Air Techniques AirStar AS10 User manual

Installation and Operation Manual
DENTAL AIR SYSTEM

SECTION PAGE
Safety Instructions .................................................... 2
Congratulations....................................................... 3
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
On-Line Warranty Registration ........................................... 3
Key Parts Identification ................................................. 4
Sizing Guide ......................................................... 5
Operating Information .................................................. 5
Site Requirements .................................................... 6
Installation Information ................................................. 8
Troubleshooting ......................................................10
Maintenance .........................................................12
Replacement Parts ....................................................14
Optional Accessories ..................................................14
Product Specifications .................................................15
FIGURE TITLE PAGE
1 AirStar Parts Location ........................................ 4
2 Overall Site Requirements .................................... 7
3 Electrical Connection......................................... 8
4 Moisture Monitor and 5 Micron Filter Location .....................12
5 AirStar Filter Location ........................................13
TABLE OF CONTENTS
LIST OF ILLUSTRATIONS
2
Use of the AIRSTAR not in conformance with the instructions specified in this manual may result in per-
manent failure of the unit.
WARNING: To prevent fire or electrical shock, do not expose this appliance
to rain in or moisture.
All user serviceable items are described in the maintenance section.
Manufacturing date code on serial number label is in the format Month YYYY.
ATTENTION USERS:
SAFETY INSTRUCTIONS
Alerts users to important Operating
and Maintenance instructions. Read
carefully to avoid any problems.
Warns users that uninsulated voltage
within the unit may be of sufficient
magnitude to cause electric shock.
MEDICAL ELECTRICAL EQUIPMENT
WITH RESPECT TO ELECTRICAL SHOCK, FIRE, MECHANICAL AND OTHER SPECIFIED HAZARDS ONLY
IN ACCORDANCE WITH UL-60601-1, CAN/CSA C22.2 NO.601.1
66CA
Indicates the ON and OFF position for
the Equipment power switch.
I ON
O OFF Indicates protective Earth Ground for the
Equipment power switch.
All AirStar compressors comply with
NFPA 99C level 3 requirements
Indicates that the equipment complies with
the Medical Device Directive 93/42/EEC.
Medical Device Safety Service
Schiffgraben 41
30175 Hannover, Germany
EC REP

3
Your AIRSTAR generates 100% oil-less, ultra-dry dental air which protects valuable handpieces
from premature failure due to the effects of moist air and the build-up of oil residue. Because no
oil is used for mechanical lubrication, there is no chance of introducing an oily film to a prepared
surface which could compromise resin retention and restorations, wasting chair time. Most
important, your patients’s health is protected with ultra-dry air that provides an environment
that is not conducive to bacterial growth.
The AIRSTAR utilizes a long stroke, small bore piston to compress the air. This piston is bonded
with an anti-friction polymer to eliminate the need for oil. The air is forced through the Membrane
Dryer System consisting of the cooler and the membrane. This system removes moisture and
air impurities providing the driest possible compressed air while maximizing performance. This
100% ultra-dry air is reserved in the main storage tank for use by the operatory air system.
The AIRSTAR features include:
• Virtually Maintenance Free • Low Pressure Dew Point
• Maximum Dryness with Quadruple Filtered Air • Uninterrupted Compressor Availability
• Compact size for space-saving installation
Since 1971, when Air Techniques pioneered the manufacture of oil-less air for dentistry,
thousands of dentists have depended on their AIRSTAR. Now that your practice has an
AIRSTAR , you, too, can depend on the delivery of 100% oil-less, ultra-dry air and efficient,
trouble-free operation.
Quickly and easily register your new AIRSTAR on-line. Just have your product model and serial
numbers available. Then go to the Air Techniques web site, www.airtechniques.com/dental,
click the warranty registration link and complete the registration form. This on-line registration
ensures a record for the warranty period and helps us keep you informed of product updates
and other valuable information.
WARRANTY
CONGRATULATIONS
ON-LINE WARRANTY REGISTRATION
Each AIRSTAR is warranted to be free from defects in material and workmanship from the date
of installation for a period as follows:
Standard Warranty: 2 years (24 months) on complete unit.
Extended Warranty: 3 years (36 months) all motors, heads and pistons.
Total 5-year Warranty on all motors, heads and pistons.
Any item returned to our factory through an authorized distributor, will be repaired or replaced at our
option at no charge provided that our inspection shall indicate it to have been defective. Dealer
labor, shipping and handling charges are not covered by this warranty.
This warranty does not apply to damage due to shipping, misuse, careless handling or repairs
by other than authorized service personnel. Warranty is void if equipment is installed or
serviced by other than dealer service personnel authorized by Air Techniques. Air Techniques,
Inc. is not liable for indirect or consequential damages or loss of any nature in connection with
this equipment.
This warranty is in lieu of all other warranties expressed or implied. No representative or person
is authorized to assume for us any liability in connection with the sale of our equipment.

