USER MANUAL - ANS America
Contents
1. 4 Ensure that this connection is fully tightened ANS Nitrogen Manual 4 5 STEP 2 Connecting the Outlet Connections e WALL Step 2a e FLOOR Step 2b Advantage Nitrogen System Options Chart Advantage Nitrogen System Option FLOOR MOUNT WALL MOUNT XA Storage Tank ST X STEP 2a Connecting the Outlet Connections Wall Unit 1 Connect Outlet to a Storage Tank right hand side of generator 2 Connect a Tire Inflation hose not Included to the Outlet of the Storage tank 3 Go to Section 6 for Start Up Plugged port STEP 2b Connecting the Outlet Connections Floor Mount 1 Connect the tire inflation hose to the outlet of the Advantage Nitrogen System right side 2 Go to section 6 for start up ANS Nitrogen Manual 15 5 5 Adjusting the pneumatic pressure switch The pressure switch PSH is factory preset such that the Advantage Nitrogen System switches off when there is no consumption and that it switches back on when there is consumption of nitrogen Note that the pressure switch will always leak a small amount of air Note All Advantage Nitrogen System models are set at 130 psig Important If operation is required at storage condition other than factory set point Adjusting the pressure switch set point is required for proper operation e If the switch set point is set too high the supply will never turn off and the compressor will run constantly e Ifitis set too low the Advantage N2. ANS America USER MANUAL Advantage Nitrogen Generator Models ANS021 ANS051 ANS076 ANS123 ANS America Corporation 1112 North Collier Boulevard Marco Island FL 34145 Tel 239 394 6099 Fax 239 394 5388 www ans america com Copyright 2007 ANS America Corporation 1 Introduction 1 1 General The Advantage Nitrogen System is a product of ANS America Corporation This manual forms an integral part of the product The manual describes the daily operation maintenance required and troubleshooting techniques if necessary Content Read the manual carefully before you start Operation of the Advantage Nitrogen System Familiarize yourself with the content Condition of change Only execute changes to the ANS Nitrogen System after explicit prior written permission by ANS America Corporation Non conformance to this rule as well as any consequential damage loss and costs are the responsibility of the owner and the user Information All information in this manual including additional drawings and technical descriptions remains the property of ANS America Corporation and may not be used other than for the use of this product copied multiplied or published to or for a third party without explicit prior written permission by ANS America Corporation 1 2 Pictograms in this manual In this manual the following pictograms are used Warning A warning shows a hazard that can cause death or serious injury Follow the
3. 6 Operation 6 1 Start up of Advantage Nitrogen System 1 Open the compressed air supply 2 Set inlet pressure per specification 3 Allow Tank to Fill NOTE If given purities are not achieved drain tank and retake steps 6 1 1 through 6 1 5 until readings are achieved 6 2 Operating the Advantage Nitrogen System 6 2 1 Floor mount model N o Loa A y Outlet Hook up the outlet connection to tire Inflate in the same manner as air Check pressure during fill po pe 6 2 2 Wall mount model N Outlet Storage Tank 4 Hook up the following outlet connection to tire 5 Inflate in the same manner as air 6 Check pressure during fill ANS Nitrogen Manual 18 6 3 Stop operation of Advantage Nitrogen System 1 Shut off the compressed air supply before you perform maintenance 2 Depressurize the system by venting the nitrogen outlet 3 Ensure that the system is fully depressurized by checking the pressure gauge TIP should the filters not be fully depressurized it is possible to depressurize them manually by slowly unscrewing the bleed screw on the bottom of the filter bowl on one of the filters Prior to reinstalling the bleed screw after venting ensure the o ring is seated properly It may be necessary to vent the filters all the way down to atmospheric pressure so that the o ring will seat 7 Maintenance Change Maintenance Kit Part Number ANS021
