Airsep AS-20-1000 User Manual
AirSep® Corporation
PSA Oxygen Generator
Models AS-20–1000
Instruction Manual
MN011-1 A12/02
Suggested List Price $75.00 (U.S.D.)
AirSep® Corporation • 260 Creekside Drive • Buffalo, NY 14228-2075 USA
Phone: (716) 691-0202 • Fax: (716) 691-1255
Ownership Data
Please take a moment to note below important information about your AirSep® Corporation
PSA Oxygen Generator. Retain this instruction manual, along with your invoice, to serve as
a permanent record of your purchase.
PSA Oxygen Generator
Model Number:
Serial Number:
Invoice Date:
Start-up Date:
AirSep Representative
Company:
Contact:
Address:
City/Town: State: Zip:
Country: Fax:
Phone: Telex:
Before you attempt to install, operate, or repair the oxygen generator,
read and thoroughly understand this instruction manual. Improper
operation can result in severe bodily injury, damage to the oxygen
generator, or poor performance.
AirSep® Corporation 12/02
Table of Contents
1.0 Introduction ..................................................................................... 1-1
1.1 General .............................................................................................1-1
1.2 Warnings, Cautions, and Notes ........................................................1-1
1.3 Symbols ............................................................................................1-2
1.4 References to Controls and Indicators with Tags or Labels ............. 1-2
2.0
Safety................................................................................................ 2-1
2.1 General .............................................................................................2-1
2.2 Potential Hazards .............................................................................2-1
2.3 Safety Publications ...........................................................................2-3
3.0
Plant Description............................................................................. 3-1
3.1 General .............................................................................................3-1
4.0
Component Descriptions................................................................ 4-1
4.1 External Components ....................................................................... 4-1
4.1.1 Adsorbers 4-2
4.1.2 Enclosure 4-2
4.1.3 Control Panel 4-2
4.1.4 Connections 4-3
4.2 Manifold Components.......................................................................4-4
5.0
Installation ....................................................................................... 5-1
5.1 Handling and Unpacking...................................................................5-1
5.2 Pre-installation Guidelines ................................................................5-2
5.3 Installation Instructions .....................................................................5-3
6.0
Operation ......................................................................................... 6-1
6.1 Initial Start-up....................................................................................6-1
6.2 Operation ..........................................................................................6-3
6.3 Shutdown..........................................................................................6-3
6.4 Normal Start-up ................................................................................6-4
AS-20—1000 Instruction Manual table of contents - i
04/02 AirSep® Corporation
6.5 Extended Shutdown..........................................................................6-4
6.6 Start-up after an Extended Shutdown............................................... 6-4
7.0
Maintenance..................................................................................... 7-1
7.1 Daily Monitoring ................................................................................7-1
7.2 Monthly Monitoring ...........................................................................7-1
7.3 Removing the Front Cover of the Enclosure (Not available on AS-450
— AS-1000 models) .....................................................................................7-2
7.4 Depressurizing the Filters .................................................................7-3
7.5 Changing Filter Elements .................................................................7-4
7.6 Depressurizing the Oxygen Generator ............................................. 7-5
7.7 Adjusting the Feed Air Regulator......................................................7-6
7.8 Adjusting the Pressure Switch ..........................................................7-6
8.0
Troubleshooting .............................................................................. 8-1
A
Appendix Technical Data............................................................... A-1
Specifications .............................................................................................. A-1
Operating Data ............................................................................................ A-9
Drawings.................................................................................................... A-10
Appendix Warranty/Returns .......................................................... B-1
B
Product Warranty......................................................................................... B-1
Limits of Liability .......................................................................................... B-2