4
Figure 1. AirStar Parts Location
KEY PARTS IDENTIFICATION
View B. Right -Side View
View A. Front View
View C. Input Power Connection Detail View
Power Line Cord
Control
Box
View D. Tank Outlet Assembly Detail View
Cooler
Membrane
Dryer
Pressure
Gauge
Supplied
Air Outlet
Hose
Tank Outlet
Valve
5 Micron
Filter
Moisture
Monitor
Pressure
Relief
Valve
Drain
Valve
Pressure
Switch
Control
Box
Motor
Power
Switches
24V Circuit
Breaker
Motor
Circuit
Breaker
Main Tank
Check Valve
Sound Reducing
Intake Filters Membrane
Dryer

5
AS10, AS21 and AS22
If a remote Control Panel is being used, the circuit breaker on the face of the
compressor Control box must be in the ON position.
The 24 volt circuit breaker must also be in the ON position. Make sure the reset
button is flush with the face of the circuit breaker. If it isn’t, push it in to reset.
If a Remote Control Panel is not being used, be sure that the yellow and the
orange wires are connected to one another. These wires are located in the
pressure switch. The circuit breaker located on the face of the compressor
Control Box is the power control for the motor.
AS30, AS50 and AS70
If a Remote Control Panel is being used, ALL switches on the face of the com-
pressor Control Box must be in the ON position.
If a Remote Control Panel is not being used, be sure that the yellow and the
orange wires are connected to one another. These wires are located on the pressure
switch. The power switches located on the face of the compressor Control Box are
the power control for each motor.
Note: Compressor motors are designed to run together. Do not run one head
at a time unless one head has failed and you are waiting for service.
The motor circuit breaker must be kept in the ON position and should not be used
as a switch.
OPERATING INFORMATION
Choosing the correct size AIRSTAR for your practice depends on the number of air
users and the anticipated air demand. To assure optimum compressor operation, the
air demands should not exceed the number of air handpiece users shown in the chart
below:
Model Recommended
Number of Users
Number of
Heads
Number of
Motors
AS10 1 - 2 1 1
AS21 2 - 3 2 1
AS22 2 - 3 2 1
AS30 3 - 4 2 2
AS50 5 - 7 4 2
AS70 7 -1 0 6 3
SIZING GUIDE

6
* Install a buck or boost transformer if service is above or below these ratings
Service Clearance: Allow 12" on all sides for all models.
Ambient Temperature: Must not exceed 105°F
Air System Plumbing Connection: 3/8" F.N.P.T. Shut-off valve and a 6 ft. pressure
hose (supplied)
Air distribution piping for all models -
1/2", type "L" or type "K" copper
If pipe volume is too great, more than 235 in3
or more than 100 ft. of 1/2" diameter pipe, a
pressure regulator should be installed between
the main tank and the distribution piping and
pressure set at 80 PSI.
Environmental:
Operating Indoor use at altitudes up to 2000m. Temperature
5 to 40°C (41 to 105°F).
Maximum relative humidity 80% for temperatures
up to 31°C, decreasing linearly to 50% relative
humidity at 40°C.
Supply voltage fluctuation of +/- 10% of nominal
voltage.
Classification:
IEC 60601-1
Protection against electric
shock (5.1, 5.2). Class I
Applied Parts: There are no Applied Parts.
Protection against harmful
ingress of water (5.3). Ordinary, IPXO
Degree of safety in the presence
of flammable anesthetics mixture
with air or with oxygen or with
nitrous oxide (5.5). Not suitable.
Mode of operation (5.6). Continuous
SITE REQUIREMENTS
AIRSTAR
10
AIRSTAR
21
AIRSTAR
22
AIRSTAR
30
AIRSTAR
50
AIRSTAR
70
Voltage Min/Max * (VAC) 105/125 105/125 200/250 200/250 200/250 200/250
Frequency (Hz) 60 60 60 60 60 60
Full Load Amps 8.0 15.0 8.0 8.0 16.0 24.0
Minimum Circuit Breaker Rating (Amps) 20 30 20 20 30 40
Minimum. Wire Size (AWG) 12 10 12 12 10 8
Requirement
AirStar Model

