Instruction book

Nitrogen generators

NGP450+, NG550+, NGP650+, NGP800+, NGP1000+,

NGP1300+
Atlas Copco
Nitrogen generators

NGP450+, NG550+, NGP650+, NGP800+, NGP1000+,

NGP1300+

Instruction book
Original instructions

COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.

March 2022
No. 2920 7211 70

www.atlascopco.com
 Instruction book

Table of contents

1 Safety precautions..........................................................................................................5

1.1 Safety icons................................................................................................................................ 5

1.2 General safety precautions.................................................................................................... 5

1.3 Safety precautions during installation................................................................................ 5

1.4 Safety precautions during operation.................................................................................... 6

1.5 Specific safety precautions..................................................................................................... 7

1.6 Safety labelling......................................................................................................................... 8

1.7 Dismantling and disposal........................................................................................................10

2 Description.................................................................................................................... 11

2.1 General description................................................................................................................ 11

2.2 Detailed description................................................................................................................13

2.3 Flow diagram............................................................................................................................ 16

2.4 Electric diagram...................................................................................................................... 18

3 Installation.....................................................................................................................19

3.1 Dimensions.................................................................................................................................19

3.2 Installation proposal............................................................................................................. 19

3.3 Electrical connections.......................................................................................................... 27

4 Controller.......................................................................................................................28

4.1 Controller functions.............................................................................................................28

4.2 Control panel.......................................................................................................................... 30

4.3 Icons used................................................................................................................................. 31

4.4 Main screen............................................................................................................................... 34

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4.5 Quick access screen................................................................................................................35

4.6 Graphic screen.........................................................................................................................35

4.7 Menu screen..............................................................................................................................36

4.8 Data menu.................................................................................................................................. 37

4.9 Service menu............................................................................................................................. 39

4.10 Week timer menu.......................................................................................................................41

4.11 Event history menu..................................................................................................................42

4.12 Machine settings menu............................................................................................................ 42

4.13 Controller settings menu..................................................................................................... 46

4.14 Access level..............................................................................................................................48

4.15 Web server................................................................................................................................49

5 Operating instructions................................................................................................. 54

5.1 Starting.....................................................................................................................................54

5.2 During operation..................................................................................................................... 55

5.3 Stopping.....................................................................................................................................57

5.4 Checking the display............................................................................................................... 57

5.5 Taking out of operation..........................................................................................................57

6 Maintenance.................................................................................................................. 58

6.1 General......................................................................................................................................58

6.2 Maintenance schedule.............................................................................................................58

7 Optional equipment...................................................................................................... 60

7.1 Outlet pressure dew point.................................................................................................... 60

7.2 External oxygen analyser..................................................................................................... 60

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8 Trouble shooting ..........................................................................................................61

9 Technical data............................................................................................................... 64

9.1 Reference conditions..............................................................................................................64

9.2 Limitations for operation....................................................................................................... 64

9.3 Performance data....................................................................................................................64

9.4 Correction factors.................................................................................................................65

10 Pressure Equipment Directives...................................................................................66

11 Declaration of conformity............................................................................................ 67

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1 Safety precautions

1.1 Safety icons

Explanation
Note: Important note

Warning: Warning

Danger: Danger to life

1.2 General safety precautions

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

1.3 Safety precautions during installation

• Install the equipment where the ambient air is cool and as clean as possible. Consult section
Reference conditions and limitations.
• During installation or any other intervention on the equipment or one of the connected
machines, the machines must be stopped, de-energized and the isolating switch opened and

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locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or
working on the machine. To this end, a suitable notice shall be affixed to the start equipment.
• Install the equipment in an area free of flammable fumes, vapours and particles, e.g. paint
solvents, that can lead to internal fire or explosion.
• The electrical connections must correspond to the applicable codes. The equipment must be
earthed and protected against short circuits by fuses in all phases. A lockable power isolating
switch must be installed near the equipment.
• For machines controlled by a central control system, a sign stating "This machine may start
without warning" must be affixed near the instrument panel.
• In multiple compressor systems, manual valves must be installed to isolate each compressor.
Non-return valves (check valves) must not be relied upon for isolating pressure systems.
• Never remove or tamper with the safety devices.
• If the maximum pressure of the compressor is higher than the design pressure of the connected
equipment, a full flow safety valve must be installed between the compressor and the
connected equipment, in order to be able to blow off the excessive pressure.
Note:
For precautions applying to the connected equipment consult the relevant instruction book.

1.4 Safety precautions during operation

Warning:
All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
• Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
• Never operate the device in the presence of flammable or toxic fumes, vapours or particles.
• Never operate the device below or in excess of its limit ratings.
• Keep all bodywork doors shut during operation. The doors may be opened for short periods
only, e.g. to carry out routine checks.
• People staying in environments or rooms where the equipment is operated shall wear adequate
personal equipment, such as ear protection and safety goggles.
• Periodically check that:
• All guards and fasteners are in place and tight
• All hoses and/or pipes are in good condition, secure and not rubbing
• There are no leaks
• All electrical leads are secure and in good order
• There is no dust coming out the unit after the first 24 running hours. If so, stop the
machine and contact your supplier
• Never modify the device in any way. Keep the equipment in original working condition.
Note:
For precautions applying to the connected equipment consult the relevant instruction book.

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1.5 Specific safety precautions

The nitrogen generator can be installed in the vicinity of the nitrogen consuming application without
the requirement for classification of the surrounding area as hazardous, provided that all necessary
measures have been taken to guarantee the maximum safety.
The nitrogen generating unit must be installed and used in observance of the instructions in this
booklet. Failure to observe these instructions will render the guarantee null and void and release
the manufacturer from all liability for direct or indirect damage or physical injury.
Hoses, pipes and connections used must be of the correct size and must be suitable for the
working pressure and purity. Never use frayed, damaged or worn hoses. Fixed piping is
recommended, especially for high purities. Connections made to the equipment must be free of
strain.
Nitrogen and oxygen are the primary components of air, they are not toxic, but when their
concentrations in air are altered, dangerous environments can be created. For an overview of
oxygen concentration in air and its corresponding effects, see the table below. The release of
nitrogen gas can expel oxygen, leading to a decrease in oxygen levels, whereas a release of
oxygen enriched air will allow for oxygen levels to increase. You should therefore never directly
inhale the produced gas, and avoid working in the immediate vicinity of the flowing nitrogen.
Appropriate ventilation should be foreseen to make sure that oxygen concentration in the room
containing the generator will not be lower then 20 vol. %, nor exceed 22 vol. %. It's recommended
to install a room oxygen alarm. Consult the installation proposal or your supplier if in doubt.
Normal oxygen concentration in air is approximately 21% by volume. In general, air containing less
than 19.5% or more than 23.5% oxygen constitutes a hazardous working environment. Typical
symptoms of oxygen deficient atmospheres are listed in the table below. (ref. ANSI Z88.2)

% oxygen at sea level (atmospheric

Effects
pressure)
>23.5 Increased fire hazard
20.9 Normal
Some adverse physiological effects occur, but
19.0
they are unnoticeable.
Increased pulse and breathing rate. Impaired
16.0
thinking and attention. Reduced coordination.
Abnormal fatigue upon exertion. Emotional
14.0
upset. Faulty coordination. Poor judgment.
Very poor judgment and coordination. Impaired
12.5 respiration that may cause permanent heart
damage. Nausea and vomiting.
Inability to perform various movements. Loss of
<10
consciousness. Convulsions. Death.

As a side product of the gas separation process that occurs in the nitrogen generator, a significant
stream of oxygen enriched air will leave the generator via the exhaust outlet.
Areas where it is possible to have an oxygen enriched or deficient atmosphere should be well
ventilated or the enriched gas should be directed to the outside atmosphere. Make sure the piping
is properly labelled and warning signs indicate the risks. No open flame or smoking are allowed in
the vicinity of oxygen vents. If required, warning signs should be posted and special precautions

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shall be taken such as installing analyzers with alarms, ensuring a minimum number of air changes
per hour, implementing special entry procedures or a combination of these.
Oxygen concentrations higher than 23.5% create greater fire hazards than normal air. Oxygen is
not combustible, but it promotes very rapid combustion of flammable materials and some materials
that are normally regarded as being relatively non flammable.
When working on or around the generator, always wear a portable oxygen sensor to indicate safe
working conditions.

