TERRA UNIVERSAL Nitrogen Generator Installation Guide
- June 8, 2024
- TERRA UNIVERSAL
Table of Contents
TERRA UNIVERSAL Nitrogen Generator
Nitrogen Generator
© Copyright 2021 Terra Universal Inc. All rights reserved. • Revised September
2021
Your Comprehensive Equipment Sourcee
Installation and Operating Guide
Proprietary Notice
This manual pertains to proprietary devices manufactured by Terra Universal,
Inc. Neither this document nor any portion of it may be reproduced in any way
without prior written permission from Terra Universal.
Safety Notice
A thorough familiarity with all operating guidelines is essential to safe
operation of the product. Failure to observe safety precautions could result
in poor performance, damage to the system or other property, or serious bodily
injury or death.
The following symbols are intended to call your attention to two levels of hazard involved in operation:
The information presented here is subject to change without notice.
Terra Universal makes no warranties applying to information contained in this manual or its suitability for any implied or inferred purpose. Terra Universal shall not be held liable for any errors this manual contains or for any damages that result from its use.
Cautions are used when failure to observe instructions could result in significant damage to equipment.
Warnings are used when failure to observe instructions or precautions could result in injury or death.
Introduction
This manual provides information on installing and operating your Terra
Nitrogen Generator.
By studying this document carefully, you can be assured of a long, efficient
service life from your system.
Description
Terra Universal’s Nitrogen Generator is designed to provide reliable dry
nitrogen without the expense and inconvenience associated with bottled
systems. It uses efficient membrane separation technology to generate nitrogen
from compressed air (see the chart below for typical system performance).
The system contains a gas pressure regulator and indicating gauge, a
flowmeter, a 1-micron air-line coalescing prefilter, a 0.01-micron air-line
coalescing filter, and the air separator membrane module. The prefilter
removes all solids 1 micron and larger, along with water droplets and most oil
aerosols. The coalescing filters remove solids 0.01 microns and larger and
99.999+% of oil aerosols, thereby protecting the membrane module from oil and
other impurities in the incoming air-line and ensuring a long service life.
Oil and moisture condensation from the prefilter and coalescing filters exits
the system through a 1/4″ slip-fit connector that can be directed to an in-
house drain.
Set-Up and Operation
Before operation, carefully unpack and inspect the Nitrogen Generator. Any damage should be reported immediately to the shipping company.
To prevent dangerously low oxygen levels and risk of asphyxiation, nitrogen- purged systems should only be installed in a well-ventilated area.
Connecting and Operating the System
- With the pressure regulator (counter clockwise rotation) and flowmeter (clockwise rotation) completely closed, connect the Nitrogen Generator to an incoming compressed air line by means of the 3/8” (5/8” for Cat. #2700-09B) inlet slip fitting on the top panel. The compressed air fed into the Nitrogen Generator should be regulated externally between 100 and 200 psi (For maximum purity, choose the highest inlet pressure possible.)
- Connect the nitrogen outlet by means of the other 3/8″ (5/8” for Cat. No. #2700-09A) quick connect fittings on the top panel.
- Open regulator (completely clockwise) and flowmeter (completely counterclockwise) to allow unrestricted flow at full line pressure. The outlet pressure will drop roughly 20-30% from the inlet pressure as the compressed air flows through the membrane. Flow and purity are determined by adjusting either the pressure regulator or flowmeter.
If consistent outlet pressure is required, set the pressure regulator at the desired level and then adjust the flowmeter to achieve the desired flow at your selected pressure. The lower the outlet flow rate at any outlet pressure level, the higher the product purity. The higher the inlet pressure at any inlet flow rate, the higher the product purity.
The light-up TUI logo serves as status indicator for inlet pressure. The LED
emits a solid-color glow under normal conditions and flashes if it detects
that the compressed air feed falls below the set-point (normally at 20 PSI).
This light is 120VAC powered and included as a convenience.
Electricity is not required for the generator to extract nitrogen from
compressed air.
Refer to flow tables on following pages for guidelines on typical purities achieved at varying pressures and temperatures. Conduct purity tests to determine the settings that meet your specifications.
