OPERATING AND MAINTENANCE MANUAL NITRONIC™ NITROGEN GENERATOR MODEL NM-300 PREPARED FOR: US ARMY CORPS OF ENGINEERS JOHN DAY DAM RUFUS, OREGON 97050 Contract # DACW57-01-P-0083 1/11/2001 Nitronics Job Number: NM-300-23/24/25 NITRONICS SYSTEMS Advanced Nitrogen GeneratorsSAFETY ‘The NITRONIC® Nitrogen System is designed for use in unclassified non-hazardous areas ONLY. If explosive or flammable vapors are present on an intermittent or continuous basis, special design features ust be incorporated to provide safe operation All compressed gases, including air and nitrogen, can be dangerous. Know and follow all safety rules when using compressed air or nitrogen and especially when breaking into compressed air or nitrogen lines to install or modify equipment. Specific safety procedures, including training of all personnel, should be developed and implemented. The NITRONIC® Nitrogen System produces nitrogen and all safety precautions that apply to compressed nitrogen should be observed. Nitrogen is an odorless, colortess and tasteless gas which WILL NOT "SUPPORT LIFE. Exposure to or inhalation of the gas must be avoided. Leakage or venting of nitrogen Into closed or poorly vented areas where personnel may be present must be avoided. ‘The waste gas vented from the NITRONIC® nitrogen cabinet is enriched in oxygen. The waste gas’ MUST be piped away from personnel areas, preferably outdoors in such a way as to prevent water vapor from condensing and freezing in the vent line. Review the nitrogen MSDS on the following pages. | | |MATERIAL SAFETY DATA SHEET itronics Systems, Inc. 1700 South 120" Street B-4 Lafayette, CO 80026 USA Phone: 303-604-1187 EMERGENCY CONTACT 24 Hour USA CHEMTREC 1-800-424-9300 SECTION 1: PRODUCT IDENTIFICATION PRODUCT NAME: NITROGEN, COMPRESSED GAS ‘SYNONYMS: NITROGEN: NITROGEN-14; NITROGEN GAS; UN 1086; N2 CHEMICAL FAMILY: inorganic, gas CREATION DATE: Jan 24 1998 REVISION DATE: July 12, 2000 ‘SECTION 2: COMPOSITION/INFORMATION ON INGREDIENTS COMPONENT: NITROGEN, COMPRESSED GAS CAS NUMBER: 7727-37-9 EC NUMBER (ETNECS): 231-783-9 PERCENTAGE: — 100.0 ‘SECTION 3: HAZARDS IDENTIFICATION NFPA RATINGS (SCALE 0-4): HEALTH=1 FIRE=0 REACTIVITY=0 WHMIS CLASSIFICATION: A EC CLASSIFICATION (CALCULATED): No classification assigned. EMERGENCY OVERVIEW: COLOR: colorless PHYSICAL FORM: gas ‘ODOR: odorless MAJOR HEALTH HAZARDS: difficulty breathing PHYSICAL HAZARDS: Containers may rupture or explode if exposed to heat. POTENTIAL HEALTH EFFECTS: INHALATION: SHORT TERM EXPOSURE: Simple asphyxiant, nausea, vomiting, and symploms of drunkenness, tingling sensation, suffocation, and convulsions. coma LONG TERM EXPOSURE: no information on significant adverse effectsSKIN CONTACT: SHORT TERM EXPOSURE: no information on significant adverse effects LONG TERM EXPOSURE: no information on significant adverse effects, EYE CONTAC ‘SHORT TERM EXPOSURE: irritation LONG TERM EXPOSURE: no information on significant adverse effects INGESTION: ‘SHORT TERM EXPOSURE: no information on significant adverse effects LONG TERM EXPOSURE: no information is available CARCINOGEN STATUS: OSHA: N NTP: N TAR SECTION 4: FIRST AID MEASURES: INHALATION ‘When safe to enter area, remove from exposure. Use a bag valve mask or similar device to perform artificial respiration (rescue breathing) if needed. Keep warm and at rest. Get medical attention immediately. SKIN CONTACT: Wash if needed. If frostbite, freezing, or cryogenic burns occur, warm affected area in warm water. If this is not available, gently wrap affected parts in blankets. Allow circulation to retum naturally. Get ‘medical attention immediately. EYE CONTACT: Wash eyes immediately with large amounts of water. Occasionally lifting upper and lower lids, until no evidence of chemical remains. Get medical attention immediately, INGESTION: Itis unlikely that emergency treatment will be required. Get medical attention, if needed, NOTE TO PHYSICIAN: For inhalation, consider oxygen ‘SECTION 5: FIRE FIGHTING MEASURES FIRE AND EXPLOSION HAZARDS: Negligible fire hazard. Containers may rupture or explode if exposed to heat. EXTINGUISHING MEDIA: Carbon dioxide, regular dry chemical. Large fires: Use regular foam or flood with fine water spray. FIRE FIGHTING: Move container from fire area if it can be done without risk. Cool containers with water spray until well afier the fire is out. Stay away from the ends of tanks. Withdraw immediately in case of rising sound from venting safety device or any discoloration of tanks due to fire. For tank, rail car or tank truck, evacuation radius: 800 meters (1/2 mile). SECTION 6: \CCIDENTIAL RELEASE MEASURESOCCUPATIONAL RELEASE: Stop leak if possible without personal risk. Keep unnecessary people away, isolate hazard area and deny entry. Stay upwind and keep Out of low areas. ‘SECTION 7: HANDLING AND STORAGE Store and handle in accordance with all current regulations and standards. Subject to storag} regulations: U.S. 051-14 29 CFR 1910. 