Nitrogen generators (commonly PSA or membrane separation nitrogen generators) may malfunction during operation due to improper operation, component aging, or environmental factors. The following are common fault phenomena, cause analysis, and solutions for reference:
I. Decreased Nitrogen Production
1. Cause Analysis
- Insufficient air compressor output pressure or volume.
- Clogged air pretreatment system (filter, refrigerated dryer), resulting in poor intake air quality.
- Aging, pulverization, or poisoning (oil/water contamination) of the carbon molecular sieve (PSA models).
- Valve (solenoid valve, pneumatic valve) leakage or abnormal switching.
2. Solutions
- Check air compressor operating parameters to ensure the output pressure meets requirements (usually 0.6~0.85MPa).
- Replace clogged filter elements (such as precision filters, activated carbon filters).
- PSA models: Check the carbon molecular sieve; replace it if it is ineffective; if poisoned by oil contamination, it needs to be regenerated or cleaned.
- Check valve sealing, clean valve core impurities, or replace damaged valves.
II. Nitrogen Purity Failure
1. Cause Analysis
- Incorrect adsorption tower switching time setting (PSA model).
- Inlet gas contains oil, water, or impurities, contaminating the adsorbent or membrane module.
- Purity analyzer malfunction or calibration deviation.
- Leakage in nitrogen outlet pipeline.
2. Solutions
- Adjust adsorption/desorption cycle time (refer to equipment manual or contact manufacturer).
- Check pretreatment system, ensuring the refrigerated dryer and filter are working properly and removing oil and water.
- Calibrate or replace the purity analyzer sensor.
- Use soapy water to check pipeline connections and repair leaks.
III. Abnormal Nitrogen generators Pressure
1. High Pressure Alarm
Cause: Exhaust valve blockage, valve not opening properly.
Solution: Clean valve or check control signals to ensure unobstructed exhaust.
2. Low Pressure Alarm
Cause: Insufficient air supply from air compressor, pipeline leak, filter blockage.
Troubleshooting: Check the air compressor outlet pressure, repair leaks, and replace the filter element.
IV. Abnormal Noise or Vibration in Nitrogen generators
1. Cause Analysis
- Wear or internal fault in the air compressor bearings.
- Loose or collapsed carbon molecular sieve inside the adsorption tower (PSA models).
- Loose piping or mechanical parts.
2. Solutions
- Stop the air compressor and inspect it; replace worn parts.
- Replenish or replace the carbon molecular sieve, ensuring even compaction during filling.
- Reinforce pipe supports and tighten bolts.
V. Automatic Control System Failure
1. Symptoms
- PLC program malfunction, no display on the touchscreen, abnormal sensor signals.
2. Solutions
- Restart the control system and check the power supply and wiring.
- Replace damaged sensors (such as pressure sensors and flow meters).
- Contact the manufacturer to update or restore the control program.
VI. Other Precautions
1. Daily Maintenance Recommendations
- Replace the filter element regularly (recommended every 3-6 months).
- Monitor the lifespan of the carbon molecular sieve or membrane module (typically 3-5 years).
- Record operating data (pressure, purity, flow rate) for easy fault prediction.
2. Safety Precautions
- Always depressurize before shutting down for maintenance to avoid injury from high-pressure gases.
- Avoid operating the equipment in high-temperature, high-humidity, or dusty environments.
If the fault cannot be resolved independently, it is recommended to contact the equipment manufacturer or a professional maintenance personnel. Different nitrogen generator models have significant design differences; please refer to the equipment manual for operation.
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Post time: Dec-06-2025