Although a source of ignition energy is always necessary in combination with flammable materials
and oxygen, control or elimination of flammables is a precautionary step.
More details about the characteristics of nitrogen or oxygen can be found in the safety data sheet
for nitrogen and oxygen, both available as a separate publication (consult your supplier).

1.6 Safety labelling

The following safety label is attached to the nitrogen generator:

Figure 1: Safety label 1627 6399 00

Translation of the text on the label

Warning:
This gas generator PRODUCES NITROGEN gas, which does not support respiration and
can cause asphyxiation.

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This gas generator RELEASES OXYGEN enriched air as its exhaust. Oxygen poses an
increased risk of fire. Products that are generally considered inflammable may ignite due to
the increased oxygen level.
Make sure there is adequate ventilation at all times.

ISO 7000 - symbol 0419 Read the instruction manual

ISO 7000 - symbol 0434b General safety alert symbol

- Warning: Risk of asphyxiation

Fire hazard:
• No open flame near the
ISO 7010 - symbol P003 generator
• Fire, open ignition source
and smoking prohibited
Warning:
• Generator can start
automatically
• Read the manual before
service or repair
1079 9903 48 • Turn off the power and
disconnect the power
supply before service or
repair
• Depressurize before
service or repair

1079 9906 29 Warning: dangerous blow off

ISO 7010 - symbol M003 Wear ear protection

Table 1: Information on safety labels

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1.7 Dismantling and disposal

Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g.
LOTO, cool-down, depressurize, discharge, etc.).
3. Separate the harmful from the safe components (e.g. drain oil from parts containing oil).
4. Refer to the disposal topic below.

Disposal of electrical and electronic appliances (WEEE)

This equipment falls under the provisions of the European Directive 2012/19/EU on waste electrical
and electronic appliances (WEEE) and may not be disposed as unsorted waste.

The equipment is labelled in accordance with the European Directive 2012/19/EU with the crossed-
out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.

Disposal of other used material

Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants, cleaning
rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and
in line with the local recommendations and environmental legislation.

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2 Description

2.1 General description

Working principle
NGP450+ up to NGP1300+ nitrogen generators are intended to produce nitrogen (N2) for industrial
purposes. They use Pressure Swing Adsorption (PSA) technology to produce nitrogen by passing
compressed air through a tank containing adsorbent material.
The adsorbents are chosen on the basis of their adsorption characteristics: the adsorbent has much
more affinity for non-product molecules than for the product gas (N2). This characteristic results in
most of the desired molecules (N2) passing through the bed and remaining in the product stream,
while undesired components (product impurities) are captured by the adsorbent.
The PSA process is inherently a batch process, as the adsorbent bed requires periodic desorption.
Consequently, PSA systems usually contain two adsorbent tanks (adsorbers) to provide operational
continuity. At any time, one of the adsorbers will be delivering product (N2) by adsorbing undesired
components of the air, while the other adsorber is being regenerated by depressurization to
atmospheric pressure. When the adsorbing adsorber approaches saturation, a set of valves quickly
switches the functions. A product tank downstream of the nitrogen generator ensures that the
delivery of nitrogen is continuous.
During the adsorption phase, compressed air flows through the sieve and oxygen molecules are
caught while nitrogen molecules pass on due to the different molecular size. The sieve continues to
adsorb oxygen until a saturation point is reached. During desorption, the entering air stream is cut
off and the oxygen is able to leave the tank at low pressure.

Figure 2: Operating principle of the nitrogen generator

Nitrogen PSA adsorbers contain Carbon Molecular Sieve (CMS) material to remove oxygen.

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The generator produces nitrogen at a purity level between 95 % and 99.999 % according to the
user requirements and the required nitrogen flow and pressure.
The nitrogen flow rate depends on the model size and the required purity.
The nitrogen pressure depends on the pressure of the compressed air at the inlet.

Variant Nitrogen purity Residual oxygen concentration

95 % 5%
96 % 4%
97 % 3%
% 98 % 2%
99 % 1%
99.5 % 0.5 %
99.9 % 0.1 %
99.95 % 500 ppm
99.99 % 100 ppm
ppm
99.995 % 50 ppm
99.999 % 10 ppm

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2.2 Detailed description

Reference Description
V1 Inlet transfer valve, adsorber A
V2 Inlet transfer valve, adsorber B
V3 Bottom equalisation valve
V6 Top equalisation valve
V7 Outlet transfer, adsorber A
V8 Outlet transfer, adsorber B
V9 Minimum pressure valve
V10 Consumer valve
V11 Inlet flushing valve
V12 Outlet flushing valve
OR01 Regeneration purge nozzle
OR02 Bottom equalisation nozzle

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Reference Description
OR03 Top equalisation nozzle
OR04 Startup nozzle
OR05 Inlet flushing nozzle
OR06 Outlet flushing nozzle
ER Elektronikon controller
BA01 Pilot air ball valve
BA02 Inlet pressure ball valve
BA03 Adsorber A presure ball valve
BA04 Adsorber B pressure ball valve
BA05 Pre-mix purity ball valve
BA06 Outlet pressure ball valve
BA07 Nitrogen purity analysis ball valve
BA08 Outlet sample ball valve
PI01 Inlet pressure gauge
PI02 Adsorber A pressure gauge
PI03 Adsorber B pressure gauge
PI04 Outlet pressure gauge
PI05 Consumer pressure gauge
PT01 Inlet pressure transmitter
PT02 Adsorber A pressure transmitter
PT03 Adsorber B pressure transmitter
PT04 Outlet pressure transmitter
FT01 Nitrogen flow transmitter
TT01 Inlet temperature sensor
FIL01 Pilot air filter
PR01 Pilot air pressure regulator
PR02 Nitrogen purity pressure regulator
PR03 Consumer pressure regulator
NRV1 Non return valve
HV1 Manual flow regulating valve
PDP01 Inlet pressure dewpoint
PDP02 Outlet pressure dewpoint (optional)
OTO01 Oxygen analyser
Y13 Inlet PDP sensor 2/2 spool valve
Y14 Purity sensor 2/2 spool valve
Y15 Outlet PDP sensor 2/2 spool valve

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Reference Description
SIL1 Blow off silencer
V4 Blow off valve, adsorber A
V5 Blow off valve, adsorber B
SAV1 Adsorber A, safety valve
SAV2 Adsorber B, safety valve
ORO7 Exhaust nozzle

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2.3 Flow diagram

Figure 3: Flow diagram 9827 2995 10

Text on image
Reference Description
(1) Pre-mix N2 sample
(2) Off spec gas [B]
(3) Pilot air
(4) Out of product scope
(5) Product tank
(6) Optional outlet PDP sensor
(7) N2 sample connection
(8) For the NGP450 to 650+ PPM these components are installed in the following
order: PR03, V10, PI05, HV1
(9) Off spec air [A]

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Legend & Tie in points

Reference Description
TP1 Air in
TP2 To product tank
TP3 From product tank
TP4 N2 outlet
TP5 Waste exhaust
A Absorber
B Absorber
SIL1 Blow off silencer
V1 Inlet transfer valve, adsorber A
V2 Inlet transfer valve, adsorber B
V3 Bottom equalization valve
V4 Blow off valve, adsorber A
V5 Blow off valve, adsorber B
V6 Top equalization valve
V7 Outlet transfer valve, adsorber A
V8 Outlet transfer valve, adsorber B
V9 Minimum pressure valve
V10 Consumer valve
V11 Inlet flushing valve
V12 Outlet flushing valve
Y1–Y12 Spool valves monostable
Y13 Inlet PDP sensor 2/2 spool valve
Y14 Purity sensor 2/2 spool valve
Y15 Outlet PDP sensor 2/2 spool valve
BA01 Pilot air ball valve
BA02 Inlet pressure ball valve
BA03 Adsorber A pressure ball valve
BA04 Adsorber B pressure ball valve
BA05 Pre-mix purity ball valve
BA06 Outlet pressure ball valve
BA07 Nitrogen purity analysis ball valve
BA08 Outlet sample ball valve
SAV1 Adsorber A safety valve
SAV2 Adsorber B safety valve
PR01 Pilot air pressure regulator
PR02 Nitrogen purity pressure regulator
PR03 Consumer pressure regulator
HV1 Manual flow regulating valve
NRV1 Non return valve
OR01 Regeneration purge nozzle
OR02 Bottom equalization nozzle
OR03 Top equalization nozzle
OR04 Startup nozzle
OR05 Inlet flushing nozzle
OR06 Outlet flushing nozzle
OR07 Exhaust nozzle
PT01 Inlet pressure transmitter
PT02 Adsorber A pressure transmitter
PT03 Adsorber B pressure transmitter

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Reference Description
PT04 Outlet pressure transmitter
PDP01 Inlet pressure dewpoint
PDP02 Outlet pressure dewpoint (Optional)
TT01 Inlet temperature transmitter
FT01 Nitrogen flow transmitter
OT01 Oxygen analyser
FIL1 Pilot air filter
FIL2 Fine outlet dust filter

2.4 Electric diagram

The electric diagram (9827 2995 01) can be found in the technical documentation, supplied with the
unit.

