N2 Manual Version 2009 11 30

Oxymat A/S :: Fasanvej 18-20 :: DK-3200 Helsinge :: Tel. +45 4879 7811 :: Fax +45 4879 7813 :: www.oxymat.
dk :: E-mail: sales@oxymat.dk
Instruction Manual
for
Nitrogen Generator Systems
N-040 N-350 N-2650 N-6500

N-075 N-600 N-3150 N-10000
N-150 N-800 N-4500 N-12000
N-225 N-1000 N-5500 N-15000
N-1850
Version 2009.11.30
Manufacturer of On-site Oxygen and Nitrogen Generator Systems

Table of Contents
WARNINGS READ BEFORE USE……………………………………………. .....................4
Pictograms on equipment............................................................................................................6
1. General Information................................................................................................................9
1.1 Oxymat Nitrogen Generators .......................................................................................9
1.2 Product warranty ..........................................................................................................9
1.3 Limits of Liability ......................................................................................................10
1.4 Conditions and Procedure for Returning the Unit for Service ..................................10
2. Product Specifications...........................................................................................................11
2.1 Performance in Sm³/hour ...........................................................................................11
2.2 Feed air supply in m³/min. .........................................................................................12
3. Nitrogen Generator Parts and Controls.................................................................................13
3.1 Basic Process Flow Description.................................................................................13
3.2 Parts Description ........................................................................................................15
3.2.1 Generator Parts...............................................................................................15
3.2.2 Receiver Parts ................................................................................................18
3.3 Connections................................................................................................................19
3.3.1 Generator Connections...................................................................................19
3.3.2. Receiver Connections ...................................................................................21
3.4 Controls......................................................................................................................21
3.4.1 Standard Control System ...............................................................................21
3.4.2 Optional Control System with Small Touch Screen ......................................23
3.4.3 Optional Control System with Touch Screen ................................................24
4. Installation.............................................................................................................................25
4.1 Unpacking ..................................................................................................................25
4.2 Pre-installation Instructions .......................................................................................25
4.2.1 Location .........................................................................................................25
4.2.2 Air Supply ......................................................................................................26
4.2.3 Power Supply .................................................................................................28
4.3 Installation..................................................................................................................29
5. Operation...............................................................................................................................33
5.1 Initial Start-Up Procedure ..........................................................................................33
5.2 Operation....................................................................................................................34
5.3 Shut-Down .................................................................................................................34
5.4 Normal Start-up..........................................................................................................35
5.5 Extended Shut-down ..................................................................................................35
5.6 Start-up after an Extended Shut-down .......................................................................35
6. Maintenance ..........................................................................................................................36
6.1 Weekly Inspection......................................................................................................36
6.2 Filter Element Replacement.......................................................................................36
6.3 Vessel Maintenance ...................................................................................................37
6.4 Valve Maintenance …………………………………………………………………38
6.5 Safety Devices............................................................................................................38
6.6 Service Check List .....................................................................................................38
7. Trouble Shooting...................................................................................................................40
7.1 Leak Test Procedure...................................................................................................43
7.2 Air Regulator Adjustment Procedure.........................................................................43
7.3 Capacity Test Procedure ............................................................................................43
7.4 Pressure Set Point Procedure .....................................................................................44
7.5 Pressure Switch Adjustment ......................................................................................44
Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 2

Tel +45 4879 7811 • Fax +45 4879 7813 • service@oxymat.dk • www.oxymat.dk
7.6 Probe Check and Calibration .....................................................................................45
7.7 Purging Procedure......................................................................................................46
8. Scrapping ..............................................................................................................................47
8.1 Dismounting...............................................................................................................47
8.2 Disposal......................................................................................................................47
Appendix A Piping Diagram.........................................................................................................

Appendix B Electrical Diagrams ..................................................................................................
Appendix C Components ..............................................................................................................
Appendix D Carbon Molecular Sieve - Material safety data sheet...............................................
Appendix E Small Touch Screen Control System ........................................................................
Appendix F Touch Screen Control System...................................................................................

WARNINGS AND IMPORTANT INFORMATION
READ BEFORE USE!
Important: OXYMAT nitrogen generators are intended for use in industrial applications
only.
Important: Upon receiving your OXYMAT Nitrogen Generator, inspect the unit thoroughly
for signs of damage. Any signs of damage, either external or internal, should be
noted on the delivery receipt, and also reported immediately to both the Freight
Company and OXYMAT. Contact OXYMAT at Tel +45 48 79 78 11 or Fax +45
48 79 78 13.
Important: The owner of the Oxymat Nitrogen Generator is responsible of keeping all the
equipment in safe working order. Parts and units must be replaced if they are
no longer in safe working condition. Installation of equipment and assembling to
other equipment must be done in compliance with current local regulations and
directions.
Important: The operator of the Oxymat Nitrogen Generator must always use safe working
methods in compliance with current local safety regulations and directions. In
case of difference between directions in the manual and local regulations the
strictest must be followed.
Warning: Use only hoses and pipes of correct size and suitable for operating pressure and
fluid. Never use hoses which are frayed, damaged or worn. Always use the
correct type and size of connections. Make sure hoses are depressurized before
disconnecting.
Warning: Lifting lugs on vessels, if present, are only for handling of the vessels if they are
detached from the PSA unit. The PSA-unit is not to be lifted by the lifting lugs
on vessels or by the pipes. The Nitrogen Generator must be lifted by the skid,
with a suitable lifting device operated by a certified or trained operator. Take
the necessary precautions to avoid units tipping over during handling.
Anchor all parts to the concrete floor by means of anchor bolts or like.
Warning: Exhaust gas from the nitrogen generator can contain more than 30 % oxygen
and be oxidizing. Exhaust gas must be lead by piping or ducts out of the room to
outdoor atmospheric air. Failure to do this may cause serious damage, injury or
death. The room where the generator is located must always be well ventilated.
Warning: Always vent nitrogen to outdoor atmospheric air. Failure to do this may cause
serious injury or death due to suffocation. The room where the generator is
located must always be well ventilated. Avoid inhalation of gases. In case of
nitrogen blow out, make sure the room is sufficient ventilated (before entering).
Use self contained breathing apparatus if necessary.
Warning: Make sure that your back-up/emergency nitrogen supply is installed with a
nitrogen pressure regulator. The pressure must be max. 7.0 bar. Check valves
must be fitted at both nitrogen delivery outlet form receiver and backup
nitrogen outlet.

Warning: The interior of the cabinet contains electrical parts that may produce electrical
hazard if not handled properly. To prevent electrical shock, care must be taken
when servicing this equipment. In general electrical installation and servicing is
to be performed by trained or authorized personnel only.
Warning: The OEM zirconium probe module and especially the heater block can get very
hot. Touching these parts may cause burns. The module can still be very hot
even after the module has been turned off. Always wait for at least 30 minutes
before touching the module. If present the probe module is placed in the lower
control cabinet.
Warning: Do not attempt to open the inspection hatch or similar unless the unit cycle
pressure gauge reads zero and the rubber hose from the filter elements is
disconnected to release pressure. Generator vessels can contain hazardous
substances. Handle only with proper protective clothing, gloves and eyewear
and according to local environment and work environment regulations. In
general mechanical and piping installation and servicing is to be performed by
trained or authorized personnel only.
Warning: Vessels must be depressurized and purged thorough with air to remove all
nitrogen before service or inspection. Always vent nitrogen to outdoor
atmospheric air. Sources of nitrogen must be positively blinded or disconnected
before service or inspection. Never rely on a closed valve. Vessel atmosphere
must be analyzed for safe oxygen content before inspection.
Important: For safety, installation and operating etc. of compressor, dryer unit or other
equipment refer to the concerned manuals of the equipment.
Warning: The compressor, air buffer or other feed air supply and pressurized equipment
must be fitted with adequate protective devises to protect against exceeding
allowable limits of the concerned equipment e.g. safety relief valves. Feed air
supply must be protected against exceeding 10 bar the maximum allowable
pressure P(S) for Oxymat Nitrogen Generators. The safety relief valves on
generator vessels and receiver tank (if supplied) are solely for the protection of
these components.
Caution: The following will cause damage not covered under the manufacturer’s
warranty. Feed air temperature T(O) above 40°°C or below 5°°C. Water, oil, rust,
scale and/or other foreign objects carryover in the feed air due to damaged filter
elements and/or plugged drains. The feed air quality must comply with
specifications to ISO/EN 8573.1: 2001 class 2.4.1 or 2.3.1, unless otherwise
stated.
Caution: OXYMAT filter elements have been selected based upon their ability to function
in severe operating conditions. Use of other than original equipment
manufacturer filters could cause damage not covered under the OXYMAT
warranty.
Caution: ***Equalization process valve shall be greased every six month. For all further
process valves it is enough to do maintenance and greasing once a year.(page 39)