101. Keep separated from incompatible substances. SECTION 8: EXPOSURE CONTROLS, PERSONAL PROTECTION EXPOSURE LIMITS NITROGEN, COMPRESSED GAS: No occupational exposure limits established, VENTILATION: Provide local exhaust ventilation system. Ensure compliance with applicable exposure limits, EYE PROTECTION: For the gas: Eye protection not required, but recommended. For the liquid: Wear splash resistant safety goggles. Contact lenses should not be worn. Provide an emergency eye wash fountain and quick drench shower in the immediate work area, CLOTHING: For the gas: Protective clothing is not required. For the liquid: Wear appropriate protective, cold insulating clothing GLOVES: Wear insulated gloves, RESPIRATOR: Under conditions of frequent use or heavy exposure, respiratory protection may be needed. Respirator protection is ranked in order from minimum to maximum. Consider warning properties before use. For Unknown Concentrations or Immediately Dangerous to Life or Health ‘Any supplied-air respirator with full-face piece and operated in a pressure-demand or other positive- pressure mode in combination with a separate escape supply, ‘Any self-contained breathing apparatus with a full face piece. ‘SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES PHYSICAL STATE: gas COLOR: colorless ODOR: odorless TASTE:tasteless MOLECULAR WEIGHT: 28.0 MOLECULAR FORMULA: N2 BOILING POINT: -321 F (-196 C) FREEZING POINT: -346 F (-210 0) VAPOR PRESSURE: 760 min Hg @ -198 VAPOR DENSITY (air=): 0.967 ‘SPECIFIC GRAVITY: Not applicable DENSITY: 1.2506 g/L WATER SOLUBILITY: 023 @ 32 F PH: Not applicable VOLATILITY: 100% ODOR THRESHOLD: Not availableEVAPORATION RATE: Not applicable SOLVENT SOLUBILITY: ‘Soluble: liquid ammonia Slightly Soluble: alcohol ‘SECTION 10: STABILITY AND REACTIVITY REACTIVITY: Stable at normal temperatures and pressure, | CONDITIONS To AVOID: Protect from physical damage and heat. Containers may rupture or explode if exposed to heat. INCOMPATIBILITIES: Metals, oxidizing materials. HAZARDOUS DECOMPOSITION: Thermal decomposition products: oxides of nitrogen | POLYMERIZATION: ‘Will not polymerize. SECTION 11: TOXICOLICAL INFORMATION Not available ‘SECTION 12: ECOLOGICAL INFORMATION Not available SECTION 13: DISPOSAL CONSIDERATIONS Dispose in accordance with all applicable regulations, SECTION 14: TRANSPORTATION INFORMATION | U.S. DOT 49 CFR 172.101. SHIPPING NAME-UN NUMBER; HAZARD CLASS; PACKING GROUP; LABEL: Nitrogen. compressed-UN 1066; 2.2: Nonflammable gas SECTION 15: REGULATORY INFORMATION, U.S. REGULATIONS: ‘TSCA INVENTORY STATUS: Y ‘TSCA 12(h) EXPORT NOTIFICATION: Not listed, | CERCLA SECTION 103 (40CFR302.4): N SARA SECTION 302 (40CFR355.30): N SARA SECTION 304 (40CFR355.40): N SARA SECTION 313 (40CFR372.65): N SARA HAZARD CATEGORIES, SARA SECTIONS 311/312 (40CFR370.21): | ‘ACUTE: Y CHRONIC: N | FIRE: N REACTIVE: N | ‘SUDDEN RELEASE: Y OSHA PROCESS SAFETY (29CFR1910.119): N | STATE REGULATIONS: California Proposition 65: NEUROPEAN REGULATIONS: EC NUMBER (EINECS): 23 1-783.9 | (Copyright 1999 Nitronics Systems. All rights reserved. NITRONICS SYSTEMS MAKES NO EXPRESS OR IMPLIED WARRANTIES, GUARANTEES OR REPRESENTATIONS REGARDING THE PRODUCT OR THE INFORMATION HEREIN, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR | USE. NITRONICS SYSTEMS SHALL NOT BE LIABLE FOR ANY PERSONAL INJURY, PROPERTY OR OTHER DAMAGES OF ANY NATURE, WHETHER COMPENSATORY, CONSEQUENTIAL, EXEMPLARY, OR OTHERWISE, RESULTING FROM ANY PUBLICATION, USE OR RELIANCE, UPON THE INFORMATION HEREIN.SYSTEM DESCRIPTION ‘The NITRONIC® Nitrogen System is a complete microprocessor controlled system requiring only suitable compressed air and electrical power supplies to produce nitrogen. ‘The NITRONIC® Nitrogen Systems separate nitrogen from compressed air (a mixture of nitrogen and ‘oxygen with argon and other trace components) using a hollow fiber, semipermeable membrane. The compressed air is passed through three filters, two with condensate traps, to remove liquid water, oll and particulates and then through the membrane to separate out the nitrogen. The hollow fiber, semipermeable membrane is a passive device with no moving parts. The driving force for separation of nitrogen is the feed pressure, which forces the oxygen through the membrane leaving the nitrogen and part of the argon. The NITRONIC® Nitrogen System is equipped with an Oxygen Sensor, an Economizer, and an Automatic Vent. The Oxygen Sensor is configured to read out in percent nitrogen (more exactly the analyzer reads percent oxygen and subtracts that from 100%) i.e. the reading is