.88 0.89 1.00 1.00
6.5 0.93 0.94 1.00 1.00
7 1.00 1.00 1.00 1.01
7.5 1.06 1.04 1.00 1.04
8 1.11 1.09 1.01 1.07
8.5 1.15 1.11 1.01 1.10
9 1.20 1.11 1.01 1.12
9.5 1.23 1.10 1.01 1.17
10 1.28 1.08 1.01 1.24
Temperature correction factors
Capacity Air ratio

Ktc Kta
Temperature (°C) % ppm % ppm
5 1.00 1.04 1.00 1.00
10 1.00 1.03 1.00 1.00
15 1.00 1.02 1.00 1.00
20 1.00 1.00 1.00 1.00
25 0.98 0.96 1.01 1.06
30 0.96 0.93 1.04 1.12
35 0.91 0.86 1.09 1.18
40 0.85 0.79 1.16 1.24
45 0.77 0.71 1.25 1.33
50 0.70 0.64 1.33 1.42
88 2920 7191 10
Instruction book
Due to the relatively slow air speeds in the receivers, the temperature of the molecular sieve
material (CMS) will be equal to the ambient temperature.
Outlet flow calculation

QOUT_ACT = QOUT_NOM x Kpc x Ktc
With
QOUT_ACT : actual outlet flow
QOUT_NOM : nominal outlet flow at reference conditions
Kpc : inlet pressure correction factor for capacity
Ktc : ambient temperature correction factor for capacity
Inlet flow calculation

1. Air ratio calculation
ARACT = ARNOM x Kpa x Kta
With
ARACT : actual air ratio
ARNOM : nominal air ratio at reference conditions
Kpa : inlet pressure correction factor for air ratio
Kta : ambient temperature correction factor for air ratio
2. Inlet flow calculation
QIN_ACT = QOUT_ACT x ARACT
Where:
QIN_ACT : actual inlet flow
QOUT_ACT : actual outlet flow
ARACT : actual air ratio
Calculation example NGP 360+

Purity : 99.50%
Qout_nom : 398 Nm³/h
Air ratio : 2.57
Qin_nom : 1023 Nm³/h
Inlet pressure : 9 bar
Max. ambient temperature : 40°C
Correction factors from tables:
Kpc : 1.25
Ktc : 0.88
Kpa : 1.00
Kta : 1.12
Calculation
1. Actual outlet flow
2920 7191 10 89
Instruction book
QOUT_ACT = QOUT_NOM x Kpc x Ktc = 398 Nm³/h x 1.25 x 0.88 = 438 Nm³/h
The actual nitrogen outlet flow will be 438 Nm³/h at 9 bar and 40°C.
2. Air ratio
ARACT = ARNOM x Kpa x Kta = 2.57 x 1.00 x 1.12 = 2.89
The actual air ratio will be 2.89 at 9 bar and 40°C.
3. Actual inlet flow
QIN_ACT = QOUT_ACT x ARACT = 438 Nm³/h x 2.89 = 1266 Nm³/h
The actual compressed air inlet flow will be 1266 Nm³/h at 9 bar and 40°C.
90 2920 7191 10
Instruction book
11 Pressure Equipment Directives
Components subject to Pressure Equipment Directive 97/23/EC (until 20/07/2016) or 2014/68/EU

(from 20/07/2016 onwards)
Parts of article 3.3 of 97/23/EC are subject to Sound Engineering Practice (SEP).
Parts of category I according to 97/23/EC are integrated into the machine and fall under the
exclusion of article I, section 3.6.
The following tables A and B contain the necessary information for the inspection of all pressure
equipment of category I according Pressure Equipment Directive 2014/68/EU and all pressure
equipment according the Simple Pressure Vessel Directive 2009/4105/EC.
Design criteria for pressure equipment:
Table A
Type Medium Design pressure Vessel volume [L] PED category

[bar]
NGP 240+ AIR 11 698 IV
NGP 300+ AIR 11 872 IV
NGP 360+ AIR 11 1115 IV
NGP 450+ AIR 11 1245 IV
NGP 550+ AIR 11 1540 IV
NGP 650+ AIR 11 1983 IV
NGP 800+ AIR 11 2480 IV
NGP 1000+ AIR 11 3158 IV
NGP 1300+ AIR 11 3950 IV
Table B
Generator Min. design Max. design Numer of cycles Wall thickness

temperature [°C] temperature [°C] (1) [mm]
NGP 240+ -10 +80 5,000,000 8
NGP 300+ -10 +80 5,000,000 10
NGP 360+ -10 +80 5,000,000 12
NGP 450+ -10 +80 5,000,000 12
NGP 550+ -10 +80 5,000,000 12
NGP 650+ -10 +80 5,000,000 14
NGP 800+ -20 +80 5,000,000 14
NGP 1000+ -20 +80 5,000,000 16
NGP 1300+ -20 +80 5,000,000 16
(1): The number of cycles refers to the number of cycles from 0 bar(g) to maximum pressure
(2): The minimum wall thickness refers to the minimum required thickness according design
calculations.
2920 7191 10 91
Instruction book
Recommendation of the manufacturer for the re-inspection time