Pictograms and labels on equipment
Label Symbol Text on label Placed
number
1 O
S9/17 Keep equipment in a On exhaust
well ventilated area and silencer
gases away from combustible
material
R8-Oxidizing
2
WARNING On front of a vessel
Equipment must be placed in
a well ventilated area. Avoid
inhalation of gases
3
On skid plate
WARNING
VOLTAGE
Turn off power and
disconnect before
service
PRESSURE
Depressurize
equipment before
service
MANUAL
See manual before
service
.
4
Information label INLET – FEED AIR On piping near inlet

5
Information label OUTLET – NITROGEN On piping near
nitrogen outlet
6
WARNING - NITROGEN On a vessel near
Avoid inhalation of gases nitrogen outlet
7
WARNING On top of a vessel
Do not lift generator unit by
lifting lugs or by pipes
8 -
On outside of (upper)
control cabinet
9 -
On front of a vessel
10
Information label Type of control system, Inside (upper) control
voltage / frequency / power panel
consumption, maximum fuse
size in power supply, probe
type (if present).
11
HOT SURFACE Inside lower control
Do not touch until cool cabinet on zirconium
probe (if fitted)

Explanation of pictograms and warnings on equipment:
1. Warning: Oxidizing exhaust. Keep equipment in a well ventilated area and gases away from
combustible material. See WARNINGS AND IMPORTANT INFORMATION.
2. Warning: Equipment must be placed in a well ventilated area. Avoid inhalation of gases.
See WARNINGS AND IMPORTANT INFORMATION.
3. Warning: See WARNINGS AND IMPORTANT INFORMATION.

Voltage - Turn off power and disconnect power supply before service or repair.
Pressure - depressurize before service or repairs.
Manual - See manual before service or repair.
4. INLET - FEED AIR: Connect to feed air supply.
5. OUTLET – NITROGEN: On generator: Connect this nitrogen outlet to nitrogen receiver inlet.
On nitrogen receiver: Connect this nitrogen outlet to your consumption.
6. WARNING – NITROGEN Avoid inhalation of gases. See WARNINGS AND IMPORTANT

INFORMATION.
7. WARNING – Do not lift generator unit by the lifting lugs or by pipes. See WARNINGS AND
IMPORTANT INFORMATION.
8. Warning: Voltage. See WARNINGS AND IMPORTANT INFORMATION.
9. Warning: Tip over hazard. See WARNINGS AND IMPORTANT INFORMATION.
10. Information of control system and requirements.
11. Warning: Hot surface. Do not touch until cool. Allow for a cooling down of Zirconium probe
module if present.

1 General Information
1.1 Oxymat Nitrogen Generators
This Oxymat Nitrogen generator is an on-site Nitrogen generating machine. Coupled with your
compressed air supply or air compressor (*), it process atmospheric air and separates the nitrogen
from other gases. The separation is accomplished with an inert ceramic material that does not
require replacement (when maintained and used according to this instruction manual). The process
is completely regenerative which makes it reliable and virtually maintenance free. The delivery
pressure can be set from 0 to 7.0 bar(g) to meet the needs of your operation.
(*) It is important to note that your compressor is an integral part of your total operation. It should
be operated and maintained in accordance with the manuals received with the compressor. An
improperly maintained compressor, refrigeration dryer or filtration system could affect the
operation of your Nitrogen generator. For use up to 24 hours a day, Oxymat recommends high
quality screw compressors only.
1.2 Product warranty

Oxymat A/S warrants all nitrogen generators to be free from defect in parts and workmanship for
one year duration, counting from the invoice date, or maximum 4000 operating hours, under normal
use and operation. Oxymat obligations under this warranty are limited to the repair (all parts and
labor free of charge, excluding filter elements) or replacement of purchase price of any such unit.
Each generator for which a warranty claim is asserted shall, at the request of Oxymat A/S, be
returned freight prepaid with proof of purchase date to the Oxymat A/S factory at the expense of the
purchaser. Any replacement parts shall be warranted as stated above for the unexpired duration of
the original one year warranty. This warranty does not extend to any generator or part if a defect or
malfunction occurs from misuse (at Oxymat sole determination), any feed air malfunction1,
improper filter element maintenance2, or external causes3. The feed air quality must comply with
ISO specification 8573-1:2001 class 2.4.1.(see 4.2.2). The warranty shall be null, void and
inoperative if the generator has been repaired or altered outside the Oxymat factory without the
express written authorization of Oxymat. The foregoing warranty is in lieu of any other warranty,
expressed or implied, in fact or in law including without limitation the warranty of merchantability
or the warranty of fitness for a particular purpose. It is expressly understood that purchaser's sole
and exclusive remedy for defect in parts is limited to enforcement of Oxymat obligation as set forth
above and Oxymat shall not be liable to the purchaser or others for loss of use of the equipment or
for other special, indirect, incidental or consequential damages.
Not withstanding anything to the contrary herein, during the product warranty period, as specified
above, Oxymat will return repaired generators freight prepaid. After the product warranty period has
expired, the customer is responsible for freight charges both ways. Said warranty shall extend and
apply to the generator only while the unit is owned and used exclusively by the original purchaser.
1
Air from your compressor must be less than 40°C before it reaches the generator, T(O)-max. High feed air
temperature will cause damage not covered under the Oxymat Product Warranty.
2
Replace the filter elements every six (6) months assuming a properly maintained air compressor. Failure to
replace filter elements on schedule will result in a void Oxymat Product Warranty.
3
Locate the system in an indoor well ventilated area that remains between 5°C and 45°C, T(S), to prevent
damage not covered under the Oxymat Product Warranty.

1.3 Limits Of Liability
Oxymat A/S shall not be liable for any special, indirect, incidental or consequential damages that
result from the use or malfunction of the machine.
1.4 Conditions and Procedure for Returning the Unit for Service
Follow the procedures below to return a generator or component for service credit:
Contact Oxymat A/S. Before you call for service assistance, have the following information readily
available:
1. The Model Number of the Generator

2. The Serial Number of the Generator
3. The Invoice Date
4. Hours of use and service history
Be sure merchandise is packed for a safe return. Oxymat is not responsible for damages that occur
to the generator or a component because of failure to follow this procedure is the sole responsibility
of the customer.
Item(s) must be returned freight prepaid.

2 Product Specifications
2.1 Performance in Sm3/hour measured at 15°°C (±5%)
Nitrogen Delivery
Purity ratings: 99,0% 99,5% 99,9% 99,99%
3 3 3
Model: Sm /hour Sm /hour Sm /hour Sm3/hour
Nitromat N-040 2,00 1,75 1,08 0,80
Nitromat N-075 5,14 4,50 2,78 2,00
Nitromat N-150 10,85 9,49 5,88 3,32
Nitromat N-225 16,56 14,49 8,97 5,06
Nitromat N-350 25,7 18,2 10,9 5,8
Nitromat N-600 36,6 25,8 15,5 8,2
Nitromat N-800 57,5 40,5 24,3 12,8
Nitromat N-1000 91,5 64,5 38,7 20,4
Nitromat N-1850 124,9 92,2 58,2 30,4
Nitromat N-2650 188,1 146,1 96,6 50,2
Nitromat N-3150 241,3 191,7 129,4 68,2
Nitromat N-4500 310,2 250,8 171,6 88,0
Nitromat N-6500 523,8 423,5 289,7 148,6
Nitromat N-10000 700,2 566,1 387,4 198,6
Nitromat N-12000 910,3 736,0 503,6 258,2
Nitromat N-15000 1120,4 905,8 619,8 317,8
Table 2.1 - Nitrogen delivery.
Dew point (all models): -70°° C
1.0 Sm³/h = 1.147 kg/hour = 16.7 litres/minute
NOTE:
The generators are designed to operate at a peak cycle pressure of 6.0 to 7.0 bar(g) and deliver 99%
pure nitrogen when supplied with a minimum feed air pressure of 7.0 bar(g). An increase of the
cycle pressure to more than 7.0 bar(g) results in higher feed air consumption and lower generation
efficiency. The generator can run higher peak cycle pressure, but only after special modification
from OXYMAT.
For operation at lower cycle pressures and/or higher flow rates, a slight modification is required.
Please contact your OXYMAT representative for assistance.