the volume percent nitrogen plus argon). The Oxygen Sensor is equipped with a purity warning. The warning is an indicator light (lit means purity is OK) on the front display panel and is also used to operate the Automatic Vent. To prevent unnecessary consumption of compressed air when nitrogen production is not required, the Nitronic system is equipped with an Economizer. The Economizer should only be used in conjunction with a nitrogen receiver. Whenever nitrogen is not being used, the pressure in the receiver will increase and will eventually reach the operating pressure. The Economizer senses the pressure in the receiver and shuts off the compressed air supply. The Economizer automatically re-opens the supply air at a preset level ‘The Automatic Vent operates from the oxygen sensor and the temperature control logic. This vents the product nitrogen with the waste gas whenever the purity falls below a preset level or the system ‘temperature falls outside a specific range. ‘The system is also equipped with a solid state Space Healer to keep the insulated enclosure at a minimum set temperature. A one-year warranty is provided by Nitronic for each NITRONIC Nitrogen system, The warranty is included on page 19.‘SPECIFICATIONS Operating System Version Nitrogen Purity (nitrogen plus argon) Maximum Air Supply Pressure Maximum Operating Air Pressure Rated Ar Supply Pressure Maximum Flow Rate at 100 psig Minimum Operating Air Pressure Air Filters Electrical Power: ‘Space Heater ‘Air Supply/Product/Drain Fittings Ventitator Vent Waste Gas Fitting Maximum Nitrogen Pressure Ambient and Supply Air Temperature Cabinet Dimensions Nitrogen Receiver Tank Flow Me Cenv22 (2.02) 95.0 to 99.9% adjustable 200 psig (safety valve setting) 125 psig (regulator adjustable) 100 psig 40 scfh @ 99.0% purity 90 psig (1) Particulate wtrap, (1) Coalescing witrap, (1) Carbon 600 watts - 140V power supply (2) Fuses ~ 10 amp, (2) 1.6 amp Terminal Board 50 watts "NPT brass 4" NPT brass 1" cPVC 10 psi below system operating pressure 65F to 100F 60" H x 24" Wx 18" D 80 gals ASME 200 psig MAWP (175 psig safety valve)| INSTALLATION ‘The NITRONIC® Nitrogen System should be installed where it will not be exposed to water. Verify that: a) The air compressor has an air receiver tank with a bottom liquid drain and the air has been treated in a coalescing fier with an automatic drain between the receiver tank and the NITRONIC® Nitrogen System b) Procedures are in place to ensure that the compressor is maintained in accordance with the manufacturer's maintenance instructions, that the air receiver is drained daily and the filters are inspected and filter elements changed on a regular basis. ©) The compressed air supply pressure does not exceed 125 psig but is at least 90 psig d) The compressed air supply temperature and ambient temperature at the NITRONIC Nitrogen System willbe in the range 65F to 100F. Open compressed air line at the connection point and allow any accumulated water, oll and particulates to blow out. Use extreme caution to prevent accidents and injuries during this operation. I after blowing out the lines, the compressed air is visible contaminated with water, oil or particulates. The operation of the coalescing filter should be checked as this indicates that they are not functioning correctly. Connect the compressed air supply to the NITRONIC® Nitrogen System using adequately sized pipe/tubing (3/4" or larger recommended). The pipeftubing must he rated for the ‘maximum air supply pressure that could be encountered. A shutoff valve, the same size as the pipe/tubing should be installed on the compressed air supply so that the NITRONIC Nitrogen ‘System can be isolated Connect the nitrogen outlet to application or the nitrogen receiver tank using adequately sized pipertubing. The pipe/tubing must he rated for the maximum air supply pressure that could he encountered, Copper or stainless steel tubing is recommended if minimizing the moisture content of the nitrogen is important. Route the filter drain line to a suitable location. Vent the waste gas vent upward and away from personnel to a safe location. This gas is ‘oxygen-rich and can increase the flammability of surrounding materials. It is recommended that 1” diameter or larger CPVC piping be used to vent the waste gas away. Connect the NITRONIC Nitrogen System to an electrical outlet of the correct voltage using the power cord supplied with the system. Nitrogen Receiver 1. The Nitrogen Receiver contains a safety valve, regulator and pressure gauge for mounting on the tank, which is mounted on four legs. The user is to install a vent valve, tank inlet block valve, check valve and outlet line valve. 