TL Series — Startup & Commissioning – South-Tek Systems

Applies to: N2-GEN Arc Suppression — TL Series · TL-450 · TL-1050 · TL-450-Plus · TL-1050-Plus · TL-1825 · TL-1725

Follow this procedure to commission the generator after it has been installed and all lines have been leak-checked. Notify personnel in the area before start-up, and make sure the start-up will not interfere with other operations. The steps differ by controller, so use the section that matches your unit.

▲ Warning Check for leaks in all fittings and valves during start-up. Shut off the air supply and depressurize the system before repairing any leak.

Initial start-up: TL-450 and TL-1050 (PLC)

With all connections complete and leak-checked, turn on the power switch and open the nitrogen outlet ball valve to the storage tank. The compressor starts and begins filling the tank, and the controller shows Run in green.
If you hear a leak or a bad connection, turn the system off, isolate and fix it, then restart.
The system fills the storage tank to about 70 PSIG, then enters Standby (Stdby, amber) and the compressor stops.
When nitrogen is drawn and the tank falls below the cut-in pressure (about 62 PSIG), the system returns to Run and recharges the tank. The pressure switch is factory preset and needs no field adjustment.

PLC controller display showing Run and Standby states

Initial start-up: Plus, TL-1825, and TL-1725 (HMI)

On external-air units (TL-1825, TL-1725), start the air compressor per its manufacturer's instructions and, once the air receiver reaches its design pressure, open the air valve to the generator. On Plus units the compressor is integral and runs when the generator starts.

Verify the power connection is 110 V or 220 V / 1 PH / 50–60 Hz as labeled on the unit, and confirm the touchscreen is in the Stopped mode (the Start/Stop button on the Home screen is red).
Bring up the air supply as described above and confirm air is reaching the generator.
Open the nitrogen supply out to the storage tank and the gas sample valve from the tank to the generator. Keep the nitrogen-to-process valve closed for now.
Toggle the Start/Stop button to green. The generator should start cycling through the valves and pressurizing.
Observe the pressure gauges for 10 minutes. The pressure should swing from bed to bed every 50 to 90 seconds. A fully pressurized bed should reach within 3 to 5 PSIG of the other bed (or of the incoming air supply pressure on external-air units), and while one bed pressurizes the other should exhaust.
Nitrogen flows to the storage tank and builds pressure. At the cut-out pressure the system enters Standby, shown on the Home screen, and production pauses.
With the system in Standby, open the nitrogen-to-process valve. The tank pressure falls, and at the cut-in pressure the system automatically restarts and refills the tank.

HMI home screen showing Standby and Running states

Note: Initial pressurization can take up to one hour to reach 65–75 PSIG on Plus units. If you are starting from 0 PSIG, holding the tank at about 60 PSIG for roughly six hours is recommended to purge atmospheric gas. On any first start-up or after a prolonged shutdown, the first few cycles may be below design purity until the beds rebalance.

Normal start-up (HMI units)

Open the air isolation valve.
Toggle the Start/Stop button to start (illuminated green).
Open any shutoff valves in the product nitrogen line to the process, and allow the system purity to rise before drawing product. If the generator or any part of the system has been open to the atmosphere, purge the residual air first.

Commissioning checks

Before handing the system over, confirm it is operating to specification:

Beds swing every 50 to 90 seconds, with one bed pressurizing while the other exhausts.
Nitrogen purity rises to the design specification once the beds rebalance.
No leaks at fittings, valves, or filter bowls.
The system reaches the cut-out pressure, holds in Standby, and restarts at the cut-in pressure.
Alarms function: test BlastOff on PLC units, and confirm the O2 and low-pressure alarm setpoints on HMI units.
Record baseline values while the system is healthy: fill time to cut-out, cycle (bed-swing) time, delivered purity, and the pressure-decay rate with the unit stopped and isolated. These baselines make later deviations easy to spot and are the fastest way to catch a developing leak or capacity loss.

Shutdown

Normal shutdown: close the nitrogen-to-process valve on the output of the storage tank, then stop the unit (toggle Start/Stop to off on HMI units; on PLC units, closing the gas-line valves is sufficient and powering down is not required).
Emergency shutdown: turn off the main power switch to stop all generator functions immediately, and close the nitrogen-to-process valve to shut off the nitrogen supply.

▲ Warning The generator remains pressurized after shutdown. Always depressurize the system before performing maintenance or opening any piping. Failure to do so may result in injury.

Need help? South-Tek Systems Service — Phone: (910) 415-1880 · Open a support ticket at support@southteksystems911.zendesk.com or through the Help Center.