OPERATION & MAINTENANCE MANUAL

Model No.: TN2T1900B2URZ

ACC Project No.: TP-18701-724
ACC Part No.: 1420160168-01
Titus Nitrogen
36 Mountain View Road
Morgantown, PA 19543
P: (610) 913-9100
F: (610) 913-9200

E-mail: support@tn2generators.com
Website: www.tn2generators.com
 TABLE OF CONTENTS
1. INTRODUCTION.................................................................................................................3
2. INITIAL INSPECTION.........................................................................................................3
3. SAFETY..............................................................................................................................3
4. UNIT DESCRIPTION ..........................................................................................................7
4.1. Unit Operation ...............................................................................................................7
4.2. Basic Component Description .....................................................................................7
4.3. Detailed Component Description .................................................................................7
5. INSTALLATION..................................................................................................................9
5.1. Unpacking ......................................................................................................................9
6. OPERATION ....................................................................................................................11
6.1. Start Up Procedure .....................................................................................................11
6.2. Description of Auto N2 Generator Switch-Over Sequences. ................................13
6.3. Manual Shut Down Sequence Procedure ................................................................16
6.4. Oxygen Analyzer Calibration Procedure .................................................................17
6.5. Operation recommendations: ...................................................................................18
7. MAINTENANCE AND INSPECTION ..............................................................................19
7.1. Every Week ..................................................................................................................19
7.2. Every Month .................................................................................................................19
7.3. Every 6 Months ............................................................................................................19
7.4. Every 2 Years ...............................................................................................................19
8. TROUBLE SHOOTING.....................................................................................................20
8.1. High Oxygen Content ..................................................................................................20
8.2. Low or No Nitrogen Flow ............................................................................................20
8.3. High Process Air Temperature ...................................................................................21
9. ACCESSORY INSTRUCTIONS ......................................................................................22
9.1. Compressed Air Inlet Filters (F1 & F2) ...............................................................22
10. SPARE PARTS................................................................................................................23
11. WARRANTY INFORMATION .........................................................................................24
APPENDIX A NITROGEN GENERATOR SPECIFICATIONS..............................................25

Page 2 of 25
1. Introduction
This manual will provide you with information on the installation, operation and maintenance
procedures to ensure complete satisfaction with this TN2 unit. This Nitrogen Generator was
designed to be simple, compact and easy to use, with few moving parts and very little maintenance.
Please review this manual carefully.

2. Initial Inspection
This unit was thoroughly inspected at the factory and found free of defects at the time of shipment.
When the unit is unpacked, it is imperative to make a visual inspection, looking for missing parts or
damage that might have occurred during shipment.

3. Safety
This manual describes the operation of the equipment and the methods for proper
maintenance and servicing. Throughout the manual are statements indicating NOTICE,
CAUTION, WARNING and DANGER. These statements should be read and understood
thoroughly before proceeding to ensure personnel safety and prevent product damage.
The use of these statements is defined below.

NOTICE!
A NOTICE statement is used to notify personnel of installation, operation, service or
maintenance information that is important but not hazard-related.

! CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate personnel injury, equipment damage or both.

! WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

! DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury. This signal word is to be limited to the most extreme
situations.

Please note that any of these may be absent from this manual depending on the nature of
the equipment, its applications and intended use.

Page 3 of 25
 NOTICE!
Please read this manual in its entirety before attempting to operate or perform
maintenance on this equipment. A thorough understanding of the operating,
maintenance, and safety procedures will ensure efficient and safe use.

Membrane separator(s) are utilized for the production of high purity nitrogen gas (from 0.1 to 5%
oxygen impurity). The nitrogen and oxygen-enriched waste streams produced by the membrane
can be hazardous if proper precautions are not taken.

! WARNING
Only personnel trained in the safe operation of and the hazards associated with this
equipment should be allowed access to it. Operators of this equipment must be fully
trained and experienced in the use and handling of industrial gases and testing oxygen
levels in enclosed areas. Reading and thoroughly understanding the material contained
in this manual is required to operate this equipment.

! WARNING
This equipment is designed to be used in unclassified non-hazardous areas only. If
explosive or flammable vapors are present, special design features must be incorporated
to provide safe operation.

! WARNING
Operation of this equipment above the rated design pressure may be hazardous. Do not
connect this equipment to the compressed air source that can exceed the maximum rated
pressure of this equipment without installing appropriate pressure controls and safety
relief devices in the air supply line to this Nitrogen Generator.

! WARNING
Gaseous nitrogen is colorless, odorless, inert, tasteless and nonflammable. Nitrogen is
non-toxic but can act as an asphyxiant by displacing the necessary amount of oxygen in
the air to sustain life (a minimum of 19% oxygen is required for life support). Leakage of
nitrogen into closed or poorly vented areas where personnel may be present must be avoided.
Safety procedures must be established and followed before entering any enclosed or poorly
ventilated area containing nitrogen generating equipment or piping.

! DANGER
The nitrogen gas generated cannot support life. Do not use as a source of breathing air.

Page 4 of 25
To protect personnel from serious injury or death due to asphyxiation, we recommend the
development of specific safety procedures. These procedures should include but not be limited to
the following:
Do not enter storage bins, tanks or any other confined spaces, even after the nitrogen purge
gas has been stopped, without some method of supplying adequate fresh air and some method
of assuring that an oxygen deficient atmosphere does not exist.
Do not use canister or filter type respirators, as these types of respirators do not protect persons
from asphyxiating atmospheres.
Do not investigate leaks without proper personnel protection. Nitrogen is colorless, odorless,
tasteless and can cause rapid suffocation of those exposed to it in higher than normal
concentrations (i.e. >78%). If a leak is suspected, evacuate the building and investigate
the leak using a self-contained breathing air supply.

All established safety procedures must be followed before entering any confined space or poorly
ventilated area containing nitrogen generating equipment or piping.