2.2 Feed air supply in FAD m3/minute are for operation with
reference to 20°°C
Feed air supply needed for above listed nitrogen delivery

Purity ratings: 99,0% 99,5% 99,9% 99,99%
Model: m3/min m3/min m3/min m3/min
Nitromat N-040
0,10 0,09 0,08 0,07
Nitromat N-075
0,26 0,24 0,20 0,18
Nitromat N-150
0,54 0,51 0,43 0,30
Nitromat N-225
0,82 0,78 0,65 0,45
Nitromat N-350
1,24 1,08 0,84 0,61
Nitromat N-600
1,76 1,54 1,19 0,87
Nitromat N-800
2,77 2,42 1,87 1,36
Nitromat N-1000
4,41 3,85 2,98 2,17
Nitromat N-1850
6,0 5,5 4,5 3,2
Nitromat N-2650
9,0 8,5 7,4 5,4
Nitromat N-3150
11,5 10,9 10,0 7,5
Nitromat N-4500
14,7 14,0 13,2 9,9
Nitromat N-6500
24,8 23,6 22,3 16,6
Nitromat N-10000
33,2 31,6 29,8 22,3
Nitromat N-12000
43,1 41,1 38,8 28,9
Nitromat N-15000
53,1 50,6 47,7 35,6
Table 2.2 – Feed air supply.

3 Nitrogen Generator Parts and Controls
3.1 Basic Process Flow Description
The OXYMAT Nitrogen Generator is designed to accept compressed air at 6.0 – 10.0 bar(g) into its
filter assembly. The supplied compressed feed air must be filtered through an air-conditioning
system consisting of water drain filter, refrigeration dryer pre- and micro filtration units, all
filtration units must be equipped with automatic drain valves for removing water and oil. The pre-
filter (if present) and micro filter removes condensed water and oil, dirt, scale, etc., and the
coalescing filter removes oil vapour (oil aerosols).
The normal process flow of air through the unit is shown in figure 1 below. After exiting the filter,
the compressed air is regulated down to 6 – 7 bar(g) and then directed by pneumatic activated
valves into one of two absorbers containing molecular sieve, unless specially modified by Oxymat
to another pressure. Molecular sieve has the unique property that it physically attracts or adsorbs
oxygen from the air, leaving the nitrogen to pass through to the receiver, and can when saturated
with oxygen be regenerated to clean sieve again by purging with nitrogen under lower pressure
conditions.
The generator unit consist of two absorbers working in alternate operation, e.g. the processes always
runs in antiphrasis to one another in such way, that one absorber with cleaned sieve delivers
nitrogen, while the other absorber regenerates saturated sieve. After a certain preset period, the
processes shifts, so that the first absorber now regenerates saturated sieve, while the second is
delivering nitrogen through a cleaned sieve. The nitrogen from the absorber is stored in the receiver.
After the receiver the pressure is regulated to 0 – 6 bar(g) depending upon the consumer’s specific
working pressure. See figure 2 next page for more detailed information on the working process.
Figure 1 - Flow Schematic for Oxymat Nitrogen Generators

Absorber 1 Absorber 2 Absorber 1
Figure 2 - Schematic P/T- diagram for OXYMAT Nitrogen Generators
The pressure drop ∆P on the accumulated nitrogen delivery must not exceed 0.5 bar(g).
Normal Process Sequence per column (refer to fig. 1 & 2 above):
A: Pressurization and nitrogen delivery. Valves V1, V4 & V61 (or V2, V3 & V62) activated
B: Pressure equalization (decreasing pressure). Valves V51 & V52 activated
C: Exhaust and purge with nitrogen (pressure drop causes oxygen release from sieve). Valve V3
(or V4) activated
D: Pressure equalization. Valve V51 & V52 activated

3.2 Parts Description
3.2.1 Generator Parts (Refer to Figure 3)
6
4
11
3
2
12
10
7
8
1
4
5
Figure 3 - Generator Parts
1. Absorbers 2. Cabinet containing electrical parts e.g. the PLC 3. Cycle pressure gauge 4. Valve for
equalization of pressure 5. Valves for cycle operation 6. Valve for delivery of nitrogen to nitrogen
receiver 7. Feed air pressure regulator with filter 8. Air inlet 9.Control valve block (solenoid
valves) 10. Safety relief valves 11. Exhaust pipe (silencer)

1. Absorbers
The absorbers contain Molecular Sieve that concentrates nitrogen from air.
2. Control Cabinet
(pages 22-24)
The cabinet contains all electrical parts. (e.g. the PLC for control of all process valves and
water drain).
3. Cycle Pressure Gauge
Indicates absorber pressure during the unit cycles. Pressure is controlled by the feed air
pressure regulator, which is set from factory. The gauge is able to read between 0 to 10.0
bar(g). Peak cycle pressure is 6.0 to 7.0 bar(g), unless specially modified by Oxymat to
another pressure.
4. Axial valve for equalization of pressure
After the pressurization cycle on each absorber the purge check valve will open for a period of
10-20 sec. and pressure equalization between the absorbers will take place.
5. Axial valves for cycle operation
These valves are controlling the pressurization and blow down cycles on the absorbers.
6. Valve for delivery of nitrogen to nitrogen receiver
This valve opens while the absorber is pressurized to deliver Nitrogen to the Nitrogen receiver
for use.

7. Feed air pressure regulator ( without or with filter)
The regulator controls the feed air flow to the absorbers, which need adequate and stable feed
air supply. Therefore an air buffer vessel is recommended to stabilize the air flow. The feed air
pressure should not at any time drop below 7 bar(g) under operation. The feed air pressure
regulator controls the inlet air pressure to 6 – 7 bar(g), unless specially modified by Oxymat to
another pressure. If the regulator is without filter - Y strainer before regulator is presented.
The strainer removes rough internal impurities coming from the Feed Air Receiver and the
pipe system.
8. Feed Air Inlet

The Feed Air Inlet is connected to the Feed Air Receiver outlet.
9. Control Valve Block (Solenoid Valves)

The valve block contains all solenoid valves, that via the PLC controls the pilot air supply
to the process and drain valves.
10. Safety relief valves
These valves ensure that the pressure in vessels does not exceed the design pressure.
11. Exhaust pipe
Blow processed air.

3.2.2 Receiver Parts (Refer to Figure 4, below)
12. Nitrogen Receiver
This stores the oxygen produced by the oxygen generator. The receiver tank provides stable
flow and purity of oxygen.
13. Safety Relief Valve Assembly with pressure outlet
Safety relief valve prevents excessive pressure from building up should a malfunction occur.
Pressure outlet on tee branch below the valve shall via the supplied hose be connected to the
pressure transmitter on top of the control panel.
14. Pressure gauge
This should under normal condition read between 4.0 – 11.0 bar(g). depending on version
15. Connections
The nitrogen generator is normally connected to the nitrogen receiver at the bottom of the
receiver, and the outlet for the consumption on the receiver top through a ball valve and a
regulator.
15
14
13
12
15
FRONT BACK SIDE
Figure 4 - Receiver Parts
12. Nitrogen Receiver 13. Safety Relief Valve Assembly with Pressure Outlet
14. Nitrogen Pressure Gauge 15. Inlet port with ball valve and outlet port with reduction valve

3.3 Connections
3.3.1 Generator Connections (Refer to Figure 4 and 5a, 5b or 5c)

16. From Pressure Outlet on Nitrogen Receiver tank to Nitrogen Pressure Switch
All models: Inside 2 mm/ Outside 4 mm nylon tube from the receiver pressure outlet to the
nitrogen pressure switch on generator control cabinet.
17. Air Inlet
Air Inlet: Pipe/Hose Connections

Model: Connection Model: Connection
Nitromat N-040 ¾” Nitromat N-1850 1”
Nitromat N-075 ¾” Nitromat N-2650 1½”
Nitromat N-600 1” Nitromat N-10000 2½”
Nitromat N-800 1” Nitromat N-12000 3”
Nitromat N-1000 1” Nitromat N-15000 3”
Table 3.1 – Air inlet connections.
7,0 - 10,0 bar(g) air supply from your compressor is connected to this fitting. Feed air (operating)
temperature must be between 5°C minimum and 40°C maximum, T(O)-min / T(O)-max.
Maximum allowable pressure P(S): 10.0 bar(g).
The feed air quality must comply with ISO specification 8573-1:2001 class 2.4.1. (see 4.2.2).
18. Condensate Outlet (Refer to figure 7a and 7b)
All models inside 4 mm outside 6 mm nylon tube from the bottom of the tank to the drain
system
This port must not be plugged.

Tubing should be connected as needed for proper disposal of condensate.

