User s manual Nitrogen generator Laser Cut
Table of contents 1. Introduction 3 2. Safety 4 3. Description of the generator 6 4. Installation 10 5. Operating instructions 16 6. Maintenance 30 7. Troubleshooting 33 8. Technical specifications 37 9. Declaration of conformity 40 10. Notes 42 2
Nitrogen generator Laser Cut 1. Introduction This document is aimed at the User of a CLAIND nitrogen generator model LA- SER CUT, and provides all information regarding use and maintenance. For more detailed information on individual components, consult the relative instruction manuals. It is presumed that the manual user is experienced in the use of pneumatic components, and in particular is aware of all safety aspects linked to the use of compressed air and nitrogen. The instruction manuals of the various system components are enclosed, together with the respective certificates of conformity with the applicable safety directives. The margin of the manual text contains the following symbols, indicating: m compulsory safety standards to be observed c electrical hazard e recommendations and important information It is strongly recommended to carefully read all safety warnings (par. 2.1.) before carrying out any operation on the generator. 3
Safety 2. Safety The nitrogen generator must be used in observance of the instructions in this booklet. Failure to observe these instructions will render the guarantee null and void and release CLAIND from all liability for direct or indirect damage or physical injury. 2.1. Warnings m The manual user is required to be an expert in handling pneumatic components and fully aware of all safety aspects linked to the use of pressure gas and the risks associated with the use of nitrogen (risk of asphyxia). m Never release nitrogen into a closed environment with inadequate ventilation: risk of fatal injury by asphyxia. m Never disconnect any pneumatic couplings before ensuring that the relative line is depressurised. m Only skilled personnel must make inspections and repairs. CLAIND denies all liability for damage caused by improper use of the system. Always contact the Technical Assistance services before performing work on the system. m The generator contains components that require connection to the electrical mains. Never perform maintenance or repairs when the system is connected to the electrical mains: risk of fatal injury by electrocution. m The system must be placed away from sources of heat. m The system must not be placed in areas subject to the accumulation of water. m The system must not be exposed to rain or wind. 4
Nitrogen generator Laser Cut 2.2. Safety devices EMERGENCY PUSHBUTTON: enables immediate shutdown of the generator, cutting of electrical power supply to the actuators. MAXIMUM PRESSURE: the safety valves (named SAF01, SAF02, SAF03, SAF04, SAF05, SAF06 -only for Model 450- and SAF07) prevent pressure in the various sections of the generator from reaching hazardous values. m The safety valves are set to correct values and must not be tampered with under any circumstances. In addition, they should be checked periodically according to local safety rules. 2.3. Technical assistance The CLAIND technical assistance can be contacted as follows: Tel. ++39 0344 56603 Fax ++39 0344 56627 e-mail: service@claind.it website:filling the form in the website www.claind.it at the Service section 5
Description of the generator 3. Description of the generator The Laser Cut nitrogen generator (see element B in the figure) enables the production of nitrogen at high pressure (up to 200 bar -20 MPa- or 300 bar -30MPa- ) if suitably powered with compressed air. The system therefore requires, in addition to the nitrogen generator (B), a section for the generation of compressed air (A) and a section for storage of the high pressure nitrogen (C). Normally the compressed air section (A) comprises the following elements, sized accordingly: compressor, drier, filter pack, storage tank. Normally the nitrogen storage section (C) comprises one or more cylinder packs, sized accordingly. Neither the compressed air section (A) nor high pressure nitrogen storage section (C) are described in this manual. S i a l a s e z i o n e a r i a c o m p 6
Nitrogen generator Laser Cut 3.1. Nitrogen generator operating principle The compressed air on inlet to the generator alternately feeds two columns containing a special molecular sieves (CMS) which separates the oxygen and nitrogen using PSA (Pressure Swing Adsorption) technology. The nitrogen produced is first stored in a LOW PRESSURE NITROGEN TANK at a maximum pressure of 10 bar (1.0 MPa) to then be compressed to the required pressure (max 200bar -20MPa- or 300 bar -30MPa-) by means of the multi-stage HIGH PRESSURE NITROGEN COMPRESSOR. The generator control system manages correct operation (activation of valves, setting to stand-by pressure values, nitrogen compressor start-up and shutdown, purity readings of nitrogen produced etc.). For further information on operation of the generator, refer to the flow diagram. 7
Description of the generator 3.2. Generator components 3.2.1. Front view A. MAIN SWITCH B. TOUCH SCREEN: operator interface; enables the display and entry of operating parameters C. EMERGENCY PUSHBUTTON D. CMS COLUMNS: carbon molecular sieves E. LOW PRESSURE NITROGEN TANK F. LP BUFFER: compressor supply tank G. HIGH PRESSURE NITROGEN COMPRESSOR: multi-stage compressor for nitrogen 8
Nitrogen generator Laser Cut 3.2.2. Rear view H. ELECTRIC POWER: routing for electric power cables I. AIR: pneumatic connection (G 3/4 female) for compressed air line J. NITROGEN OUTLET HIGH PRESSURE: pneumatic connection (1/4 G Female) for high pressure nitrogen line - Max 200 bar (20MPa) or 300 bar (30MPa) according to model - K. AIR CMS: pneumatic connection for the air delivery from main module to CMS module L. N2 CMS: pneumatic connection for the nitrogen return from CMS module to main module M. OUTLET NITROGEN LOW PRESSURE: pneumatic connection (G 3/4 female) for an optional nitrogen low pressure line N. V001: pneumatic connection to the PNV01 valve V002: pneumatic connection to the PNV02 valve V003: pneumatic connection to the PNV03 valve V004: pneumatic connection to the PNV04 valve V005: pneumatic connection to the PNV05 valve V006: pneumatic connection to the PNV06 valve O. DRAIN: Drain of exhaust gases from the compressor 9
Installation 4. Installation 4.1. Installation area requirements 4.1.1. Humidity and dust To avoid risks of damage to electronic components, install the generator in an environment subject to limited relative humidity and low concentrations of dust. The generator must also be protected against drips, rain and wind. 4.1.2. Temperature The ambient temperature in the generator installation area must be between 5 C and 40 C. Install away from heat sources. Avoid direct exposure to sunlight. 4.1.3. Positioning When choosing the installation area for the generator, as well as the dimensions and the weight of the unit, take into account the following. MAIN MODULE: leave a clear space of at least 1 metre from the right-hand side to enable correct intake of cooling air; leave a clear space of at least 1 metre on the rear side of the main module to enable correct outlet of spent cooling air; leave a clear space in front of the unit to enable easy access by the operator to the control panel and to facilitate panel opening. CMS MODULE: leave a clearance of 45cm between the main module left side and the CMS module right side to allow their pneumatic connection; leave a clearance of 60cm at the rear side to allow maintenance operations. 10
Nitrogen generator Laser Cut 4.2. Pneumatic connections The figure illustrates the components constituting a typical nitrogen generation system, in which the LASER CUT generator is one of the components. The couplings for pneumatic connections between the various system elements (nitrogen generator, compressed air tank, high pressure nitrogen tank) are found at the rear of the generator. 11
12 Installation
Nitrogen generator Laser Cut 4.2.1. Air inlet The properties of the compressed air on inlet play an important role with regard to the performance and lifetime of the nitrogen generator. As well as the minimum flow rate requirements (outlined in the paragraph 8 Technical Specifications) the compressed air used should be of a quality that meets the following specifications (ISO 8573-1; class 1-4-1): Dew point:< 3 C Maximum oil concentration:< 0.01 mg/m3 Maximum particle concentration (diameter 0,1 m)< 0.1 mg/m3 e If a lower quality of compressed air is used, this could cause irreversible damage to the generator. In this case, Claind denies all liability for damages and any costs for repairs will be charged to the client e For optimal operation of the nitrogen generator, the pressure of the compressed air on inlet to the unit should never fall below 8.5bar e The purity of the nitrogen produced is reduced when the air pressure on inlet lowers. Therefore the installation of a compressed air reserve tank is recommended, sized accordingly. In the event of any doubt or uncertainty with regard to the above, contact Claind for advice on the type of compressed air system (compressor, drier, filters, tank) most suited to the specific application CONNECTION Locate the air coupling (G 3/4 female), marked AIR at the rear of the generator connect the compressed air tank to the generator (the piping must be adequate to air pressure and flow rate) 4.2.2. Nitrogen outlet The high pressure nitrogen produced by the generator must be conveyed to a suitable storage system, used to absorb peaks in consumption and to compensate for technical shutdown times of the nitrogen compressor. m The nitrogen storage system elements (i.e. the components installed downline of the NITROGEN outlet of the generator) must be suitable sized for the maximum admissible pressure of the nitrogen generator Normally, the storage system comprises one or more cylinder racks equipped with suitable accessories ( ramps on inlet and outlet, multi-stage pressure reducer on outlet etc.) PRESSURE: the maximum admissible pressure is indicated at the rear of the generator (205 or 305 bar) 13
Installation FLOW RATE: The nitrogen flow rate depends on the required model and purity. For details, refer to paragraph 8 Technical Specifications PURITY: The generator produces nitrogen at a set purity level (between 99,99% and 99,999%) according to the user requirements at the time of the purchase order. The generator is set at the Claind factory for this purity level and cannot be modified by the User at a different level without the intervention of a qualified Claind technician. CONNECTION Locate the coupling (1/4 G Female) marked OUTLET NITROGEN HIGH PRES- SURE at the rear of the generator connect the high pressure hose using couplings suited to the nominal pressure of the generator m Secure the flexible hoses with safety wires e the high pressure installation kit provided by Claind is sized for a maximum admissible pressure at 205 bar 14
Nitrogen generator Laser Cut 4.3. Electrical power supply e The power line cable is not supplied with the generator and should be therefore installed by the User. e The safety devices for the power line (Switch and Fuses) are not supplied with the generator and should be therefore installed by the User c For the installation of the electrical safety device (switch and fuses) and the correct sizing of the power line cables, see the following drawing 15
Operating instructions 5. Operating instructions 5.1. User interface The user can interact with the generator through a touch screen display for: start and stop commands, alarm acquisition, display of operating status and display of event history. 16
Nitrogen generator Laser Cut 5.1.1. Menu This diagram illustrates the screens accessible by the user and keys for access to the various pages e to press the buttons on the touch screen please never use sharp objects, which may cause irreparable damage to the screen 17
Operating instructions 5.1.2. Introduction page (page00) This page is displayed on start-up of the generator. It enables access to the following pages: OPTIONS 1 (page 08), by pressing OPTIONS SYSTEM DATA (page09), by pressing SYSTEM DATA CONTROL PANEL (page 03), by pressing ESC 5.1.3. Options (page08) The relative icons on this page can be pressed to enable entry of the language. e the languages currently available are Italian and English 18
Nitrogen generator Laser Cut Starting from this page it s possible to: return to the INTRODUCTION PAGE (page00), press ESC enable settings for the Energy saving mode pressing Energy saving mode configuration 5.1.4. System data (page09) In this page it s possible to enable settings of the AUTOMATIC START, that is the activation of automatic restart after shutdown of the generator due to temporary power failure. e this function, if activated, enables nitrogen production to be resumed automatically following a power failure This page also displays a number of important counters for generator operation: number of motor starts nitrogen compressor operating hours general operating hours time remaining for generator restart 19
Operating instructions 5.1.5. Operator panel (page03) This is the most important screen page. It enables access to the buttons START, STOP and ACK ALM (alarm acquisition), displayed only when enabled in the various operation phases. This page also displays messages regarding the generator operating status. The right section also displays the main process values (nitrogen pressure and purity). This page also enables access to the following pages: LP SYNOPTIC (page 10), by pressing SIN LP GRAPH (page 22), by pressing GPH HISTORY (page 19), by pressing HIS INTRODUCTION PAGE (page00) by pressing PAR 20
Nitrogen generator Laser Cut 5.1.6. Synoptic (page 10 and 11) SYNOPTIC page enables the user to: monitor variation of a number of parameters such as: air pressure on inlet, pressure in CMS molecular screens, nitrogen pressure in LP tank (low pressure), residual oxygen concentration display the status (green=open, red=closed) of the process valves. Press key >>> or <<< to access SYNOPTIC page 2, which provides further information regarding the nitrogen compressor and the high pressure nitrogen reserve. e further details of these pages are obtained by pressing the required component on screen (e.g. the LP nitrogen tank) 21
Operating instructions 5.1.7. History (page19) The HISTORY page displays the last relevant events during generator operation (alarms, important status changes). The button DEL HIS allows to clear the page. 5.1.8. Graph (page22) The GRAPH page displays the trends of pressure in the low pressure nitrogen tank over the last 10 minutes. The keys at the lower section of the screen enables the user to interrupt, restart or delete recording of these data. 22
Nitrogen generator Laser Cut 5.2. Generator start-up To switch on the generator, set the main switch A to ON on the front panel of the generator. The touch screen initially displays the CLAIND logo and after a few seconds shows the OPERATOR PANEL (page03) with the message WAIT scrolling across the screen. At the end of the wait time (100 seconds), the message GENERATOR READY is displayed with the START button. 5.3. Entry of the language and (optional) of the Energy saving mode From the OPERATOR PANEL press the button PAR for access to the INTRO- DUCTION PAGE (page00), to set the required language 5.3.1. Energy saving mode settings The Energy saving mode is used to define two ways of working of the Laser Cut generator. Setting two different high pressure stand-by thresholds is possible to produce nitrogen when electric power costs less, instead when it s more expensive the generator is stopped till when the high pressure is under the MIN - HP reservoir pressure - Energy saving mode threshold. 5.3.1.1. Energy saving mode enabling Starting from the Operator panel page, go to the Presentation page clicking on the PAR key: 23
Operating instructions From the Presentation page go to the Options 1 page clicking on the OP- TIONS key: In the OPTIONS 1 page is possible to use the Energy saving mode key to enable or to disable the Energy saving mode. The current status is represented by the white lable showing Energy saving mode ON or Energy saving mode OFF, even on the key there is a label showing the option status ON / OFF. 24
Nitrogen generator Laser Cut 5.3.1.2. Energy saving mode date/time settings When the Energy saving mode is enabled in the OPTIONS 1 page is available a yellow key Energy saving mode configuration : Go to the Energy saving mode - set date/time page clicking on this key, where it is possible to set the current date, time and day of the week. Fields enclosed in the black frame are used to set the calendar while fields in the left represent the current calendar. Click on the Set Time key to save the calendar changes. 25
Operating instructions Go the Energy saving mode - set times clicking on the scroll key at the bottom right of the page. Here it s possible to set for which day and at what time to use the Energy saving mode choosing one or more days by clicking on the key showing the name of the day. Activating the Energy saving mode for a day its label becomes green and appear the fileds to set the on and off times: For every day is possible to set time slot with this range; from 00:00 to 23:59, so for example to set the Energy saving mode from Thursday at 17:00 (05:00 p.m.) to Friday at 06:00 (06:00 a.m.) make this settings: 26
Nitrogen generator Laser Cut 5.3.1.3. Stand by threshold settings: Go to the OPTIONS 2 page clicking on the scroll key at the bottom right of the page. If the Energy saving mode is enabled, in this page is possible to set two different stand-by threshold, one for the Energy saving mode operation and the other for normal operation: The MIN threshold represent the minimum high pressure value under which the generator restart, while the MAX threshold represent the high pressure value at which the generator is on stand-by. 5.3.1.4. Energy saving mode indicator: In the Operator Panel page there is a blinking icon showing this message: Energy saving mode. This icon appears when the generator is working in Energy saving mode. 5.3.1.5. 27
Operating instructions 5.4. Nitrogen production m Please ensure the electrical connection is made correctly (and in particular the direction of compressor rotation*) as well as the pneumatic connection of the compressed air line and the high pressure nitrogen line. Ensure that the high pressure nitrogen hoses are fitted with safety valves. * in case of wrong rotation direction, an alarm OIL PRESSURE or MOTOR ROTA- TION will appear: see chapter 7.1.5 for more details Enter the CONTROL PAGE (page03) and press the START button. During nitrogen production, the molecular sieves (CMS) and nitrogen compressor operate more or less continuously on the basis of the utility nitrogen requirements. The pages HISTORY, GRAPH AND SYNOPTIC can be displayed but we recommend returning to the OPERATOR PANEL as this provides more information on generator operation. This page also enables the user to stop production (STOP) or acknowledge alarms (ACK ALM). 5.5. Repeating alarm and buzzer signals There s the possibility to repeat the alarm and buzzer signals as shown below: 1. in case of alarm, it s enabled the power relay, whose contacts work as follows: Status Working conditions Closed contact Open contact Terminal board X1 Not working No alarm 11,12 11,14 22,23 Working Alarm 11,14 11,12 22,24 2. in case of alarm, it s enabled the buzzer on the display-interface. It s possible to add an external sonic signal, using the two power relay contacts 11KA2as shown below: Status Working conditions Closed contact Open contact Terminal board X4 Not working Buzzer OFF 11,12 11,14 15,16 Working Buzzer ON 11,14 11,12 14,16 It s possible to silence the external sonic signal directly from the display or remotely through a switch connected to 6 and + X1 terminals. 28
Nitrogen generator Laser Cut 5.6. Stop the generator In the event of an emergency, press the emergency button on the front panel. m generation shutdown in this way does not enable depressurisation of the molecular sieves (CMS), which may thus remain under pressure However, in normal conditions the generator should be shut down as follows: enter the CONTROL PANEL page (page03) press STOP. 5.7. Generator shutdown Press STOP (see previous paragraph) wait for few seconds to enable depressurisation of the molecular screens. During this interval, the message WAIT is displayed when this time elapses, the message GENERATOR READY is displayed set the main switch to OFF. 29
Maintenance 6. Maintenance To facilitate routine preventive maintenance tasks, the generator is equipped with counters set to countdown mode during operation. When the time interval between one scheduled maintenance task and another elapses, the generator notifies the user by means of a yellow flashing message at the top left of the OPERATOR PANEL page. Press on this message to display the following page Press YES to acknowledge the warning and reset the maintenance schedule counters. The same warning is then displayed again when the new time interval elapses. Press POSTPONE to exit this page and return to the OPERATOR PANEL; in this case the maintenance request message continues to flash to remind the user of the need for maintenance as soon as possible. e Never acknowledge the maintenance warning (i.e. do not press YES) unless the required maintenance task has been performed. 30
Nitrogen generator Laser Cut 6.1. Maintenance schedule Please see the following scheme: LASER CUT 225 31
Maintenance LASER CUT 450 WARNING: Only experienced personnel must do maintenance. CLAIND rejects any responsability for damages caused by uncorrected uses of the plant. Please contact CLAIND service department before doing any operation on the plant. 32
Nitrogen generator Laser Cut 7. Troubleshooting 7.1. Alarms Any malfunctions or useful information for the operator are displayed on the touch screen in two different ways: WARNING: indicates an anomalous condition that may require intervention of the operator, but gas production is not shut down ALARM: indicates a condition that prevents continuation of gas production. In this case the generator shuts down production and activates depressurisation. Therefore the generator must be shut down, after which eliminate the cause and restart the generator In both cases an acoustic warning signal is activated. To shut off the acoustic signal, press a text key on the screen to display the EVENT HISTORY page. From the EVENT HISTORY page, press ESC to access the OPERATOR PANEL where a red indicator shows the cause of the alarm. The same page also displays the flashing yellow button ACK AMP to enable acquisition of the alarm. The following section lists the possible warning and alarm messages. 7.1.1. ALARM: Air pressure too high CAUSE: activated when the compressed air pressure on inlet to the generator exceeds the maximum admissible value. REMEDY: check the compressed air system for faults 33
Troubleshooting 34 check the pressure sensor PT00 7.1.2. ALARM: Air pressure too low CAUSE: activated when the compressed air pressure on inlet to the generator falls below the minimum admissible value for control of the pneumatic valves. REMEDY: check the compressed air system for faults (compressor stationary, valves closed etc.) check the pressure sensor PT00 7.1.3. ALARM: CMS pressurisation failure CAUSE: activated when the compressed air pressure and/or flow rate on inlet to the generator is inadequate to guarantee efficient pressurisation of the molecular screens. REMEDY: check the compressed air system for faults (compressor stationary, compressor settings modified, valves closed, significant leaks, air intake for other utilities, etc.) check the pressure sensors PT00 and PT01 ensure correct operation of screen vent valves PNV02 or PNV04 7.1.4. ALARM: LP reservoire pressure too low CAUSE: activated when the LP (low pressure) nitrogen reserve pressure falls below the minimum admissible value. This indicates a serious system fault REMEDY: contact a CLAIND service centre 7.1.5. ALARM: Motor rotation CAUSE: during electrical hook-up, the power line phases are inverted and cause incorrect direction of rotation of the compressor motor. compressor oil exceeds the alarm setting REMEDY: if this occurs on initial start-up, check the direction of compressor rotation e To check the direction of compressor rotation, proceed as follows: inspect component D01: if it lightens it means that the power supply lines are not connected correctly in this case, switch off the generator and disconnect the main power swap two lines (examples L1 and L2) switch on again the generator
Nitrogen generator Laser Cut now, the component D01 should be not lightened and the alarm condition should be disappeared 7.1.6. ALARM: Oil pressure CAUSE: 6 seconds after the restart of the compressor, if the oil pressure reaches at least 3.5 bar, the PS05 pressure switch switches off REMEDY: the level is under the minimum admissible value the PS05 pressure switch is out of order 7.1.7. ALARM: N2 compressor contactor open CAUSE: excessive electrical absorption by compressor REMEDY: contact a CLAIND service centre 7.1.8. ALARM: stage critical pressure CAUSE: the pressure switch of one of the compressor stages (PS01, PS02, PS03 or PS04) indicates a pressure value exceeding the maximum admissible value REMEDY: contact a CLAIND service centre 7.1.9. ALARM: suction pressure too high / too low CAUSE: the nitrogen pressure on inlet to the compressor exceeds admissible values REMEDY: contact a CLAIND service centre 7.1.10. WARNING: HP storage pressure too low CAUSE: the nitrogen pressure in the high pressure reserve falls below the minimum admissible value. This may be caused by excessive nitrogen consumption by the utility REMEDY: check nitrogen consumption 7.1.11. WARNING: Oxygen content over the threshold The generator is producing nitrogen with an oxygen content exceeding the maximum admissible value. In this condition, the generator automatically activates by-pass mode to enable purification of the nitrogen in the low pressure reserve. 35
Troubleshooting If this condition persists, the generator is unable to reach the rated flow rate and therefore other alarms may trip. CAUSE: oxygen analyser supplied incorrect values low flow rate and/or air pressure on inlet air on inlet contaminated with oil vapours malfunction of a vent valve (PNV03 or PNV04) REMEDY: check characteristics of air on inlet check operating time of oxygen analyser contact a CLAIND service centre 36
Nitrogen generator Laser Cut 8. Technical specifications maximum operating pressure according to model: 200 bar (20 MPa) or 300 bar (30 MPa) nitrogen flow rate from 5.4 to 32.4 Nm3/h according to model and purity setting nitrogen purity from 99.95 to 99.999% nitrogen dew point on outlet -50 C atmosph.pressure air pressure on inlet 6.5 13 bar air dew point on inlet < 3 C in pressure oil concentration on inlet air < 0.01 mg/m³ particulate concentration (d=0.01µm) on inlet air < 0.1 mg/m³ compressed air consumption from 62.1 to 288 Nm3/h according to model and purity setting ambient temperature 5 40 C 37
Technical specifications Model 225 Model 450 cooling air flow rate 75 m3/min 160 m3/min electrical power supply 380/440 Vac 3ph+N; 50/60Hz 380/440 Vac 3ph+N; 50/60H nitrogen compressor model SV 225-250 N SVc 450-350 N generator electrical power absorption 8 kw 16 kw recommended minimum power cable section 2.5 mm2 6 mm2 noise level < 70 db(a) 38
Nitrogen generator Laser Cut DIMENSIONS AND WEIGHTS Model 225 Model 450 width with 1 CMS module (a1) 290 cm 340 cm width with 2 CMS modules (a2) 330 cm 380 cm width with 3 CMS modules (a3) 370 cm 420 cm width with 4 CMS modules (a4) 410 cm 460 cm depth (b) 110 cm 110 cm height (h) 207 cm 207 cm total weight with 1 CMS module 1500 kg 1650 kg total weight with 2 CMS modules 2150 kg 2300 kg total weight with 3 CMS modules 2800 kg 2950 kg total weight with 4 CMS modules 3450 kg 3600 kg 39
Declaration of conformity 9. Declaration of conformity 40
Nitrogen generator Laser Cut 41
Notes 10. Notes 42
Claind srl Via Regina, 24 22016 Tremezzina Loc. Lenno (CO) - Italy Tel +39 0344 56603 Fax +39 0344 56627 e-mail service@claind.it N2 LaserCut eng Rev9.fm