! CAUTION
The permeate gas vent stream of this Nitrogen Generator can be enriched with oxygen
concentrations from 21% to as high as 40%. While oxygen itself will not burn, it will readily
support the combustion of materials, which under normal circumstances would not burn, and it
will accelerate the burning of materials, which will burn, such as many building materials and
clothing. All oxygen-enriched streams from the membrane must be vented outdoors, at least 12
feet above grade, into an area that:
Will minimize contact with personnel and equipment.
Is away from enclosures and any areas with inadequate air circulation, or areas near
combustion sources.

! WARNING
Nitrogen leaks into confined areas may result in a decrease of the oxygen content below safe
breathing levels. Check all piping connections for leaks and repair prior to use.

! CAUTION
Never turn the compressed air flow off to the unit while power is on, as compressed air must
always be flowing for proper operation of the heaters and to avoid product and unit damage from
overheating and poor temperature control.

Specific procedures should be developed for the safety of personnel and maintenance of this
equipment. Appropriate labels must be continuously displayed in all areas where personnel might
be exposed to an oxygen deficient atmosphere under normal or upset conditions.

NOTICE
Disassembly of the membrane separator should not be attempted, as this would void the
warranty and or cause damage to the separator
Page 5 of 25
 ! CAUTION
Only qualified personnel who are familiar with Federal, state and local electrical codes should be
allowed access to electrical equipment. Good, safe electrical practices must always be followed
when working around or on electrical equipment. Such practices would include de-energizing,
locking out and tagging all sources of electrical power. These procedures are to prevent not
only electrical shock but also to prevent the equipment from operating during maintenance.

! WARNING
Maintenance must only be done when the unit is fully de-pressurized.

UNDER NO CIRCUMSTANCES SHOULD SAFETY FEATURES BE DEFEATED.

Regular maintenance and operational checks must be performed on certain critical components to
guarantee safe operation. See the Maintenance sections for instructions.
Appropriate labels must be continuously displayed in areas around the equipment, where
personnel might be exposed to a nitrogen atmosphere under both normal and under unusual
circumstances. Please read and be familiar with the safety information in the manual, before
starting.
Safety information and the MSDS sheets on both Nitrogen and Oxygen are located at the end of
this manual.
To view the most current Material Safety datasheet (MSDS) for Nitrogen or Oxygen please go to:
http://www.airproducts.com/msds/search.asp

Page 6 of 25
4. Unit Description
4.1. Unit Operation
The Nitrogen Generator uses semi-permeable, hollow-fiber membrane technology to separate
and recover nitrogen from compressed air. Atmospheric air generally contains 78%
nitrogen, 21% oxygen and 1% other gases. The membrane uses the principle of selective
permeation to produce high purity nitrogen. Conceptually, the hollow-fiber membrane is
like a porous drinking straw. Compressed air is forced through the center of the straw.
Each gas has a characteristic permeation rate, which is a function of its ability to dissolve
and diffuse through a membrane.
Oxygen is a "fast" gas and is selectively diffused through the membrane wall while nitrogen
is allowed to travel along the inside of the fiber, thus creating a nitrogen rich product stream.
The oxygen-enriched exhaust gas, or permeate, is vented from the membrane separator at
atmospheric pressure. The driving force for the separation is the difference between the
partial pressure of the gas on the inside of the hollow fiber and that on the outside.
A typical membrane separator contains thousands of fibers, which are bundled and
encased at both ends in epoxy resin. The ends of the bundles are cut which leaves the fiber
bores open on both ends, allowing the gas to travel from one end to the other. The bundles of
fibers are enclosed in a suitable casing. The casing protects the fibers and routes the gas
properly from feed to product end.
In the membrane separator, compressed air flows down the inside of hollow fibers. "fast"
gases - oxygen, carbon dioxide, and water vapor, and a small amount of "slow" gases,
pass through the membrane wall to the outside of the fibers. These are collected at
atmospheric pressure as the exhaust permeate, or waste, stream and should be vented to a
safe location (see the Safety information in Section 3 and the Installation information in
Section 5). Most of the "slow" gases and a very small amount of the "fast" gases continue to
travel through the fiber until they reach the end of the membrane separator, where the
product nitrogen gas is piped to the application.

4.2. Basic Component Description

Pressurized compressed air from a customers process air compressor is fed to one of two
parallel and identical Nitrogen Generating units. The generators coalescing filters
automatically remove any condensate, oil droplets and particles in the air. The air is heated
and fed into the membrane(s) where the oxygen and water vapor are removed and dry nitrogen
is generated. Product purity is controlled by regulating the gas flow through the unit by using
an adjustable globe type purity valve downstream of the membrane(s) and a nitrogen back
pressure regulator, which helps control the nitrogen flow. The purified nitrogen is then
delivered through an automatic valve and check valve.

4.3. Detailed Component Description

4.3.1. Inlet Filters (F1 & F2)
The compressed air is filtered by two coalescing filters with automatic drain traps. These
are designed to remove the remaining liquid water and oil droplets, as well as particles,
to a level where the membrane(s) will not be contaminated. The filter elements must be
replaced every 6 months, to ensure that the membranes are properly protected (see the
maintenance section) and to maintain the warranty. A differential pressure indicator is
provided at the top of each filter that helps indicate when the elements need to be
changed. The liquid water and oil from the compressed air unit must be prevented from
entering the membrane(s), as this will cause permanent damage to the membrane(s).

Page 7 of 25
4.3.2. Process Electric Air Heater
The heater has two functions. It provides an optimum operating temperature for the
membranes for efficient operation and consistent purity and prevents condensation of
water and oil in the membrane(s), to avoid damage. The temperature is controlled by a
temperature controller with an over-temperature shutdown.
4.3.3. Nitrogen Membrane Separator(s)
The membrane separator removes oxygen from compressed air to deliver high quality
nitrogen to downstream processes. In some units multiple separators are piped in
parallel to provide sufficient nitrogen generation capacity.
4.3.4. Nitrogen Purity Valve (V3)
This globe type valve (see photo below) controls the nitrogen flow.

