TECHNICAL INFORMATION

Installation, Operation and Maintenance

®
Balston AN Series Nitrogen Generators Models AN0200, AN0400,
AN0500, AN1000, and AN2000

These instructions must be thoroughly read and understood before installing and operating
this product. Suitable personnel using reasonable care should perform all installation,
operation, and maintenance procedures for the Balston AN Series Nitrogen Generators. If
you have any questions or concerns, please call the Technical Services Department at
800-343-4048, 8AM to 5PM Eastern Time (North America only). For other locations, please
contact your local representative.

Introduction Balston AN Series Nitrogen Generators generate nitrogen gas (N2) from compressed air. The purity
of the nitrogen is a function of compressed air flow rate, compressed air pressure, and downstream
nitrogen demand. The separation membranes may be combined with filters, flow controls, pressure
controls, and other auxiliary equipment to produce a nitrogen generator. The separation module
may also be used on its own (with adequate prefiltration, flow controls, etc.) as an integral compo-
nent of a complete OEM product. Design control is left to the equipment manufacturer.

Technology Balston AN Series Nitrogen Generators modules consist of bundles of hollow fiber membranes.
The compressed air enters the center bore of these fibers and travels the length of the fibers. As
the air passes through these hollow fibers, oxygen (O2) and water molecules (H2O) pass through
the membrane wall at a higher rate than nitrogen molecules (see Figure 1). This results in a high
purity, dry nitrogen gas stream exiting the membrane module. The oxygen enriched permeate
stream exits the membrane module through ports on the side of the module at a very low (atmo-
spheric) pressure.

Each module is designed to produce nitrogen at purities between 95% and 99.5% (Note: Nitrogen
purity value includes Argon content.) The purity of the product nitrogen is defined by the pressure
and flow conditions of the compressed air and by the nitrogen consumption dictated by customer
demand.

The Balston AN Series Nitrogen Generators have at least one stage of coalescing prefilter included
in the product. Models AN0200, AN0400, AN0500, AN1000, and AN2000 all include one pre-filter
with grade BX filter element (99.99% efficient at 0.01 micron) and automatic float drain. Models
AN0200DX, AN0400DX, AN0500DX, AN1000DX, and AN1000DX include two stages of coalescing
pre-filter with grades DX and BX filter elements and automatic float drains, one stage of activated
carbon scrubber, and a post scrubber particulate filter.

Compressed Air

Figure 1 - Flow Schematic

For assistance, call toll-free at 800-343-4048 Parker Hannifin Corporation 1

Bulletin TI-AN2000
Influence of Process The performance of the separation membrane (i.e., the purity of the nitrogen produced) is depen-
Parameters dent upon the way it is operated. The influence of the most important process parameters is
explained below.

1 Flow rate: For a given operating pressure, as the product nitrogen demand changes, the purity
! of the nitrogen product (as a function of oxygen content) will also change, but the total com-
pressed air consumption will remain relatively constant. As the nitrogen demand increases, the
nitrogen purity decreases. As the nitrogen demand decreases, the nitrogen purity increases.
2 Temperature: Balston AN Series Nitrogen Generators will operate optimally at room tempera-
ture (65-75°F, 18-24°C). As the ambient temperature increases, the compressed air consump-
! tion will increase. The user is advised to operate the membranes in a location where the
temperature will not become unnecessarily high.
3 Compressed Air / Membrane Operating Pressure: As the compressed air pressure to the
module increases, the flow capacity and the compressed air consumption also increase (90-
100 psig optimum).
4 Backpressure: The membrane module permeate port should be open to atmosphere. If
backpressure is applied to the permeate port, the purity and capacity of the membrane will
decrease. If excess backpressure is applied, the membrane may rupture.