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3 Installation

3.1 Dimensions
The dimension drawing can be found on the USB, supplied with the unit.

Drawing Size Purity variant

1839 0004 72 NGP450+ PCT
1839 0004 73 NGP550+ PCT
1839 0004 74 NGP650+ PCT
1839 0004 75 NGP800+ PCT
1839 0004 76 NGP1000+ PCT
1839 0004 77 NGP1300+ PCT
1839 0004 81 NGP450+ PPM
1839 0004 82 NGP550+ PPM
1839 0004 83 NGP650+ PPM
1839 0004 84 NGP800+ PPM
1839 0004 85 NGP1000+ PPM
1839 0004 86 NGP1300+ PPM

Note:
Dimension drawings are subject to change. Please consult your supplier to get the latest
versions of the dimension drawings.

3.2 Installation proposal

For a good functionality of the gas generator and for the safety of the installation, it is paramount
that the installation does not deviate from the prescribed installation proposal.

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Reference Description
1 Piping
2 Compressor
3 Dryer
4 Inlet filtration
5 Air tank
6 Safety valve
7 Nitrogen generator
8 Product tank
9 Nitrogen label
10 Outlet filtration
11 Waste exhaust
12 Gas outlet

Installation area requirements

• Indoor use is recommended.
• Humidity and dust: to avoid risk of damage to electronic components, install the generator in an
environment subject to limited relative humidity and low concentration of dust. The generator
must also be protected against water droplets, rain and wind. According to the Low Voltage
requirements (EN61010), indoor use is recommended for this unit.
• Temperature: the ambient temperature in the generator installation area must be between 5˚C
(41 ˚F) and 50 ˚C (122 ˚F) or between -10°C (14°F) and 50°C (122°F) with the low ambient
option. Install the generator away from heat sources. Therefore, also avoid direct exposure to
sunlight.
• UV radiation: as the unit is not resistant to UV radiation, protect the unit from direct sunlight.
• Positioning: when selecting the installation area for the generator, take into account minimum
clearances required for operation and maintenance. A minimal free space of 1000mm around

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the generator is recommended. Consult the Installation proposal drawings further in this
chapter. Install the generator on a level floor, suitable for taking its weight

Handling and positioning of the nitrogen generator

The generator must be handled using suitable equipment such as a crane or a forklift truck and only
use the designated lifting slots and lugs.
Remove all packing material, taking care not to damage the generator.

Inlet air quality

The properties of the compressed air at the inlet of the nitrogen generator, as well as the minimum
pressure and flow rate requirements, play an important role in its performance and lifetime.
The compressed air used should be of a quality that meets ISO 8573-1:2010 class 2-4-1 for the
standard machine and 2-3-1 for machines with the low ambient option. Besides that, following
components should not exceed the prescribed concentrations:
• CO2 < 500 ppm
• CO < 1 ppm
• CH4 < 2ppm
• CH2H2 < 0.5ppm
• CnHm < 1ppm
• H2S < 0.01 ppm
• NH3 < 1 ppm
• CL2 < 0.02 ppm
• NOx < 0.06ppm
• SOx < 0.04 ppm
Warning:
Using a lower quality of compressed air will cause irreversible damage to the generator. In
such case, the manufacturer denies all liability for damages and any costs for repairs will be
charged to the client.
Warning:
The installation must be done by trained, authorized personnel only.
In case of any doubt regarding the installation, contact your supplier for advice on the most
suitable compressed air system (compressor, dryer, filters, tanks) for the specific application.
To achieve the forementioned air quality, the following air treatment components should be installed
after the compressor.
• Compressed air dryer
• below 5°C (41°F): a dryer type that can provide a PDP of -20°C (-4°F) or lower is
required (ISO 8573-1:2010 Class x:3:x). Only possible with the low ambient option.
• from 5°C (41°F) to 29°C (84°F): an integrated dryer can be used to provide a PDP of
3°C (37°F) (ISO 8573-1:2010 Class x:4:x).
• from 30°C (85°F) and above: an oversized refrigerant dryer needs to be sized at max
load and max temperature conditions to always provide the required PDP of 3°C (37°F)
(ISO 8573-1:2010 Class x:4:x). This could require a stand-alone dryer.
• Filtration

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• to achieve the forementioned air quality, a suitable oil coalescing filter must be installed
downstream of the dryer.
• in case an oil injected compressor is used, a suitable carbon tower filter must be
installed downstream of the oil coalescing filter.
All coalescing filters should be fitted with a drain tube. This drain should not end up in the
wastewater. For draining of pure condensate water, an oil/water separator should be installed.

Piping
Consult the dimensions table in the section Performance data to select the correct piping
diameters.
Place the components of the installation as close to each other as possible to avoid long pipes and
excessive pressure drops. Avoid distances exceeding 5 m (16.4 ft) between the various
components. In case this length is exceeded, the diameter of the piping needs to be oversized. In
the latter case, the maximum pipe length is limited to 10 meters (32.8 ft).
All pipes should be installed stress-free and should be adequately supported.
Note:
Only rigid pipes can be used for nitrogen, as most flexible hoses are permeable for oxygen
molecules which can affect the final outlet purity.
The use of AIRnet piping system is highly recommended.

The installation must be entirely leak-free in order to produce nitrogen at the requested level.
The pressure rating of all piping between the compressor and the inlet air receiver must be
sufficient for the maximum pressure of the compressor. All piping downstream of the air tank must
be sufficient for 11 bar(g).

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Figure 4: Tie in points

Reference Description
TP1 Air in
TP2 To product tank
TP3 From product tank
TP4 Gas outlet
TP5 Waste exhaust
For a reliable flow measurement, the flow profile before entering tapping point 3 must be laminar. To
obtain a laminar flow profile, the following straight inlet runs upstream of the flow sensor at TP3
must be respected. The distance is measured from the flow sensor and includes the straight pipe
installed on the unit.

Disturbance Minimum straight inlet run

1 x 90° elbow 15 x DN
2 x 90° elbow (in same plane) 20 x DN
2 x 90° elbow (in different planes)
35 x DN
or outlet dust filter

Unit size Straight pipe length installed on unit

PPM PCT
NGP450-650+ 700 mm / 27.5 in 1130 mm / 44.5 in
NGP800-1300+ 750 mm / 29.5 in 1500 mm / 59.0 in

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Compressor
The nitrogen generators can be used with oil injected compressors as well as with oil free
compressors as long as the correct filters are used to guarantee the required inlet air quality.
The NGP+ generators utilise a non-continuous process called pressure swing adsorption to
produce nitrogen. Hence, the inlet flow is variable. Therefore, the compressor needs to be
oversized compared to the average inlet flow. Contact your supplier for advice on the most suitable
compressed air system.
To produce nitrogen at a constant purity, a constant inlet pressure is mandatory.
Warning:
If a failure in gas supply (e.g. due to a power failure, the activation of an electrical safety
device, or a generator fault) is - even temporarily - not admissible, it can be advisable to
foresee a backup nitrogen source to enable provisional supply of gas (totally or partially
automatic).

Parallel installation
In a parallel installation, one or more compressors can be used:
• For redundant operation, a dedicated compressor for each generator is recommended.
• When operating two or more generators in parallel at the same time, one single compressor or
common feed air header can be used. In this case the following conditions must be met:
• Each nitrogen generator should be equipped with a dedicated air tank.
• Each air tank should be preceded by a check valve.
• The feed air pressure towards the air tanks should be stable.