Purity
4.3.5. Nitrogen Back Pressure Regulator (R1) Valve
This regulator provides a constant nitrogen flow from the membrane(s) across the purity
valve, to minimize product purity fluctuations. It also limits the maximum nitrogen flow
from the unit, to maintain the proper oxygen purity.
4.3.6. Electric 3-Way Vent Solenoid (V4 & V5)
This valve controls the delivery of the nitrogen product gas. It is controlled by a manual
selector switch. Under normal conditions, when the unit is energized and the switch is in
the N2 Process position, the solenoid is energized and nitrogen is delivered to the
process. When the unit is de-energized or when the unit is energized and selector
switch is in the N2 vent position during start-up, nitrogen is automatically vented to
atmosphere, to prevent the delivery of off specification nitrogen.
4.3.7. Check Valve (V6)
This prevents back-flow and loss of nitrogen through the membrane separator
when it is not in operation.

Page 8 of 25
5. Installation
5.1. Unpacking
Caution should be exercised to make sure the equipment is not damaged during handling. The
crate must be removed carefully. The machine must not be used for leverage when removing
packaging materials. Visually inspect all mechanical and electrical parts for damage and to
make sure nothing has come loose due to shipping and handling.

! CAUTION
Follow all national and local electrical and mechanical codes, as required. Only qualified
and trained personnel should install and operate equipment.

! CAUTION
Two lifting lugs are located at the top of the Nitrogen Generator enclosure for handling. To
avoid damage, a spreader bar must be used to properly lift the Generator.

5.1.1. Refer to the specifications in Appendix A and the drawings provided.

5.1.2. The nitrogen unit is designed for outdoor service but must be installed where the
ambient temperature does not go below +40F (4C).
5.1.3. The area needs adequate space to permit maintenance, cleaning and adjustment etc.
5.1.4. Connect the required electrical power to the unit through a main line disconnect (field
supplied) as indicated on the nameplate. Refer to the specifications in Appendix A.
Because the controllers and sensors are sensitive to industrial noise the unit must be
properly connected to true earth ground. This is the only power connection necessary
as the unit is completely pre-wired.
5.1.5. Connect clean, oil vapor and liquid water free compressed air to the Air Inlet. See the
minimum compressed air inlet line size requirement in the specifications section
(Appendix A). Note that the unit will run more efficiently at higher air pressures

! CAUTION
All piping connections must be made using Teflon tape.

5.1.6. Note that the (2) coalescing inlet compressed air filters have an internal condensate trap
that is designed to remove small amounts of water droplets from un-dried incoming
compressed air but they are not designed to remove liquid water. Make sure that
hazardous vapors, like solvents, sulphur dioxide, chlorides, ammonia or ozone, are not
being introduced into the compressed air unit that is feeding the Generator.
5.1.7. Connect appropriate drain lines to the Drain Vents at rear of cabinet. If the drains are
not piped away, oily water may spray down periodically from the automatic drains. Pipe
so condensate will run downhill and be readily observable. Provisions must be made for
proper disposal of the oily condensate that will be present if a lubricated compressor
is used. Dumping condensate into municipal sewers is generally not permitted.

Page 9 of 25
5.1.8. The oxygen-enriched permeate gas from the membrane must be vented outdoors, at
least 12 feet above grade, into an area that:
Will minimize contact with personnel and equipment.
Is away from enclosures and any areas with inadequate air circulation, or areas near
combustion sources.

! WARNING
This gas is oxygen-rich and can increase the flammability of surrounding material.

Options for the vent permeate piping material are:

Carbon steel pipe or tubing.
304 or 316 Stainless Steel.
Silfab-2 hose (2-ply silicone coated fiberglass).
CPVC pipe (note CPVC becomes brittle in cold temperatures).

! CAUTION
PVC pipe in not acceptable, as it is not compatible with the oxygen levels present in
the vent permeate gas. PVC is flammable when used in this application.

! WARNING
The vent permeate gas stream of this Nitrogen Generator can be enriched with
oxygen concentrations from 21% to as high as 40%. While oxygen itself will not burn,
it will readily support the combustion of materials, which under normal circumstances
would not burn, and it will accelerate the burning of materials, which will burn, such
as many building materials and clothing. All oxygen-enriched streams from the
membrane must be vented outdoors, at least 12 feet above grade, into an area that:
Will minimize contact with personnel and equipment.
Is away from enclosures and any areas with inadequate air circulation, or areas
near combustion sources.
The preferred method is venting outside in a manner that water cannot condense
and freeze in the vent line.

Page 10 of 25
6. Sequence of Operation

! WARNING
Never turn the compressed air flow off to the unit while the Nitrogen Unit is on and
operating. While unit is energized, air must be flowing to prevent overheating and possible
equipment damage.
Only qualified and properly trained personnel should operate this equipment.

This Titus Nitrogen system contains two independent nitrogen units connected to a common inlet
and outlet, Unit A located on the left side and Unit B on the right side. One unit will be supplying
the nitrogen required by the process while the other unit is in stand-by mode. Every seven days the
units will switch from one to the other to maintain consistent operating hours. The automatic
switchover time can be adjusted by accessing the maintenance screens on the HMI. This
sequence of operation assumes that Unit A is in the operating position and Unit B is in the stand-
by position. Note that Unit A is considered the default nitrogen generator.

6.1. Start Up Procedure

6.1.1. Before starting:
Decide on which Nitrogen Generator to start, unit A (left unit) or unit B (right
unit), by using the 3-way selector switch SS1 (located on the door of the
enclosure.
Both off/on selector switches SW1A & SW1B (located on the door of the
enclosure) must be in the off position.
Both red emergency E-stop push-buttons ESPB-A & ESPB-B should be in the
off position, with the red mushroom fully pushed in.
Fully open the process air block valves on both N2 generator units, including V1A
& V1B on the air inlet and V9A & V9B on the N2 outlet.
Both oxygen analyzer sample 3-way calibrate valves V7A & V7B, must be in the
Analyzer Run position.
Confirm that Circuit Breakers CB1A & CB1B are both closed.