4. 1 carbon dioxide water vapor and some traces of inert gasses Pressurized air A is fed through the hollow fiber membrane B The various air components diffuse through the wall of the membrane The diffusion rate differs for the various gasses Oxygen and water vapor have a high diffusion rate and permeate rapidly through the membrane wall Nitrogen has a low diffusion rate and permeates slowly through the membrane wall At the exit of the membrane C pressurized nitrogen is released 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 The Nitrogen produce by the Advantage Nitrogen System should be stored in a storage vessel The storage vessel acts as a buffer for the Advantage Nitrogen System and is needed for proper operation of the auto shutoff feature The Advantage Nitrogen System shutoff feature will switch on and off depending on the nitrogen demand ANS America Corporation can provide the storage vessel as well as proper sizing if required ANS Nitrogen Manual 5 3 3 Process parameters The nitrogen production depends on these parameters Flow rate The lower the flow rate of compressed air through the hollow fiber membrane the more oxygen can permeate through the membrane wall As a result the nitrogen produced at the outlet will have a higher purity Nitrogen purity can be adjusted upward with
5. L1386 11169 L1386 Inlet Pressure Gauge Pressure Inlet Pressure Gauge a ER EE Fa BXFLTER BOK0292 Second Stage Fitraon Separates the O2 and water vapor from M1 Gas Separation Membrane NA Compressed Air FCV Flow Control Valve 5582 L1386 Sets the capacity amp N2 purity v2 Check Valve BO4 0345 0345 Isolates Downstream Isolates Downstream Check Valve Valve PSH Pressure Switch E dd On Off Control Controls V1 Pl 2 Pressure Gauge 11169 L1386 Outlet Pressure Gauge DPS 1 Test Point for Test Gauge For Service Only Nitrogen Storage Tank Min 30gal Buffer for Automatic Shut Off ANS Nitrogen Manual 7 MODELS ANS051 ANS076 ANS123 Valve Stem Port on Front gt OUT Standard Outlet F1 Is the only Filter with the DPI indicator IST Storage Tank PART CODE DESCRIPTION NUMBER OPERATION Pi Pressure Gauge Pressure Gauge 11169 11169 1386 _ Inlet Pressure Gauge Pressure Inlet Pressure Gauge mE DX FILTER With DPI Indicator uu DX First Stage Filtration m exrurer AS Second Stage Fitration Fa BXFte COANOAO BX Particulate Frio CH lieu NUN E Gas Separation Membrane Separates the O2 and water vapor from Compressed Air Flow Control Valve 5582 L1386 Sets the capacity amp N2 purity B Non Return Valve 75543 L1452 Isolates Downstream Check Valve PSH Pressure Switch IE See O
6. Mounting Plate a Loosen the four screws located on the male plate on the Advantage Nitrogen System b Carefully Drop in system onto the Wall plate as shown below and lock the four Philips screws as shown below 2 Philips screws located on left and right side of the male mounting plate FLOOR 7 It is recommended to install a drip leg on the inlet side of the system to catch loose particles and liquid water in the piping system Consult a local plumber for assistance if needed ANS Nitrogen Manual 13 5 4 INSTALLATION STEP 1 Connect Inlet Connection Warning e Make sure that the inlet and pipe are free of dust particles metal parts and curls liquids and grease before you connect the Advantage Nitrogen System 1 Ensure that a drip leg is installed and equipped with a drain system Drain out drip leg as needed to prevent any water getting into the inlet of the Advantage Nitrogen System 2 Install shut off valve and regulator as shown below NOTE Ensure that these components are as close to the inlet of the Advantage Nitrogen System as possible Regulator Compressed Customer Supplied Alt with Pressure Gauge LL Product N2 ANS GENERATOR shut Off valve Custamer Supplied Drip Leg Customer Supplied i 3 Connect the compressed air supply into the inlet of the Advantage Nitrogen System Y connection left hand side of generator PSH See section 5 7 for more information
7. instructions Caution A caution shows a danger that can cause damage to the equipment Follow the instructions Warning Risk of death due to suffocation A of fire Oxygen enriched air leads to an increased risk of fire in the event of contact with inflammable products High pressure risk Follow the instructions with respect to compressed gasses SY A WV AF instructions with respect to the environment 9 ANS Nitrogen Manual 1 1 3 Identification and service The identification plate is located on the left side of the Advantage Nitrogen System and shows its characteristics For service and technical assistance please contact ANS America Corporation 1112 North Collier Boulevard Marco Island FL 34145 239 394 6099 phone 239 394 5388 fax WWW ans america com 1 4 Use in accordance with purpose The ANS nitrogen generator is intended to make nitrogen out of normal ambient air The system is based on gas separation membrane technology Each different or further use will not be in conformity with this purpose ANS America will not accept any liability for improper use Only use this Advantage Nitrogen System in a technically perfect condition refer to section 5 2 in conformity with the purpose as described above 1 5 User instructions Only properly trained personnel are allowed to work on the ANS nitrogen generator The user must be aware of hazards related to operating the Advantage Nitrogen Syst