Connecting to an existing air net

If the NGP+ is connected to a tank from an existing air net that has other consumers, this existing
tank shall be followed by a check valve and a dedicated air tank for the NGP+.
It is very important that the pressure in the existing air net is stable. If this cannot be guaranteed, it
is required to install a check valve followed by a pressure regulator upstream of the air tank.
Example of installation:

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Reference Description
1 Check valve
2 Pressure regulator
This pressure regulator should be set at the lowest working pressure of the existing tank (AIR 1) in
order to maintain a constant inlet pressure for the NGP+ nitrogen generator. See graph below as
reference:

Figure 5: Pressure regulator setting

Safety valve
Warning:
In case the installed compressor has a maximum outlet pressure higher than 11 bar(g), a
safety valve must be installed on the inlet air receiver with a relief pressure of maximum 11
bar(g). Size the safety valve to blow off the full flow of all compressors that may be feeding
the air receiver.

Product tank
The product tank is used to ensure a stable outlet nitrogen purity and a stable nitrogen pressure.
Consult the dimensions table in the section Performance data to select the correct product tank
size.
If a larger buffer capacity is required, follow the following recommendations:
• The maximum product tank size is one size bigger than the recommended size.

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Note:
Note that a larger product tank will have longer start-up and flushing times.
• If more buffer capacity is required, a storage tank of any size can be installed at the outlet
(TP4), downstream of the generator. This way, the storage tank is always filled with the
correct nitrogen purity.

Note:
The storage tank should be flushed with nitrogen before commissioning.
When the generator is expected to experience large pressure fluctuations (larger than 2 bar), it is
also advised to install a storage tank.
Example of installation:

Nitrogen label
Place the supplied nitrogen labels 1622 5408 03 on the product tank and, if installed, on the storage
tank. Make sure that these labels are visually clear.

Outlet filter
A high-efficiency dust filter type must be installed between the product tank and the nitrogen
generator.

Exhaust
It is recommended to guide the exhaust of the nitrogen generator outside of the installation room.
Standard ventilation ducting may be used to guide the exhaust gas outdoors. Consult the
dimensions table in the section Performance data ), to select air channel diameters.
The standard channel diameters are sized for a ducting length of 10 meters. If this length is
exceeded, the diameter of the channel needs to be oversized, to limit the backpressure during
exhaust.
Prevent using short-radius bends. Preferably, do not install a bend directly downstream of the
exhaust.
Warning:
• Do not direct the exhaust air towards hot surfaces or heat sources. Increased oxygen
levels can increase the risk for fire and explosion hazard.

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• Keep the exhaust open at all times. Do not block or make the exhaust pipe opening
smaller. This might cause decreased performance of the generator or even cause the
muffler to explode.

Ventilation
The ventilation requirements in the machine room depend on if the waste gas is routed outdoors or
not.
• Natural ventilation can be sufficient for one air change per hour:
• Ventilation openings shall have an area > 1/100 of the room’s floor area.
• Ventilation openings should be placed diagonally opposite to each other.
• Ventilation openings should not be obstructed.
• Forced ventilation is required for two or more air changes per hour:
• Contact an authorized specialist for the sizing and installation of the ventilation system.
• A safety warning in case the ventilation unit fails is required.
Waste gas is not routed outdoors
When the waste gas is not routed outdoors, thorough ventilation of the room is needed to prevent
build-up of oxygen causing an increased fire hazard. The ventilation flow into the room must be at
least 11 times the full load output flow of the generator at the selected purity.
Waste gas is routed outdoors
When the waste gas is routed outdoors, good ventilation of the room is still required to prevent
build-up of nitrogen due to potential leaks in the installation. At least one air change per hour is
required.
Warning:
• Make sure the compressor doesn't take in ambient air with increased oxygen content.
This could reduce the performance of the generator significantly and might impose a
risk of safe operation of the compressor.
• Special consideration to the ventilation of underground rooms, pits, trenches, etc. is to
be given. Oxygen is heavier than air and thus tends to accumulate in low lying areas.

3.3 Electrical connections

Electric power supply
Danger:
For safety reasons, the following instructions must be observed strictly.
The electrical installation must comply with current standards, in particular regarding the
earthing line.
Recommendations:
• Always connect the earthing line.
• The main socket must be located in an easily accessible position.
• Low voltage fuses on the unit and fuse installation at customer location is specified on
the service diagram included in the documentation. Before any service intervention on
the unit please make sure that the electrical power is totally disconnected. Therefore,
please unplug the unit from the main power supply.

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4 Controller

4.1 Controller functions

Figure 6: Elektronikon™ Touch controller

Introduction
The controller has the following functions:
• Controling the unit
• Protecting the unit
• Monitoring components subject to service
• Automatic restart after voltage failure (ARAVF)

Automatic control of the unit

The controller maintains the automatic operation of the unit based on the required purity settings. It
does so by adaptinh the cycle (Variable Cycle Saver) or entering standby during periods without
qxygen consumption.

Shutdown
Several sensors are provided on the unit. If one of the measured signals exceeds the programmed
shutdown level, the unit will be stopped.
Example: If the inlet pressure exceeds the programmed shutdown level, the unit will be stopped.
This will be indicated on the display of the controller.
Warning:
Before remedying, consult the Safety precautions.

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Before resetting a warning or shutdown message, always solve the problem. Frequently
resetting these messages without remedying may damage the unit.

Shutdown warning
A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, a message will
appear on the display and the general alarm LED will light up to warn the operator before the
shutdown level is reached.
The message disappears as soon as the warning condition disappears.
When the shutdown warning is shown, press stop button to stop the unit and wait until the unit has
stopped; Switch off the voltage, inspect the uni and remedy if necessary. Th warning message will
disppear as soon as the warning condition disappears.

Service warning
A number of service operations are grouped as a Service Plan. Each Service Plan has a
programmed time interval. If the service timer exceeds a programmed value, this will be indicated
on the display to warn the operator to carry out the service actions belonging to that Service Plan.
When the service warning is shown, stop the unit, switch off the voltage and carry out the required
service actions.

Automatic restart after voltage failure (ARAVF)

The controller has a built-in function to automatically restart the unit when the voltage is restored
after voltage failure.
For units leaving the factory, this function is made inactive. If desired, the function can be activated.
Consult your supplier.
Warning:
If the function is activated and provided the controller was in the automatic operation mode,
the unit will automatically restart if the supply voltage to the module is restored. The
Automatic Restart After Voltage Failure (ARAVF) label shall be glued near to the controller.

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4.2 Control panel

Figure 7: Control panel

Reference Designation Function

Shows the unit operating
condition and several icons to
1 Touch screen navigate through the menu.
The screen can be operated by
touch.
Flashes in case of a shut-down,
2 Warning sign is lit in case of a warning
condition.
3 Service sign Lit when service is needed.
Lit when the unit is running in
4 Operation sign
automatic operation.
Indicates that the voltage is
5 Voltage sign
switched on.
6 Stop button Stops the unit.
This button starts the unit. The
7 Start button operation sign lights up. The
controller is operative.

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4.3 Icons used

Menu icons

Menu Icon Menu Icon Menu Icon

Status

Inputs

Data Outputs

Counters

Auxiliary
Equipment
Parameters

Overview

Service Service Plan

Service
Service
History
Service
Functions

Clean Screen

Week
Week Timer
Remaining
Running Time

Event History Saved Data

Alarms

Regulation
Machine
Settings Control
Parameters
Auxiliary
Internal
Equipment
SmartBox
Parameters

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Menu Icon Menu Icon Menu Icon

Auto Restart

Ethernet
Network Settings
Settings
CAN Settings

Language

Localisation Date/Time
Controller
Settings
Units

User
Password

Help

Information

Status icons

Icon Description
Unit running

Machine Control Mode, LAN

Automatic Restart After Voltage Failure

Week Timer Active

System icons

Icon Description

Basic User

Advanced User

Service User

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Icon Description

Antenna 25%

Antenna 50%

Antenna 75%

Antenna 100%

Change between screens (indication)

Menu

Reset

Auto Restart

Filter(s)

Input icons

Icon Description

Pressure

Temperature

Special Protection

Open

Closed

Note:
This chapter gives a general survey of available icons. Not all icons mentioned in this chapter
are applicable to every machine.

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4.4 Main screen

Function
The main screen is the screen that is shown automatically when the voltage is switched on. It is
switched off automatically after a few minutes when there is no touch input.