6.1.2. This sequence of operation assumes that nitrogen unit A is in the operating
position and Unit B is in the stand-by position.
If only N2 Generator unit A is to be used, turn this selector switch SS1 (located
on door of the enclosure) to the Run A position.
If only N2 Generator unit B is to be used, turn this selector switch SS1 to the
Run B position.
When selector switch SS1 is in the center Auto position, one N2 Generator will
be on-line and operating and the other N2 Generator is in stand-by mode and will
automatically go on-line only if there is an alarm with the on-line generator.

Page 11 of 25
6.1.3. Nitrogen Generator Sequence of Operation when selector switch SS1 (located
on the front panel), is in Auto position (Normal Operation).

This describes the operation when Unit A is on and Unit B is in stand-by mode.
The system can operate in the reverse where Unit B is on and Unit A is in standby.
6.1.3.1. Turn on the air compressor (by customer) and open any customer supplied
inlet compressed air valves.
6.1.3.2. Fully pull out both red emergency E-stop push-button ESPB-A & ESPB-B
so they both are in the on position.
Both enclosure heaters should be energized and should be set at 100F
and controlling at about 100F, as long as the temperature is below 100F.
6.1.3.3. Turn the Unit A off/on selector switch (SW1-A) to the on position. The
Programmable Logic Controller PLC-A is energized, and, if there is proper
inlet process air pressure per PT1A:
White light Unit A Power On light is lit on the on-line N2 Generator.
The PLC-A Operator Interface HM1-A touch-screen is booting up and
within one minute will show the home screen.
Air solenoid block valve V2A is energized and opens.
Process air heater A is energized and the PLC-A is controlling the air
temperature to the membrane module(s). Refer to the Operating
Interface.
Nitrogen is vented thru 3-way valve V4AA & its 3-way pilot solenoid
valve SV4BA is de-energized.
The Oxygen Analyzer A is energized and goes through a warm up and
stabilization process, during which its LED lights flash. After about two
minutes, these LED lights stop flashing and the green run light on the
analyzer is lit. It will monitor oxygen level.

If there is a Check Inlet Air Filter warning on the Operator Interface screen,
reset it using reset button on the Operator Interface touch-screen
6.1.3.4. When the oxygen analyzer is stabilized, the unit is now in auto N2 delivery
mode where the oxygen analyzer controls the delivery of nitrogen. The N2
separators will continue to warm up and stabilize for a few minutes
(depending on how long the unit has been idle and exposed to air, and the
oxygen purity required) and the off-specification nitrogen will continue to
vent. Once the oxygen (O) content is below the set point of alarm #1 (legend
AH) of the oxygen analyzer (refer to the set points in Appendix A):
3-way solenoid valve SV4BA is energized, 3-way valve V4AA stops
venting nitrogen and nitrogen is now being delivered to the process.
Green light Unit A Running is lit & nitrogen is being delivered to the
process.
Red light Alarm 1 on the O2 analyzer is off.
Operator Interface indicates that Unit A is on-line.
Unit A is delivering nitrogen to the process.
If required, adjust the nitrogen flow & purity using the nitrogen (V3A)
purity control globe valve (located in upper left hand corner on
enclosure & has a red handle per photo below).

Page 12 of 25
 Note that on an initial cold start when the power to the Generator has been
off, it will take additional time for the system to warm up to meet the
specified O2 content. This is normal.

6.1.3.5. Activate unit B by turning the off/on switch SW1B to the on position.
Programmable Logic Controller PLC-B is energized.
The Oxygen Analyzer B is energized and goes through a warm up and
stabilization process, during which its LED lights flash. After about two
minutes, these LED lights stop flashing and the green run light on the
analyzer is lit. It will monitor oxygen level.
Once the PLC-B finishes booting, the Operator Interface will be on the
home screen.
Unit B now is in stand-by mode and this is indicated on the Unit B
Operator Interface screen.

6.1.4. Nitrogen Generator Sequence of Operation when selector switch SS1 is in the
Run-A position (Unit B is off).
This sequence describes the operation of Unit A on, however the system can operate
in the reverse where Unit B is on:

Unit A in energized and the start-up is the same as in section 6.1.1, except that Unit
B will not be activated or powered and it will not be in stand-by mode. Nitrogen is
being delivered from Unit A only.

6.2. Nitrogen Generator Sequence of Operation of Auto N2 Generator Switch-Over.

6.2.1. Auto N2 Generator Switch-Over - Alarm Details
With the selector switch SS1 (located on the front of the control panel) in the center
Auto position Nitrogen Generator Unit A will continue to run until one of the
following conditions occur:
One unit is powered off by the customer.
One unit has a partial or complete power failure or electrical fault.
Oxygen content becomes higher that the set point of alarm #1 (AH), on the O 2
Analyzer A after about a (2) min delay (refer to the set point in Appendix A). This
alarm condition will be indicated on the HMI Operator Interface. Once the alarm
clears, the reset button on the operator interface must be depressed.
Process Air Pressure is lower than the low-level set point of the pressure
transmitter PT1-A after a less than about a 30 sec delay (refer to the set points in
Appendix A). The process hearer is de-energized immediately. This alarm
condition will be indicated on the PLC Operator Interface. Once the alarm clears,
the reset button on the operator interface must be depressed.
Process nitrogen pressure is lower than the Low set point of the pressure
transmitter PT2-A after less than a 30 sec delay (refer to the set points in
Appendix A). This alarm condition will be indicated on the PLC Operator Interface.
Once the alarm clears, the reset button on the operator interface must be
depressed.

Page 13 of 25
 Process air temperature from the process heater is higher than the set point of the
temperature transmitter TAHA after a very short delay (refer to the set points in
Appendix A). The Process heater A is de-energized and off and this alarm
condition will be indicated on the PLC Operator Interface. The cause of this over-
temperature must be corrected before unit A can be put back into service. Once
corrected and the alarm clears, the reset button on the operator interface must be
depressed.