8. 000 Quality System Certified Em WWW ans america com ANS Nitrogen Manual 2
9. MKANS021 1Y Filter F1 Filter F2 ANSO051 ANSO76 ANS123 Table 7 1 Maintenance scheme Spare Parts List Part Number Inlet Outlet Pressure Gauge 11169 L1386 Pressure Switch Assembly B04 0333 Replacement Bowl Drain Assembly C02 2384 Check Valve B04 0345 Pressure Relief Valve B02 0434 Table 7 2 Spare Parts List ANS Nitrogen Manual 19 7 1 Removing Top Front Access Panel NOTE This ts required in order to replace the dust filter and carbon module CAUTION Ensure air supply is shut off and the system is not pressurized 1 Located on the back of the system there are qty 4 7 16 hex bolts that secure the Top Front Access Panel to the unit a Screws are located on the back side of the system Fig 7 1 ANS Nitrogen Manual 20 7 2 Replace filter element Fig 7 2 Replace filter element 1 Turn off the air supply 2 Let the system depressurize until the pressure gauge at Fig 3 4 1 or 3 4 2 Pl1 reads O0 psi 3 Unscrew the bleed screw F slowly to ensure that the filter is depressurized 4 Turn the filter bowl E counter clockwise and pull the bowl from the filter housing A 5 Unscrew the blue knob D 6 Remove the old filter element C 7 Clean the sieve B and the filter house if necessary 8 Install a new filter element C 9 Assemble the parts in the reverse order ANS Nitrogen Manual 21 7 3 Clean automatic drain 1 Open the filter by untwi
10. T 3 Teflon pipe seal tape or other suitable thread sealant for the NPT thread connections 4 It is required for the Advantage Nitrogen System floor model to be bolted to the floor if removed from pallet If left on pallet make sure floor is level ANS Nitrogen Manual 11 Caution Ensure Advantage Nitrogen System is properly secure and bolted to the floor if removed from pallet If system left on pallet insure it s placed on a leveled floor 1 Floor model can be left on pallet or 2 Bolt to Floor or Wall a Bolt to floor by securing four 3 8 bolts not supplied to the four mounting holes located on the tank s feet Position the generator in the desired location mark hole pattern and drill holes for anchoring the 3 8 bolts see following illustration TOP VIEW 5 Wall Mount Instructions a For wall mounts systems Secure the following plate to a concrete wall concrete block wall or drywall with studs either metal or wood Secure plate to wall with four 4 bolts or screws not supplied b Mount Wall mount bracket roughly around 51 from floor to center of bracket As shown below NOTE It is the customer s responsibility to ensure that the wall mounting is strong enough to prevent any injury or damage to the Advantage Nitrogen System and complies with all local ordinances and building codes WALL WALL PLATE DIMENSIONS FLOOR ANS Nitrogen Manual 12 6 Securing the Advantage Nitrogen System to
11. airs e Do not tamper or experiment with the equipment Do not exceed the technical specifications for the Advantage Nitrogen System 2 2 Compressed air Warning e Ensure that the feed air pressure can not exceed 188 psig Ensure that the equipment and the attendant piping is connected correctly for the pressures required e Depressurize the Advantage Nitrogen System and the connected systems before you disconnect parts of the system The sudden escape of compressed air can cause serious injury or damage 2 3 Nitrogen and oxygen The Advantage Nitrogen System generates nitrogen as a product Oxygen enriched air is released as waste AA Warning e Nitrogen can cause suffocation e Oxygen enriched air leads to increased risk of fire in the event of contact with flammable products Make sure that there is adequate ventilation at all times e Do not install the Advantage Nitrogen System in an area where explosive substances may be present ANS Nitrogen Manual 3 2 4 Safety precautions Warning e Ensure there is sufficient ventilation e Only feed the Advantage Nitrogen System with air e Keep the air feed to the Advantage Nitrogen System clean and free of vapors of organic solvents and other contaminants Do not place the Advantage Nitrogen System ina room where organic solvent vapors may be present e Install the peripheral equipment and piping according to all applicable local regulations ANS America Corporation is not re