Returning the Oxygen Generator or a Component for Service ................... B-2
C
Appendix Parts List........................................................................ C-1
AS-20 Parts ................................................................................................. C-2
AS-45 Parts ................................................................................................. C-3
AS-80 Parts ................................................................................................. C-4
AS-160 Parts ............................................................................................... C-5
AS-250 Parts ............................................................................................... C-6
AS-450 Parts ............................................................................................... C-7
AS-750 Parts ............................................................................................... C-8
AS-1000 Parts ............................................................................................. C-9
table of contents - ii AS-20—1000 Instruction Manual
AirSep® Corporation 12/02
List of Illustrations
Figure 4-1 External Components — Front View ...................................... 4-1
Figure 4-2 Control Panel — AS-45 and AS-80 Models
Figure 4-3 Manifold Components — AS-160 and AS-250 Models
Figure 4-4 Manifold Components — AS-750 Model
Figure 5-1 Typical Installation Arrangement............................................ 5-3
Figure 5-2 120 Gallon Oxygen Receiver
Figure 7-1 Interior View of AS-45 and AS-80 Models
Figure 1 General Arrangement Drawing – AS-20
Figure 2 Flow Schematic – AS-20
Figure 3 Electrical Schematic – AS-20 (120V)
Figure 4 Electrical Schematic – AS-20 (220V)
Figure 5 General Arrangement Drawing – AS-45
Figure 6 General Arrangement Drawing – AS-80
......................................................... A-12
................................................... 5-5
...................................... A-13
...................................... A-13
............................ 4-3
.......... 4-4
................................ 4-5
............................. 7-3
................................ A-11
................................ A-14
................................ A-15
Figure 7 General Arrangement Drawing – AS-160
Figure 8 General Arrangement Drawing – AS-250 .............................. A-17
Figure 9 Flow Diagram – AS-45 through AS-250
Figure 10 Electrical Diagram – AS-45 through AS-250 (120V)
Figure 11 Electrical Diagram – AS-45 through AS-250 (220V)
Figure 12 General Arrangement Drawing – AS-450
Figure 13 General Arrangement Drawing – AS-750 ............................ A-21
Figure 14 Flow Diagram – AS-450 through AS-750
Figure 15 Electrical Schematic – AS-450 through AS-750 (120V) ...... A-23
AS-20—1000 Instruction Manual list of illustrations - i
.............................. A-16
................................. A-18
............ A-19
............ A-19
............................ A-20
............................. A-22
04/02 AirSep® Corporation
Figure 16 Electrical Schematic – AS-450 through AS-750 (220V) ...... A-23
Figure 17 General Arrangement Drawing– AS-1000
Figure 18 Electrical Schematic – AS-1000 (120V)
Figure 19 Electrical Schematic – AS-1000 (220V)
Figure 20 Flow Diagram – AS-1000
........................................................ A-26
................................. A-25
................................. A-25
............................ A-24
ii - list of illustrations AS-20—1000 Instruction Manual
AirSep® Corporation 12/02
1.0 Introduction
1.1 General
This instruction manual provides descriptions of the AirSep Corporation PSA
Oxygen Generator Models AS-20, AS-45, AS-80, AS-160, AS-250, AS-450, AS750, and AS-1000, as well as instructions for their installation, operation, and
maintenance. The Appendix of this instruction manual also includes pertinent
drawings and component literature.
To ensure safe operation and proper maintenance of the oxygen generator, AirSep
Corporation recommends that you keep this instruction manual readily available for
reference.
1.2 Warnings, Cautions, and Notes
As you read this instruction manual, pay special attention to the WARNING,
CAUTION, and NOTE messages. They identify safety guidelines or other important
information as follows:
Provides information that can prevent severe bodily injury or
death.
Cautions against the risk of electric shock.
Provides information important enough to emphasize or repeat.
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12/02 AirSep® Corporation
1.3 Symbols
IEC 417, No. 5019 Protective conductor terminal
IEC 417, No. 5007 On (supply)
IEC 417, No. 5008 Off (supply)
ISO 3864, No. B.3.6 Caution, risk of electric shock
ISO 3864, No. B.3.1 Caution (refer to accompanying
documents)
1.4 References to Controls and Indicators with Tags or Labels
This instruction manual uses uppercase characters (e.g., ON/OFF switch) to refer
to controls and indicators identified by tags or labels. Numbers inside parentheses
(e.g., V-2) identify manually operated flow controls (e.g., manual valves). Refer to
Chapter 4 for a description of the oxygen generator components.
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AirSep® Corporation 12/02
2.0 Safety
2.1 General
Oxygen, the most abundant of the elements, makes up approximately 50 percent
of the earth’s crust. In its free state, oxygen forms approximately one-fifth of our air by
volume. Although classified as a non-flammable gas, oxygen supports combustion.