Note that a low process air or N2 pressure or a high process air temperature will reset
automatically and clear, if the alarms clear before the time delay ends and no action is
required.

The Operator Interface will display the status of the Generator.

6.2.2. Auto N2 Generator Unit Switch-over Sequence - due to Alarm:

6.2.2.1. If unit A has been supplying nitrogen, the PLC-A will provide a signal to
Unit B and the PLC-B indicates that Unit B should now initiate its
emergency start up procedure.
6.2.2.2. The on-line unit A N2 Generator immediately stops delivering N2 and goes
into stand-by.
6.2.2.3. The off-line N2 Generator Unit B is now energized and goes through its
start-up sequence. Nitrogen is delivered to the process, as follows:
3-way pilot solenoid Nitrogen valve SV4BB is energized and 3-way
valve V4A-B switches from the vent position to deliver nitrogen.
White light Unit B Power On light is lit on the on-line N2 Generator.
Air solenoid block valve, V2A is energized and opens.
Process air heater B is energized and PLC-B is controlling the air
temperature to the membrane modules. Refer to the Operator Interface.
Oxygen Analyzer B will monitor the oxygen level, which should be
decreasing rapidly as unit B warms up.
Green light Unit B Running is lit.
The B unit Operator Interface displays the status of the Generator.

6.2.2.4. Unit A Generator that was on-line automatically goes off-line and goes into
stand-by, as follows:
Unit A Operator Interface will now indicate that it has alarms.
Air inlet solenoid block valve V2-A is de-energized and closes.
3-way solenoid valve SV4B-A is de-energized & nitrogen is now vented
thru 3-way valve V4A-A to depressurize the unit.
Green light Unit A Running is off.
White light Unit A Power on remains lit.
Process air heater A is de-energized & is off.
Programmable Logic Controller PLC-A remains energized.
Oxygen Analyzer A remains on.

Page 14 of 25
6.2.3. Auto N2 Generator Unit Switch-Over Sequence Normal based on Set Time:
After 7 days of operation (this is adjustable thru the Operator Interface), if the selector
switch SS1 in the center Auto position, the units will switch from one to the other to
maintain consistent operating hours. There will be no alarms as this is a normal
operation.
6.2.3.1. If unit A has been supplying nitrogen, the PLC-A will provide a signal to Unit
B PLC-B indicating that Unit B should now initiate its normal start up
procedure, as follows:
Air solenoid block valve V2-B is energized and opens.
Process air heater B is energized and the PLC-B is controlling the air
temperature to the membrane modules. Refer to the PLC-B main
display.
White light Unit B Power On light is lit on the on-line N2 Generator.
Nitrogen is vented thru 3-way valve V4A-B and its 3-way pilot solenoid
valve SV4B-B is de-energized.
Oxygen Analyzer B will monitor the oxygen level, which should be
decreasing rapidly as unit B warms up.
6.2.3.2. When the oxygen level falls below the Hi oxygen set point of the Oxygen
Analyzer B (refer to the set point in Appendix A).
3-way solenoid valve SV4B-B is energized and the 3-way valve V4A-
B switches, so the venting of the nitrogen stops & nitrogen is now
being delivered to the process from Unit B.
Green light Unit B Running is lit.
Red light Alarm 1 on the O2 analyzer is off.
6.2.3.3. Unit A is signaled from PLC-B to go off-line and go its normal shut down
procedure, as follows:
Process air heater A is de-energized & is off.
3-way solenoid valve SV4B-B is de-energized & nitrogen is now being
vented thru 3-way valve V4A-B to depressurize the unit.
Green light Unit A Running is off.
After a short time delay so the process heater is cooled, air inlet solenoid
block valve V2A is de-energized and closes
White light Unit A Power off light is off.
Programmable Logic Controller PLC-A remains energized and indicates
unit B is in a Stand-By mode.
Oxygen Analyzer A remains on but will not be actively monitoring the
oxygen level.
No alarms will be indicated.

6.2.4. Manual N2 Generator Unit Switch-Over Sequence:

The Nitrogen systems can be switched from one Unit to the other manually, as follows
6.2.4.1. If unit A has been supplying nitrogen and unit B is to be run, turn selector
switch selector SS1 to the B position. The PLC-A will provide a signal to
Unit B PLC-B indicating that Unit B should now initiate its normal start up
procedure.

Page 15 of 25
 6.2.4.2. The off-line unit B N2 Generator is energized and goes thru its start-up
sequence. Nitrogen is immediately delivered to the process from Unit B, as
follows:
3-way pilot solenoid Nitrogen valve SV4B-B is energized and 3-way
valve V4A-B switches from the vent position to deliver nitrogen.
Air solenoid block valve, V2--A is energized and opens.
Process air heater B is energized and PLC-B is controlling the air
temperature to the membrane modules. Refer to the PLC-B main
display.
Oxygen Analyzer B will monitor the oxygen level, which should be
decreasing rapidly as unit B warms up.
Green light Unit B Running is lit.
6.2.4.3. Unit A goes off-line, stops delivering N2 and shuts down, as follows:
Unit A Operator Interface will now indicate the operations conditions.
Air inlet solenoid block valve V2A is de-energized and closes.
3-way solenoid valve SV4B-A is de-energized & nitrogen sops flowing
to the process and is now vented thru 3-way valve V4A-A to
depressurize the unit.
Green light Unit A Running is off.
White light Unit A Power off light remains on.
Process air heater A is de-energized & is off.
Programmable Logic Controller PLC-A remains energized.
Oxygen Analyzer A remains energized but will not be monitoring the
oxygen level.