2 The receiver and piping should be pressurized with nitrogen from the NITRONIC Nitrogen ‘System and leak tested using a soap solution after installation 103. The receiveris also equipped with a pressure switch that is adjustable and capable of sounding an alarm when low pressure Is reached. 4. For multiple generators simultaneously supplying one nitrogen tank a check valve must be installed downstream of each generator and the nitrogen tank pressure tap must be relocated to downstream of the check valve. See attached drawing. L 22 2 WARN Saas | ___Allpiping connections should be installed with teflon tape and leak-checked before. | 9peration. Nitrogen leakage into confined areas may result in a decrease of the oxygen _ ent below safe breathing levels, ie START UP AND OPERATION 1. Open front cabinet door. Open inlet air valve. This is a manual valve with yellow vertical sliding handle. Open is in the up position. 2. Set air pressure at the NITRONIC® Nitrogen System using the pressure regulator. Air pressure must be between 90 psig and 125 psig. System is rated at 100 psig 3. Tum on power by sliding ON/OFF switch on front bottom of Nitronics Terminal Board to ON position. The green LED2 will light up and make a short “beep” sound to indicate system is on. 4. Close cabinet door. The red POWER ON indicator lamp on the front panel should be lit. To allow the user to interact with the system, it is equipped with a two line 40 character Liquid Crystal Display, six status lamps, and a four-button keypad user interface. This Front Panel Display allows the user to set the system parameters and monitor the purty of the nitrogen being produced, the nitrogen pressure, as well as the membrane and heater operating temperatures etc. Setting Parameters ‘The four front panel buttons are SYSTEM STARTISTOP, SELECT SETTINGS and UP and DOWN. The STARTISTOP button starts and stops the system. The SETTINGS button places the system in setting mode so that the eight parameters listed below can be set by the user adjusted by the UP and DOWN buttons. The factory settings have been chosen to enable the system to be run with no initial changes from the user. ‘System Operating Parameter Adjust Mode The parameter adjust mode can be entered when the system is powered up by pressing the SELECT SETTINGS button, The following parameters will appear on the LCD one at a time, by repeatedly pressing the SELECT SETTINGS button and the user can set each one by pressing the UP or DOWN buttons. Press the SYSTEM STARTISTOP button to leave adjust mode at any time. Parameters Low | High | Factory Setting] JOO Se//iwg [ System ON Pressure (psi) [30 [720 60 65° ‘System OFF Pressure (Osi) 50 | 120 90 7 ‘Air Heater Set Temp (F) 70_| 130 110 10° ‘Space Heater Set Temp (F) _| 80] 730, 7 | 70° Purity Set Point (%) 95.0 | 99.9 98.0 Aes Maximum Filter DP 4 45 3 3 Filler Drain Time (B73) iii eae [aan 2 Oxygen Sensor Calibration (days) 4 7 z 7 uNa pe"T ‘When power is applied to the system the Air Heater is disabled, and all of the Solenoid Valves remain closed. The LCD display shows the following message (readings are for example only): System in STANDBY Mode ‘Software Version 2.02 To start the system the System Start/Stop button must be pressed once. At this point the LCD display will show the following message: ‘System WARMING UP, Wait for Ready Lamp The system will hen enable the Air Heater fo obtain an air temperature of 110 Deg F (or user set point) and allow heated compressed air into the separator membrane. The membrane is heated by the air passing through it until the membrane sensor is above the set point and the purity of the waste Nitrogen is better than the set point The user desired purity 95-99.9 % is adjustable by turning the black knob on the front panel as indicated. This should be done once the system is in RUNNING mode. When the system is at temperature the message on the LCD display will change to the following: ‘System RUNNING Press STOP to Shut Down At this point the system will begin to produce Nitrogen. While the system is running or warming up the system pressures, temperatures, as well as the Nitrogen flow rate and purity are displayed on the bottom line of the LCD display in three groups of four parameters, which change at five-second intervals. ‘The first set of parameters are displayed as follows’ C Nitrogen: 075psi_Nitrogen Purity: 98.0% Where: Nitrogen: Indicates the pressure in PSI within the Nitrogen Tank. Purity: Indicates the purity of the N2 output from the membrane, The second set of parameters are displayed as follows: Heater: 110F Membrane: 80F Hours: 000002 Where: Heater: Indicates the temperature of the air leaving the air heater. Membrane: Indicates the temperature of the Nitrogen Separator. Hours: Indicates the number of hours the system has run for. ‘The third set of parameters are displayed