19. Nitrogen Receiver
Connections from generator to nitrogen receiver

Model: Note Connection Model: Note Connection
Nitromat N-040 a 3/8-3/4” Nitromat N-1850 b ½-1”
Nitromat N-075 a 3/8-3/4” Nitromat N-2650 c ½-1½”
Nitromat N-150 a 3/8-3/4” Nitromat N-3150 d ½-1½”
Nitromat N-225 a 3/8-3/4” Nitromat N-4500 e ¾-2”
Nitromat N-350 A 3/8-3/4” Nitromat N-6500 e 1-2½”
Nitromat N-600 b ½-3/4” Nitromat N-10000 e 1-2½”
Nitromat N-800 b 1/2-3/4” Nitromat N-12000 e 1-2½”
Nitromat N-1000 B 1/2-1” Nitromat N-15000 e 1-2½”
Table 3.2 – Connections from generator to receiver.
NOTES:
a) For connection: supplied 10/12 ID/OD plastic tube to be used.
b) For connection: use 22 ID/OD pipes of max 6 meters length, and material in Cu or AISI 314L,
for use in nitrogen service.
c) For connection: use 28 ID/OD pipes of max 6 meters length, and material in Cu or AISI 314L,
d) For connection: use 35 ID/OD pipes of max 6 meters length, and material in Cu or AISI 314L,
e) For connection: use 42 ID/OD pipes of max 6 meters length, and material in Cu or AISI 314L,

3.3.2 Receiver Connections (Refer to Figure 4)
20. Nitrogen outlet port (if receiver is delivered by Oxymat):
Connections from Nitrogen Receiver to consumption

Nitromat N-040 3/8” Nitromat N-1850 1’’
Nitromat N-075 3/8” Nitromat N-2650 1½’’
Nitromat N-350 1/2” Nitromat N-6500 2”
Nitromat N-600 1/2” Nitromat N-10000 2 ½”
Table 3.3 – Connections from receiver to consumption.
Nitrogen from the generator enters the receiver through the bottom of the receiver and exits at the
top.

3.4 Controls
3.4.1 Standard Control System (Refer to Figure 5a)
22. Digital Pressure Switch for Nitrogen Receiver

Register the pressure in the nitrogen receiver/surge tank
23. Operation Mode Selector Switch

Modes: Auto Operation, Manual Operation and Stand-by.
Placing the switch in the auto position causes the unit to run in on/off operation depending on
consumer’s oxygen demand. Placing the switch in the manual position forces the generator to
run continuously in alternation operation. Placing the switch in Stand-by position will stop the
generator after the completion of cycles.
24. Power/OFF
Switch for turning the power supply ON or OFF. This is placed on the side of the cabinet.
25. Hour Meter

The hour meter counts operating hours when the generator is in manual or auto position.
Figure 5a – Standard Control Panel
22. Digital Pressure Switch for Nitrogen Receiver/Surge tank 23. Operation Mode Selector Switch
24. Power/OFF 25. Hour meter

3.4.2 Optional Control System with Small Touch Screen (if present)
(Refer to Figure 5b)
26. Power/OFF
Switch for turning the power supply ON or OFF. This is placed on the side of the cabinet
27. Touch Screen

Finger operated Touch Screen – see instruction manual for touch screen control system in
appendix.
Figure 5b – Control Panel with small Touch Screen
26. Power/OFF 27. Touch screen
Nitrogen pressure switch is placed inside the lower cabinet.
For further detailed information – see separate Control System Manual in appendix.

3.4.3 Optional Control System with Touch Screen (if present)
(Refer to Figure 5c)
28. Power/OFF
Switch for turning the power supply ON or OFF. This is placed on the side of the cabinet
29. Touch Screen

Finger operated Touch Screen – see instruction manual for touch screen control system in
appendix.
30. Digital Pressure Switch Column 1 (Optional)

Register the pressure in column 1
31. Digital Pressure Switch Receiver/surge Tank (Optional)

Registers the pressure in the nitrogen receiver/surge tank
32. Digital Pressure Switch Column 2 (Optional)

Register the pressure in column 2
Figure 5c – Control Panel with Touch Screen
28. Power/OFF 29. Touch screen 30. Digital pressure switch Column 1 31. Digital pressure switch
receiver/surge tank 32. Digital Pressure Switch Column 2

4 Installation
4.1 Unpacking
You should have received the Oxymat Nitrogen Generator and the Instruction Manual needed for
proper installation of the unit. The Nitrogen Receiver Tank (if supplied) is shipped separately.
Place and unpack the shipment at the pre-determined location with a hard plane and level surface,
and check if the delivery is complete according to shipment and delivery lists. If any packages or
parts are missing, notify the Freight Company and Oxymat A/S at once. The manufacturer is not
liable in loses caused during shipment.
WARNING: Lifting lugs on vessels, if present, are only for handling of the vessels if they are
detached from the PSA unit. The PSA-unit is not to be lifted by the lifting lugs on vessels or by
the pipes. The Nitrogen Generator must be lifted by the skid, with a suitable lifting device
operated by a certified or trained operator. Take the necessary precautions to avoid units
tipping over during handling.
The column vessels must be pressurized to protect the sieves from ambient moisture.
IMPORTANT: Upon receiving your Oxymat Nitrogen Generator, inspect the unit thoroughly
for signs of damage. Any signs of damage, either external or internal, should be noted on the
delivery receipt, and also reported immediately to both the Freight Company and Oxymat.
Contact Oxymat at Tel +45 48 79 78 11 or Fax +45 48 79 78 13. The manufacturer is not liable
in damage caused during shipment.
4.2 Pre-installation Instructions

It is necessary to consider the location, space available, air supply, and power supply prior to
installing your Oxymat Nitrogen Generator.
IMPORTANT: for safe installation and operation etc. of compressor, dryer or other
equipment refer to manuals concerned for the equipment.
4.2.1 Location
1. Climatic Requirements:
The generator must be located in a well ventilated indoor area which remains above 5°°C and
below 45°°C T(S). Operating the generator in an area below 5°C or above 45°C, could cause
damage not covered under the manufacturers warranty.

2. Physical Characteristics:
Generator Characteristics
Floor Height Load Floor Height Load
Model: Model:
space cm kg space cm kg
Nitromat N-040 35x35 130 75 Nitromat N-1850 120x80 230 1100
Table 4.1 – Generator Characteristics.
Size of Receivers
Model: Volume Diameter Model: Volume Diameter
Litres cm Litres cm
Nitromat N-040 150 40 Nitromat N-1850 3000 128
Table 4.2 - Size of Receivers
4.2.2 Air Supply (Feed Air)

Air from your compressor or feed air supply must be less than 40°C, T(O)-max, before it reaches
the Nitrogen Generator. High feed air (operating) temperature will reduce the performance of the
Nitrogen Generator and will cause damage not covered under the manufacturer's warranty. Low
feed air (operating) temperatures may cause freezing of components and damage not covered under
the manufacturer's warranty.
WARNING: The compressor, air buffer or other feed air supply and pressurized equipment
must be fitted with adequate protective devises to protect against exceeding allowable limits of
the concerned equipment e.g. safety relief valves. Feed air supply must be protected against

exceeding 10 bar(g) the maximum allowable pressure P(S) for Oxymat Nitrogen Generators.
The safety relief valves on generator vessels and receiver tank (if supplied) are solely for the
protection of these components.
The feed air quality must comply with ISO specification 8573-1:2001 class 2.4.1., e.g. maximum
number of particles per m³ is as following:
class Maximum size of the particles per m³ Particle size Concentration
Particle size, d
µm
≤ 0,10 0,10 < d ≤ 0,5 0,5 < d ≤ 1,0 1,0 < d ≤ 5,0
Μm mg/ m³
2 Not 100 000 1 000 10 Not applicable Not applicable
specified
Dew point +3°C & residual water content max. 6 g/m³ and residual oil content max. 0.01 mg/m³.
WARNING: Use only hoses and pipes of correct size and suitable for operating pressure and
fluid. Never use hoses, which are frayed, damaged or worn. Always use the correct type and
size of connections. Make sure hoses are depressurized before disconnecting.
The connections of hoses, if used must be are done with high quality connection systems. E.g.a
clamp system or compression end fittings depending on the type of hose applied.
It is not recommended to use ordinary hose clips.
IMPORTANT: All hoses and piping must be routed out of harms way and secured to prevent
accidental pulling of hoses piping or connections.
The hose/piping used to bring air from the compressor to the air buffer vessel and from the air
buffer to the Nitrogen generator should be dimensioned to supply the needed feed air flow at a
pressure between 6,0 - 10,0 bar(g). The dimensions must at least be:
Air Inlet: Pipe/Hose Connections

Table 4.3 – Air inlet connections.