6.3. Manual Shut-Down Procedure

Turn the Controls off/on switch of the Generator that is to be shut-down (either SW1A
and or SW1B) to the off position.
White light Unit A (or B) Power On light is off.
Green light Unit A (or B) Running light is off.
Process air heater is de-energized.
3-way solenoid valve SV4-A (or SV4-B) is automatically de-energized and nitrogen is
now venting thru the off-spec N2 vent valve V4A-A (or V4A-B) and depressurizing the
unit.
Air solenoid block valve, V2-A (or V2-B) is de-energized and closes.
O2 analyzer A (or B) is de-energized.
Programmable Logic Controller PLC-A is de-energized.
PLC-A Operator Interface HM1-A is de-energized.
To complete the shut-down, full close the process air block valve on both N2 generator
units, including V1A & V1B on the air inlet and V9A & V9B on the N2 outlet.

6.4. Emergency Shut-Down Procedure

Full push in one or both mushroom red emergency E-stop push-buttons that power Unit A
ESPB-A and or Unit B ESPB-B, so they are in the off position.
White light Unit A (or B) Power On light is off.
Green light Unit A (or B) Running light is off.
Process air heater is de-energized.
3-way solenoid valve SV4-A (or SV4-B) is automatically de-energized and nitrogen is
now venting thru off-spec N2 vent valve V4A-A (or V4A-B) and depressurizing unit.
Page 16 of 25
 Air solenoid block valve, V2-A (or V2-B) is de-energized and closes.
O2 analyzer A (or B) is de-energized.
Turn the Controls off/on switch of the Generator that is to be shut-down (SW1A and
or SW1B) to the off position.
Full close the process air block valve on both N2 generator units, including V1A &
V1B on the air inlet and V9A & V9B on the N2 outlet.

6.5. Additional Operating Notes:

6.5.1. The off-line Unit can be fully de-pressured for maintenance etc.
6.5.1.1. On the unit that is off-line, fully close the process air block valves, including
V1A (or V1B) on the air inlet and V9A (or V9B) on the N2 outlet.

6.5.1.2. Press the Vent Mode button on the Operator Interface.

Air solenoid block valve, V2-A (or V2-B) is energized & opens.
Unit A (or B) is venting thru off-spec N2 vent valve V4A-A (or V4A-
B) & depressurizing the unit.

6.5.1.3. When done press the Vent Mode button on the Operator Interface, so it
shows as being off.
Air solenoid block valve, V2-A (or V2-B) is de-energized & opens.
Unit A (or B) is now in a normal mode and is not in the Vent mode.

6.5.2. N2 Generator Unit Switch-Over Sequence when SS1 is changed from Run A (or
Run B) to Auto position.

When the 3-way selector switch, either in Run A or Run B position, is moved to
the center Auto position:

6.5.2.1. If Unit A: is the de-fault N2 Generator it will continue to be on-line.

6.5.2.2. If Unit B is default N2 Generator, it will switch over to Unit B per section
6.2.2 but with no alarms.

6.6. Oxygen Analyzer Calibration Procedure

The oxygen analyzer should be calibrated when the unit is commissioned, on a monthly
basis, and when the sensor is replaced. It uses the compressed inlet air to span the
analyzer on the oxygen in the air. Refer to the analyzer manual for details. Note that Alarm
#1 contact on the analyzer (legend AAH), is frozen during the calibration so it will not give a
nuisance alarm. The calibration procedure is as follows:
Fully turn the analyzer 3-way calibrate valve V7-A (or V7-B), located inside the
enclosure, a turn from the Analyzer Run position to the Analyzer Calibrate position.
Air with 20.9% oxygen will enter the analyzer. This high oxygen content from the oxygen
analyzer will put the unit in a vent mode where the nitrogen is vented and not delivering
to the process.

Page 17 of 25
 Press the Mode key on the analyzer once. The analyzer display will show cal for
calibrate and alarms will be blocked during this calibration period.
Allow a few minutes for the analyzer to stabilize.
Once the analyzer reading stabilizes, use the Up and Down keys on the analyzer, as
required, to adjust the reading to 20.9%.
When the % O2 reading stabilizes, press the Mode key (4) times so the analyzer is in
the Run mode.
Fully turn the analyzer 3-way calibrate valve V7-A (or V7-B) a turn, from the
Analyzer Calibrate position to the Analyzer Run position.
The Fault, Run and alarm LED lights on the analyzer will flash for about (2) minutes
while the analyzer stabilizes.
After two minutes, these LED lights stop flashing and the green run light on the
analyzer is lit and the unit can be put back on line.

6.7. Air Filter Warning:

If the process air pressure falls below the low pressure set point (refer to the set point in
Appendix A), a Air Filter Warning message is displayed on the Operator Interface.

6.8. Operation information & recommendations:

The unit performance will be better if the control box door is kept closed, as this will allow
the membrane to be kept warmer.
The optimum operating process air temperature of the membrane is about 115F.
The membrane will produce more nitrogen at a better purity when fed with higher
pressure air.
A higher nitrogen flow and or a lower compressed air pressure will increase the oxygen
content.
A lower nitrogen flow and or a higher compressed air pressure will reduce the oxygen
content.

Page 18 of 25
7. Maintenance and Inspection
It is recommended that maintenance and inspection be done on a scheduled basis. Maintenance
requirements will naturally vary widely for each installation and with specific operating conditions. It
is suggested that a complete inspection be performed with necessary maintenance at the end of the
first month, the first three months, and the first six months. These inspections will be indicative of
how often future maintenance will be necessary.

! WARNING
Before doing any maintenance on the unit:
Disconnect all electric power before opening the control box (if supplied) to do any electrical
work or repair. Electric power may be supplied from different sources. Electric supply should
be through a separate disconnect switch with properly sized overload protection.
Depressurize the unit completely before removing any pressure-containing component. Refer
to Maintenance Instructions.

To properly protect the membrane(s), the inlet compressed air filter elements must be replaced
every 6 months even though the filter pop up indicator (differential pressure indicator) is in the
green zone. See the instruction on the filters in the Vendor section at the end of this manual.

! CAUTION
Liquid water and oil from the compressed air unit must be prevented from entering the
Generator, as this will permanently damage the membrane(s).