As an active element, it combines directly or indirectly with all elements except the
rare gases. Oxygen is an invisible gas that is colorless, odorless, and tasteless.
To ensure your safety, thoroughly read and familiarize yourself with this entire
section of this instruction manual. In addition, AirSep Corporation strongly
recommends that you review this section periodically.
2.2 Potential Hazards
Oxygen vigorously accelerates the burning of combustible
materials. In an oxygen-enriched atmosphere, many materials
that do not burn in normal air require only a slight spark or
moderate heat to set them aflame.
To reduce the risk of fire or explosion, keep gasoline, kerosene,
oil, grease, cotton fibers, wood, paint, and other combustible
material away from all parts of the oxygen generator.
Do not allow smoking, open flame, or usage of electronic
devices that may generate sparks (e.g., cellular telephones)
within 15 m (50 feet) of any part of the oxygen generator.
Post “NO SMOKING OR OPEN FLAMES” signs conspicuously
near the location of the oxygen generator.
Take extreme care to keep all oxygen piping and vessels clean.
To avoid fire or explosion, oxygen clean all surfaces that can
come in contact with the product oxygen. Check all oxygen fittings
for leaks with an oxygen-compatible, leak-detecting solution.
To prevent fire or electrical shock, locate the oxygen generator
indoors, away from rain or any other type of moisture.
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12/02 AirSep® Corporation
Before you attempt to install, operate, or repair the oxygen
generator, read and thoroughly understand this instruction
manual and the component manuals located in Appendix D of
this instruction manual. Improper installation, operation, or
repairs can result in severe bodily injury, damage to the oxygen
generator, or poor performance.
The interior of the oxygen generator control cabinet contains
electrical parts that can produce an electrical shock hazard if
not handled properly. To prevent electrical shock, read and
thoroughly understand Section 8 — Troubleshooting in this
instruction manual before you service the oxygen generator.
AirSep oxygen generators are sold for use in industrial
applications only. Contact AirSep Corporation or an authorized
AirSep representative before you use this unit for any medical
application.
Disconnect power before servicing oxygen generator.
Do not disconnect protective earth:
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AirSep® Corporation 12/02
2.3 Safety Publications
The safety section of this instruction manual is not a complete summary of
required safety precautions. Review the following publications for additional
information on the safe handling of oxygen:
“Standard for Bulk Oxygen Systems at Consumer Sites;” NFPA No. 50; National
Fire Protection Association; 1 Batterymarch Park; P.O. Box 9101; Quincy,
Massachusetts 02269-9101 USA.
“Oxygen;” Pamphlet G-4; Compressed Gas Association; 1725 Jefferson Davis
Highway; Arlington, Virginia 22202-4102 USA.
“Cleaning Equipment for Oxygen Service;” Pamphlet G-4.1; Compressed Gas
Association; 1725 Jefferson Davis Highway; Arlington, Virginia 22202-4102
USA.
AS-20—1000 Instruction Manual 2-3
AirSep® Corporation 12/02
3.0 Plant Description
3.1 General
The AirSep Corporation PSA Oxygen Generator is a self-contained unit that utilizes
Pressure Swing Adsorption (PSA) technology to produce oxygen on site. The
oxygen generator uses compressed air as a feed gas to produce oxygen. The
compressed air flows through a filter assembly before the air enters the adsorber
vessels. A particulate filter removes condensed water, oil, dirt, scale, etc. from the
feed air, then in most models, a separate coalescing filter removes additional oil
and water vapor.
The oxygen generator uses in its adsorber vessels an inert ceramic material called
molecular sieve to separate compressed air into oxygen and other gases. The
unique properties of molecular sieve allow it to attract, or adsorb, nitrogen
physically from air under pressure. This allows oxygen to exit the adsorbers as a
product gas. The process valves on the oxygen generator then direct the oxygen to
the oxygen receiver for storage until needed by your application.
While one adsorber produces oxygen, the other depressurizes to exhaust the
waste gases it adsorbed (collected) during the oxygen production cycle. The entire
oxygen generating process is completely regenerative, which makes it both reliable
and virtually maintenance-free. The molecular sieve does not normally require
replacement when maintained and used according to this instruction manual.