as follows: Inlet Air: 100psi@O66F Filter: Where: Inlet Air: Indicate the pressure and temperature of the inlet air. Fitter Indicates the pressure drop across the inlet air filter. VENTI/FLOW: Indicates when Nitrogen is being vented or flowing ‘Oxygen Sensor Calibration in Progress Un-Calibrated Reading: 79.0% Shortly after the system begins to operate the system will calibrate the internal Oxygen Sensor. The first time that this occurs, it will take 5 minutes, and subsequent sensor calibration cycles will last 3 minutes. A 2calibration cycle will occur every 1-7 days (set by user) while the system is running (ready to produce Nitrogen). ‘System READY Press STOP to Shutdown When the nitrogen tank pressure reaches the OFF pressure of 90 psi, or as set by the user, the system will go into READY mode. The system will shutdown the air heater and air supply valve. The system will restart automatically when the ON pressure is reached. In addition to the information displayed on the LCD panel, status lamps also show the current operating state of the equipment. These lamps are as follows: POWER ON - Illuminated whenever power is applied to the system. SYSTEM READY - __ Illuminated when the system is at temperature & ready to produce Nitrogen PRODUCING - Illuminated when the system is actually producing Nitrogen. NITROGEN PURITY OK- Illuminated while the Nitrogen purity is OK, above 98.5%. The desired purity is NOME Ly, adjustable with the black knob on the front display panel. SERVICE - Illuminated when the input air fitters are dirty, FILTERS SYSTEMFAULT- _iluminated when the system shuts down due to a detected fault. A full description of the fault will be given on the LCD panel. System Fault Detection The following detectable system faults cause the FAULT lamp to be illuminated, and the system will retum to its standby state. The bold text below will be displayed on the LCD panel for each fault ‘System Shut Down ~ Over Temperature The air heater or membrane temperature has risen above 135 Deg F causing the system to shut down to protect the membrane from damage. ‘System Shut Down - Heater Failure ‘The air pre-heater has failed and the system is unable to reach its operating temperature after 30 Minutes of heating, ‘System Shut Down ~ Air Filter Blocked ‘The pressure differential across the Input Air Filters is greater than the user set DP in psig, and the fitter elements require replacement. (This parameter is first checked 3 Minutes after the system begins to operate, and is subsequently checked at 30 Second intervals). ‘System Shut Down - Input Air Too Hot The temperature of the input air from the compressor is above 130 Deg F, and the system has shut down to protect the membrane from damage. System Shut Down ~ Low Air Pressure ‘The pressure of the input air from the compressor is below 80 PSI, and the system has shut down, as it is not possible to produce adequate Nitrogen at this low pressure. Purity Adjustment Adjust the purity valve (knob on front door panel) to give desired purity, turn clockwise to increase purity Band visa versa. Allow ten minutes between adjustments for intial adjustments and thirty minutes between adjustments for the final adjustment. This step can be started during the stabilization period but must be completed after the system has stabilized. The Sensor Regulator is factory set for 2-3 psi, this can be observed on the regulator pressure gauge. If the gauge is not reading correctly adjust it by liting the knob to unlock it and turning the knob. Lock it again by pressing down on the knob. Ifthe NITRONIC® Nitrogen system is used with a nitrogen receiver tank, adjust the purity valve when the tank pressure is 20 or more psi below the operating pressure. DO NOT re-adjust the purity valve as the tank pressure approaches the operating pressure (the purity readout will show an increase in purity as the tank pressure approaches the operating pressure). Analogue Input Calibration To calibrate the five analogue inputs (PT1-PT4 and OX1), power the unit up and press both arrow keys together. The system will then enter calibration mode where the current reading on all 8 analogue channels is displayed on the LCD panel. This must be done within ten seconds of powering up the system, To calibrate PT1 to PTA apply a signal from the pressure sensor and adjust the appropriate potentiometer Until the system reading agrees with the gauge reading. For PT1 adjust VR1, for PT2 adjust VR2, for PTS adjust VR3, and for PT4 adjust VR4 fer Gh To calibrate OX1 adjust VRS “until the system shows 79,0% with the sensor in open air. TS1 to TS3 are pre-calibrated, and should simply be checked against the ambient temperature. Downloading New Firmware to the System New application software may be downloaded to