With a properly dimensioned hose/piping1, the feed air pressure must not be less than 6 bar(g)
at inlet point during operation. The use of an improperly size of hose/piping will result in reduced
nitrogen generating capacity.
The required flow of feed air is listed in section 2: Product Specifications.
It is recommended to have a shut off valve installed where the air inlet hose/piping is connected to
the compressed air supply or if present on the air buffer vessel to facilitate safe depressurization of
the hose/piping before removal of connections.
Max length of hose: 3 meters
4.2.3 Power Supply

Warning: The interior of the cabinet contains electrical parts that may produce
electrical hazard if not handled properly. To prevent electrical shock, care must be taken
when servicing this equipment. In general electrical installation and servicing is to be
performed by trained or authorized personnel only.
1. 110-240V, 50-60 Hz, single phase, 1.0 ampere

Proper voltage must be provided to the generator at all times.
Maximum fuse on power supply 10 ampere.
Improper voltage will cause damage not covered under the manufacturer's warranty. To
protect your PLC on the generator Oxymat recommend the use of electrical filters.
2. Power should be supplied to the unit from a grounded electrical outlet with a 3-prong plug.
It is recommended to use a circuit that will not be accidentally turned off, as this will cause the
unit to stop cycling. If power is off and the unit is being used, the product vessel will
depressurize.
3. In order to prevent production stop and purity drop in case of electric power failure, a UPS
(power backup) is recommended as an option.

4.3 Installation
4 4 5 2 1 3
COMPRESSOR
AIR
DRYER
COAL
TOWER FEED
AIR
TANK NITROGEN
GENERATOR
NITROGEN
RECEIVER
TANK
Figure 6 - Installation Setup (Elevation)
1. Main installation parts (pre-assembled):

1. Generator Unit c/w internal piping & electric cabinet
2. Feed Air Tank
3. Receiver Tank
4. Compressor Unit c/w Dryer and Filters
5. Carbon Tower c/w Micro Filter
The necessary parts are either in scope of supply or required local by costumer.
2. Unpacking and handling in general:

On receipt of the aggregate, check that the individual parts correspond with those listed on the
delivery note.
When unloading, check immediately for possible damage to all parts, such as dents, scratches,
corrosion, torn electric cables, bent pipes, or the like. In case of defects or damage, the carrier
and supplier shall be informed immediately.
The aggregate shall only be lifted according to suppliers instructions, and in case of
compressor/air-dryer delivery, special care must be taken to the instructions noted in the
compressor suppliers manual. In order to avoid squeezing of instruments, piping, etc., use a
suitable lifting device.

Warning: The column vessels must be pressurized to protect the sieves from ambient
moisture.
3. Placement of aggregate:
Place all the main parts in their final positions on hard, plane and level surfaces. Make sure
that sufficient space between parts is available for maintenance and inspection. Up-line the
parts to proper horizontal and vertical positions and anchor all parts to the concrete floor by
means of anchor bolts or like.
Configuration A (Position 1): Existing (Feed) Air Tank, new Nitrogen Generator
and existing Receiver Tank
Configuration B (Position 1 & 2): Existing Compressor/Air Dryer, new Feed Air Tank,
new Nitrogen Generator and new Receiver Tank.
Configuration C (Position 1, 2 & 3): New Compressor/Air Dryer, new Feed Air Tank,
new Nitrogen Generator and new Receiver Tank.
Configuration D (Position 1, 2, 3 & 4): As Configuration C with addition of a Coal Tower
(Oil Mist Absorber).
Figure 7 (Below): Filters and Water Drains.
4. Installation connections between supplied parts and existing equipment:

(Refer to figure 6 above)
Configuration A (Position 1):

- Connect air hose/pipe from an upper port on Feed Air Tank to inlet filter on Generator. –
see notes below table 3.1 section 3.
- Connect nitrogen hose/pipe from generator outlet valve on top of generator to the nitrogen
receiver bottom valve – see notes below table 3.2 section 3.
- Install the Drain System according to Figure 7a, as follows:
- Mount the Auto Drain Valve at the bottom of the Feed Air Tank via a tee as shown on fig.
7a below.
- Install all 3 hoses from the Pre-filter, Micro-filter and the compressor manual drain to the
inlet port on the Auto Drain Valve (refer to Figure 7a).
- Connect outlets from respectively Auto Drain Valve, Compressor Automatic Drain and
Air Dryer to an Oil Separator or like (refer to Figure 7a), unless other things are agreed
and approved by OXYMAT A/S.
- Connect tube form receiver pressure outlet to pressure switch.
- As the Auto Drain Valve is controlled by the PLC via a Solenoid Valve – connect the
actuator port on the Auto Drain Valve to the outlet port on the Solenoid Valve (refer
to Figure 7a).
- In case of a receiver mounted compressor package (e.g. compressor with integrated
receiver), connect the drain system as shown on Figure 7b.
- Finally remember to run an exhaust pipe (steel pipe) from the silencer and out of the room
to outdoor atmospheric air. For generators N040 – N1850 use at least pipe or duct of 100
mm nominal diameter. For generators N2650 – N15000 use at least pipe or duct of 160
mm nominal diameter. Mark the outlet of the pipe with a “No Smoking or Open Flame”
sign.

Figure7a. Drain System – Separate feed Air receiver
Figure7b. Drain System – Compressor mounted air receiver

WARNING: Exhaust gas from the nitrogen generator can contains more than 30 % oxygen
and can be oxidizing. Exhaust gas must be lead by piping or ducts piped out of the room to the
outdoor atmospheric air. Failure to do this may cause serious damage, injury or death. The
room where the generator is located must always be well ventilated.
OPTIONAL - For on-line back-up or surge needs, we recommend that backup Nitrogen is
connected directly on the Nitrogen outlet pipe (through a check valve), and that the pressure on the
backup Nitrogen is approximately 0.3 Kg/cm2 below the regulator setting on the Nitrogen generator.
WARNING: Make sure that your back-up/emergency Nitrogen supply is installed with a
Nitrogen pressure regulator, the pressure must be max. 7.0 bar(g), unless specially modified
by Oxymat to higher pressure. Check valves must be fitted on both backup nitrogen supply
and nitrogen outlet from receiver tank.
Very important: Check all fittings for leaks as described in section 7.1 or use a suitable leak
detecting fluid.
Note: The installation of the back-up nitrogen as described in steps F & H, although not
required, is strongly recommended.
Inspect every piece of safety device for defects, correct installation and function.
Configuration B (Position 1 & 2):

- Make all the installations and note the cautions mentioned under the Configuration A.
- Additionally connect air hose/pipe from Air Dryer outlet via the Pre-filter and the Micro-
filter (new or existing) to the inlet port at the bottom of the Feed Air Receiver Tank.
- Also connect your nitrogen application/consumption to the pressure regulator on nitrogen
outlet at the top of the nitrogen receiver tank.
Configuration C (Position 1, 2 & 3):

- Make all the installations and note the cautions mentioned under previous configurations.
- For the compressor installation – follow the instructions in the compressor supplier’s
manual – read this manual before installation!
Configuration D (Position 1, 2, 3 & 4):

- Make all the installations and note the cautions mentioned under previous configurations.
- Connect the coal tower (Oil Mist Absorber) equipped with a second Micro-filter on the
outlet. The Coal Tower inlet is placed on top of the tower, and the outlet is placed at the
bottom of the tower.
If the delivery includes a separate Feed Air Tank, the coal tower is placed after the first
Micro-filter on the Air Dryer and before the Feed Air Tank.
If the Feed Air Tank is an integrated part of the compressor, the Coal Tower location is
after the Feed Air Tank, and the Auto Drain Valve is in this case placed on the side of the
Feed Air Tank instead of the bottom of the tank (refer to Configuration A).

5 Operation
5.1 Initial Start-up Procedure
To start the Nitrogen Generator for the first time, follow the steps below:
1. Remove transport brackets at the air dryer (if present).