Refer to the illustrations, located in Appendix A of this instruction manual, for a
detailed flow diagram, an electrical schematic, and general arrangement drawings
of all oxygen generator models referenced in this instruction manual as well as
typical cycle sequences and operating pressure levels.
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AirSep® Corporation 12/02
A
4.0 Component Descriptions
The drawings in this section illustrate the location of the main components of the
various oxygen generator models. All models include similar components unless
noted otherwise; however, the location and size of these components varies
among the different models. Refer to Appendix A of this instruction manual for
general layout drawings and specifications for all oxygen generator models
referenced in this instruction manual. In addition, the oxygen generator requires use
of an oxygen receiver to provide stable flow and purity for short-term surges of feed
oxygen above the rated capacity of the oxygen generator.
4.1 External Components
Figure 4-1 below illustrates on two models the external components viewed from
the front of the oxygen generator.
dsorbers
Control Panel
Enclosure
AS-45 Model AS-750 Model
Figure 4-1 External Components — Front View
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12/02 AirSep® Corporation
4.1.1 Adsorbers
The adsorbers, or beds, are vessels that contain the molecular sieve used to
adsorb (attract) nitrogen from compressed air and allow oxygen to pass through as
the product gas.
4.1.2 Enclosure
The enclosure protects the control system components of the unit (e.g., circuit
board, pressure switch, fuses, and transformer).
Disconnect power before opening and/or removing enclosure.
Power Cord
(U.S. units) The power cord, and its grounded plug, connects the oxygen
generator to a properly grounded electrical outlet to supply electrical power to
the oxygen generator.
(CE units) A fully qualified electrician must install the appropriate electrical
connection on the end of the power cord for a properly grounded electrical
outlet to supply electrical power to the oxygen generator.
Fuse Holder
The fuse holders contain fuses to protect the electrical components of the oxygen
generator. On the AS-450 through AS-1000 models, the fuse holders are mounted
in the control panel.
Fuses must be replaced with the same type and amp rating as
the original fuses.
4.1.3 Control Panel
The control panel on the oxygen generator contains the controls needed to operate
the oxygen generator and monitor its operation. Examples of typical control panels
are shown in figure 4-3. Not all components are available on every generator. On
the AS-450 through AS-1000 models, the gauges are mounted directly on the
manifolds and the hour meter is inside the control panel.
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AirSep® Corporation 12/02
A
Feed Air
Pressure Gauge
On/Off Switch
Cycle Pressure
Gauge
Hour Meter
uto/Manual
Switch
Oxygen
Receiver
Pressure
Gauge
Manual Drain
Button
Figure 4-2 Control Panel — AS-45 and AS-80 Models
On/Off Switch
The l/O power switch starts and stops the operation of the unit. The green indicator
light illuminates to indicate that the oxygen generator is receiving electrical power.
Auto/Manual Switch
The AUTO/MANUAL switch selects the operating mode for the oxygen generator.
In the AUTO position, the oxygen generator cycles on and off to meet oxygen
demand. In the MANUAL position, the oxygen generator cycles continuously. The
amber indicator light on the AUTO/MANUAL switch illuminates only when the
oxygen generator produces oxygen.
Manual Drain Button
The oxygen generator uses an automatic valve to periodically drain excess
moisture extracted from the feed air. The manual drain button allows you to
operate the automatic drain valve manually at any time during operation.
Hour Meter (Not available on AS-20 model)
The hour meter indicates the total number of hours the oxygen generator cycles.
FEED AIR PRESSURE Gauge (Not available on AS-450 — AS-1000 models)
The FEED AIR PRESSURE gauge indicates the pressure of the feed air as the air
enters the generator prior to the feed air regulator.
CYCLE PRESSURE Gauge (Not available on AS-450 — AS-1000 models)
The CYCLE PRESSURE gauge indicates the pressure of the feed air before the air
enters the adsorbers. The feed air regulator controls the pressure indicated on the
CYCLE PRESSURE gauge.
ADSORBER PRESSURE Gauges (AS-450 — AS-1000 models only)
The adsorber pressure gauges indicate the pressure in the two adsorbers.
OXYGEN RECEIVER PRESSURE Gauge
The OXYGEN RECEIVER PRESSURE gauge indicates the oxygen pressure in the
oxygen receiver.