the CPU card by using its in-built flash monitor. This may also be accessed via a direct connection to the modem port on the CPU card. ‘The modem port is the 25 way D-Type connector labeled “RS232", it operates at 9600 baud, 8 data bits, no parity, 1 stop bit. To cause the CPU to run the flash monitor as opposed to the application program itself, a toggle switch is provided, (above and to the left of the electronics). When the toggle is switched to TRANSFER the flash Monitor runs, and when it is switched to RUN the application program runs. If a viable application rogram cannot be detected then the flash monitor runs regardless of the state of the toggle switch. irect Connection Transfer ‘The simplest way to transfer the new application program when a direct connection can be made is to use the "Windows Terminal” program, and the following instructions assume that this is the case. ‘Assuming that the CPU is currently running an application, which needs to be updated, the following procedure should be followed: Power down the system and disconnect the modem (if fitted) from the RS232 port. Replace the modem with a programming cable connected to your computer's serial port. Run “Windows Terminal’ on your computer and configure it for 9600, 8 data bits, no parity, and 1 stop bit on the appropriate serial port ‘Switch the toggle switch to “TRANSFERT and re-apply power to the system. The flash monitor should now sign on with the following banner: *CSI Infact 2 CPU Bootstrap Monitor Version 1.4. Press '?' For Help Screen.” If you do not see this re-check your connections, baud rates etc. 4 7To erase the current ap ion program type "ERASE" at the *CSI>" prompt, To download the new application program type “PROG I ('I" as in India)" when the "CSI>" prompt returns. Wait for the “GO I" prompt before continuing. Using “Windows Terminal" select “Transfer” followed by “Send Text File”. Enter the name of the file to be transferred, a HEX file, and then press the OK button. The bar graph at the bottom of the screen will show the progress of the download (which should take approximately 5 - 10 minutes). When this is complete the "CSI>* prompt will return, and the power should be switched off again. Switch the toggle switch to “RUN’, and replace the modem (if fitted). Re-apply power and the new application should run Modem Data Transfer Power down the system. Connect a direct dial telephone line to the modem. Switch the toggle switch to “TRANSFER' and re-apply power to the system. To perform the remote upgrade via modem (XMODEM), call the unit using “Windows Terminal" and as soon as the connection is established press ENTER. The unit should respond with a "CSI>" prompt. At this prompt type "ERASE PROGRAM IN FLASH followed by enter. Again you will receive a “CSI>* prompt, and you should then use the “ERASE” command to make sure that the flashes are fully erased. When this process is complete type "PROG 8. ‘As soon as the unit is ready to receive the new program, use "Windows Terminal’ to transfer a BINARY file. The download will take several minutes, but it will announce that the process has finished when it transfers the last bits of data. As soon as it finishes you must type "RUN" followed by enter to start the new program. ‘The power should be switched off again. Switch the toggle switch to "RUN". Disconnect the telephone line. Re-apply power and the new application should run, HARDWARE ~ JO ALLOCATION for CSENF1D, CSI-NF3 & CSI-NF4 DIGITAL OUTPUTS - (CON-OP on CSI-NF1D) Pins 182 — Input Air Heater Switching Signal. Pins 384 —Un-used Pins 5&6 — $3 Oxygen Sensor Calibration Solenoid. Pins 7&8 — S4 Nitrogen Fill/Vent Solenoid, Pins 9810 — S5 Air Supply Solenoid Pins 11812 — $6 Filter Drain Solenoid Valve, Pins 13814 — Space Heater signal Pins 15816 — Un-used. PRESSURE SENSOR INPUTS - (PTI to PT4 on CSI-NF4) PTt '~ Tank Nitrogen Sensor. PT2 —Un- used PTS ~ Air Filter Pressure Drop. PT = Supply Air Pressure. OXYGEN SENSOR INPUT - (OX! on CSI-NF4)Ve = NIC. A - Sensor +ve. B - Sensor -ve. GND - connected with -ve or +ve TEMPERATURE SENSOR INPUTS ~ (TS1 to TS3 on CSI-NF4) 1st = Membrane Heater Temperature. Ts2 Air Heater Temperature. Ts3 = Supply Air Temperature = +12v. = Signal (Qutput from LM34DZ temp sensor (10mV/Deg F). = ov. = +12v. - Signal (Open Collector NPN). -ov Economizer To prevent unnecessary consumption of compressed air when nitrogen production is not required, the Nitronic. system is equipped with an Economizer mode. The Economizer should only be used in Conjunction with a nitrogen receiver. Whenever nitrogen is not being used, the pressure in the receiver will increase and will eventually approach the system operating pressure. The Economizer senses the pressure in the receiver and shuts off the compressed air supply when the nitrogen receiver pressure reaches the user set ON pressure. The Economizer automatically re-opens the supply air when the nitrogen receiver reaches the user set OFF pressure. Space Heater The unit is equipped with a space heater that keeps the enclosure and membrane at a set temperature determined by the user. The space heater is ON when the Air Heater is OFF and the system is in Standby mode. Automatic Vent ‘The Automatic Vent is operated by the Oxygen Sensor and the temperature control logic. ifthe nitrogen purity falls below the factory purty setting, the nitrogen gas will be vented with the waste gas and the PURITY OK light will be off. If the membrane temperature falls below the set point, the nitrogen gas will bbe vented with the waste gas. Nitrogen Receiver 1. The nitrogen receiver must be purged to remove air. 2. Close the receiver tank outlet line vaive (user installed) and allow the tank pressure to Increase to about 10 psig below the operating pressure. 3. Vent the receiver by carefully opening the tank vent valve (user installed); stop venting when the receiver pressure falls to 10 psig; do not let the receiver pressure fall to 0 psig as this may allow air to re-enter the receiver. 4, Repeat the pressurization and venting cycle of steps 2 & 3. 5, Purge until desired purty is achieved 166. Re-pressurize the receiver and then commence using the nitrogen. OPERATING INSTRUCTIONS Note: Nitronics recommends keeping records of the system's operation and maintenance. These records will assist in troubleshooting the system. Normal Operation ‘Check both filters daily. If the condensate is not observed draining from the filter drain, then the automatic drains are not functioning correctly and the NITRONIC® Nitrogen System must be shut down, itis recommended that new filter eler 001 filtration is critical to the performance of the system. Delaying replacement of the elements or failure to replace them can permanently reduce the unit's output. DEPRESSURIZE FILTERS BEFORE SERVICING. 2. All air receivers and fiters should be inspected at least daily and drained of any accumulated water. 3. Read nitrogen purity and temperatures daily. Adjust purity if needed, 4, Record operating data on a system operating checkiist. Standby ‘The system can be placed in Standby mode by pressing the Starl/Stop button on the front panel any time the system is running. This will stop nitrogen production and close the Air Supply Solenoid valve. NOTE: Depending upon when the system is placed into STANDBY mode, the system may briefly vent the nitrogen upon restarting flow. The system should recaver quickly and begin delivering on-spec nitrogen very shortly thereafter. ‘Shutdown 1. The NITRONIC® Nitrogen System may be shutdown temporarily by stopping nitrogen flow or air supply. Restart by restarting the nitrogen flow or air supply. Nitrogen purity will be achieved ‘soon after restarting. 2. For extended shutdown stop nitrogen flow at the application, close inlet air valve and then turn off the main power. Follow start-up instructions for restarting. MAINTENANCE ‘The only routine maintenance required is replacement of the filter elements and oxygen sensor. There are no components within the cabinet other than the two regulators, which require adjustment by the user. 7To ensure performance of the NITRONIC® Nitrogen System and to obtain maximum compressor life, follow all compressor maintenance schedules recommended by the compressor manufacturer. Cleaning ‘The NITRONIC® Nitrogen System cabinet can be cleaned by washing with a damp cloth and mild soap and water. Filters aty Part Description Element Change Every 1 Particle Filter NorgrenF74G 4338-04 5 micron 6 months 1 Coalescing Filter Norgren F74C 4344-01 .01 micron 6 months 1 Carbon Filter Norgren F48 665-08, 6 months ‘A pressure drop indicator is mounted on the F74G and F74C filters and will tum from green to red when the filter must be changed. In addition the "Service Filters" indicator light will go on if the pressure drop across the two filters is greater than the set DP. All three filter elements must be changed at least every six months, Continuing to operate the NITRONIC® Nitrogen System for an extended period beyond six ‘months could result in low air pressure and hence in low flow or decreased nitrogen purity. In addition, the membrane could be damaged, To Change filter elements: 1, Shuldown the NITRONIC® Nitrogen System and shutoff compressed air supply. Allow system to depressurize. 2. Unscrew the two sorews holding the drain valve to the rubber mounts. Drop the valve down by pressing in on the PNEUFIT push-in fitting and pulling down on the valve. Remove the nylon tubing between the two filters by pushing in on the PNEUFIT fittings. The filters can now be serviced individually, 3, The F46 carbon fiter does not have a drain line and step 2 above is not required. 