2. Turn on the power supply to the air dryer (if present).
3. Remove transport brackets at the compressor (if present).
4. Turn on the power supply to the compressor (if present).
5. Make sure, that all shut off valves between the plant items are open
6. Let the compressor keep running and observe that the compressor shifts to unloaded
operation, when the compressor pressure has reached the pressure stop set point.
7. Carefully and gentle open for feed air supply to the generator.
8. Turn on the electric power supply to the generator.
9. Switch the mode selector to manual position.
10. Ensure that the drain system works properly by checking, that exhaust air appears from the
drain water outlet for about 1.5 second every 5 minutes.
11. Be aware that air and condensate might be exhausted automatically from compressor and air
dryer during start up – this is not a mal function.
12. Shut off the nitrogen application/consumption and prepare for Leak Test:
a. Let the plant run in manual mode, until the nitrogen receiver pressure reaches a
minimum of 5 bar(g).
b. Turn the mode selector switch to stand-by/off, and the generator will stop after a little
while, when the actual operation cycle is completed.
c. Shut off the feed air supply.
d. If coal tower is installed, close of oil indication tube. If fitted with purity monitoring
probe close of the pressure reduction valve on probe inlet.
e. Read and note the pressure P1 in nitrogen receiver, column 1, column 2 and feed air
tank.
f. Let the plant stand still (rest) and isolated in pressurized condition for an hour.
g. After an hour read and note the pressure P2 in nitrogen receiver, column 1, column 2
and feed air tank.
h. Then determine an eventually pressure drop as the difference between P1 and P2 for
each component.
i. The Leak Test is OK, if the pressure drop after one hour pressurized isolation is less
than 0.1 bar(g). In case of leaks they must not cause more than 0.1 bar(g) pressure drop
per hour.
j. If closed open for coal tower oil indication tube and reset the pressure reduction valve
on probe inlet t 1.0 bar(g).
13. Close the shut off valve between the generator and the nitrogen receiver tank and prepare for
Capacity Test.
a. Read and note the pressure in the nitrogen receiver tank – called the starting pressure:
P1 (bar).
b. Rapidly open the shut off valve between the nitrogen receiver tank and the nitrogen
application/consumption and rapidly close it again after exactly one minute. This will
achieve the real and exact consumption for a one minute period.
c. Now read and note the final pressure P2 (bar).
d. Determine the capacity by using the formula: (P1 – P2) x (Volume of nitrogen receiver
tank in litres) = capacity in litres per minute. Check the result with the stated capacity in

the Design Review Certificate.
14. To obtain the design purity in nitrogen receiver purge the tank with nitrogen as follows:
a. Check that nitrogen consumption is closed off.
b. Open up for flow from feed air supply/compressor.
c. Start the feed air supply/compressor.
d. Start the generator and let it run for about 15 minutes.
e. Check that pressure in nitrogen receiver reaches the value stated in Design Review
Certificate.
f. Open for nitrogen consumption. Adjust flow to approximately to 50 % of design flow
(refer to Design Review Certificate).
g. Let the generator run in manual mode until design purity is reached. Duration 0.5 - 8
hours depending on purity and capacity.
h. When design purity is reached close off nitrogen consumption switch generator to auto
mode and let the generator run until it stops automatic. This should occur within 10
minutes. If the generator does not stop as described refer to section 7.4 for pressure set
point procedure.
15. At the end of this period, observe the feed air pressure gauge and the cycle pressure gauge on
the generator for at least 5 complete cycles, to make sure that the generator starts and stops
within the allowable limits, as follows:
a. Observe that the feed air pressure should be no less than 7.0 bar(g) unless stated
otherwise by manufacture.
b. Observe that the peak cycle pressure should not increase above 7.0 bar(g) unless stated
otherwise by manufacture (Design Review Certificate).
16. Now the plant is ready for normal operation.
IMPORTANT: When the generator is being started up for the first time, or after a long shut-
down period, it is possible that the nitrogen receiver tank is full of air. Before the generator
can supply nitrogen of design purity, any air in the nitrogen receiver tank must be purged.
Refer to step 14 above for guidance.
WARNING: Always vent nitrogen outdoor. Nitrogen concentrations higher than 78 % in the
air can without warning cause serious personal injury or death.
5.2 Operation
The Oxymat Nitrogen Generator can operate in either Auto or Manual mode or can be in Stand-by
mode. The operation mode is selected on the mode selector switch – refer to Section 3.4.
- In Auto Mode the generator runs in an on/off operation depending on the actual nitrogen
consuming demand.
- In Manual Mode the generator runs in a continuous, forced operation used for rising of
nitrogen purity, rising nitrogen receiver pressure etc.
- In Stand-by Mode the generator stand still - ready for the next re-start.
5.3 Shut-Down
1 Turn of nitrogen application/consumption
Close off central nitrogen application/consumption. This will insure that the nitrogen receiver
tank is full the next day even if a nitrogen discharge valve is left open.
Ensure that the mode selector switch is in the AUTO position, and wait until the generator
stops cycling. This allows the receiver tank to fill completely with nitrogen for immediate use

required. It also allows the unit to shutdown at the proper point in the cycle.
NOTE: Failure to wait or immediate or accidental stop of operation during a cycle will result
in temporary lower nitrogen purity during subsequent use.
2 Turn off Power

- Turn the selector switch to Stand-by position.
- Turn off the compressor power switch (if present).
- Turn off the air dryer power switch (if present)
- Turn off the generator power switch
5.4 Normal Start-up

- Turn on the air dryer power supply (if present)
- Turn on the compressor power supply (if present), or open for the central compressed feed air
supply.
- Observe that the feed air pressure is OK
- Turn on the power supply to the nitrogen generator.
- Turn the mode selector switch in manual position.
- Observe that the drains are working
- Observe that the peak cycle pressure do not excess the value stated Design Review Certificate.
- Turn the mode selector switch in auto position.
- After a while observe that the generator automatically stops, when the nitrogen receiver
pressure gauges reaches approximately 6.0 bar(g), unless stated otherwise by manufacture in
Design Review Certificate.
- Further observe that the generator automatically re-starts after about 0.5 pressure drop. If the
generator does not starts or stops like this refer to section 7.4 for pressure set point procedure
and adjustment.
5.5 Extended Shut-Down

To shut down the Oxymat Nitrogen Generator for 24 hours or longer, complete all steps in Section
5:3 – Shutdown. In addition perform the following:
Fully close all manual valves to isolate the nitrogen in the nitrogen receiver, to prevent the loss of
pressure in the nitrogen receiver, in order to enable a normal Start-up. Turn off all electric powers,
e.g. on compressor, air dryer and generator.
Keep columns pressurized and sealed to protect contained sieve against ambient moisture.
If generator is fitted with purity monitoring probe, close of the pressure reduction valve on probe
inlet.
5.6 Start-up after an Extended Shut-Down

After an extended shutdown or an unexpected shutdown, such as an electric power failure, you must
purge the nitrogen receiver of any low purity nitrogen before the nitrogen generator can supply
nitrogen within the purity specifications.
To purge the nitrogen receiver, follow step 14 in Section 5.1 – Initial Start-up Procedure.

6 Maintenance
WARNING: The interior of the cabinet contains electrical parts that may produce
electrical hazard if not handled properly. To prevent electrical shock, care must be taken
when servicing this equipment. In general electrical installation and servicing is to be
performed by trained or authorized personnel only.
Monitoring the operation of the unit on a regular schedule is the best way to insure a long life for
your Oxymat Nitrogen Generator. The generator's operation should be monitored both daily and
monthly as described in the following sections.
External and internal inspection of vessels and other pressurized equipment must be carried out
according to local regulations.
6.1 Weekly inspection
The weekly inspection of the nitrogen generator consists of for a few minutes every week simply
observe the operation of the unit to make sure that the automatic filter bowl drain system and air
buffer drain system is functioning properly. Plugging of the drain systems will cause water/oil
carry-over into the adsorber vessels, and will cause severe damage to the adsorbent which is
not covered under the manufacturer’s warranty.
Observe that the Filter Drain Port and air buffer drain port is not plugged. Air should discharge from
these ports (or the end of the tubes if connected) for 1.5 seconds every 5 to 10 minutes when the
generator is running.
Do also observe your air supply system on weekly basis, check oil level and operating temperature
on the compressor, and check function of your refrigeration dryer as well as filter elements placed
after the refrigeration dryer, the pressure gauges on the filter elements must not be in red area at any
time of operation.
Refer to the concerned manuals of the equipment for service instructions.
6.2 Filter Element Replacement
The expected life of the pre-filter elements is 6 months or 4.000 working hours with proper
maintenance of air compressor.
The expected life of the micro filter elements is 6 months or 4.000 working hours with proper
maintenance of air compressor and pre-filters.
It is recommended to replace active coal in carbon tower, yearly. At the very latest – when the oil
indicator mounted on carbon tower turns red.
Improper compressed air quality could affect the operation of your nitrogen generator. The filter
element(s) supplied with each unit have been selected by manufacturer based upon the units feed air
requirements.

CAUTION: The following will cause damage not covered under the manufacturer’s warranty:
- Feed air (operating) temperature T(O) above 40°C or below 5°C.

- Water, oil, rust, scale and/or other foreign objects carryover in the feed air can damage filter
elements and/or plugged drains.
WARNING: Oxymat filter elements have been selected based upon their ability to function
in severe operating conditions. Use of other than original equipment manufacturer filters
could cause damage not covered under the Oxymat warranty.
The only maintenance required on your Oxymat Nitrogen Generator is periodically changing the
filter elements. If you perform this simple, inexpensive procedure, you can assure yourself years of
trouble free use.
WARNING: Do not attempt to remove the filter bowls unless the units cycle pressure gauge
reads zero and the rubber hose from the filter elements is disconnected slowly to release
pressure.
Note that the first filter from the air inlet port is the pre-filter and the second filter is the micro filter.
Filter element replacement
1. Close off feed air supply to generator.