Description

Reference Designation Function

The home button is always shown and can be
1 Home button
tapped to return to the main screen.
On the main screen, the screen information bar
shows the serial number of the machine. When
2 Screen information
scrolling through menus, the name of the
current menu is shown.
The access level button is always shown and
3 Access level button can be tapped to change the current user
access level.
The alarm button can be tapped to show the
4 Alarm button current alarms. If an alarm occurs, the icon on
the button will be red.
The service button can be tapped to show the
5 Service button
service information.
6 Status This icon shows the current status of the unit.
Indicates which page you currently see.
7 Page indicator
Swipe left or right to go to another screen.
Tap the field to view the type of measurement.
This will be shown in the screen information bar.
These fields can contain a Examples of values shown:
8, 9, 10, 11 certain value, depending on the
type of the unit. • Temperatures
• Pressures
• Purity level
The menu button is always shown and can be
12 Menu button
tapped to go to the menu.

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4.5 Quick access screen

Function
The screen is used to directly access some frequently used functions.

Procedure
The quick access screen can be viewed by swiping left, starting from the main screen.

Description

Through this screen, several important settings can be viewed and modified.

Function Description
Setpoints Several setpoints can be modified by tapping this icon.
The control mode can be changed by tapping this icon.
• Local control via start/stop buttons
• Remote control via digital input(s)
Control mode
• LAN control via the network.
When in remote or LAN control, the start/stop buttons on the
controller will not work.
The display language of the controller can be changed by
Display language
tapping this icon.
Week timer Week timers can be set by tapping this icon.
The remaining running time can be set and modified by tapping
Remaining running time
this icon.
The reception quality of the internal antenna can be monitored.
Each bar represents 25% reception strength. If the four bars are
Internal SmartBox
filled, the reception strength is 100%. If only one bar is filled, the
reception strength is just 25%.

4.6 Graphic screen

Function
The screen is used to consult the status of the adsorbers and shows the main sensor data.

Procedure
The graphic screen can be viewed by swiping left twice, starting from the main screen.

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Description

4.7 Menu screen

Function
This screen is used to display the different menus where settings can be viewed or changed.

Procedure
The menu screen can be viewed by tapping the menu button or by swiping right, starting from the
main screen.

Description

Reference Designation Function

The data menu contains the status of the unit,
information about the inputs, outputs and
(1) Data
counters. The auxiliary equipment can also be
viewed through this menu.
The service menu contains the service
(2) Service information. The "clean screen" function can be
used to clean the touchscreen.
Multiple week timers and a remaining running
(3) Week timer
time can be set through this menu.
In case of an alarm, the status information of the
(4) Event history unit is saved and can be viewed through this
menu.
Alarms settings, regulation settings and control
parameters can be changed through this menu.
Auxiliary equipment parameters can also be
(5) Machine settings changed.
The automatic restart function can be set
through this menu. This function is password-
protected.

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Reference Designation Function

Network settings, localisation settings and a
user password can be set through this menu.
(6) Controller settings
There is also a help page available and the
controller information can be shown.

Menu structure
Operating the controller can be done by swiping through screens and tapping icons or menu items.

This is the main structure. It can differ depending on the configuration of the unit.

4.8 Data menu

Function
This screen is used to display the following submenus:
• Status
• Inputs
• Outputs
• Counters
These submenus can be entered by tapping the icons.

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Procedure
To enter the Data menu screen:
1. Tap the Menu button.
2. Tap the Data icon.

Description

Reference Designation
(1) Status menu
(2) Inputs menu
(3) Outputs menu
(4) Counters menu

Status menu
Tap the Status icon to enter the Status menu.

This menu shows the current status of the unit.

If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the
reset button.
Warning:
Before remedying, consult the Safety precautions.
Before resetting a warning or shutdown message, always solve the problem. Frequently
resetting these messages without remedying may damage the unit.

Inputs menu
Tap the Inputs icon to enter the Inputs menu.

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This menu shows information about all the inputs.

Outputs menu
Tap the Outputs icon to enter the Outputs menu.

This menu shows information about all the outputs.

Danger:
Voltage-free outputs may only be used to control or monitor functional systems. They should
NOT be used to control, switch or interrupt safety related circuits. Check the maximum
allowed load on the label.
Warning:
Stop the unit and switch off the supply before connecting external equipment. Check the
Safety precautions.

Counters menu
Tap the Counters icon to enter the Counters menu.

This menu shows an overview of all actual hours and counters of the unit and controller.

4.9 Service menu

Function
This screen is used to display the following submenus:
• Service
• Service Functions (visible as advanced user)
• Clean Screen
These submenus can be entered by tapping the icons.

Procedure
To enter the Service menu screen:
1. Tap the Menu button.

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2. Tap the Service icon.

Description

Reference Designation
(1) Service
(2) Service Functions (only visible as advanced user)
(3) Clean Screen

Service menu
Tap the Service icon to enter the Service menu.

This menu shows the remaining Running Hours and the remaining Real Time Hours until the next
service. The first row (A) shows the Running Hours when the first service is needed (green), the
second row shows the Real Time Hours (blue)
A service overview can be viewed by tapping icon (1).
The service plan can be viewed by tapping icon (2). Through this menu, the service plan can be
modified:
1. Tap the desired service plan. A selection screen will pop up.
2. Change the Running Hours by tapping ‘–’ or ‘+’.
3. Confirm by tapping ‘V’ or decline by tapping ‘X’.
The service history can be viewed by tapping icon (3).
When a service plan interval is reached, a message will appear on the screen. When service has
been performed, the service timer can be reset by tapping the reset button (4).

Clean screen
Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the touch
screen.

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The touch screen and the start and stop button become inactive for 15 seconds.

4.10 Week timer menu

Function
This screen is used to set up to 4 different times with each up to 8 settings per day.
The week timers can be activated through this screen.
A Remaining Running Time can be set from 5 up to 240 minutes.

Procedure
To enter the Week Timer menu screen:
1. Tap the Menu button.
2. Tap the Week Timer icon.

Description

Reference Designation Function

If less than 4 weeks are programmed, tap the ‘+’
(1) Add or select week
button to add a week.
(2) Remove week Tap to remove a programmed week timer.
A selection screen pops up. The user can
choose the correct week by tapping ‘–’ or ‘+’
(3) Activate week timer
and can confirm by tapping ‘V’ or decline by
tapping ‘X’.
A selection screen pops up. The user can
Remaining running change the remaining time by tapping ‘–’ or ‘+’
(4)
time and can confirm by tapping ‘V’ or decline by
tapping ‘X’.
A selection screen pops up. The user can
(5) Add setting change the setting by swiping up or down and
confirm by tapping ‘V’ or decline by tapping ‘X’.

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4.11 Event history menu

Function
This screen is used to display the saved data in case of an alarm.
These submenus can be entered by tapping the icons.

Procedure
To enter the Event History menu screen:
1. Tap the Menu button.
2. Tap the Event History icon.

Description

Reference Designation
(1) Saved Data

Saved data
Tap the Saved Data icon to enter the Saved Data menu.
Scroll through the items swiping up and down in this list. The event date and time is shown at the
right side of the screen.
Press on one of the items in the list for more information reflecting the status of the unit when the
shutdown occurred.

4.12 Machine settings menu

Function
This screen is used to display the following submenus:
• Alarms
• Regulation
• Control Parameters
Only visible if the machine has adaptable parameters.
• Aux. Equipment Parameters
• Auto Restart
These submenus can be entered by tapping the icons.

Procedure
To enter the Machine Settings menu screen:

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1. Tap the Menu button.

2. Tap the Machine Settings icon.

Description

Reference Designation
(1) Alarms menu
(2) Regulation menu
(3) Control Parameters menu
(4) Aux. Equipment Parameters menu
(5) Auto Restart menu

Alarms menu
Tap the Alarms icon to enter the Alarms menu.

Alarms are grouped per type.

When pressing on one of the items in the underlying list, the warning and/or shutdown levels are
shown for this alarm.

Regulation menu
Tap the Regulation icon to enter the Regulation menu.

Setpoints can be modified and capacity control can be consulted through this menu.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection

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When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

Purity menu
Tap the Purity icon to enter the Purity menu.
In this menu, the purity settings are entered.

Minimum purity
The minimum purity that is allowed in the installation. Below this purity, the supply of oxygen will be
cut-off and the generator will be flushing the product tank until the minimum purity has been
reached.
Purity setpoint
The nominal required purity for the installation. The generator will use this setpoint to regulate the
Variable Cycle Saver algorithm, in order to achieve the correct purity at the correct energy
consumption in all situations.