12. clockwise and decreased by turning it counter clockwise Be careful with turning the pressure rod counter clockwise If you loosen too much the pressure rod could back all the way out When decreasing the pressure set point turn the pressure rod counter clock wise until the system turns off and then turn counter clock wise another 1 4 of a turn to ensure the compressor will shut off 7 The differential screw does not need adjustment Erroneous setting causes the pressure switch to pop repeatedly Should its setting be changed erroneously reset it as follows A Loosen lock nut 2 B Turn the differential screw clockwise until it can go no further and turn it counter clockwise 1 4 turn Retighten all locknuts being careful not to twist pressure rod Once the set point is adjusted it is important to test the system as follows Allow some nitrogen to vent from the storage vessel e g open a valve slowly until the compressor system turns back on Close the vent source and see if system turns off If so the set point is adjusted correctly retighten lock nut on adjustment screw If the compressor system does not shut off you will need to lower the set point slightly until the compressor system shuts off It is recommended to repeat this test 3 times to ensure that the set point on the pressure switch is set correctly ANS Nitrogen Manual 17
13. em and processes connected to it The user is responsible for the safety of personnel nearby All personnel working on the Advantage Nitrogen System must have free access to the applicable manuals 1 6 Liability ANS America Corporation will not accept any liability if The instructions in this manual are not fully adhered to Replacement parts are used which are not approved by the manufacturer The system is operated incorrectly The system is fed with gases other than air The system is modified without notification and authorization of the manufacturer Maintenance and repair are not carried out according to the instructions ANS Nitrogen Manual 2 2 Health safety and environmental aspects 2 1 General Correct use of the Advantage Nitrogen System nitrogen generator is important for your personal safety and for trouble free functioning Incorrect use can cause damage to the Advantage Nitrogen System lead to incorrect Nitrogen generation and or result in excess air consumption Warning e Read this manual before you start the installation and begin operation of the Advantage Nitrogen System Prevent accidents and damage to the Advantage Nitrogen System Contact your supplier if you detect a problem that you cannot solve with this manual e Use the Advantage Nitrogen System in accordance with its purpose Only service engineers that are qualified to work on pneumatic equipment are allowed to do the installation maintenance and rep
14. itrogen System will not take advantage of all of the pressure available from your compressed air supply The system will operate reliably just not at maximum capacity and pressure Upon commissioning the system allow the system to run so that the storage tank fills After a period of time the nitrogen storage pressure should stop rising the system turns off and there is no more demand for air from your compressor If the compressor system does not shut off the pressure switch is set too high and the set point on the pressure switch needs to be reduced so the system turns off If the compressor shuts off as expected there may be an opportunity to increase the performance of your system If your compressor is capable of high PSI CFM you may want to try to increase the set point on the pressure switch set This will increase the pressure of nitrogen in the storage tank that is available for filling tires A Warning Never set the pressure switch so that the technical specifications of the Advantage Nitrogen System are exceeded this can cause serious injury and or damage see Chapter 4 1 for specifications The maximum pressure set point in the tank is 188 psig DO NOT EXCEED THIS PRESSURE ANS Nitrogen Manual 16 Adjust the pressure switch as follows 1 Loosen lock nut 1 Y The set point for the pressure switch can be increased by turning the pressure rod at the finger grip