Initial Calibration
The frequency at which to replace pre-filters will vary depending on your
application and system set-up. To help determine the frequency for your
system, check the pre-filter every three months until the color indicator on
the pre-filter turns yellow, which signifies that it’s time to replace it with
a new pre-filter. Use the elapsed-time data from this procedure to set up a
filter maintenance schedule that corresponds to your workflow. By doing this,
the membrane filter will last indefinitely.
Maintenance
The membrane module inside the Nitrogen Generator is designed to operate maintenance-free as long as the prefilter and coalescing filters effectively remove impurities (particularly oil vapor) from the feed air.
A slide indicator on these filters changes color (from green, to yellow, and then to red) when the filter element inside either unit needs to be replaced (see Figure 1). This indicator should be monitored monthly. Under continuous use at 100 PSI, filters will operate for approximately two years (20,000 hours).
Replacing Filter Elements
- Open the front housing panel of the Nitrogen Generator to expose the filters (see Figure 1).
- Rotate the self-locking bayonet head 1/8 turn counterclockwise to release it from the bowl (see Figure 2).
- Pull the filter element to release it from the head. Remove the bottom filter element cap.
- Attach the bottom cap to the replacement filter element and push it into the filter head until it locks in place.
- Rotate the filter head 1/8 turn clockwise to reattach it to the filter bowl. Close the front panel.
Replacement Filter Elements
Cat. #
- 1-micron Prefilter 2700-15
- 0.01-micron Coalescing Filter 2700-16
Nitrogen Membrane
- For Model 2700-09B 2700-36
- For Model 2700-11B 2700-37
- For Model 2700-12B 2700-38
Specifications and Performance Data
- 2700-09B 24”W x 14”D x 68.25”H
- 2700-11B 24”W x 12”D x 49.25”H
- 2700-12B 20”W x 12”D x 35.25”H
- 157 lbs. 0 – 400 SCFH
- 96 lbs. 0 – 100 SCFH
- 58 lbs. 0 – 20 SCFH
Includes polypropylene leveling feet; excludes other hardware.
- Housing: Powder-coated white CR steel cabinet with polyethylene leveling feet
- Feed Air Pressure: 200 PSIG MAX
- Feed Air Temperature: 40°F to 122°F
- Nitrogen Outlet Flow: See graphs on page 5.
- Prefilter: One-micron absolute filtration. Dual glass micro-fiber filter beds coalesce and remove water droplets. Remaining oil content: 1 ppm by weight. Includes slide indicator (to indicate need for filter change), liquid level indicator and internal drain. ISO 8573.1 Quality Class – Solids: Class 2, Oil Content: Class 4
- Coalescing Filter: Absolute filtration of 0.01μm particles; 99.999+% oil removal efficiency. Includes slide indicator (to indicate need for filter change), liquid level indicator and internal drain. ISO 8573.1 Quality Class – Solids: Class 1, Oil Content: Class 1
- Membrane Module: Semipermeable hollow fiber bundles.
- Electrical: Power not needed to generate nitrogen, but low-pressure indicator light requires 120VAC. User-supplied air compressor may require electricity.
Nitrogen Flow Rate and Air Feed Required In SCFH
Operating conditions: 14.7 psi (1013 mbar) @ 20°C (68°F)
Notes: 1. Terra’s nitrogen generating membranes separate oxygen from pressurized air. The composition of the product is determined by measuring the residual oxygen content. The nitrogen content is calculated by subtracting the residual oxygen content from 100 %. Air is composed of nitrogen (78.1%), oxygen (20.9 %), Argon (0.9 %), CO2 (0.03 %), and some trace inert gases. Therefore it should be born in mind that the value that is normally called the nitrogen content actually is the inert gas content.
Operation with 3-5HP Oilless Air Compressors
The efficiency of our nitrogen generators can be improved by installing an additional 30 gal. external tank to the 3HP air compressor units and an additional 60 gal. external tank to the 5HP units. The external tanks are mandatory in order to achieve the rated specs. Without an external tank, N2 generator will lose pressure much faster and reduce the nitrogen output. For instance, if the nitrogen generator is set to the minimum of 53 Psi output, the pressure will drop below 45 psi within 15-20 minutes of use and the compressor will not be able to keep up with the nitrogen generator output and will keep losing pressure.