Safety/Precautions 1 Nitrogen is nontoxic and largely inert. It can act as a simple asphyxiant by displacing oxygen in
! air. Inhalation of nitrogen in excessive concentrations can result in unconsciousness without
any warning symptoms such as dizziness, fatigue, etc.
2 The membrane module vents oxygen enriched air from the permeate port. Adequate ventila-
tion of the space surrounding the membrane module is required to prevent a possible explosion
! hazard. The ventilation rate of the space depends on the capacity of the membrane module
and the space in which it is installed.
3 Do not screw the threads of pipe fittings too deeply in the ports of the modules. If the pipe
fitting contacts the hollow fibers, the membrane may be damaged.
4 Balston AN Series Nitrogen Generator modules must be installed in a vertical orientation. The
compressed air should be fed from the bottom so the feed stream in the first part of the module
is in an upward direction. This will allow condensate to drain under adverse conditions.
5 Engineering and installation of Balston AN Series Nitrogen Generators and related piping and
appendages must be done according to standard procedures by qualified personnel. Parker
does not assume responsibility for incorrect design or installation of the membrane module.
6 All contaminants which may be detrimental to the membrane (e.g., particulate matter, welding
slag, oil droplets, water droplets, hydrocarbon vapors, etc.) should be removed from the
compressed air supply before it is introduced to the membrane module.
7 The compressor intake air that is subsequently fed to the gas separation membranes
must be clean and free from organic solvent vapors or other contaminants. Do not
operate the system in an area where organic solvent vapors may be introduced into the
compressed air supply. If organic vapors are present, the intake of the compressor should be
plumbed to the outside and carbon protection should be employed in the design.
8 It is important that the compressed air condensate separation and removal system is working
properly. In order to prevent condensation within the piping to the membrane or within the
membrane itself, install the filters as close as possible to the inlet of the membrane module.
9 Systems based on Balston AN Series Nitrogen Generators are pressurized while operating.
Depressurization may last for some time after the pressurized feed air has been switched off.
Before servicing, make sure the system is fully depressurized. The installation of pressure
gauges at various locations in the system will assist in monitoring system pressure.
10 For safe operation, the ambient temperature must remain between 36°F and 104°F (2°C and
40°C). For optimal performance, the temperature should remain between 59°F and 77°F (15°C
and 25°C). The system should be located to prevent frost formation that can cause irreparable
damage.
! 11 The maximum inlet air pressure must not exceed 189 psig (13 bar).

2 Parker Hannifin Corporation Bulletin TI-AN2000

 12 Balston AN Series Nitrogen Generators are designed to operate on compressed air only. Do
! not feed the membrane with any gas other than compressed air.
13 To ensure efficient and safe operation, regular maintenance must be performed on the system.
This would include changing pre-filters at regular intervals as well as servicing the air compres-
sor at a regular frequency according to the instructions supplied by the compressor manufac-
turer.
14 In applications where the oxygen content in nitrogen is critical (i.e. blanketing explosive
chemicals or packaging food for extended shelf life), an oxygen monitor or trace analyzer
should be used in conjunction with safety interlocks, backup systems, and/or alarm systems to
assure proper nitrogen purity levels at all times. (Parker Hannifin offers an oxygen analyzer,
P/N 72-730, as part of its product line. Contact your local representative for more information.)
15 Systems containing Balston AN Series Nitrogen Generators must be operated by well-trained
personnel. The safety of all associated personnel is ultimately the responsibility of the end
! user of the Balston membrane module. The user must be made aware of safety hazards
related to operating membrane gas separation systems. The end user is responsible for
training and safety of operating personnel.

Installation

For the smaller membrane modules, the compressed air consumption is relatively low. For systems
containing these modules, piston compressors are the best choice. For the larger membrane
modules, an adequately sized oil-injected screw compressor would be the best choice. A preferred
installation diagram is shown below.