7
Figure 2. Overall Site Requirements
SITE REQUIREMENTS
Remote 24 Volt Switch with Pilot Light
(sold separately)
3/8” FNPT End fitting
1/2” Copper Main Air Line
Compressor Interconnect Cable Remote Switch
for Future Use
Use 18 Gauge, 4 Conductor, Interconnect Cable Between Compressor and Remote Switch
Connection to 24 V Switch Only Connection without
24 V Switch
Electrical Box Connections
Yellow 2
Brown 4
Orange 3
2
4
3
2
Yel
4
Brn
3
Org
Type Style
AS10 5-20R
NEMA*
AS21
AS22 6-20R
NEMA*
AS30
AS50 Hard
Wired**
AS70
L1
L2
GND
Building Power
Supply Panel
36” max 2” Pipe & flexible hose for
Air Intake supplied with
Remote Air Intake Kit Manifold
13” max
Control Cable 18
Gauge 3 Conductor
Connect to orange,
yellow & brown wire
OUTSIDE AIR PIPE
2-Inch Pipe for Air Intake.
Must be protected from rain and animals
Shroud &
Screen
Screen Shroud &
Screen
Remote Air Intake
Kit Manifold
(see detail) Drip
Leg
Buck/Boost
Transformer
(optional)
Equipment Power
Connection
Plug or Hardwire
as Required
Air
Intake
Kit includes 70” of clear PVC
Tubing per Number of Cylinders
Air Intake Manifold Detail
Apply Teflon Tape To
Threads and Screw
Fitting Into Filter
12” min
24” max
12”
min
36” max distance
between intake
pipe & compressor
*Hospital Grade Receptacle
**Disconnect Needed for Service
Green
Dot
Green
Dot

8
AIRSTARs are installed by authorized Air Techniques dealer service technicians. Please review these installa-
tion guidelines to make sure that your AIRSTAR will work to capacity for your office. (See Site Requirements,
pages 6 and 7)
Your AIRSTAR should be installed in a well ventilated area, with at least 12 inch
clearance on each side for service access and to prevent overheating during high demand periods. If
other equipment is located in the vicinity, the ambient temperature of the area must not exceed 105°F.
The installation site should be clean and dry to prevent the air intake filters from clogging. If there is a
concern about the quality of air where the AIRSTAR is placed, we recommend an optional Remote
Air Intake (See Optional Accessories, page 14) which allows the compressor to intake clean air from a
remote location.
Air distribution piping for all models should be 1/2", type "L" or type "K" copper.
The minimum voltage for an AS10 or AS21 is 105 Volts. The minimum voltage required for an AS22,
AS30, AS50 or AS70 is 200 Volts. Install a boost transformer if the service is below these ratings.
Note: If voltage is higher than 125V/250V, install a bucking transformer.
AIR SYSTEM PLUMBING CONNECTION:
The Tank Outlet Assembly (See Figure 1, View A), (the storage tank outlet for the dry air) is connected to
the operatory air system via a 3/8" F.N.P.T. shut-off valve and 6 foot length of pressure hose (supplied).
ELECTRICAL CONNECTION:
If your AIRSTAR comes with a line cord, plug it into a hospital grade electrical outlet.
If your AIRSTAR comes with open electrical connections, it must be wired directly in accordance with
local electrical codes. (See Figure 3 below.)
INSTALLATION INFORMATION
GREEN
BLACK
WHITE
Figure 3. Electrical Connection Box
SOME AIRSTAR
MODELS
L1
L2
GND

9
POST INSTALLATION CHECK
Make Sure Everything Is Running Properly
After your AIRSTAR has been installed and before it is put into operation, be sure to follow
the check-out procedure detailed below:
Check that Intake Filter(s) are fully seated into the compressor head(s) and that the Tank
Outlet Valve is closed.
Turn on the electricity. Check the incoming line voltage. It should be at least 105 Volts
for the AS10 and AS21; and 200 Volts for the AS22, AS30, AS50 and AS70. This
voltage should remain at or above these levels while the AIRSTAR is running. If
not, install the appropriate boost transformer and check that the correct main circuit
breaker and wire size are being used.
Check pump-up and recovery times as detailed below and compare to the times in
the table.
Turn on the AIRSTAR’s power and determine the pump-up time from 0-115 PSI.
See the table below.
Drain the storage tank to 80 PSI and determine the recovery time from 85 to 115 PSI.
See the table below.
INSTALLATION INFORMATION
If the recovery time differ as listed above, call authorized dealer for service.
Model Number of
Motors/Heads
Pump-up Time
0-115 PSI Maximum
Recovery Time
85-115 PSI Maximum
AS10 1/1 2 minutes, 55 seconds 48 seconds
AS21 1/2 3 minutes, 10 seconds 47 seconds
AS22 1/2 3 minutes, 10 seconds 47 seconds
AS30 2/2 3 minutes, 10 seconds 47 seconds
AS50 2/4 2 minutes, 50 seconds 42 seconds
AS70 3/6 2 minutes, 40 seconds 40 seconds