4.1.4 Connections
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12/02 AirSep® Corporation
The oxygen generator provides the connections described below.
Air Inlet
The feed air inlet provides a connection for the feed air hose from the air
compressor.
Oxygen Outlet
The oxygen outlet provides a connection for the oxygen hose to the oxygen
receiver.
Condensate Drain Outlet
The condensate drain outlet provides a connection for a hose to drain condensate
from the oxygen generator filters.
4.2 Manifold Components
Figure 4-4 below illustrates the manifold components of the oxygen generator.
The location and presence of components may vary between the various models
of generators.
Particulate Filter
Coalescing Filter
Feed Air Valves
Equalization Valves
Manual Air Inlet
Valve
Check Valves
Filter Drain Valve
Feed Air Regulator
Circuit Board
Muffler
Manual Filter outlet Valve
Waste Valves
Pressure Switch
Product Valve
Flow Controller
Figure 4-3 Manifold Components —
AS-160 and AS-250 Models
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AirSep® Corporation 12/02
Equalization Valves
Check Valves
Manual Product Valve
Mufflers
Feed Valves
Manual Air Inlet
Particulate Filter
Figure 4-4 Manifold Components —
AS-750 Model
Automatic Equalization Valves
The automatic equalization valves enable the pressure in the adsorbers to equalize
after the product oxygen exits from one of the adsorbers.
Automatic Feed Air Valves
The automatic feed air valves control the flow of the feed air as the air enters the
adsorbers.
Automatic Product Valve
The automatic product valve controls the flow of product oxygen from the
adsorbers.
Waste Valves
Feed Air Regulator
Coalescing Filter
Automatic Waste Valves
The automatic waste valves control the flow of waste gas as it exits the adsorbers.
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12/02 AirSep® Corporation
Check Valves
The check valves ensure that product gas does not flow back into the adsorbers.
Circuit Board
The circuit board controls the cycle time and sequence of operation of the solenoid
and drain valves.
Coalescing Filter
The coalescing filter removes condensed water, oil vapor, and other contaminants
from the feed air before the air enters the adsorbers.
Feed Air Regulator
The feed air regulator is set at the AirSep Corporation factory. The feed air regulator
controls the amount of air pressure at which the oxygen generator cycles.
Filter Drain Valve
This automatic valve removes moisture from the filters through tubing connected to
an outlet at the back of the oxygen generator.
Flow Controller (Not available on AS-20 and AS-450 — AS-1000 models)
The flow controller ensures consistent flow of the delivered product oxygen.
Manual Filter Outlet Valve
This manual valve controls the flow of feed air from the feed air regulator after the
filters to the automatic feed air valves.
Manual Inlet Valve
This manual valve controls the flow of feed air from the air compressor to the filter
assembly.
Particulate Filter (Not available on AS-20 model)
The particulate filter, or prefilter, removes particulates from the feed air before the
air enters the coalescing filter and then the adsorbers.
Pressure Switch
When the oxygen generator operates in Auto mode, the pressure switch monitors
the oxygen pressure in the oxygen receiver. When the pressure in the oxygen
receiver increases to approximately 380-415 kPa (55-60 psig), the pressure switch
circuit closes and the oxygen generator starts a timed shutdown that stops the unit
at the end of the shutdown sequence. When the pressure in the oxygen receiver
decreases to approximately 310 kPa (45 psig), the pressure switch opens to
activate the oxygen generator, and oxygen production begins. When the oxygen
generator operates in Manual mode, the pressure switch circuit remains open and
the oxygen generator cycles continuously.
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AirSep® Corporation 12/02
Relief Valves (not shown)
The relief valves, one on each adsorber, ensure that the pressure in the adsorbers
does not exceed the rated maximum pressure of the adsorbers.
Transformer
The transformer provides the proper voltage for the electrical components of the
oxygen generator.
AS-20—1000 Instruction Manual 4-7
AirSep® Corporation 12/02
5.0 Installation
5.1 Handling and Unpacking
AirSep Corporation ships the oxygen generator on a wooden skid covered by a
container. The container also includes an accessory box containing all the
accessories for the unit and an instruction manual needed to install the unit
properly. The oxygen receiver, if supplied, is shipped on a separate skid.