1 2 3 4 5 6 7 8

P P
PROTECTION
CARBON

SEPARATOR
MEMBRANE
DX BX DX
MODULE
VALVE VALVE

Legend:
1 Compressor
-Piston compressor (or oil injected screw)
equipped with buffer vessel
-Maximum operating pressure: 189-218
psig (13-15 bar)
-Pressure switch settings:
OFF: Maximum operating pressure
ON: 30 psig (2 bar) below max pressure
-Capacity: 10% excess capacity with respect
to maximum air consumption of module;
compressed air consumption based on 50%
duty cycle.
NOTE: Buffer vessel should be equipped
with timer controlled drain for failsafe
condensate removal.
2 Air cooler/Refrigerated dryer – Equipped 5 Activated carbon filtration – Balston CI
with water separator and timer controlled filter cartridge (Grade 000) or carbon bed(s)
drain. (Note: For AN0400 and larger (P/N 75304)
membranes, a refrigerated dryer should be
installed.) 6 Particulate filter – Prevent carbon dust
particles from damaging membrane module.
3 Coalescing pressurized air filters –
Balston® Grade DX (93%, 0.01 µm) and 7 Membrane separator module
Grade BX (99.99%, 0.01µm). Include 8 Receiver - Storage or buffer.
automatic drain.
NOTE: Valves shown are recommended to
4 Pressure regulator – Reduce the air aid in servicing.
pressure to a constant pressure slightly
lower than the switch-on pressure of the
compressor. The pressure regulator
installed at this location will have a drying
influence on the air as a result of the
pressure reduction.

For assistance, call toll-free at 800-343-4048 3

 Installation

Designing a Nitrogen 1 Protect the Balston AN Series Nitrogen Generator Module: The membrane module must be
Generator protected from water and oil vapor and droplets which are present in most compressed air
systems. Exposure of the membrane to these components could affect the performance of the
module.

A Condensate removal:
1 Cool the compressed air with an adequately-sized aftercooler, or refrigerated dryer.
2 Remove condensate with coalescing prefilters.
3 Install automatic (and failsafe) drains on all filters and receivers.

B Prevention of condensation:
1 Keep the distance between the outlet of final filters and inlet of the membrane module
as short as possible.
2 Prevent low ambient temperatures <50°F (<10 °C). If the equipment is installed in a
location where temperatures lower than 50°F (10°C) occur, the installation of a
compressed air dryer is strongly recommended.
3 Place modules in a vertical position and feed them from below.
4 Make sure the operating temperature is above the inlet dewpoint of the compressed
air.
5 Use a carbon bed and particulate filter.

2 Minimize Backpressure at the oxygen permeate port. Keep the pressure of the permeate as
close to atmospheric pressure as possible to optimize module performance and prevent
potential damage from rupture. If the permeate must be piped away, use adequately sized
piping to avoid backpressure on the module.

3 Avoid excessive pressure drop at the inlet of the module. Pressure drops of the com-
pressed air will decrease the capacity and the delivery pressure of the module. Optimal sizing
of piping, connections, filters and valves will minimize pressure drop.

4 Adapt your system to local ambient conditions. Balston AN Series Nitrogen Generators can
be operated at ambient temperatures between 36°F and 104°F (2°C and 40°C) and with a
maximum operating pressure of 189 psig (13 bar).
A Ambient temperature. At low temperatures, post condensation (condensation after the
prefilter or in the membrane) may occur. At high ambient temperatures, compressed air
consumption will increase. Compressor oil carry over will increase at higher temperatures.
Recommendation:
1 If ambient temperatures will be lower than 41°F(5°C), install a compressed air dryer
(or chiller) and a membrane heater (to maintain membrane temperature at 70°F/21°C).
2 If ambient temperatures will be higher than 104°F (40°C), install a pressurized air
chiller and carbon bed.
B Feed Pressure. If the compressed air supply temperature varies with time, the com-
pressed air consumption of the module will increase and module performance will be affected.
To avoid temperature effects on the nitrogen quality and volume, design the system to operate
at 90% of compressor capacity. The minimum compressed air operating pressure is 80 psig.

5 Leak Check. After plumbing, pressurize various portions of the system and check for leaks with
soap bubble solution. For smaller generators, nitrogen product leakage will obviously result in
decreased capacity. The entire plumbing system should be free from leaks.