Warranty
Products Manufactured by Terra: Terra Universal, Inc., warrants products that it manufactures to be free from defects for a period of 12 months for parts and 90 days for labor, commencing from the date of shipment. This limited warranty covers parts and labor, but not transportation and insurance charges. Terra’s sole responsibility is to repair or replace, at its option, any part of the product that proves defective or malfunctioning during this time limit. In some cases, components incorporated in Terra Universal products are covered by additional warranties from component manufacturers; obtain specific information from Terra sales representatives. Repairs may be completed by 3rd party service agents approved by Terra Universal. Terra Universal reserves the rights to limit this warranty based on a service agent’s travel, working hours, the site’s entry restrictions and unobstructed access to serviceable components of the product.
This warranty is void if the equipment is abused or modified by the customer, is operated outside Terra’s operating instructions or specifications, or is used in any application other than that for which it is specified. This warranty does not include routine maintenance or service procedures, shipping damage, nor damage from misuse, intentional or unintentional abuse, neglect, natural disasters, or acts of God.
Products Manufactured by Others: Terra Universal, Inc., warrants that, to the best of its ability, Terra’s representations of products that are manufactured by others reflect the manufacturer’s representations, subject to change without notice. Sole warranty for these products is the original manufacturer’s warranty that is passed forward to the purchaser and constitutes the customer’s sole remedy for these products. Detailed warranties for distributed products are available through Terra sales representatives.
Freight Shortage or Damage: Upon receipt of any equipment from Terra Universal, Inc., customer shall immediately unpack and inspect for damage or shortage. The customer shall not accept a damaged package or a short shipment until the carrier makes a “damage or shortage” notation on both the carrier’s and customer’s copy of the freight bill or delivery receipt. Service title passes when the shipment is loaded, so customer is responsible for filing and collecting a freight claim. Any replacement products must be ordered and paid for separately. For Terra’s “Policy and Procedures for Returning Goods,” see Terra’s Internet site: www.TerraUniversal.com.
Generally, customers can improve the chance of collecting on a freight claim by following these procedures:
- formally requesting that the carrier inspect the shipment immediately upon suspecting damage or shortage to verify condition;
- notifying the carrier upon discovery of concealed damage and requesting an inspection within 15 days of receipt, both in person or phone and following up via mail;
- keeping the shipment as intact as possible, including retaining original packaging materials and keeping the product as close to the original receiving location as possible;
- holding salvage for disposition by the carrier. All Claims: Terra Universal expressly disclaims all other warranties, expressed or implied or implied by statute, including the warranties of merchantability or fitness for intended use. Terra Universal is not responsible for consequential or incidental damages arising out of the purchase or use of the products supplied by Terra Universal. Terra Universal is not liable for damage to facilities, other equipment, products, property or personnel of others, or of their agents, suppliers, or affiliated parties, which is caused or alleged to have been caused by products supplied by Terra Universal. In any event or series of events, Terra Universal’s total liability for any and all damages whatsoever is limited to the lesser of the actual damages or the original invoice cost of the items alleged to have caused the damage.
The customer’s sole and exclusive remedy for any cause of action whatsoever is repair or replacement of the non-conforming products or refund of the actual purchase price, at the sole option of Terra Universal. All claims must be made in writing within 90 days of the date the product was shipped. Any claims not made within this time limit shall be deemed waived by the customer. Terra Universal is not responsible for any additional costs of repair caused by poor packaging or in-shipment damage during return.
Warranty Returns: All warranty returns must be authorized in advance by Terra Universal and approved under an RMA. Unless approved in advance for good reason, all returns must be in original condition, including all manuals, and must be packaged in original packaging materials. All returned goods are to be shipped to Terra Universal, freight prepaid at customer’s expense. See Terra’s “Policy and Procedure for Returned Goods.
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Terra Universal, Inc. • TerraUniversal.com • 800 S. Raymond Ave. • Fullerton, CA 92831 • TEL: 714-578-6000 • FAX: 714-578-6020
References
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- Terra Universal - Cleanrooms, Pass-Throughs, Hoods, Desiccators, Gloveboxes