7.1. Every Week

Inspect the inlet compressed air filters by looking at the differential pressure gauge at top of
each filter to make sure it shows green on the air pressure drop indicator, indicating the filter
element is okay. Replace immediately if the indicator on top is in the red zone.
7.2. Every Month
Check unit for air leaks or flow obstructions and correct as required. Inspect the filters to make
sure the elements dont need to be changed and that the auto drains are working and that the
filter bowls are not full of condensate (water).
7.3. Every 6 Months
The inlet compressed air filter elements must be replaced every 6 months, in order to properly
protect the unit and to maintain the warranty on the unit. The element replacement must be
documented to maintain the warranty. See the instructions in the Vendor Instruction part of this
manual.
7.4. Every 2 Years
Replace the oxygen analyzer sensor cell per the instructions in the analyzer manual provided.
Note that as this cell reaches the end of its life, it will read lower a lower and lower oxygen
reading. This reading will eventually go to zero oxygen, even when there is oxygen in the
nitrogen, so it is important to replace this cell before it goes bad. Order the cell when it will be
used as it has a limited shelf life.

Page 19 of 25
8. Trouble Shooting

8.1. High Oxygen Content

8.1.1. Check the filters elements for fouling. Is the differential pressure gauge at the top of
each filter in the green zone and okay? Have the filter elements been replaced in
the last (6) months? Note that the elements can look okay but still need to be
replaced, because of high particle loading in the interior of the element, which has
reduced its effectiveness. Replace the elements, as required. See the instruction on
the filters in the Vendor section at the end of this manual.
8.1.2. Are the filter bowls full of water? See the instruction on the filters in the Vendor section
at the end of this manual.
8.1.3. Is the air temperature on the Operator Interface set per the set point in Appendix A? If it
is not controlling the temperature properly:
Is the power on? If not, check the fuse and the power supply and replace or reset,
as required.
Is the air pressure low, as this will turn off the heater via the low air pressure
transmitter (PT1) and this alarm condition will be indicated on the Operator
Interface? Increase the air pressure to the unit, if required
Is the heater getting power? If there is no power, check fuses, circuit breakers and
the 24 vdc power supply.
8.1.4. Is the air pressure to the generator less than the set point shown in Appendix A or does
it periodically drop below the design inlet pressure? If so, increase the inlet air pressure.
Consider removing any restrictive inlet piping, like quick connects or small ID tube
fittings, increasing the airline size and simplifying the air piping so there are fewer turns.
See the recommended minimum inlet piping inside diameter in Appendix A.
8.1.5. Is the oxygen content too high at start-up when venting? Reduce the Nitrogen vent flow
by closing off spec N2 vent needle valve slightly, located at the top of the control panel.
See the set point in the specifications in Appendix A.
8.1.6. Is the Nitrogen flow too high per the specifications in Appendix A? If so, reduce the N2
flow by slightly closing the nitrogen Purity Control metering valve (V3A) located in the
control panel.
8.1.7. Check the process air and particularly the nitrogen piping for leaks.
8.1.8. Are the space heaters at the bottom of the box on and set at 100F (40C)?

8.2. Low or No Flow

8.2.1. Increase the N2 flow by slightly opening the appropriate nitrogen Purity Control
metering valve V3A (or V3B), located in the control panel.
8.2.2. Is the air pressure to the generator much less than the design pressure, even for short
periods of time? If so, increase the inlet air pressure. Remove any restrictive inlet
piping.
8.2.3. Look for restrictions or leaks in the inlet compressed air piping. Check filters for
elements that need to be changed and filter bowls full of water.
8.2.4. Check the 3-way nitrogen solenoid valve SV4B-A (or SV4B-B), for proper operation.
8.2.5. Is the check valve V6A (or V6B) located at the nitrogen outlet opening properly?
8.2.6. Is the V2 air inlet solenoid valve opening?

Page 20 of 25
8.3. High Process Air Temperature
8.3.1. Look for air or nitrogen gas leakage, causing the flow to the heater to be too low,
causing the temperature controller to not control well.
8.3.2. Is the temperature control set point correct; see component set point in Appendix A.
8.3.3. Is the temperature control thermocouple installed properly?
8.3.4. Is the air pressure to the generator much less than the design pressure, even for short
periods of time? If so, increase the inlet air pressure.

8.4. Low Process Air Temperature

8.4.1. Has there been a heater shut-down? Is the Operator Interface showing any alarms on
the display? If it has tripped on over-temperature, wait until the temperature falls below
the set point per the component set point in Appendix A. Then reset the alarm using the
Operator Interface.
8.4.2. Is the air temperature on the Operator Interface set per the specifications in Appendix A?
Adjust if required.
8.4.3. Is the nitrogen flow to high? Close slightly the nitrogen Purity Control metering valve
V3A (or V3B), located in the control panel.
8.4.4. Check the heater; is it getting power? Is there power to the generator? If not, check
the fuse, circuit breakers and the power supply.
8.4.5. Is the air pressure low, as this will turn off the heater via the low air pressure switch
(PT1) and this will be indicated on the Operator Interface? Check the set point per
Appendix A. If so, increase the air pressure to the unit.

Page 21 of 25
9. Accessory Instructions

9.1. Compressed Air Inlet Filters (F1 & F2)

This procedure is for replacing the filter element for the (2) compressed air inlet filters. Make
sure the correct filter element is installed in the correct filter.

! WARNING
The air inlet valve (located immediately upstream of the filters) must be fully closed and the
air pressures (as read on the pressure gauge that is immediately downstream of the filters)
must be fully depressurized and read 0 psi. Serious injury may result if the filter bowl is
removed when there is pressure in the bowl.