To unpack the oxygen generator, follow these guidelines:
1) Inspect the shipping container, and open it immediately upon receipt.
2) If the exterior of the carton is severely damaged, note it on the freight bill
before you sign it.
You must submit a damage claim within 24 hours of receipt.
In the case of concealed or hidden damage, a claim must be
filed within 15 days of receipt. A claim can be filed only by
the consignee. The AirSep Product Warranty does not
shipping damage.
cover
3) Unpack the unit, and remove any protective wrapping and packaging. Retain
the carton and packaging to facilitate future shipping and transporting of the
unit.
4) Place the unit in an upright position, and thoroughly inspect the enclosure
and all external components (e.g., control panel) for damage.
5) Open the enclosure or control panel, and inspect the interior for loose or
damaged parts.
To prevent electrical shock, make sure the main power supply
is disconnected when you remove the enclosure, inspect the
internal components, and install the oxygen generator and
oxygen receiver.
6) Inspect all wiring to ensure that no wires are broken and no push-on
connector is off its terminal. If a wire is disconnected, reconnect the wire to
the most obvious terminal.
7) After inspecting the interior, close the enclosure or control panel on the unit.
8) Locate the instruction manual inside the accessory box. Read the entire
manual before installing and operating the unit.
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12/02 AirSep® Corporation
5.2 Pre-installation Guidelines
Before you install the oxygen generator, and oxygen receiver, if supplied, refer to
the Specifications section in Appendix A of this instruction manual to determine
applicable floor space, feed air, and power requirements for your particular model.
The oxygen generator may use feed air at specifications outside
those shown in Appendix A of this instruction manual; however,
use of such feed air may require modification of the oxygen
generator at the AirSep Corporation factory to ensure the
product oxygen meets the specifications shown in Appendix A.
Consult your sales representative to determine whether your
oxygen generator requires modifications for your application.
Locate the oxygen generator in an area where the ambient air
temperature remains between 4°C (40°F) and 44°C (111°F) to
prevent damage not covered under the AirSep Corporation
Product Warranty.
To prevent fire or electrical shock, locate the oxygen generator
away from rain or any other type of moisture.
Make sure the area that surrounds the oxygen generator is well
ventilated, and provide sufficient space around the unit [at least
one meter (three feet)] to allow for cool air flow as well as to
allow safe operation and maintenance.
AirSep oxygen generators are sold for use in industrial
applications only. Contact AirSep Corporation or an authorized
AirSep representative before you use this unit for any medical
application.
5-2 AS-20—1000 Instruction Manual
AirSep® Corporation 12/02
Do not disconnect protective earth:
5.3 Installation Instructions
Refer to Figure 5-1 below for the recommended installation arrangement for the
oxygen generator. The numbers in the drawing correspond to the step numbers in
this section.
1
4
Figure 5-1 Typical Installation Arrangement
3
2
1) Connect the red air hose provided with the oxygen generator accessories
from the on-site air supply to the feed air inlet connection on the oxygen
generator. Refer to the Table 5.1 to determine the proper size for the feed air
inlet connection and feed air hose for your model.
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12/02 AirSep® Corporation
Model Feed Air Inlet Connection Size Feed Air Hose Size
AS-20,
AS-45
AS-80
AS-160,
AS-250
AS-450
AS-750 1” NPT Female fitting next to V-2 1” ID minimum
AS-1000 1” NPT Female fitting next to V-2 1” ID minimum
¼” NPT female bulkhead fitting with a ¼” NPT
male x ¼” NPSM ball-end joint adapter
¼” NPT female bulkhead fitting with a ¼” NPT
male x ⅜” NPSM ball-end joint adapter
½” NPT female bulkhead fitting with a ½” NPT
male x ¾” NPSM ball-end joint adapter
¾” NPT female bulkhead fitting with a ¾” NPT
male x ¾” NPSM ball-end joint adapter
Table 5-1 Feed Air Connection Sizes and Hose Sizes
¼” ID minimum
⅜” ID minimum
½” ID minimum
¾” ID minimum
2) Install your oxygen receiver. If AirSep Corporation provided your oxygen
receiver, assemble the receiver as follows (See Figure 5-2.):
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