15. n Off Control Controls V1 P2 Pressure Gauge 11169 L1386 Outlet Pressure Gauge DPS 1 Test Point for Test Gauge For Service Only Nitrogen Storage Tank Min 30gal Buffer for Automatic Shut Off ANS Nitrogen Manual 8 Advantage Nitrogen System Specifications o ANSO1 ANS05a1 ANS076 ANS123 Nominal Conditions 20 C 68 F Ambient Pressure O2 enriched 1013 mbar a 14 7 psig waste stream Max Pressure Drop 4 psig 0 28 bar 6 psig 0 42 bar 8 psig 0 55 bar 10 psig 0 69 bar Compressed Air Specifications MA Maximum Inlet Pressure 188psig 13 0 Bar g Minimum Inlet Pressure 100psig 6 8 Bar g Compressed Air Temperature 50 1049 F 10 40 Range 1 lt 0 01 mg m lt 100 non condensing Air Consumption at nominal 13 5scfm 20scfm 31 5scfm Conditions 1 Ambient Conditions o O 2 50 C 36 122 F frost free Less E Less id Less I Air quality eem without PI Dimensions and Connections Dimensions Stand Alone Wall 58 5 Hx17W11 D Dimensions Stand Alone Tank Mount 75 H x 25 5 W 31 D Weight Stand Alone 200lbs Storage Tank Weight 400lbs Inlet Connection Yo NPT Yo NPT Yo NPT Yo NPT Outlet Connection Yo NPT Yo NPT Yo NPT Rud c ds 2 1 SCFM 5 1 SCFM 7 6 SCFM 12 3 SCFM Conditions Purity at specified capacity S 5 96 by Volume id dii 1 Temperatures lower than 68 F 20 C will resul
16. odule ANS Nitrogen Manual 25 7 5 Replace Particulate Filter F3 Fig 7 10 1 Using a 1 adjustable wrench unscrew the filter s bowl assembly as shown below and then lift off bowl Fig 7 11 2 Unscrew the filter element retainer and remove and replace filter element and then reinstall and tighten filter bowl back onto filter assembly ANS Nitrogen Manual 26 8 Troubleshooting Compressed air supply too low Check increase the air supply Check increase the air supply Lower the temperature If possible Delivery of E A air temperature is too oe i temperature if nitrogen g p i OO or ab ehi Air filters are polluted Change the air filters Leak in piping Check for leaks in piping repair Automatic drain is continuously open Check the automatic drain Nitrogen outlet line is blocked Check open the outlet line Blockaae Check the compressed air delivery to the compressor Increase feed pressure adjust Peed eS us ON setpoint of pressure switch Ambient temperature is too high Lower the temperature if Advantage possible Nitrogen System Toes nol Compressed air temperature is too Lower the temperature if automatically A IIK are polluted EN Leak in piping Check for leaks in the piping repair Nitrogen outlet is open Close outlet Automatic drain is continuously open l ANS America 1112 North Collier Blvd Marco Island FL 34145 239 394 6099 ext 10 239 394 5388 fax N 9
17. sponsible for customer installed piping e Regular maintenance should be performed on the Advantage Nitrogen System to ensure proper and safe operation e Ensure that instructions concerning health and safety are compliant with local regulations 2 5 Environmental aspects The use and maintenance of the Advantage Nitrogen System does not include environmental dangers Most parts are made of metal and can be disposed of in a manner consistent with local regulations The packaging of the Advantage Nitrogen System is 100 recyclable w g e Make sure that instructions concerning health safety and environment are compliant with all local regulations e Keep the ambient temperature between 2 50 C 36 122 F frost free e Do not connect hot compressed air directly from a compressor to the inlet of the Advantage Nitrogen System ANS Nitrogen Manual al 3 Description of the appliance 3 1 General The Advantage Nitrogen System separates compressed air into nitrogen and an oxygen enriched air stream The separation system is based on Parker Filtration and Separation membrane technology The compressed air comes from a central system or from a dedicated compressor 3 2 Separation principle Separation layer X Support layer B Pressurised ar Mitrogen Fig 3 1 Separation principle A Pressurized air inlet F Fast B Hollow fiber membrane S Slow C Nitrogen outlet Ambient air contains nitrogen 78 1 oxygen 20 9 argon
18. sting the bowl 1 4 turn counter clockwise 2 Unscrew the nut F 3 Remove the drain unit B E from the filter bowl A 4 Remove the O ring E 5 Carefully pull the floating house B from the seat D Do not bend the needle C 6 Clean the parts with soap and water Make sure that the needle bore is open and clean 7 Assemble the parts in the opposite direction Make sure that the parts are dry before reassembly Fig 7 3 Clean drain filter The filter drains are easily cleaned Simply remove the bowl from the filter assembly and rinse with soap and water ANS Nitrogen Manual 22 7 4 Replace Carbon Bed Not required for the ANSO21 1 To remove the carbon module loosen the JIC 77 compression fittings with an adjustable wrench See image below for locations Top and Bottom 2 Using a deep socket ratchet remove the two 9 16 bolts that secure the top part of the module ANS Nitrogen Manual 23 3 While holding the carbon module with one hand carefully unscrew the two Philips screws that secure the bottom part of the module Fig 7 7 4 Toremove module drop and rotate this module to gain the clearance of the elbow fitting Fig 7 8 5 Remove bracket from carbon module Save bracket nuts and washers and assemble them back onto the replacement module ANS Nitrogen Manual 24 Save Backet nuts and washers Fig 7 9 6 Follow the previous steps to reinstall caroon m
19. t in a decrease in air consumption Temperatures higher than 68 F 20 C will result in an increase in air consumption ANS Nitrogen Manual 9 5 Pre Installation Requirements Follow the sections in this chapter to install the Advantage Nitrogen System 5 1 Transport A Warning Put the Advantage Nitrogen System in the original box to transport it over longer distances For qualifications of installation personnel refer to section 2 1 5 2 Define location 1 Advantage Nitrogen System should be installed in a fixed location The location must meet following requirements e Indoors e Dry Vibration free No continuous direct sunlight e Away from heat sources Properly ventilated room Easy accessibility for operation and service See required foot print Perform the complete installation procedure again if you move the Advantage Nitrogen System to a new location 5 3 Unpack and check equipment refer to section 5 3 1 1 Open the packaging 2 Insure that all components are delivered 3 Insure that the available compressed air meets specification Oil content of the compressed air is below 0 01mg m e If the Advantage Nitrogen System is connected to a house air system ensure that the compressed air pressure and quality is always as prescribed The capacity must be sufficient e f the Advantage Nitrogen System is connected to a stand alone compressor ensure that the compressor works properl
20. the flow control valve Note The Flow Control Valve is sealed with a Tamper Evident Label Please contact Technical Support if you want to increase Nitrogen purity by decreasing the flow A Warning Increasing the flow rate will lower the nitrogen purity The flow rate is factory set for optimal performance Temperature The Advantage Nitrogen System operates optimally at a temperature between 20 30 C 68 86 F Outlet purity remains stable over the rated temperature range If the temperature increases the pressurized air consumption will also increase Do not place the system in a room where the temperature may rise unnecessarily high Allow enough piping between the compressor exit and the Advantage Nitrogen System inlet so that the hot compressed gas has time to cool within the specifications listed in this manual Membrane pressure A higher membrane pressure will increase the capacity i e nitrogen output of the Advantage Nitrogen System Note This will also increase N2 purity of the system as long as the flow control valve is not adjusted External pressure There must be atmospheric pressure at the vent or permeate outlet The capacity of the nitrogen gas decreases strongly if the vent or permeate pressure exceeds atmospheric pressure ANS Nitrogen Manual 6 MODEL ANS021 Valve Stem Port on Front L OUT Standard Outlet ST Storage Tank Pki Pressure Gauge Pressure Gauge 11169
21. y Refer the instructions of the compressor manufacturer Ensure that the after cooler and the water separator of the compressor work correctly e f installed ensure that the pressurized air dryer is of proper size and that it is in working order ANS Nitrogen Manual 10 5 3 1 Parts Checklist a Items included in the package 1 Advantage Nitrogen System nitrogen generator wallmount or floorstanding 2 Installation and operation manual 3 Nitrogen Storage Tank ST Floor Mount Only Tank has pressure relief valve located on top DO NOT REMOVE or ADJUST b Customer supplied materials 1 Storage tank wall mount 2 Shut off valve with inlet regulator 3 Drip leg with manual or automatic drain 4 Tire inflation hose amp chuck 5 3 2 Items Required by Customer for Proper Installation WALL or FLOOR mounted a menm ee a a o a ee eee Regulator i COM pressed Custom er Supplied Air with Pressure Gauge 1 Product N2 l i Shut G valve Customer Supplied l Drip Leg Customer Supplied i Customer pre installation requirements e Drip leg with a manual or an automatic drain e Regulator with a pressure gauge e Shut off valve 1 House or compressed air source meeting Advantage Nitrogen System requirements see specifications The inlet connections are NPT for all models 2 Outlet connection from Advantage Nitrogen System Generator on standard base units only Y NP
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