Capacity control
Tap the Capacity control icon to enter the Capacity control menu.
In this menu, you can view the operation of the Variable Cycle Saver.

Generator capacity
The generator capacity shows the amount of flow the generator is able to produce at the current
temperature, pressure and purity setpoint.
Consumption level
The consumption level is the relative amount of flow that is currently consumed.
Modulation level
The modulation level is the capacity at which the generator is currently running. If the capacity is
showing less than 100%, the Variable Cycle Saver is active and less energy is being consumed.

Control parameters menu

Tap the Control Parameters icon to enter the Control Parameters menu.

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This menu shows information about the cycle times.

Auxiliary equipment parameters menu

Tap the Aux. Equipment Parameters icon to enter the Aux. Equipment Parameters menu.

This menu shows an overview of all the auxiliary equipment fitted.

Through this menu, the parameters of the auxiliary equipment can be changed.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

Auto restart menu

Tap the Auto Restart icon to enter the Auto Restart menu.

Through this menu, the automatic restart can be activated. The activation is password protected.
The automatic restart settings can also be changed.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

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4.13 Controller settings menu

Function
This screen is used to display the following submenus:
• Network Settings
• Localisation
• User Password
• Help
• Information
• Main Chart
These submenus can be entered by tapping the icons.

Procedure
To enter the Controller Settings menu screen:
1. Tap the Menu button.
2. Tap the Controller Settings icon.

Description

Reference Designation
(1) Network Settings menu
(2) Localisation menu
(3) User Password menu
(4) Help menu
(5) Information menu
(6) Main chart

Network settings menu

Tap the Network Settings icon to enter the Network Settings menu.

Ethernet Settings
The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified.

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CAN Settings
The list of CAN Settings is shown. When CAN is turned off, the settings can be modified.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

Localisation menu
Tap the Localisation icon to enter the Localisation menu.

Language
The language setting of the controller can be modified through this menu.
Date/Time
The date and time settings of the controller can be modified through this menu.
Units
The units displayed can be modified through this menu.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping
up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.

User password menu

Tap the User Password icon to enter the User Password menu.

The user password can be activated or deactivated through this menu. Enter and confirm a user
password to activate, repeat to deactivate.

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Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.

Help menu
Tap the Help icon to enter the Help menu.

This menu can show a link to the web page of your supplier, a helpdesk phone number or other
helpful information.

Information menu
Tap the Information icon to enter the Information menu.

This menu shows information about the controller.

Main chart
Tap the Main chart icon to enter the Main chart menu.

This menu shows a configurable chart displaying real-time data.

4.14 Access level

Function
Through this pop-up screen, the access level settings can be viewed or changed.

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Procedure
The Access Level screen can be viewed or changed by tapping the Access Level button at the
upper right corner of the screen.

Description

Reference Designation Function

A basic set of parameters is visualized, no
(1) User
password required.
A basic set of parameters can be modified, no
(2) Service
password required.
(3) Full This access level is not accessible to end users.
(4) Decline Tap to decline the selected user level.
(5) Confirm Tap to confirm the selected user level.

Service access level

Tap the Service access level icon (1) and confirm (2).
The screen information bar (1) now shows the current status of the unit instead of the machine
serial number.
The Received Signal Strength Indicator (RSSI) value is now shown in the Internal SmartBox menu.
See section Quick access screen.
In the service menu, an extra menu item is now available. See section Service menu.

4.15 Web server

All controllers have a built-in web server that allows direct connection to the company network or to
a dedicated PC via a local area network (LAN). This allows to consult certain data and settings via
a PC instead of the display of the controller.

Getting started
Make sure you are logged in as administrator.
• Use the internal network card from your computer or a USB to LAN adapter.

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• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).

Configuration of the network card

• Go to Network and Sharing Center (1).

• Click on Change adapter settings (1).

• Select the Local Area Connection, which is connected to the controller.

• Click with the right button and select Properties (1).

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• Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts,
uncheck other properties if they are checked. After selecting TCP/IPv4, click on the Properties
button (2) to change the settings.

• Use the following settings

• IP Address 192.168.100.200(1)
• Subnetmask 255.255.255.0(2)
Click OK (3) and close network connections.

Configure a company network (LAN) connection

• Ask your IT department to generate a fixed IP address in your company’s network. That IP
address will be excluded from the DNS server, so it will be reserved for the controller. Also get
the correct Gateway and Subnet mask settings. For example:
• IP = 10.25.43.200
• Gateway = 10.25.42.250
• Subnet mask = 255.255.254.0
• Connect the controller to the company's network (LAN) by using a UTP cable (min. CAT 5e).

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• Adapt the network settings in the controller.

• Put the controller in advanced mode by navigating to Menu > Controller settings >
Network settings > Ethernet settings.

• Switch off the ethernet communication to allow the editing of the settings.

• Adapt IP adress
• Adapt Gateway IP
• Adapt Subnetmask
• Switch on the Ethernet communication
• Wait a few minutes so the controller can be connected to the LAN network.

Configuration of the web server

®
The internal web server is designed and tested for Microsoft Internet Explorer. Also Opera, Mozilla
Firefox, Safari and Chrome should work.
Viewing the controller data
Note:
All screen shots are indicative. The number of displayed fields depends on the selected
options.
• Open your browser and type the IP address of the controller you want to view in your browser
(in this example http://192.168.100.100). The interface opens.

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Navigation and options

• • The banner shows the unit type and the language selector. In this example, three languages
are available on the controller.

• • On the left side of the interface, you can find the navigation menu. If a license for ESi is
foreseen, the menu contains 3 buttons:

• Machine: shows all generator settings.

• ES: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.

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5 Operating instructions

5.1 Starting
Start-up procedure
For the designation of the components, see section Flow diagram.
1. Make sure all ball valves between the generator and the receivers are opened and the ball
valve after the compressor is closed.
2. Make sure the following ball valves inside the generator are closed: BA05 and BA08.
3. Make sure the following ball valves inside the generator are opened: BA01, BA02, BA03, BA04,
BA06, BA07.
4. If using a refrigerant dryer, make sure it is not running in energy efficient mode. This mode can
cause an increase of outlet dew point and a shutdown of the generator as a consequence.
5. Switch on the refrigerant dryer 10 minutes in advance of the compressor (if applicable).
In case of inlet temperatures below 5°C: Switch on an adsorption dryer well before starting the
generator. Make sure the PDP of the adsorption dryer is below -20°C before starting the
generator.
6. Start the compressor.
7. Slowly open the valve after the compressor so the compressor can slowly fill the air receiver
with dry compressed air. Opening the valve too fast can increase the dewpoint after the dryer.
This will require the generator to flush the air receiver which extends the start-up procedure.
8. Enter the required nitrogen purity in the controller by navigating to Menu > Machine settings >
Regulation > Purity. The controller will use this setting to tune its capacity to the consumed
nitrogen flow (Variable Cycle Saver feature).
9. Enter the minimum required nitrogen purity in the controller by navigating to Menu > Machine
settings > Regulation > Purity. The generator will stop supplying nitrogen to the outlet when
the purity drops below this setting and will start flushing the product tank to increase the outlet
purity.
10. Make sure the pilot air pressure regulator PR01 is set to a pressure between 5 and 6 barg (73 -
90 psi).
11. Check the inlet dew point on the controller display. If this value exceeds the inlet dewpoint
setpoint, the air receiver needs to be flushed until a value below the setpoint is reached. The
flushing of the inlet receiver will be done automatically by the generator. During this time, the
generator is in standby. For standard generators the setpoint is 6°C. For the low ambient
version, the setpoint is -20°C.
12. Start the generator by pushing the start button on the controller. The generator will now start
automatically. During "startup" the product tank is filled through restriction orifice OR04 until the
pressure difference between the air tank and product tank is less than the delta pressure
setting . During "flushing" the oxygen tank is flushed through orifice OR06 until the purity in the
vessel is equal to the minimum purity setting as entered in step 8. Flushing can take up to 2
hours for “PCT” generators and up to 6 hours for "PPM" generators. After flushing, the
generator is ready for nitrogen production.
13. Regulate the outlet nitrogen pressure with pressure regulator PR03 to the requested nitrogen
pressure.
14. Make sure the outlet flow measured by FT01 does not exceed the nominal flow of the nitrogen
generator. Regulate the flow by controlling HV1. Exceeding the nominal flow will cause the

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purity to drop. If the purity drops below the minimum purity setting, the outlet flow is cut off to
enable flushing of the nitrogen receiver. The nominal flow is continuously calculated by the
generator and can be found by navigating to Menu > Machine settings > Regulation >
Capacity control. More flow means lower nitrogen purity, less flow means higher nitrogen
purity. The purity in the nitrogen receiver can be read on the main screen.
15. Set the time and date by navigating to Menu > Controller settings > Localisation > Date/
Time.
16. Set the required warning and shutdown levels in the Alarms menu (navigating to Menu >
Machine settings > Alarms).
17. Adjust the compressor pressure if necessary: the compressor should be running continuously in
order to ensure a stable inlet pressure. If the compressor enters unload during the cycle,
increase the pressure setpoint, respecting the limits of operation.

5.2 During operation

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

Automatic operation mode

In automatic mode, the generator will apply capacity control in 5 stages:

Nitrogen consumption level compared to Capacity control

nominal generator capacity
100 % Normal operation
Less than 80 % Cycle time modulation stage 1
Less than 60 % Cycle time modulation stage 2
Less than 40 % Cycle time modulation stage 3
Less than 1 % Standby

Inlet PDP protection

As standard, the NGP+ is equipped with an inlet PDP protection feature. When the inlet air PDP
exceeds the flushing setpoint, the PSA cycle is automatically shut down and an inlet flushing cycle
is started. For the standard units the flushing setpoint is 5°C (41°F), units with the low ambient
option installed have a setpoint of -20°C (-4°F). During this cycle, the inlet flushing valve V11 allows
a small flow of air through OR05 to the silencer, which will reduce the load on the dryer and allows
the inlet air receiver to be dried until the required dewpoint is achieved.

Variable cycle saver

NGP+ generators are equipped with the Variable Cycle Saver (VCS) feature. This feature enables
the controller to modulate the capacity (and thus the required amount of compressed air) depending
on the consumed nitrogen flow.
The capacity is controlled by varying the cycle times. A lower capacity means longer cycle times, a
higher capacity means shorter cycle times. By doing this, the outlet purity can be maintained
constant and as a consequence less compressed air will be used (energy saving up to 70%).

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The feature also enables a generator which has been sized for high temperature to use less energy
when it is colder than the temperature for which the generator is sized.

Overflow protection
To protect the generator from being overloaded, the adsorbers are protected by the minimum
pressure valve V9 (see section Flow diagram).
During normal operation, i.e. when the pressure difference between the air receiver and nitrogen
receiver is less than the Delta Pressure setting, the minimum pressure valve is open.
If the nitrogen demand would become too high,, the pressure difference will increase and when it is
higher than the Delta Pressure setting, minimum pressure valve V9 will close. At this stage, the
flow is restricted by startup nozzle OR04 as long as the pressure difference between the air
receiver and the nitrogen receiver is larger than the Delta Pressure setting. To recover from this
state, the outlet flow must be restricted to the nominal flow of the generator or less. When the
pressure difference becomes smaller than the Delta Pressure setting, the generator will wait 10
minutes before opening minimum pressure valve V9.

Guaranteed purity
To protect the installation from low purity that could harm its process, the NGP+ is equipped with a
guaranteed purity control. The minimum purity that is allowed in the installation can be set in the
controller Menu > Machine settings > Regulation > Purity.
If the purity in the nitrogen receiver becomes lower than the Minimum Purity setting, the flow to the
installation is cut off by closing consumer valve V10. At the same time, outlet flushing valve V12 is
opened to flush the nitrogen receiver with a flow, controlled by flushing nozzle OR06. This way, the
purity in the nitrogen receiver is recovered as fast as possible. Once the measured purity is better
than the Minimum Purity setting, flushing valve V12 will close and consumer valve V10 will open.

Changing the purity

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

Variant Nitrogen purity Residual oxygen concentration

95 % 5%
96 % 4%
97 % 3%
% 98 % 2%
99 % 1%
99.5 % 0.5 %
99.9 % 0.1 %
99.95 % 500 ppm
99.99 % 100 ppm
ppm
99.995 % 50 ppm
99.999 % 10 ppm

The % variant has an oxygen sensor with a measurement range from 0 % to 25% oxygen level.
The ppm variant has an oxygen sensor with a measurement range from 0 ppm to 1000 ppm oxygen
level.

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Both variants are optimized in cycle times, purge flow and nozzle sizes to deliver maximum
performance at the desired purity.
To change the desired outlet purity, navigate to Menu > Machine settings > Regulation > Purity.
Based on this setting, the generator will adapt its capacity control and apply cycle time modulation
when necessary. When changing the purity setting, the Minimum Purity setting also needs to be
changed. Based on this setting, the generator will only allow nitrogen with a better purity than the
Minimum Purity setting to be sent to the installation.

Standby mode
When the nitrogen consumption stops, the generator will enter standby mode automatically. All
sensors remain powered to sense any changes to the output flow, nitrogen purity and pressure
levels. When the sensors detect that there is a leak or the flow restarts, the generator will start
producing nitrogen instantaneously.

5.3 Stopping
To stop the generator for longer periods, press the stop button on the controller. The generator will
finish its current cycle and vent both adsorber vessels.
Only stop the compressor and dryer after the generator has vented both adsorber vessels.
If the installation is to be started up shortly after (e.g. after a weekend), it is advised not to use this
function. Instead, stop the consumption of nitrogen which will turn the generator in stand-by mode
automatically. This enables a start-up time of less than one minute, compared to up to one hour if
the unit is completely stopped.

5.4 Checking the display

Check the display regularly for readings and messages.

5.5 Taking out of operation

Procedure
1. Stop the generator and close the air inlet and nitrogen outlet valve.
2. Depressurize the generator as described in section Depressurize the generator.
Switch off the voltage and disconnect the generator from the mains.
3. Close the ball valves towards the generator and depressurize the air and nitrogen connections.

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6 Maintenance

6.1 General
User maintenance is restricted to visual inspections. Do not attempt to modify or repair the
apparatus.
All maintenance and repairs shall be carried out by authorized trained personnel.
Atlas Copco offers serveral types of service contracts. Consult your Atlas Copco Customer Center
for more information.

6.2 Maintenance schedule

General
To maintain the generator efficiency and to reduce the risks of faults, strictly observe the
recommended maintenance schedule.
The following table specifies the frequency of the recommended maintenance operations,
expressed in operating hours of the generator:

Programmed service interventions

Frequency Service plan Activity

Check the controller for information on the purity,
Daily
alarms and service messages.
• Check fitted connections in and around the unit
for potential leaks
Every 4000h of operation or
A • Check for damaged wiring or loose connections
every 6 months (1)
• Replace the in- and outlet filter cartridges
• Replace the activated carbon filter
Every 8000h of operation or Replace the inlet dew point sensor and outlet dew
B
every year (1) point sensor (optional)
Every 16000h of operation • Replace the built-in pilot air filter cartridge.
C
or every 2 years (1) • Replace the pneumatic valves V3 and V6
Every 40000h of operation • Replace the oxygen sensor
D
or every 5 years (1) • Replace the bellows on NGP800-1300+
Every 32000h of operation Replace the pneumatic valves V1, V2, V4, V5, V7
E
or every 4 years (1) and V8

(1): whichever comes first.

After maintenance activities, the service counter will be reset by the service specialist.
Note:
Proper and timely maintenance is extremely important to safeguard the lifetime of the
molecular sieves bed. The manufacturer cannot take any responsibility for improper
functioning of the generator if maintenance is not done as prescribed. In this respect, regular

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maintenance of all equipment upstream of the generator, including but not limited to the
compressor and the filter package used is of extreme importance. For maintenance
instructions of this equipment, please be referred to the instruction manual of the equipment
involved.

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7 Optional equipment

7.1 Outlet pressure dew point

An outlet pressure dew point sensor (PDP02) is available as an extra measure to monitor the dew
point of the consumed nitrogen. This feature is especially useful if the nitrogen dew point is a critical
parameter in the process where the nitrogen is used.
Note that the outlet dew point of a nitrogen generator is not stable and can make large variations
depending on operating conditions. The highest outlet dew point will be -40 °C PDP, but this can
drop down to -70 °C in some cases.

7.2 External oxygen analyser

An external oxygen analyser is available for the means of monitoring the oxygen level in the room
where the nitrogen generator is installed.
If the storage tank is located in another room, it's recommended to install a second external oxygen
analyser near the storage tank.