Several flow diagrams for the various Balston AN Series Nitrogen Generators are shown at
the end of this bulletin. These drawings are not to scale, and only represent general recom-
mendations for installation.

4 Parker Hannifin Corporation Bulletin TI-AN2000

 Operation

Start up / Operation
1 Open the compressed air supply slowly to allow the system to pressurize. (After the com-
pressed air supply has reached the designed operating pressure)
2 Adjust product flow until the desired oxygen concentration is achieved.
3 Check proper functioning of automatic drains and filters.
4 Monitor system pressure and adjust outlet pressure if necessary to suit the application.

Shutdown
1 Stop the compressor or shut off compressed air supply
2 Bleed the pressure from the system.
Note: Closing the outlet valve (from the module) will not prevent compressed air consumption
because the membrane permeate port is still open to atmosphere.

Principal Specifications Principal Specifications

OEM Nitrogen Generators Models AN0200, AN0400, AN0500, AN1000, AN2000

Atmospheric Dewpoint -20°F to -80°F (29°C to -62°C)
Particles > 0.01 micron None
Suspended Liquids None
Min/Max Operating Pressure (1) 70 psig/175psig (12 Bar)
Min/Max Pressure Drop (@95% N2, 125 psig) 10 psig/30 psig
Recommended Ambient Temperature ≤ 77°F (25°C)
Electrical Requirements None

Flow Rates AN0200 - Product Flow Rate at Pressure and 70°F(21°C), SCFH

Inlet Pressure, psig

Nitrogen Purity, % 160 145 130 115 100 85
99.5 61 48 42 38 32 26
99 108 84 73 67 56 45
98 175 137 118 109 91 73
97 228 179 155 143 119 95
96 303 237 205 190 158 126
95 357 279 242 223 186 149
Max feed air
required, SCFM 17.8 13.9 12.0 11.1 9.3 7.4

AN0400 - Product Flow Rate at Pressure and 70°F(21°C), SCFH

Inlet Pressure, psig

Nitrogen Purity, % 160 145 130 115 100 85
99.5 119 93 81 74 62 50
99 215 168 146 134 112 90
98 349 273 237 218 182 146
97 457 357 309 286 238 190
96 607 474 411 379 316 253
95 714 558 484 446 372 298
Max feed air
required, SCFM 35.6 27.8 24.1 22.2 18.5 14.8

For assistance, call toll-free at 800-343-4048 5

 Operation

Flow Rates AN0500 - Product Flow Rate at Pressure and 70°F(21°C), SCFH

Inlet Pressure, psig

Nitrogen Purity, % 160 145 130 115 100 85
99.5 154 120 104 96 80 64
99 242 189 164 151 126 101
98 336 263 228 210 175 140
97 470 368 319 294 245 196
96 611 477 413 382 318 254
95 691 540 468 432 360 288
Max feed air
required, SCFM 34.4 26.9 23.3 21.5 17.9 14.4

AN1000 - Product Flow Rate at Pressure and 70°F(21°C), SCFH

Inlet Pressure, psig

Nitrogen Purity, % 160 145 130 115 100 85
99.5 278 218 189 174 145 116
99 470 368 319 294 245 196
98 739 578 501 462 385 308
97 975 762 660 610 508 406
96 1277 998 865 798 665 532
95 1509 1179 1022 943 786 629
Max feed air
required, SCFM 75.2 58.8 50.9 47.0 39.2 31.3

AN2000 - Product Flow Rate at Pressure and 70°F(21°C), SCFH

Inlet Pressure, psig

Nitrogen Purity, % 160 145 130 115 100 85
99.5 557 435 377 348 290 232
99 941 735 637 588 490 392
98 1478 1155 1001 924 770 616
97 1949 1523 1320 1218 1015 812
96 2554 1995 1729 1596 1330 1064
95 3024 2363 2048 1890 1575 1260
Max feed air
required, SCFM 150.7 117.7 102.0 94.2 78.5 62.8

Maintenance
1 Compressor: The compressor must be serviced regularly, according to the manufacturer’s
instructions.
2 Filters: Check differential pressure indicators on filters (if included). Change filter elements if
indicated by differential pressure indicator. Change filters regularly on annual or bi-annual
basis.