Following actions are to be executed by authorised service personnel, unless stated differently in
the applicable legislation. The stated time interval has as reference the day of start-up of the unit.
• Every 6 months: visual check of the vessel (tank) material on the outside (exposed) for
traces of strong corrosion. Consult the service department of your supplier if necessary.
• Further re-inspection of the pressurized components should be carried out according to the
local regulations. Contact your Notified Body for more information.
92 2920 7191 10
Instruction book
12 Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Contact address:

Atlas Copco Airpower n.v.
P.O. Box 100
B-2610 Wilrijk (Antwerp)
Belgium
(2): Applicable directives
(3): Standards used
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that
is supplied with this device.
2920 7191 10 93
No. 2920 7191 10 / 2018 - 03 - Printed in Belgium Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
COMMITED TO SUSTAINABLE PRODUCTIVITY
We stand by our responsibilities towards our customers, towards the
environment and the people around us. We make performance stand
the test of time. This is what we call — Sustainable Productivity.
www.atlascopco.com

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INSTRUCTION BOOK

PSA NITROGEN GENERATORS

1.1 SAFETY ICONS................................................................................................................................... 5

1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................5

1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 5

1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7

1.6 SPECIFIC SAFETY PRECAUTIONS FOR NITROGEN GENERATING EQUIPMENT...................................................... 8

1.7 SAFETY LABELLING ON NITROGEN GENERATORS........................................................................................9

2.1 GENERAL DESCRIPTION..................................................................................................................... 11

2.2 DETAILED DESCRIPTION..................................................................................................................... 12

2.3 FLOW DIAGRAM................................................................................................................................14

2.4 ELECTRIC DIAGRAM...........................................................................................................................16

3.3 ELECTRICAL CONNECTIONS.................................................................................................................22

4 Elektronikon® Graphic controller............................................................................... 23

4.2 CONTROL PANEL.............................................................................................................................. 24

4.3 ICONS USED.................................................................................................................................... 25

4.4 MAIN SCREEN..................................................................................................................................27

4.5 CONTROL MODE SELECTION................................................................................................................30

4.6 OPERATION MODE SELECTION............................................................................................................. 31

4.7 CALLING UP MENUS.......................................................................................................................... 31

4.8 INPUTS MENU...................................................................................................................................32

4.9 OUTPUTS MENU............................................................................................................................... 33

4.11 EVENT HISTORY MENU.......................................................................................................................36

4.12 SERVICE MENU................................................................................................................................ 36

4.13 PROTECTIONS MENU......................................................................................................................... 40

4.14 WEEK TIMER MENU...........................................................................................................................40

4.15 INFO MENU......................................................................................................................................50

4.16 MODIFYING SETTINGS........................................................................................................................50

4.17 WEB SERVER.................................................................................................................................. 58

4.18 PROGRAMMABLE SETTINGS.................................................................................................................64

5.2 CHECKING THE DISPLAY.....................................................................................................................68

5.3 TAKING OUT OF OPERATION................................................................................................................69

6.1 GENERAL RECOMMENDATIONS AND PRECAUTIONS................................................................................... 70

6.2 MAINTENANCE SCHEDULE...................................................................................................................70

6.3 DISPOSAL OF USED MATERIAL............................................................................................................. 71

7 Adjustments and service............................................................................................. 72

7.1 CALIBRATION CHECK OF THE OXYGEN SENSOR....................................................................................... 72

7.2 REPLACEMENT OF THE O2 SENSOR..................................................................................................... 74

8.1 OUTLET PRESSURE DEW POINT........................................................................................................... 77

8.2 EXTERNAL OXYGEN ANALYSER............................................................................................................ 78

10.1 REFERENCE CONDITIONS................................................................................................................... 85

10.2 LIMITATIONS FOR OPERATION.............................................................................................................. 85

10.3 PERFORMANCE DATA.........................................................................................................................85

10.4 CORRECTION FACTORS......................................................................................................................88

11 Pressure Equipment Directives...................................................................................91

1.1 Safety icons

1.2 General safety precautions

1.3 Safety precautions during installation

1.4 Safety precautions during operation

1. Persons switching on remotely controlled machines shall take adequate precautions to

1.5 Safety precautions during maintenance or repair

1.6 Specific safety precautions for nitrogen generating

% oxygen at sea level (atmospheric pressure) Effects

Although a source of ignition energy is always necessary in combination with flammable

1.7 Safety labelling on nitrogen generators

The following safety label is attached to the nitrogen generator:

Information on safety labels:

ISO 7000 - symbol 0419 Read the instruction manual

ISO 7000 - symbol 0434b General safety alert symbol

- Warning: Risk of asphyxiation

ISO 7010 - symbol P003 Fire hazard:

1079 9903 48 Warning: