Pneumatech PMNG-800HP Installation, Operation & Maintenance Manual

Brand: Pneumatech

Model: PMNG-800HP

Type: Installation, Operation & Maintenance Manual

This manual is also suitable for

PMNG Series

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PMNG Cabinet Series

Membrane Nitrogen Generators

Installation, Operation & Maintenance Manual

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Model PMNG-800HP – Serial No. 0210-G137961-034818

INSTALLATION, OPERATION, AND MAINTANANCE MANUAL

TABLE OF CONTENTS

1.O GENERAL

1.1 INTRODUCTION Page 4

1.2 SYSTEM DESCRIPTION Page 4

1.3 MODEL INFORMATION Page 4

1.4 SERVICE INFORMATION Page 4

2.0 SAFETY Page 5

2.1 GENERAL Page 5

2.2 BREATHING Page 5

2.3 COMBUSTION Page 5

2.4 PRESSURE Page 5

2.5 ELECTRICAL Page 6

2.6 ENVIRONMENTAL Page 6

3.0 INSTALLATION INSTRUCTIONS Page 6

3.1 GENERAL Page 6

3.2 LOCATION AND SETTING OF UNIT Page 6

3.3 ELECTRICAL SERVICE Page 6

3.4 CONDENSATE DRAIN CONNECTIONS Page 6

3.5 NITROGEN PIPING CONNECTION Page 7

3.6 PERMEATE GAS CONNECTION Page 7

3.7 COMPRESSOR RECIRCULATION CONNECTION Page 7

3.8 COMPRESSED AIR INLET CONNECTION Page 7

3.9 NITROGEN TANK CONNECTION Page 7

3.10 ELECTRICAL SUPPLY CONNECTION Page 7

4.0 DESCRIPTION OF SYSTEM Page 8

5.0 PRE-START INSPECTION Page 10

6.0 INITIAL START UP and ADJUSTMENTS Page 10

6.1 NITROGEN SYSTEM SETUP Page 10

6.2 NITROGEN PURITY SAMPLING SYSTEM SETUP Page 10

6.3 ECONOMIZER ADJUSTMENTS Page 11

6.4 CRITICAL ADJUSTMENTS Page 11

7.0 OPERATING INSTRUCTIONS Page 11

7.1 GENERAL DESCRIPTION Page 11

7.2 OPERATION OF THE UNIT Page 11

1. MANUAL SYSTEM Page 11

2. AUTOMATIC SYSTEM Page 11

3. HEATER & CONTROLS Page 11

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4. POWER-ON LIGHT Page 12

5. ON/OFF SELECTOR Page 12

6. PURITY VENT Page 12

7. MAIN FLOW METER Page 12

8. ECONOMIZER Page 12

9. ∆P SWITCH/GAUGE & LIGHT Page 13

10. HOURMETER Page 13

8.0 OPERATION & MAINTENANCE Page 13

8.1 HEATER & CONTROLS Page 13

8.2 HIGH TEMPERATURE THERMOSTAT Page 14

8.3 ROUTINE MAINTENANCE Page 14

9.0 ROUTINE MAINTENANCE SCHEDULES Page 15

10.0 RECOMMENDED SPARE PARTS Page 16

11.0 WARRANTY Page 18

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1.0 GENERAL

1.1 INTRODUCTION -

This manual describes the installation, operating, and maintenance

instructions for the Pneumatech PMNG Cabinet Series membrane nitrogen generator. Please read

and be familiar with this manual before attempting to operate the unit. Although this unit is very

simple to operate, the user will be working with high-pressure gas that must be handled with

caution. Compressed gas, if handled improperly, can result in serious or fatal injury.

H2O Vapor

CO2

1.2 SYSTEM DESCRIPTION - The PMNG utilizes a

hollow fiber semi-permeable membrane for the separation o

nitrogen and other gases from a compressed air stream. The

membranes divide the air into two streams; one is essentiall

nitrogen along with argon and traces of other inert gasses. The

other stream is oxygen plus carbon dioxide, hydrogen and other

trace gases. While fast gases such as oxygen, carbon dioxide

and water vapor quickly permeate the membrane surface, most

of the nitrogen flows inside the membrane fiber as a separate

product stream. Millions of fibers, about the size of a human

hair, can be packed into a single module. This provides a ver

large membrane surface area that efficiently produce large

quantities of nitrogen. This system is designed to deliver

nitrogen plus other inert gases at specified concentration.

Because water vapor is being permeated out of the gas stream,

the resulting atmospheric dew point is -65°F or below.

A connection has been provided to pipe the permeate gases away from the unit. The system is

designed to operate with feed air from a plant compressed air system that has been dried to at leas

+40 degree F pressure dew point. The membrane modules are protected from hydrocarbons by a

highly efficient, six-step filtration system. This system consists of a combination of particulate,

coalescing filters and carbon adsorption. The result is air purity with a heavy hydrocarbon carryover a

or below 2 parts per billion.

1.3 MODEL INFORMATION - PNEUMATECH MODEL NO. PMNG-800HP-V01

NITROGEN GENERATOR

1.4 SERVICE INFORMATION - FOR QUESTIONS CONCERNING THE OPERATION,

MAINTENANCE OR REPAIR OF THE PMNG UNIT, CONTACT YOUR LOCAL

PNEUMATECH DISTRIBUTOR. CONTACT PNEUMATECH, INC. FOR THE

DISTRIBUTOR IN YOUR AREA.

Pneumatech, Inc.

4909 70TH Avenue

Kenosha, Wisconsin (USA) 53144

Phone: 262-658-4300 Fax: 262-658-1945

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2.0 SAFETY

2.1 GENERAL -

This unit has electrical equipment and standard process plant components, which

can be hazardous to individuals unfamiliar with such equipment. It is the users’ responsibility to

permit only trained and qualified process plant operators familiar with the handling of compressed

gases to operate this equipment

2.2 BREATHING -

This unit is designed to produce high purity nitrogen from 95-99.995% purity.

Nitrogen is a colorless, odorless gas that will not support life. If released in an unventilated area, it

will displace the oxygen and can cause injury or death from asphyxiation. A general indication of

what can potentially occur at depleted levels of oxygen is given below:

Oxygen Content - Effects and Symptoms

15-l9% Decreased ability to work strenuously. May impair coordination and may induce early

symptoms in persons with coronary, pulmonary, or circulatory problems. Note that at

below 15% oxygen content, personnel will require assistance from others to be

evacuated from the area.

l2-l4% Respiration increases with exertion, pulse rate increases, coordination is impaired, and

perception and judgement are also affected.

10-12% Respiration further increases in rate and depth, poor judgement, blueness of lips.

8-10% Mental failure, fainting, unconsciousness, ashen face, blueness of lips, nausea, and

vomiting.

4-6% Coma in 40 seconds, convulsions, respiration ceases, cardiac arrest, death.

Nitrogen gas represents an extreme asphyxiation hazard when not handled properly. Product

gas should not be vented or otherwise discharged except through the normal piping system.

Appropriate signs should be placed in the area of the nitrogen system warning of the hazards.

2.3 COMBUSTION - The waste gas (permeate) vented out of the system is oxygen enriched; it

typically contains 35%-40% oxygen, but can be as high as 45% oxygen. While oxygen will not

burn, oxygen concentrations above 25% will support combustion of other materials much more

readily than air. For example, materials that smolder in air could burn fiercely in this

atmosphere. It is imperative that vent gas be discharged only in safe, well-ventilated areas. If the

unit is located in a poorly ventilated room, the waste gas must be piped to a ventilated atmosphere

for release.

2.4 PRESSURE -

The feed air pressure supplied to the generation unit can be as high as 200 PSIG.

The nitrogen product is then delivered to the user’s system at a pressure within 40 PSIG of inlet

pressure. Systems utilizing gas boosters for raising the pressure of the nitrogen product can operate

at pressures of 4500 PSIG and higher. Normal precautions for pressurized systems should be

observed during operation, service, or troubleshooting. Always isolate components that are to be

serviced, venting pressure before disconnecting lines or dismantling components.

CAUTION: NITROGEN IS AN ASPHYXIANT. BEFORE ENTERING

AN ENCLOSED OR POORLY VENTILATED AREA CONTAINING

NITROGEN GENERATION OR TRANSMISSION EQUIPMENT AND

PIPING, FOLLOW ALL ESTABLISHED SAFETY PRECAUTIONS AND

PROCEDURES.

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2.5 ELECTRICAL - The system utilizes three-phase and/or single-phase alternating current for

power and control. It should be protected with a disconnecting device as dictated by national and

local electrical codes. Ensure that the unit is connected to an adequate earth-ground before applying

power.

2.6 ENVIRONMENTAL -

The automatic drains for the entire system are connected to a single

header. These drains release collected oil and water. Because the condensate from this equipment

may contain oil, it must be disposed of properly. Oil concentrations in the water could be

approximately l50-200ppm.

3.0 INSTALLATION INSTRUCTIONS

3.1 GENERAL - The Pneumatech PMNG Cabinet Series membrane nitrogen generator is designed for ease of

installation. Since it is a packaged system, there are few connections to be made before the unit can be

placed into operation. A single point air inlet, electrical connection, condensate drain, and a final nitrogen

gas, nitrogen tank connection are required for a proper installation. If required, the waste gas (permeate)

can be piped away from the unit utilizing a singe connection.

3.2 LOCATION AND SETTING OF UNIT - The unit should be installed indoors on a level surface capable

of supporting the static weight of the equipment. No special foundations or anchor bolts are required for

the installation but may be used at the discretion of the customer. If the surface is not level, shims and

mounting bolts are recommended as a solution. Please contact Pneumatech, Inc. if a leveling problem

occurs during installation. The unit should be installed in a well-ventilated area where the ambient

temperature range will be between 40 and 104°F.

3.3 ELECTRICAL SERVICE - This machine requires a 120 volt, 1 phase, 60 Hertz, 20 ampere electrical

supply with an earth ground. All interconnect wiring has been provided.

3.4 CONDENSATE DRAIN CONNECTIONS - A ¼” NPT (F) bulkhead connection is provided on the

utility end (back) of cabinet to connect to the floor drain or other disposal to pipe away oily condensate

from the system. Please note that it is normal to find oil in the condensate when feed compressor source is

of the lubricated type. (Refer to par. 2.6 Environmental.)

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3.5 NITROGEN PIPING CONNECTION - The final nitrogen connection is made into a ½” NPT (F)

bulkhead connection on the utility end (back) of cabinet. No other check valves are required or

recommended beyond this point. An isolation ball valve is provided for field installation by others.

3.6 PERMEATE GAS CONNECTION - A 1” NPT (F) connection has been provided to pipe permeate

(waste gases) away from the machine. (Refer to section 2.3 Combustion.) Note: If piped away from unit,

use a minimum size of 1”. For each ten (10) feet of piping, increase one pipe size with no more than 50

feet in length is recommended to prevent back pressure. Back pressure to the membranes will reduce their

performance.

3.7 COMPRESSOR RECIRCULATION CONNECTION – On optional High-Purity Systems a 1” NPT (F)

connection has been provided to pipe the waste gas from the second membrane or set of membranes, which

are connected in series. This line can be connected to the intake of a dedicated feed compressor to improve

nitrogen generator efficiency. This line will contain 90-95% nitrogen. (Please refer to Section 2.2

Breathing) If not used with dedicated compressor, and the area is not ventilated well, this line should be

connected with the permeate line and discharged from the area.

3.8 COMPRESSED AIR INLET CONNECTION – A 1” NPT(F) connection is provided for the feed

air inlet. An isolation ball valve is provided for field installation by others.

3.9 NITROGEN TANK CONNECTION – A ¼” NPT(F) connection is provided for connection to the

nitrogen tank downstream of the nitrogen generator. This is to check purity in systems with oxygen

analyzers, and for sensing system pressure on systems with booster compressors.

3.10 ELECTRICAL SUPPLY CONNECTION – A ½” NPT(F) connection is provided with flexible

conduit to the control box.

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Inside the PMNG nitrogen generation unit, the first ite

the feed air comes in contact with is an inlet isolatio

valve, which is shipped loose for installation in the field.

For systems with the optional EconoMizer™, an ai

actuated ball valve. Next is the 6-Step filtration system,

which utilizes a combination of particulate, coalescing

and carbon adsorption technologies. Oil carryover fro

system is expected to be in the 2 parts per billion range,

with maximum solid particle size .1 micron. All filters

are fitted with automatic condensate drains. The

optional panel mounted differential pressure switch-

gauge (if fitted) measures the filter system pressure drop.

If the pressure exceeds the 10 PSID setting a warning

message is displayed. Most units are fitted with the ai

circulation heater and controls, and is installed in the ai

stream before the nitrogen membrane(s) but after the

final filter and pressure regulator. This heater maintains

a constant temperature of compressed air to the

membranes enhancing stability and performance.

Controls for the heater are installed on the instrumen

panel.

4.0 DESCRIPTION OF SYSTEM - The PMNG Cabinet Series membrane nitrogen generator is a

modular system consisting of pre-filtration, separation, and distribution sections. Controls for the

system are included in the nitrogen separation unit.

Ambient air enters the feed air compressor, which is typically an oil injected rotary screw air

compressor via its inlet filter. Air is compressed and travels through an aftercooler and, in most

systems, a refrigerated air dryer.

OPTIONAL EQUIPMENT

MEMBRANE N2SYSTEM

MEMBRANE

BUNDLES

HEATER

AIR

INLET

MANUAL

PURITY

CONTROLLER

OXYGEN

ANALYZER

NITROGEN

VENT

COALSECING

FILTERS

CARBON

BED

PARTICLE

FILTER

ECONOMIZER

PRESSURE

SWITCH

AUTO

PURITY

CONTROLLER

ECONOMIZER

VALVE

DRAIN

6-Step Filtration

EconoMizer™

2-Way Valve

Heater

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The nitrogen membrane module(s)

are located in the heated air stream.

On low purity multiple module

systems 99.5% and below, the

membranes are connected i

arallel. On high purity multiple

module systems 99.5% or higher,

they are connected in series o

combination of series and parallel.

High purity systems have separate

ermeate connections. One is

strictly waste gas, but the second

one is a line that can be re-circulated

back to the feed compressor intake

to enhance purity and productivity.

After the air passes through the

membrane bundle(s) it is essentiall

nitrogen plus trace amounts of iner

gasses and the specified oxyge

content. A built-in flow meter is

there to constantly monitor nitroge

flow. Oxygen content (purity) is

controlled by a manual valve or b

the optional AutoPure™ automatic

urity/flow control system. If the

unit is fitted with the latter, it will

have a proportionally controlled

valve that gets its control signal

from a dual loop process controller.

The controller constantly monitors

the output signal from the oxyge

analyzer, comparing it to the se

oint (user selectable), and throttling

the automatic valve to match the

urity level to the set point. After the

nitrogen passes this point it goes

through a non-return valve and ou

via the outlet isolation valve.

Membranes

Non-Return

(Check) Valve

Oxygen Analyzer

System

Nitrogen

Flowmeter

AutoPure™

Valve

Manual Flow Valve

Operator Interface,

Temperature &

Purity Controllers,

Hour meter

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5.0 PRE-START INSPECTION - Before attempting to start the unit check the following:

1. Check that the electrical service matches the requirements listed in section 3.3 Electrical Service.

2. Check that the circuit breaker or fused disconnect and power cables are properly sized to meet the

machine’s amp rating.

3. Check that the unit has been installed according to the instructions in Section 3.0 Installation Instructions.

6. Check that there are no loose lines or loose wires.

6.0 Initial Start Up and Adjustment – It is recommended that your cabinet series high purity membrane

nitrogen generator be started and adjusted initially by a qualified technician. The following instructions are

presented for your information. CAUTION: If users readjust certain components, part or all of the

warranty may become void. After initial start up, only minor adjustments should be necessary by the

operator.

6.1 Nitrogen System Setup

1. Remove the right upper side panel and slowly open the inlet ball valve until pressure is equalized

in the nitrogen system.

2. Listen for any air leaks. It will be normal to hear or feel gas escaping from the permeate and

compressor recirculation ports on the backside of the unit. Systems with EconoMizer™ will not

pressurize past 2-way valve until the Start button on the Operator interface is pressed. At this

time, a by-pass solenoid valve is energized to slowly pressurize the system. There is an adjusting

valve that controls how fast the system will reach pressure. Adjust valve so the system

pressurizes in 30-45 seconds.

3. If equipped with oxygen analyzer, its display should be illuminated at this time. On systems with

Heater and/or AutoPure™ Options, their displays will energize only after units reach full

pressure.

4. Press the Start button on the operator interface on the front gauge panel.

5. Adjust needle valve on re-pressurizing circuit to pressurize system between 30 & 45 Seconds

after pressing run button (units equipped with EconoMizer™)

6. The heater controller and the purity controllers should be making their self-adjustments.

7. Calibrate oxygen sensor as described in 6.2 below.

8. Observe the nitrogen membrane pressure gauge and the inlet air pressure gauge. Adjust the

membrane pressure regulator to 15 PSIG below the lowest expected supply pressure. Turn

clockwise to increase turn counterclockwise to decrease pressure.

6.2 Nitrogen Purity Sampling System Setup

1. If unit is equipped with the optional oxygen analyzer, make sure the analyzer is calibrated before

using the generated nitrogen. High purity systems utilize gases which are calibrated at a known

oxygen content to calibrate othe oxygen analyzer. The trace oxygen (PPM O2) utilizes a two

point calibration (high range and low range). The 5-way valve located under the analyzer on the

front panel allows for sensing the gas from four locations; two of which are the Calibrate High

and Low Span Gas Positions. Calibrate with the High Span first and then repeat using the Low

Span. Note: Valve on the Span Gas tanks should be closed when not in use to avoid loss of

contents in between calibration intervals.

2. Make sure the Purity Sampling System is properly set so that damage to the oxygen analyzer does

not occur and proper readings can be obtained.

3. There should be no valve on the discharge of the sensor. The sensor is designed to operate at or

near atmospheric pressure. Over pressurizing can damage the sensor.

4. There are two pressure regulators on the high purity system. One is located inside the cabinet

behind the panel mounted regulator. Set the one inside the cabinet at 30-40 PSIG. Adjust the

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analyzer pressure regulator on panel until the flow reaches 2-3 SCFH by pulling out on the yellow

knob and turning clockwise to increase, and counter-clockwise to decrease pressure or flow rate.

5. The needle valve on the oxygen sample flow meter should be turned counter clockwise to open

fully. A change in main regulator set pressure may require re-adjustment.

6. Allow oxygen content reading on display to stabilize.

7. Press Mode Button until “CAL” appears in display. After releasing button, the display will

indicate an oxygen content. Press !keys to make the display agree with the Span Gas content.

8. Process may need to be repeated to fine tune.

9. When calibrated, Press MODE Key until RUN is displayed. Release MODE button.

10. Once the display settles in agreement with the span gas contents, the unit is calibrated. Switch

the 5-Way valve to the “Monitor N2 Outlet” position.

6.3 EconoMizer™ Adjustments – If system has been equipped with an energy saving EconoMizer™

control system, there are field adjustments necessary to proper operation.

6.4 Critical Adjustments – There are certain settings and adjustments that should not be tampered

with. If these are re-adjusted without written consent of Pneumatech, Inc., all or part of the warranty

on the unit may become void.

These are the as follows:

1. Heater controller is factory adjusted for from 70-105 degrees F and should not be re-adjusted

above 110 degrees or membrane performance can decline over time. Temperature in excess of

125 degrees F will damage the membrane material.

2. High temperature safety switch has been factory set at 120 degrees and should not be re-adjusted.

3. A membrane inlet pressure switch is supplied with all units with the heater option. If pressure is

on the system there will be airflow to the heater. The pressure switch is factory set to

approximately 85-90% of the inlet pressure and should not be re-adjusted unless the inlet pressure

to the membrane is re-adjusted.

7.0 OPERATING INSTRUCTIONS

7.1 GENERAL DESCRIPTION - Pneumatech Model PMNG Series nitrogen gas generator is a complete

system that is factory assembled, tested, and ready for service. The system requires connection to the

user’s system as described in Section 3.0.

7.2 OPERATION OF THE UNIT – The basic standard system is manually controlled. In this system, the

user needs to follow the instructions in section 6.1, paragraphs 1,2 & 8.

1. Manual System – On manually controlled systems, a flow controller, located between the nitrogen

discharge manifolds, needs to be adjusted so that the system delivers the specified flow rate using

built-in flow meter.

2. Automatic System – On automatically controlled systems, only the oxygen content set point needs

to be adjusted. This is done on the purity controller by pressing the ! [up or down arrow] keys to

reach the desired oxygen content. All other settings in the controller have been factory set and do

not require further adjustment. The purity set point has been factory set as called out in either the

purchase order or job specifications. There is a manual by-pass valve in the event that servicing

needs to be done to the automatic valve. Simply close the isolation ball valves that supply the

automatic valve and open the ball valve that isolates the manual flow controller. If the manual

controller has been preset to the necessary flow rate or oxygen content at start-up, no further

adjustments are necessary. A small set screw adjusts the flow and uses a 3/32” allen wrench.

3. Heater & Controls – If the unit is supplied with a heater, it has been factory set for optimum

performance and operates automatically. Adjustments outside the specified temperature range will

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affect warranty. Instructions are given for adjustment in section 9, if for any reason the controller

must be replaced or re-adjusted.

4. On/Off Selector Switch – If the unit is supplied with heater and controls, (but no Operator

Interface), the panel will have an On/Off selector switch to start & stop the system. The unit will

requires pressure on the system before the heater will run. Systems with Operator Interface, have a

Power OFF/On switch.

5. SurePure™ Purity Vent – This is a system that will vent off-spec nitrogen to atmosphere until the

product gas meets the required purity. Unit is shipped factory set as called out in either the

purchase order or job specifications. If unit is supplied with the automatic purity vent the user can

adjust the HI Alarm (Alarm 1) on the oxygen analyzer to dictate when the generator is within

acceptable limits on delivered oxygen content. Simply, press the Mode button on the oxygen

analyzer and toggle until Alarm 1 appears. Press the [Up Arrow] or [Down Arrow] key until the

desired setting. Press the Mode button repeatedly until “Run” appears. In approximately 2 minutes,

the unit will go back to normal. The setting must be greater than the purity controller set point as

described in section 7.2, paragraph 2 above.

6. Main Flow Meter – Each unit is equipped with a nitrogen flow meter and on cabinet systems is

panel mounted.

7. Economizer – If the unit is supplied with this option, the system will also have a nitrogen storage

tank downstream of the generator unit. The purpose of this option is to save energy and run time on

the unit during times of low or no demand. There are high (PS2) and low (PS3) pressure switches

to be set. The low-pressure switch (PS3) should be set slightly above the minimum acceptable

pressure to allow at least 5 minutes of operation from storage. This can be calculated using the

following formulae.

MPsMPP =+∆ Where: MP = Minimum Pressure

MPs = Minimum Pressure Setting of PS3

∆

P = Pressure difference between MPs & MP

Storage ∆=

×7.14 Where: Storage = Rate x Minutes

14.7 = Atmospheric pressure (PSI)

Rate = Maximum demand flow rate in SCFM

SCFM = SCFH ÷ 60

V = Volume in Standard Cubic Feet (SCF)

SCF = Tank volume in gallons ÷ 7.4805

Example:

You have a minimum pressure requirement of 40 PSIG, a 1060-gallon tank, and a maximum

demand of 450 SCFH. Calculate the minimum pressure setting.

1. Solve for SCFM (450 ÷ 60) = 7.5 SCFM

2. Solve for SCF (1060 ÷ 7.4805) = 141.7 SCF

3. Solve for Storage (7.5 SCFM x 5 minutes) = 37.5 SCF of Storage

4. Solve for ∆Ρ PSID

9.3

7.141 7.145.37 =

5. Solve for MPS (40 PSIG + 3.9 PSID) = 43.9 PSIG minimum switch setting.

The low-pressure switch (PS3) should never be equal to or greater than the setting of high-pressure

switch (PS2). In fact, it should be at least 10 percent lower to avoid control problems due to drift of

the pressure switches.

The high-pressure switch (PS2) should be set at least 25 PSIG below the minimum required inlet

pressure to the unit to allow for pressure drop through the unit due to normal pressure drop and

filter particle buildup.

Page 13 of 18

8. ∆

∆∆

∆Ρ

ΡΡ

Ρ Gauge & Message – If unit is supplied with this option, the filter elements can be changed

whenever the differential pressure exceeds the setting on the switch. This switch is factory adjusted

to approximately 10 PSID and should not require adjustment. A light will illuminate along with a

message to alert the operator that the filter elements need changing.

9. Hourmeter – The hour meter will be energized any the generator is actually making nitrogen. The

hour meter does not run when the economizer is active. The pressure switch (PS1) controls when the

hourmeter runs.

8.0 Operation & Maintenance

8.1 Heater Controls

A. Initial Setup

With unit pressurized and On/Off Switch in the on position, locate the CAL controller on the

electrical enclosure door. Upon power up a new controller will need to be programmed. Initially

it will display “inPt : none”

1. Input Type

Initially “inPt : none” is displayed. Press and hold * and press"#keys to locate tC K and

release the buttons. Press " once and the display will now read “unit : none”.

2. Select Units

Press and hold * and press"#keys to locate oF and release the buttons. Press " once and

the display will now read “SP1.d : none”.

3. Setpoint Device

Press and hold * and press"#keys to locate SP1.d:SSd and release the buttons.

4. Save to Memory

Press and Hold "#keys simultaneously for 3 seconds to enter initial configuration into

controller memory. The display will now read “ParK” because a setpoint has not been

entered yet.. Auto Tune needs to be performed before the final set point is entered.

B. Auto Tune

1. Set Temperature

Press the * and " until the temperature set point is about 15 degrees above the upper display

reading to allow autotune to perform properly.

2. Tune

Press the "#keys simultaneously for 3 seconds and “Tune” should appear in the display.

3. Tune at Setpoint

Press * and " until tune:At.SP appears Press "#keys simultaneously for 3 seconds. Unit

will auto tune to proper setting. If auto tune does not give desired results, PID values can be

input manually using the following procedure.

C. Manual Tuning

1. Enter Tuning

Press the "#keys simultaneously for 3 seconds and “Tune” should appear in the display.

2. Proportional Band

Press the " key until bAnd appears. Hold the * and " keys until a value of 5.8 is reached.

3. Integral

Press the " key until int.t appears. Hold the * and " keys until a value of 4.5 is reached.

4. Derivative

Press the " key until dEr.t appears. Hold the * and " keys until a value of 16 is reached.

D. Temperature Setpoint

Press and hold the * and "# until the lower display reaches the desired temperature set point.

Release keys and the new setpoint is established.

Page 14 of 18

8.2 High Temperature Thermostat

A. Initial Setup

Press SET key once to get to Units

B. Set Units

Press the "key until oF is displayed. Press SET key once to get to Setpoint Temperature.

C. Setpoint Temperature

A small “blinking” S1 will appear in the upper left of the display. Press the "#keys to advance

to the desired setpoint of 120 degrees F. Each press of the key will advance one degree. Press the

SET key once to get to the Differential Temperature Mode.

D. Differential Temperature

A small “blinking” DIF1 will appear in the middle left of the display. Press the "#keys to

advance to the desired differential of 5 degrees F. Each press of the key will advance one degree.

Press the SET key once to get to the Heating/Cooling Mode.

E. Heating Mode

C1 or H1 will appear in the display. Press the " key until H1 is displayed. Press the SET key

once to get back to the monitoring mode. Programming is now complete.

8.3 Routine Maintenance

A. Isolate Unit

1. Disconnect Power to the Unit

2. Close isolation valves (customer mounted ) and allow pressure to vent off the system.

B. Change Filters

1. Unscrew the housing from the filter head and drain off any oil in the housing into a suitable

container. Stuff clean rag into filter bowl to keep unit clean while changing the elements.

2. Unscrew the locking nut on the bottom of the element and discard the element. Replace the

element with a new one of the appropriate grade and replace the locking nut. Do not over

tighten..

3. Auto drain – Each filter is fitted with an internal automatic float drain to carry away

condensate (water & oil). There should only be a small amount of liquid in the housing. As

the level of the oil increases, the float rises and discharges liquid from the housing. If a large

amount of oil is found, remove the auto drain, clean or replace.

4. Replace Filter housing. After replacing the element, remove the rag and screw the housing

back on to the filter head. Do not over tighten. Housing is sealed with an o-ring, so gently

hand tighten.

5. Repeat this process for all three (3) filters.

C. Change Carbon - Once per year or every 4000 hours, replace the carbon in the carbon vessel. The

vessel will need to be removed from the machine to re-fill with carbon.

1. Disconnect the union fittings at the top and bottom of the housing.

2. Remove the bolts in the mounting brackets (floor and side brace) that hold the vessel in place

and remove the vessel from the unit.

3. Unscrew one of the screens from either end (3/4” nipple) to allow access to the carbon. Take

precautions to not damage the threads. Drain the carbon into a container and replace with

fresh BM-000427 carbon.

4. Replace screen.

5. Re-mount the vessel, connect the piping and secure.

6. Unit is now ready to put back on line.

Page 15 of 18

9.0 ROUTINE MAINTENANCE SCHEDULE

Daily

2. Check for air and nitrogen leaks. Tighten or re-tape fittings as necessary.

3. Check that the Membrane Inlet pressure is as established upon setup of the equipment

4. Check that the inlet air temperature is less than 105°F and pre-cool if necessary.

5. Check that hour meter (if equipped) is operative.

Weekly

1. Clean unit as necessary.

2. Check that the differential pressure on the filtration system does not exceed 10 PSID. The filter

elements need to be replaced when differential pressure reaches 10 PSID.

Every three months

1. Check operation of all safety relief valves

2. Calibrate oxygen sensor (if equipped) See section 6.4

Annually or longer intervals

1. Replace all filter elements on the unit at 8000 hours. If the unit is equipped with differential

pressure switch/gauge, the filter elements should be changed at 10 PSID.

2. Change the carbon in the carbon adsorber bed. Units with a functioning hourmeter can run for

8000 hours before changing carbon.

3. Every three - five years, return oxygen analyzer for factory sensor replacement and re-calibration.

Page 16 of 18

10.0 SPARE PARTS

Spare Parts – PMNG-800HP Nitrogen Generator – SN: 0210-G137961-034818

QTY REFERENCE Part # DESCRIPTION Stock

Level Rec.

QTY

2 Filter 1 (4), Filter 3 (7) Q-095-15 Coalescing Filter Element, Pre-filters No. 1 & 3 1 2

1 Filter 2 (5) C-095-15/G4 Coalescing Filter Element, 2nd stage pre-filter 1 1

18 Carbon Tower (9) BM-000427 Air separation grade carbon (lbs.) 1 18

1 SV4 (38) VA-001822 Solenoid Valve,.5"NPT,N.O.,200PSI,120V 2 1

2 SV2 (25,39) VA-000131 Solenoid Valve,.5” NPT, N.C., 300PSI,120V 2 1

2 Membrane (19) RG-002672 Membrane, Nitrogen 3 0

1 PLC EC-000024 PLC, 10 AC In, 8 Relay Out, 120VAC 3 0

1 Operator Interface EC-000018 Panel, Operator Interface, EZ-220P 3 0

1 Cable EC-000019 Cable, PLC-Panel, EZ-2CBL 3 0

4 Regulator (31) VA-000807 Regulator, .125” 3 0

1 Relief Valve (6) VA-001531 ASME safety valve, 1/4", 150 PSI, 2 1

1 Heater (13) RG-000419 Circulation heater,.75 kW, 120-1-60 3 0

1 Check Valve (26) VA-002870 Check Valve,.5",EPR Seat 2 1

1 SSR 1 EC-001771 Solid State Relay, 25 AMP 2 1

1 1FU EC-002718 Fuse, 15 Amp, 250V, Glass 2 1

1 HC EC-001769 Heater Controller 3 0

1 APC EC-003865 Automatic Purity Controller, Dual Loop 3 0

1 AV (24) VA-003004 Automatic Purity Control Valve 3 0

3 PS1, PS2, PS3 EC-001962 Pressure Switch 2 3

1 DPG-PS4 GM-000503 Gauge, ∆P Switch-Gauge, 0-15 PSID 3 0

3 Press Gauge (2,18,36) GM-000497 Gauge, 0-200 PSIG, 3.5” Dia., Panel Mount 2 3

1 Reg-Pilot (11) VA-000547 Precision Regulator, Pilot, .25”, CR200H 3 0

1 Flow Valve (22) VA-003013 Controller, Flow, Manual, .25” NPT 3 0

1 Regulator (12) VA-000566 Regulator, Pilot Operated, 1” 3 0

1 BV-1” (1) VA-000986 Valve, Ball, 1” NPT 3 0

3 BV-.25” (23) VA-000002 Valve, Ball, .25” NPT 3 0

1 BV-.5” (27) VA-000971 Valve, Ball, .5” NPT 3 0

1 TC (17) GM-000253 Thermocouple, 2.5” Stem, 5Ft PVC wire 2 1

1 TC Fitting (17) 2-2FH4BZ-B Thermocouple Fitting 2 1

1 TS1 (16) EC-002372 Thermostat, Sensor, 1-stage, -30-225°F 3 0

1 C1 EC-002598 Contactor, 20 AMP, Heater 2 1

1 SV3 (35) VA-001411 Valve, Solenoid, 3-way, Economizer 2 1

2 Needle Valve (21) VA-000086 Valve, Needle, .5” NPT 3 0

1 2FU EC-002612 Fuse, 2 AMP 2 1

10 3-4 FU, 6-12 FU EC-000280 Fuse, .5AMP, 250V, Glass 2 10

1 Regulator (29) VA-002864 Regulator, Pressure, 5000 PSI,0-250PSI, .25” NPT 3 0

1 5FU EC-002411 Fuse, 1 AMP, 250V,Glass 2 1

1 GND EC-002705 Ground Bar, 4-14 3 0

1 Flowmeter (20) GM-000759 Flowmeter, 0-130 SCFH 3 0

1 Flowmeter-O2 (32) GM-000535 Flowmeter, .5-5SCFH, with SS Valve 3 0

1 BV-1”/Act (3) VA-002828 Valve, Ball, Brass, 1” NPT, with Actuator 3 0

1 SV1 (44) VA-001409 Valve, Sol, 4 Way, .25” 2 1

Page 17 of 18

SPARE PARTS (Continued)

Spare Parts – PMNG-800HP Nitrogen Generator – SN: : 0210-G137961-034818 Stock

Level Rec.

QTY

QTY REFERENCE Part # DESCRIPTION

1 HM EC-002082 Meter, Hour, 115-1-60 2 1

1 O2 (33) EC-004065 Analyzer, Oxygen, Trace (ppm) 3 0

1 PI-42 (42) GM-000041 Gauge, Pressure, 0-160, 1.5”, .125” NPT 2 1

1 BV (28) VA-002156 Valve, Ball, Brass, .125”, 5-Way, Panel Mnt. 3 0

1 24VDC CA-000264 Power, Supply,24VDC, .75 Amp 3 0

1 SW-1 EC-001634 Power OFF/ON Switch, 2-Position,Toggle 3 0

1 SW-2 EC-000180 PLC OFF/ON Switch, 2-Position,Toggle 3 0

1 CR1 EC-001038 Relay, 3-Pole, 120V 2 1

1 EC-000973 Relay, Socket 2 1

1 EC-000591 Clamp, Relay 2 1

1 I/P Transducer (45) EC-003066 I/P Transducer, 4-20mA 2 1

1 DP Trans. (37) EC-003866 Differential Pressure Transmitter, 4-20mA 2 1

3 Auto Drain RF-001281 Float Drain, Internal (Kit) 2 1

2 Filter Complete P4Q-095-15/F001-F002 Filter 1 & 3 complete 3 0

1 Filter Complete P4C-095-15/G4-F001 Filter 2 Complete 3 0

1 Screen (10) RG-002811 Screen, Carbon, 3 0

1 Thermowell EC-002068 Thermowell, Assy 3 0

LEGEND FOR SPARE PARTS

QTY – Actual Quantity in System

REFERENCE – Elect. Schematic Reference or Brief Description

STOCK LEVEL 1 – Routine Maintenance (Recommended Spares)

STOCK LEVEL 2 – Repair Parts-Short Term (Optional Spares)

STOCK LEVEL 3 – Replacement Parts-Long Term

REC. QTY – Recommended Stock Level

Page 18 of 18

11.0 WARRANTY

Pneumatech PMNG-800HP Installation, Operation & Maintenance Manual

Brand: Pneumatech

Model: PMNG-800HP

Type: Installation, Operation & Maintenance Manual

This manual is also suitable for

PMNG Series

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Pneumatech PMNG-800HP Installation, Operation & Maintenance Manual

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