2. Carefully disconnect the 4/6 mm rubber drain tube the bottom of the filter to depressurize.
3. Turn the filter element counter clockwise and remove the element.
4. Remove check valve form old filter element and install the check valve on the new filter
element.
5. Install new filter element with check valve.
6. Reconnect tube to the check valve at the bottom of the filter element.
7. Perform a leak test.
6.3 Vessel Maintenance

WARNING: Vessels must be depressurized and purged thorough with air to remove all
nitrogen before service or inspection. Always vent nitrogen to outdoor atmospheric air.
Sources of nitrogen must be positively blinded or disconnected before service or inspection.
Never rely on a closed valve. Vessel atmosphere must be analyzed for safe oxygen content
before inspection.
Examples of disconnecting or blinding of nitrogen sources:

Generator vessels: Disconnect feed air supply and nitrogen receiver.
Nitrogen receiver: Disconnect generator nitrogen outlet, nitrogen backup and nitrogen consumption.
External and internal inspection of vessels and other pressurized equipment must be carried out
according to local regulations.
When your Oxymat Nitrogen Generator is installed and operated according to the prescribed
conditions, it is not needed to do internal inspection of generator vessels on regular basis.
If vessel sieve is replaced inspect vessels for corrosion or other damage. Replace if needed.
Refer to sieve material safety data sheet for handling and safety instructions of sieve.
Receiver vessel should be inspected internal every 4 years or according to local regulations.

6.4 Valve Maintenance
All valves should be inspected, cleaned and lubricated within period of 12 months or after 8.000
operating hours. Important notice: Upper and lower equalization valves require initial maintenance
after 2000 hours of operation. After this, it can follow the normal maintenance frequency.
Valve cleaning and lubrication
1. Stop the Nitrogen generator.

2. Close off feed air supply to generator.
3. Close and disconnect buffer vessel.
4. Depressurize the column vessels by opening safety valves.
5. NOTE! The vessels must never be left unpressurized more than 2 hours.
6. Carefully disconnect and remove the upper and lower pipe set.
7. Seal the inlets of the vessels by using tape to avoid any contamination of vessel content by the
moist.
8. Disassemble the pipe sets and disassemble the valves.
9. Remove all the particles, dirt, residual oil etc. from inside the valve.
10. Clean and lubricate the valve.
11. Reinstall the valve as well as the pipe sets.
12. Perform a leak test.
6.5 Safety Devices

Visual inspect safety relief valves and other safety devices for dirt or damage.
If there is debris in the valve seat scavenge the valve as follows: Pressurize vessel and loosen the top
screw one turn to. This should remove debris from the valve.
Retighten the top screw.
Always wear personal protection of hearing, hands, eyes etc.
6.6 Service Check List

When performing the stated monitoring/maintenance, it will be an advantage to follow and use the
Service Check List shown on next page.

Service Check List
4000 hours
8000 hours
Type: ________________________________________________________
Installation
Series no: _____________________ Hour meter: ____________________
1. Service compressor according to suppliers instructions
x x
x x
2. Check of refrigeration air dryer incl. drain according to suppliers instructions
x
3. Check of pressure in air tank, coloumn tanks and product tank x x x
4. Check of cycle time and cycle interval x x x
5. Check of product purity x x x
6. Check of product consumption (flow) x x x
7. Chech of drain system x x x
8. Replace filters (pre- and micro filter) x x
9. Replace pre-filter after coalescing tower x x
10. Replace active coal and oil indicator yearly (recommended) p.35 (6.2)
11. Replace micro filter and sterile filter/bacterial filter x
12. Inspection of pressure regulator (replace if required) x x
13. Cleaning of strainer x x
14. Cleaning and inspection of proces valves (if required change) x
15. ***Check valve disassemble and inspect (if required change membrane - Oxymat) x x
16. Replace of Zeolit/CMS if required/on demand
17. Leak test x x x
18. Check of safety valves x x x
19. Check and reset of pressure switchs x x x
20. Check of manometers x x x
21. Check of pipes/hoses, pipe and hose connections, cables, plugs etc. x x x
22. Check of solenoid valve block, leakage/function x x x
23. Point 3-5 to be repeated x x x
24. Check of purity sensor. Calibrate if required (electro galvanic: Weekly) x x x
25. Control of clients consumption incl. flow x x x
26. Affixing of service sticker x x
27. Hand over copy of service check list to the client x x
28. Fill in timesheet incl. spare parts list x x
Remarks to client:
Date:
Service technician:
*** equalization valve shall be greased every six month

7 Trouble Shooting
Most common operation failure is insufficient nitrogen purity due to inadequate flow rate (capacity)
caused by too heavy leakage or other capacity problems. If a purity problem occurs, it is strongly
recommended at once to uncover these eventually problems before any other initiative are taken –
so follow the Route Diagram shown below:
Figure 8 – Route Diagram / Purity Problem Solving
Purity
Problem
Flow OK
Problem Yes No
Leak Test
Leaks present
Capacity
Test
Leaks
No Yes Removal
Corrections
OK
Run Check Sensor

Generator in (if present)
No Yes
Manual Mode Calibrate/replace
Purity
Problem
Check OK
function on Yes No
V1
Repair/ Malfunction
replace on V1
Continue on
Yes No next page

Continued from
previous page
Check
function on
V2
Repair/ Malfunction
replace on V2
Yes No
Check
function on
V3
Repair/ Malfunction
replace on V3
Yes No
Check
function on
V4
Repair/ Malfunction
replace on V4
Yes No
Continue on
next page

Continued from
previous page
Check
function on
V51/V52
Repair/ Malfunction
replace on V51/V52
Yes No
Check
function on
V6
Repair/ Malfunction
replace on V6
Yes No
OK
Figure 8 – Route Diagram / Purity Problem Solving

7.1 Leak Test Procedure
1. Shut off the nitrogen application/consumption.
2. Let the plant run in manual mode, until the nitrogen receiver pressure reaches a minimum of 5
bar.
3. Turn the mode selector switch to stand-by/off, and the generator will stop after a little while,
when the actual operation cycle is completed.
4. Shut off the feed air supply.
5. If coal tower is installed, close of oil indication tube. If fitted with purity monitoring probe
close of the pressure reduction valve on probe inlet.
6. Read and note the pressure P1 in nitrogen receiver, column 1, column 2 and feed air tank.
7. Let the plant stand still (rest) and isolated in pressurized condition for an hour.
8. After an hour read and note the pressure P2 in nitrogen receiver, column 1, column 2 and feed
air tank.
9. Then determine an eventually pressure drop as the difference between P1 and P2 for each
component.
10. The Leak Test is OK, if the pressure drop after one hour pressurized isolation is less than 0.1
bar. In case of leaks they must not cause more than 0.1 bar pressure drop per hour.
11. If closed open for coal tower oil indication tube and reset the pressure reduction valve on
probe inlet t 1.0 bar.
7.2 Air Regulator Adjustment Procedure

1. Unlock lock on adjustment knob.
2. To increase pressure turn clockwise.
3. To decrease pressure turn counter clockwise.
4. Make small adjustments and let system cycle through one cycle before making another
adjustment.
5. If readings are still incorrect, make another adjustment until you are within manufacturer's
specifications stated in Design Review Certificate.
7.3 Capacity Test Procedure

1. Close the shut off valve between the generator and the nitrogen receiver tank.
2. Read and note the pressure in the nitrogen receiver tank – called the starting pressure: P1
(bar).
3. Rapidly open the shut off valve between the nitrogen receiver tank and the nitrogen
application/consumption and rapidly close it again after exactly one minute. This will achieve
the real and exact consumption for a one minute period.
4. Now read and note the final pressure P2 (bar).
5. Determine the capacity by using the formula: (P1 – P2) x (Volume of nitrogen receiver tank in
litres) = capacity in litres per minute. Check the result with the stated capacity in the Design
Review Certificate.