9.1.1. With no pressure in the unit, unscrew the filter bowl by turning it counter-clockwise either
by hand or with a filter wrench (dont use a monkey wrench).
9.1.2. Remove the existing filter element. Insert the new filter element into the filter bowl. The
new filter element number must match that listed on top of the filter housing. Make sure
the correct filter element is installed, as each filter requires a different filter element and
they look the same.
9.1.3. Replace the filter bowl by turning it clockwise either by hand or with a filter wrench, until
it is tight and make sure the filter bowl is on correctly and safely.
Note: The elements in each filter are different (although they may look the same) and must be
installed in the proper filter housing! When replacing the filter elements, make sure the model
number on the element corresponds with the model number on the filter housing. Note that the
elements cannot be cleaned or blown out. Filters must be in a vertical position for the
automatic traps to work properly.
These filters are supplied with the following features:
Automatic trap to drain away any accumulated liquid water or oil.
Differential pressure indicator on top of filter heads. The needle on the indicator will move
from green to red when the pressure drop across the filter element becomes too high, and
the element requires replacement.
Filter bowl that is easily removed so the filter elements can be inspected or replaced.

Page 22 of 25
10. Spare Parts
Item Description Part # Qty
1st Stage Compressed Air Filter Element (1 micron)*: THF150PE 2
2nd Stage Compressed Air Filter Element (.01 micron)*: THF150FE 2
Oxygen Analyzer Sensor Cell (order when required): T13518 2
Fuse 20 amp 230 vac (1 & 2 FU) T19182 8
Fuse 5 amp 230 vac (3 & 4 FU) T16156 8
Fuse 10 amp 24 vdc (6 to 9 FU) T19105 4
Fuse 5 amp 24 vdc (6 to 9 FU) T19104 24

NOTICE
*These are recommended spare parts. All filter elements must be replace every 6 months
to protect the nitrogen membranes and maintain the warranty.

Make sure the filter elements are installed in the correct order, with the 1.0 micron filter in the
1st filter and the 0.01 micron filter in the 2nd.
Spare parts can be ordered from Titus Nitrogen. See the contact information on the cover
page of this manual.

Page 23 of 25
11. Warranty Information
The TN2 Exclusive 2-Year Bumper-To-Bumper Warranty
TN2 Nitrogen Generators are warranted to be free from defects in material and workmanship for a
period of two (2) years from date of shipment. This warranty is subject to the following terms and
conditions:

11.1. The unit has been appropriately sized and selected for the application.

11.2. The equipment has been installed and used in accordance with the Operation & Maintenance
(O & M) Manual.

11.3. Routine maintenance of consumable items has been performed according to the procedures
outlined in the O & M Manual.

11.4. Those items that require routine or occasional maintenance for the proper operation of the
nitrogen generator such as filter drain valves and replacement elements are not covered by
this warranty.

11.5. Other equipment used in conjunction with the nitrogen generator including, but not limited to,
the air compressor, aftercooler and separator have been installed and used in accordance
with their manufacturers instructions.

11.6. Damage to, or poor performance from, TN2 nitrogen generators caused by the following
conditions are not covered under this warranty:
Operating the equipment beyond its design limits
Modification of the equipment by, or on the behalf of, the end-user
Excessive contamination from external sources
Misapplication or misuse of equipment

The Titus Companys liability is limited to the repair of, refund of purchase price paid for, or
replacement in kind at the sole discretion of The Titus Company. In no event shall The Titus
Company be liable or responsible for any incidental or consequential damages, even if the possibility
of such incidental or consequential damages has been made known to The Titus Company.

Page 24 of 25
 Appendix A - Nitrogen Generator Specifications
General Specification:
Nitrogen Purity: 95 to 99.9%
Air Supply Pressure: 80 to 125 PSIG (5.5 to 8.6 Kg/cm2)
Air Supply Temperature: 59 to 125F (15 to 52C)
Ambient Temperature Range: 40 to 120F (4 to 49C)
Nitrogen Delivery Pressure: about 20 PSI (1.4 Kg/cm2) below air supply pressure
Electrical Power: 230V/1PH/60HZ
Enclosure: NEMA 4X & IP54
Customer Specifications:
Air feed pressure: 80 PSIG (5.5 Kg/cm2) to 120 PSIG (8.3 Kg/cm2)
Air feed flow required (nominal): 52 SCFM (84 NM3.hr)
Air feed dew point: -40F (-40C)
Nitrogen purity (% Oxygen Free): 95%
Nitrogen flow: 20 SCFM (32.2 NM3.hr)
Connections:
Compressed Air Supply: (1) 1 150 lb RF Flange
Permeate & N2 Vent Gas: (2) 2 150 lb RF Flange
Nitrogen Delivery: (1) 3/4 150 lb RF Flange
Condensate manifold from filter drains: (1) 3/4 Fnpt
Recommended Minimum Customer Piping:
Compressed Air Supply: 1.5 pipe
Permeate & N2 Vent Gas: 2.5 pipe each (if over 20 ft)
Nitrogen Delivery: 3/4 pipe
Condensate manifold from air filter drains: 3/4 pipe
Component Set Points:
Process air temperature control (PLC TIC: 115F (46C)
Over-temperature temperature (PLC AH): 140F (46C)
Low air pressure alarm (transmitter PT1): 70 psi (4.8 Kg/cm2)
Low-Low air pressure alarm (transmitter PT1): 60 psi (4.1 Kg/cm2)
Low N2 pressure (transmitter PT2): 59 psi (4.1 Kg/cm2)
Regulator, back pressure R2: 40 psi (2.8 Kg/cm2
Enclosure Space Heater: 100F (38C)
Off-spec vent throttling valve V5: Full Open
Alarm delays:
High Oxygen (O2) normal operation: 10 sec
High Oxygen (O2) initial cold start: 20 min
High Process Air Temperature Shut-Down: 30 sec
Low Process Inlet Air Pressure Shut-Down: 10 sec
Low Process Nitrogen discharge Pressure Shut-Dow: 10 sec
Oxygen Analyzer:
Range: 0 to 25%
High oxygen alarm AH: 5% O2
Drawings:
Flow: 994-PID
Electrical: 994-WD
General Arrangement: 994-GA
Page 25 of 25