Figure 8: General arrangement

Note that adequate ventilation of the machine room is always necessary and ducting the exhaust of
the generator outside is highly recommended.

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

High dryer pressure dew point

The inlet pressure dew point of a standard nitrogen generator should be 3 °C and may not exceed 5
°C. With the low ambient option, the inlet pressure dew point requirement is further reduced to
-20°C. NGP+ nitrogen generators are equipped as standard with an inlet dew point monitoring
sensor, which monitors the dew point of the incoming air.
A high dew point can be caused by an overload of the dryer, which can occur during startup. When
using a refrigerant dryer, this can be prevented by switching on the dryer before the compressor.
When the compressor is switched on, the outlet flow of the compressor should be reduced by

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means of choking with a ball valve. This causes the produced compressed air to have enough time
to pass the dryer and fill the air receiver with the correct quality of inlet air.
If the air receiver has been filled with air that has a high dew point, the air receiver will be purged
automatically by the generator. As a consequence, the dewpoint of the air receiver will drop to the
required level for operation.

Alarm - Failed To Pressurize

This alarm is triggered when adsorber A or B failed to build up pressure. In normal working
conditions, the pressure inside an adsorber vessel should rise to the inlet pressure during the
production state. If this does not happen, the process of producing nitrogen has to be halted.
Check the following possible causes:
• Make sure the inlet air pressure is higher than 5 bar (72 psi).
• Make sure the pilot air pressure regulator PR01 is regulated to the correct pressure.
• Check if pneumatic valves are actuating by checking the position indicators of the valves.
• Contact your supplier.

Alarm - Failed To Blow Off Vessel A (or Vessel B)

This alarm is triggered when adsorber A (or B) failed to depressurize. In normal working conditions,
the pressure inside an adsorber vessel should lower to the atmospheric pressure during the
regeneration state. If this does not happen, the process of producing nitrogen has to be halted.
Check the following possible causes:
• Make sure the pilot air pressure regulator PR01 is regulated to the correct pressure.
• Make sure the exhaust opening is not blocked.
• If the exhaust is connected to outdoors, make sure the exhaust line is sized correctly. Refer to
section Installation proposal for details.
• Check if pneumatic valves are actuating by checking the position indicators of the valves.
• Consult your authorized supplier.

Alarm - High working pressure

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

Alarm - Low Working Pressure

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

Alarm - High Inlet temperature

This alarm is activated when the inlet temperature exceeds 50 °C (122 °F). This is the maximum
inlet temperature of the generator.
Make sure that the inlet temperature does not exceed 50 °C (122 °F).

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Alarm - Low Inlet temperature

This alarm is activated when the inlet temperature drops below 5°C (41°C) or below -10°C (14°F)
for machines with the low ambient option.
Make sure the inlet temperature does not go below the minimum value.

No outlet pressure
The NGP+ nitrogen generator features protections against overflow and regulations for guaranteed
purity. Because of these features, it is able to shut off the pressure to the outlet by control valves.
If no pressure is available at the outlet, check the protection conditions of the generator:
• Is the generator started up properly? This can be checked by comparing the pressure of the air
tank to the pressure of the product tank. The difference in pressure should be less than 0.5 bar
(7.25 psi).
• Make sure the nitrogen receiver is able to build up pressure by checking that there are no
restrictions in the piping between the generator “to product tank” connection and the product
tank. Double check that the connection diameter is corresponding to the installation proposal.
• Check the purity of the produced nitrogen. This parameter is displayed on the main screen.
This parameter should be higher than the Minimum Purity setting before pressure will be
available on the outlet.

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9 Technical data

9.1 Reference conditions

Air pressure at generator inlet 7 bar 102 psi

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

9.2 Limitations for operation

Inlet air quality (standard) Class [2-4-1] acc. ISO 8573-1:2010

Inlet air quality (low ambient option) Class [2-3-1] acc. ISO 8573-1:2010
Compressed air inlet pressure, maximal 10 bar 145 psi
Compressed air inlet pressure, minimal 5 bar 72 psi
Compressed air temperature, maximal 50 °C 122 °F
Compressed air temperature, minimal
5 °C 41 °F
(standard)
Compressed air temperature, minimal
-10 °C 14 °F
(low ambient option)

9.3 Performance data

Outlet flow rate at reference conditions Nm3/h
If the feed air pressure or temperature deviates from reference conditions, the performance of the
nitrogen generator will have to be corrected.

Purity NGP450+ NGP550+ NGP650+ NGP800+ NGP1000+ NGP1300+

95 % 970 1187 1421 1780 2258 2871
96 % 876 1073 1284 1608 2040 2594
97 % 787 963 1152 1444 1831 2329
98 % 680 833 997 1249 1584 2014
99 % 557 682 816 1023 1298 1650
99.500 % 471 577 690 865 1097 1395
99.900 % 337 412 493 618 784 996
99.950 % 258 315 377 473 600 762
99.990 % 197 242 289 362 459 584
99.995 % 176 215 258 323 410 521
99.999 % 127 155 186 232 295 375

Flow reference conditions: 20°C, 1000mbar, 0% relative humidity. During testing of the units, the
rejection limit is + or – 5 % of the nominal nitrogen flow.

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Dimensions and weight

NGP450+ NGP550+ NGP650+ NGP800+ NGP1000+ NGP1300+

Width mm 2703 2788 2880 3684 3773 3860
Length mm 2100 2100 2300 3121 3121 3121
Height mm 3028 3022 3025 3987 4211 4423
Weigth ton 5.6 6.4 7.3 8.7 10.1 12.3
Air tank
fixed
l 6000 8000 10000 12000 16000 20000
speed /
product tank
Air tank
l 5000 6000 8000 10000 12000 16000
VSD

Mechanical connections

NGP450+ NGP550+ NGP650+ NGP800+ NGP1000+ NGP1300+

DN 100 150
Air inlet
inch 4 6
To product DN 80 100
tank inch 3 4
From DN 80 100
product tank
inch 3 4
PCT
From DN 40 50
product tank
inch 1 1/2 2
PPM
N2 outlet DN 80 100
PCT inch 3 4
N2 outlet DN 50
PPM inch 2
Waste
mm 400 600
exhaust

9.4 Correction factors

If the inlet pressure and/or ambient temperature differ from the reference data, the nominal
performance figures need to be corrected
As a general rule, higher pressures increase the capacity while higher temperatures reduce the
capacity. Consult your supplier for more details.

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10 Pressure Equipment Directives

Components subject to Pressure Equipment Directive 2014/68/EU
Parts of article 4.3 of PED 2014/68/EU are subject to Sound Engineering Practice (SEP).
Parts of category I according to PED 2014/68/EU are integrated into the machine and fall under the
exclusion of article I, section 3.6.
The following tables A and B contain the necessary information for the inspection of all pressure
equipment of category I according Pressure Equipment Directive 2014/68/EU and all pressure
equipment according the Simple Pressure Vessel Directive 2014/29/EU.
Design criteria for pressure equipment:

Type Medium Design pressure Vessel volume PED category

[bar] [L]
NGP450+ AIR 11 1245 IV
NGP550+ AIR 11 1540 IV
NGP650+ AIR 11 1983 IV
NGP800+ AIR 11 2480 IV
NGP1000+ AIR 11 3158 IV
NGP1300+ AIR 11 3950 IV

Table 2: Table A

Type Min. design Max. design Numer of cycles Wall thickness

temperature [°C] temperature [°C] (1) [mm] (2)
NGP450+ -10 80 5,000,000 10
NGP550+ -10 80 5,000,000 10
NGP650+ -10 80 5,000,000 10
NGP800+ -20 80 5,000,000 8
NGP1000+ -20 80 5,000,000 10
NGP1300+ -20 80 5,000,000 10

Table 3: Table B

(1): The number of cycles refers to the number of cycles from 0 bar(g) to maximum pressure
(2): The minimum wall thickness refers to the minimum required thickness according design
calculations.

Recommendation of the manufacturer for the re-inspection time

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

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11 Declaration of conformity

Figure 9: Typical example of a Declaration of Conformity document

(1) Contact address:

Atlas Copco Internationaal B.V.
Technologieweg 19
4906 AC Oosterhout
Netherlands
(2) Applicable directives
(3) Standards used

On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.

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2920 7211 70 - EN © Printed in Atlas Copco Internationaal B.V.. All rights reserved. Designs and
specifications are subject to change without notice or obligation… March 2022