4. Unscrew the fiter bow and remove the fiter bow. Unscrew fer element and replace with new element using new ‘0' ring supplied with element. Ensure correct element is installed on each filter. 5. Clean bow! screw threads and inspect bow! "O” ring (replace if needed). Refit bow! onto fiter. Reinstall nylon drain line on fiters and PNEUFIT push-in fiting on drain valve, Screw valve back on to rubber mounts. 6. _ If fiter leaks after changing the elements, shutdown again and check that the bow is tight onto fiter, then recheck that bow! 0' ring and threads are clean and undamaged. 7. Record the date of the replacement of the filter elements in the system maintenance log. ‘TROUBLE SHOOTTNG Inspect all maintenance items and follow trouble-shooting guide if the system is not performing as specified. If performance cannot be restored afler trouble shooting, call Nironics Systems for service 18Low Nitrogen Flow or Purity “Tho most ikely cause of low nitrogen flow or purity is low supply air pressure, which will be apparent from the pressure reading on the NITRONIC® Nitrogen system front display panel. Check the fiters (which, if completely loaded could result in a pressure drop). Check the compressor for reduced output pressure if the NITRONIC® Nitrogen system troubleshooting is inconclusive. Another possible cause of low purty may be due to failure of the automatic fiter drains. Refer tothe following section The dual filters automatically drain at the end of every production cycle (when nitrogen receiver is full) and every 1-8 hours of run time set by the user. If condensate is not draining from the filters, the automatic drain system is not functioning correctly and the NITRONIC® Nitrogen System should be shut down. Extended operation with a malfunctioning automatic drain could result in liquid water entering the NITRONIC® Nitrogen System and thus low nitrogen purity. The automatic drain is operated by means of a solenoid valve. If you suspect the valve to be the problem call Nitronics service for further information, Oxygen rement aty Part Description Change Every 1 ‘Oxygen Sensor Figaro KE-50 (modified) 12 months ‘The Oxygen Sensor should be replaced every six months. To replace oxygen sensor: 1. With the system off, open the front door of the cabinet. Unplug the sensor cable, 2. Remove sensor by unscrewing the brass, hexagon shaped, sensor housing assembly counterclockwise. Discard sensor housing assembly 3. Install teflon tape on threads of new sensor housing, 4. Install new sensor by screwing clockwise onto the sensor cap. Tighten sensor to insure a leak free seal 5. Reconnect the sensor cable and close front door. 6. _ Record the date of the sensor replacement on the system mi NITRONIC® SYSTEM WARRANTY AND REMEDY Nitronics Systems warrants that the system will be free from defects due to materials or workmanship for one (1) year after shipment by Nitronics. If within thirty (30) days after Buyer's discovery of any such defects, Buyer nolifies Nitronics thereof in writing, Nitronics shall, at its option and as the exclusive remedy for this warranty, promptly repair or replace that portion of the system found to be defective. Failure by Buyer to give Nitronics such written notice within the applicable time period specified above, shall be deemed a waiver of Buyer's claim for such defects. This warranty is subject to proper installation and operation in accordance with Nitronics's System Installation and Operating Instructions, ‘and good industrial practices. 19LIMITATION OF WARRANTY Subject to the foregoing warranty, NITRONICS MAKES NO REPRESENTATION OR WARRANTY OF ANY KIND. EXPRESS OR IMPLIED. AS TO MECHANTASILITY, FITNESS FOR A PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO THE SYSTEM WHETHER USED ALONE ‘OR IN COMBINATION WITH OTHER EQUIPMENT NOT SUPPLIED BY NITRONICS. 20san NBOOULIN —_ Aqyay ONIONGOwd — WELSAS Oo Oo inva WLSAS No waMod oO ‘swersks solUORIN ADSM SULT OSHO E BAOBV AVTdSIG G91 NO SNOILONMLSNI MOTIOS “+ 'SNOLLOMULSNI YOLVYANSS N3SOULIN GAONVACVSam (0002/21 “2 “SMBISAS SOINOKLIN See asm ae ON © SHGLSAS.SOINOLIN 0 Maa WLUNSCI NOS mw rood ann ain anus ee 2s san "HP vin i an sve svn D awn a on Sea] ee] \ gage LES a Om ainns aie in Q mane os seo we ann O inns walsas ae a asneay ao ‘dO1S/LEVLS q vow) © Aav3s reisas NOUV TSW i es 3 { 3 veooaut behaas XXXXX aa Annes ® os sears AVIdSIO TANYA INOUE We mou avy ais ty aSS38HOS rosa, Naa \ aS ‘aIONSOS \ suv: Sosues / Saw in93e anw. MOSS eS aan itera amzus X11 wats oo WVYOVIG NOIWVLNSNNYLSNI GNV MOT4 YOLVYANAD NADOULIN OINOMLIN Dx} , TOE urnabooziiz SWALSAS SOINOUL! 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