7.4 Pressure Set Point Procedure
The pressure in the nitrogen receiver tank controls start and stop of generator in auto mode.
1. Determinating the nitrogen receiver tank peak pressure P1:

a. Switch generator to manual mode
b. Shut off nitrogen consumption.
c. Let the generator run for 10 minutes or more.
d. Read and note the maximum nitrogen receiver pressure during this period. This is the
peak pressure P1.
2. Calculating stop set point pressure and restart hysteresis set point:
e. Calculate the stop set point pressure P2 by subtracting 0.05 bar from peak pressure P1.
P2 = P1 - 0.05.
f. The hysteresis set point (normal value 0.5 bar) controls when the generator restarts.
Example: Measured peak pressure P1: 6.50 bar

Stop set point pressure P2 = P1 - 0.05 = 6.50 - 0.05 = 6.45 bar
With hysteresis set to 0.5 bar the generator will restart when the pressure in nitrogen
receiver tank has decreased 0.5 bar. Restart at = P2 - 0.50 = 6.45 - 0.50 = 5.95 bar
How this start and stop process is adjusted and controlled depends on generator control system type.
The above mentioned nitrogen receiver pressures must be read out and adjusted according to
system.
For generators equipped with standard control system refer to section 7.5.
For generators equipped with small or large touch screen control system refer to the separate control
system manuals in appendix.
7.5 Pressure Switch Adjustment

On models with standard control system the pressure switch controls when the generator stops and
starts in auto position.
The SMC pressure switch reads out in Mpa (mega Pascal) or bar. 0.1 MPa = 1.0 bar
With controls set in auto mode the pressure switch is from factory set to turn off the generating
process at approx. 6 - 7 bar(g) and to start up again when pressure in nitrogen receiver is decreased
0.5 bar.
1. To adjust settings:
Press “⇑” for 2 seconds until display flashes

Press “SET” until display flashing shows “n-1”
Use “⇑” or “⇓” to change upper set point
Press “SET” until display flashing shows “H”
Use “⇑” or “⇓” to change lower set point
n-1 is limit for when the generator stops cycling because receiver is full.
H is the hysteresis that is deducted from n-1 to start generator at lower receiver pressure.

Oxymat recommend that there is approx. 0.5 bar hysteresis between auto start and stop
WARNING: A changing to a higher set point may result that the generator will not stop
automatically.
It is recommended to swift to manual position when requiring nitrogen with a very high
concentration.
Refer to section 7.4 for set point procedure.
7.6 Probe Check and Calibration

Only Oxymat Nitrogen Generators with touch screen control system have a probe for monitoring the
purity of produced nitrogen.
Oxymat Nitrogen Generators with standard control system does not have purity measurement as a
feature.
Procedure for checking the probe depends on the type of probe fitted.
See probe type on information label inside control panel.
If present the probe module is placed in the lower control cabinet.
Zirconium OEM probe:
WARNING: The entire probe module and especially the heater block can get very hot.
Touching these parts may cause burns. The module can still be very hot even after the module
has been turned off. Always wait for at least 30 minutes before touching the module.
IMPORTANT:
- Do not touch the sensor’s ceramic probe.
- Do not blow cold air or gas onto the sensor when it is warm.
- Do not bend or tear the twisted steel pipe.
- The measuring gas must be pure and dry. Use a filter on the ingoing gas if needed.

For reference use a gas with known content of nitrogen and with minimum 98.5 % nitrogen e.g.
industrial nitrogen 99.7 %.
1. Go to purity reading mode on control system display.

2. Detach the gas inlet hose from the reduction valve by the probe.
3. Gently flow known reference gas in the gas inlet of the reduction valve. Maximum pressure 1
bar.
4. Read the purity on display.
If readout corresponds to the applied gas, reconnect the gas inlet hose to the reduction valve by the
probe.
If readout does not correspond to the applied gas the probe should be replaced or calibrated by an
authorised company. Contact Oxymat A/S or your local Oxymat representative for further
information.
Electro galvanic probe:

Before checking the probe it shall have the same temperature as the environment and the reference
gas. It can take up to an hour depending on the temperature difference.
For reference use a gas with known content of nitrogen e.g. industrial nitrogen 99.7 %.
1. Go to purity reading mode on control system display.

2. Detach the gas inlet hose from the probe.
3. Gently flow known reference gas in the probe gas inlet . Maximum pressure 1 bar.
4. Read the purity on display.
If readout corresponds to the applied gas, reconnect the gas inlet hose to the probe inlet.
If readout does not correspond to the applied gas the probe should be calibrated or replaced
Refer to separate control system manual for probe calibration procedure.
Contact Oxymat A/S or your local Oxymat representative for further information.
7.7 Purging procedure

To obtain the design purity in nitrogen receiver purge the tank with nitrogen as follows:
1. Check that nitrogen consumption is closed off.

2. Open up for flow from feed air supply/compressor.
3. Start the feed air supply/compressor.
4. Start the generator and let it run for about 15 minutes.
5. Check that pressure in nitrogen receiver reaches the value stated in Design Review Certificate.
6. Open for nitrogen consumption. Adjust flow to approximately to 50 % of design flow (refer to
Design Review Certificate).
7. Let the generator run in manual mode until design purity is reached. Duration 0.5 - 8 hours
depending on purity and capacity.
8. When design purity is reached close off nitrogen consumption switch generator to auto mode
and let the generator run until it stops automatic. This should occur within 10 minutes. If the
generator does not stop as described refer to section 7.4 for pressure set point procedure.

Scrapping
8.1 Dismounting
By the time when the equipment is no longer in use - dismount as follows:
- Disconnect, remove and collect all wires into a wire scrap pile
- Dismount, remove and collect all electronics into an electronics scrap pile
- Disconnect, remove and collect all hoses and other plastics into a plastic scrap pile
- Empty absorbers from the molecular sieve, and fill it into bags.
- Dismount all pipes and sort all metal parts into steel or Cu scrap piles.
- Collect all organic, flammable materials into a separate scrap pile.
Dispose the different categories of waste in a via designated collection facilities appointed by the
government or local authorities according to local regulations. Correct disposal and recycling will
help preventing potential negative consequences to the environment and human health.
8.2 Disposal
The molecular sieve is a non toxic organic material, which can be disposed along with the rest of
sorted scrap. However the disposal must be done according to national and local laws and rules.
Refer to material safety data sheet for correct handling of molecular sieve and proper personal
protection.


N2 Manual Version 2009 11 30

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

N2 Manual Version 2009 11 30

Uploaded by

Copyright:

Available Formats

Oxymat A/S :: Fasanvej 18-20 :: DK-3200 Helsinge :: Tel. +45 4879 7811 :: Fax +45 4879 7813 :: www.oxymat.

Nitrogen Generator Systems

N-040 N-350 N-2650 N-6500

Manufacturer of On-site Oxygen and Nitrogen Generator Systems

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 2

Appendix A Piping Diagram.........................................................................................................

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 3

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 4

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 5

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 6

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 7

3. Warning: See WARNINGS AND IMPORTANT INFORMATION.

4. INLET - FEED AIR: Connect to feed air supply.

6. WARNING – NITROGEN Avoid inhalation of gases. See WARNINGS AND IMPORTANT

8. Warning: Voltage. See WARNINGS AND IMPORTANT INFORMATION.

9. Warning: Tip over hazard. See WARNINGS AND IMPORTANT INFORMATION.

10. Information of control system and requirements.

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 8

1.2 Product warranty

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 9

1. The Model Number of the Generator

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 10

Table 2.1 - Nitrogen delivery.

Dew point (all models): -70°° C

1.0 Sm³/h = 1.147 kg/hour = 16.7 litres/minute

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 11

Feed air supply needed for above listed nitrogen delivery

Table 2.2 – Feed air supply.

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 12

Figure 1 - Flow Schematic for Oxymat Nitrogen Generators

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 13

Figure 2 - Schematic P/T- diagram for OXYMAT Nitrogen Generators

Normal Process Sequence per column (refer to fig. 1 & 2 above):

B: Pressure equalization (decreasing pressure). Valves V51 & V52 activated

D: Pressure equalization. Valve V51 & V52 activated

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 14

3.2.1 Generator Parts (Refer to Figure 3)

Figure 3 - Generator Parts

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 15

3. Cycle Pressure Gauge

4. Axial valve for equalization of pressure

5. Axial valves for cycle operation

6. Valve for delivery of nitrogen to nitrogen receiver

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 16

8. Feed Air Inlet

9. Control Valve Block (Solenoid Valves)

10. Safety relief valves

11. Exhaust pipe

Blow processed air.

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 17

FRONT BACK SIDE

Figure 4 - Receiver Parts

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 18

3.3.1 Generator Connections (Refer to Figure 4 and 5a, 5b or 5c)

17. Air Inlet

Air Inlet: Pipe/Hose Connections

Table 3.1 – Air inlet connections.

18. Condensate Outlet (Refer to figure 7a and 7b)

This port must not be plugged.

Oxymat A/S • Fasanvej 18-20 • DK-3200 Helsinge • Denmark 19

Connections from generator to nitrogen receiver

Table 3.2 – Connections from generator to receiver.