6 Parker Hannifin Corporation Bulletin TI-AN2000

 Flow Diagrams

PART NUMBER FLOW DIAGRAM

AN0005DX
AN0005DX

MEMBRANE
NITROG EN

MODULE
PRO DUCT
AN0020DX
AN0020DX
AN0050DX
AN0050DX
DX
FILTER
BX
FILTER
CI
FILTER
AN0100DX
AN0100DX COMPRESSED
AIRIN

NITRO GEN
PRO DUCT

AN0200DX
AN0200DX

MEMBRANE
CARBON

MODULE
TOWER
AN0400DX
AN0500DX
AN1000DX
AN0500DX DX
FILTER
BX
FILTER
DX
FILTER

AN1000DX
CO MPRESSED
AIR IN

NIT RO GEN
PRO DUCT

MEMBRANE
MODULE
CARBON

CARBON
TOWER

TOWER
AN2000DX
AN2000DX DX BX DX
FILTER FILTER FILTER

CO MPRESSED
AIR IN

AN0005
AN0005
AN0020
AN0020
AN0050
MEMBRANE

AN0050 NITROGEN
MODULE

PRODUCT
AN0100
AN0100
AN0200
AN0200 COMPRESSED BX
AIR IN FILTER
AN0500
AN0400
AN1000
AN0500
AN2000
AN1000
AN2000

AN0400

For assistance, call toll-free at 800-343-4048 7

 Troubleshooting

All troubleshooting activities should be performed by suitable personnel using reasonable care.

Symptom Course of Action

Loss of Outlet Pressure Check the pressure and flow of compressed air and nitrogen. Flow should not exceed capacity of membrane.
Check operating pressure to assure that it is greater than 80 psig (5.5 barg).
Check the system for leaks.

Loss of Outlet Flow Check operating pressure to assure that it is greater than 80 psig (5.5 barg).
Check the nitrogen flow. Adjust if necessary.
Check the system for leaks.
Check drains on prefilters (if applicable).

Purity is Lower than Specified
Operating Conditions
Check setting of flow rate compared to specification.
Check the operating pressure to assure that it has not varied from the original reading.
Measure the temperature and dewpoint of the inlet air. The recommended temperature is 68°F (20°C) and the
recommended dewpoint is 60°F (15°C) or lower.
Calibrate oxygen analyzer (if needed).

Air Leak Through Drains of Prefilters
(if installed)
Check inlet pressure. It should be greater than 15 psig (1 barg) to seal drain.
Remove tubing from the drain outlet, hold finger over drain opening for a few seconds to allow pressure to build and
drain to seal.
Remove bowl from filter assembly and rinse with water.
If leak persists, replace automatic float drain (P/N 21552)
Call Technical Service Representative.*

* To arrange for system service or to order replacement parts, contact the Technical Services Department at 1-800-343-4048, 8AM-5PM Eastern Time (North America only).
For other locations outside North America, please call your local representative.

8 Parker Hannifin Corporation Bulletin TI-AN2000

 Illustrations

Model AN0200

Filter Membrane

Model AN0400
Filter Membrane

For assistance, call toll-free at 800-343-4048 9

Illustrations

Model AN0500

Filter

Membrane

Models AN1000, AN2000 Membrane

Filter

Parker Hannifin Corporation Parker Hannifin UK Ltd

Filtration and Separation Division
100 Ames Pond Drive, P.O. Box 1262
Tewksbury, MA 01876-0962
Tel: 978-858-0505 Fax: 978-858-0625
10
Hermitage Court, Hermitage Lane
Maidstone, Kent ME16 9NT, England
Tel: +44 (0) 1622-723300 ©Parker Hannifin Corporation 2002
Fax: +44 (0) 1622-728703 Printed in U.S.A. Bulletin TI-AN2000
Parker Hannifin Corporation Bulletin TI-AN2000