10
TROUBLESHOOTING
Problem Possible Cause Possible Solutions
1. Motor does not start. a. No electric power. a. Check circuit breaker at main power
panel.
b. Power not connected. b. Check 24 Volt remote connections.
c. Defective circuit breaker. c. Circuit breaker needs to be replaced.
Call your authorized Air Techniques
dealer for service.
2 .Motor tries to start,
circuit breaker trips off.
(* See bottom page 10)
a. Voltage too low.If each
compressor head runs
separately,but will not run
together, the voltage is too low.
a. AS10 and AS21 require a minimum of
105 Volts. AS22, AS30, AS50 and AS70
require a minimum of 200 Volts. If the
voltage is below the required minimum,
a boost transformer must be installed.
Call your authorized dealer.
b. Power supply cable too small. b. See SITE REQUIREMENTS Table.
c. Loose electrical connection. c. Call your authorized dealer for service.
3. Unusual noise. a. Intake filter(s) not seated cor-
rectly.
a. Remove filter(s). Replace if clogged or
dirty. When installing, make sure filter
chamber is clean and rubber flange on
top of filter is pushed all the way down
into the metal cylinder
b. Intake filter(s) clogged or dirty. b. Replace filter(s). ( PN 89831)
c. Motor noise. c. Call your authorized dealer for service.
d. Air leaks d. Call your authorized dealer for service.
e. Check cooling fans e. If fan is loose or broken, call your
authorized dealer for service.
4 Compressor cycles but
no pressure buildup to
115 psi.
a. Motor noise. a. Replace filter(s). ( PN 89831)
b. Leak in compressor. b. Close the storage tank outlet valve.
Check all fittings for leaks. If a leak is
found, call your authorized dealer for
service.
c. Pressure switch needs to be
adjusted.
c. Disconnect the main power supply.
Drain the storage tank slowly until a
“click” is heard. Storage tank pressure
should read 85 PSI on the pressure
gauge.
Close the tank outlet valve, turn on the
power switch and verify the pump-up
time for your model AirStar. Call your
authorized dealer if the pump-uptime is
incorrect. (See Post Installation Check
for pump-up times.)

11
*DIAGNOSTIC PROCEDURE FOR DEFECTIVE COMPRESSOR HEAD(S)
1. Put power switches in the OFF position.
2. Reset the circuit breaker if it was previously tripped.
3. Test heads by turning ONE on at a time. If the motor fails to start, or the circuit breaker trips, the problem may be in that compressor
head. Leave the power switch for the effective head in the OFF position. Call your Authorized Air Techniques dealer for service.
NOTE: One head may be run TEMPORARILY while waiting for service.
4. If all heads run independently, but will not run together, check the line voltage. If the voltage is within the min./max. voltage required
in PRODUCT SPECIFICATIONS, call your Authorized Air Techniques dealer for service.
TROUBLESHOOTING
Problem Possible Cause Possible Solutions
5. Compressor cycles
even when there is no
air demand from the
operatory.
a. Leak in the compressor. a. Disconnect the main power supply.
Drain the storage tank slowly until a
“click” is heard. Storage tank pressure
should read 85 PSI on the pressure
gauge.
Close the tank outlet valve, turn on
the power switch and verify the pump-
up time for your model AirStar. Call
your authorized Air Techniques dealer
if the pump-uptime is incorrect. (See
Post Installation Check for pump-up
times.)
b. Leak in the office air system. b. Look at the moisture monitor
(see KEY PARTS to locate).
If it is blue, perform the following:
1. With the AirStar’s power switch
ON, drain the storage tank to
85 PSI to start the compression
cycle.
2. When the cycle shuts off at 115
PSI, close the storage tank outlet
valve.
3. Wait 5 minutes and open the stor-
age tank outlet valve.
4. If the pressure drops, the air leak
is in the office air system or deliv-
ery units and not in the AirStar.
Call your dealer or plumber for
service.
If it is pink, see #6 below
6. Moisture monitor is not
blue (pink or white).
a. Leak in the office air system. a. If the moisture monitor is pink, there is
too much moisture in the system. Call
your authorized Air Techniques dealer
for service.
b. Compressor keeps cycling. b. Check the SIZING GUIDE. There may
be excessive air demands placed on
the AirStar. A larger capacity model
may be required.

12
Like all precision products, your AIRSTAR requires a certain amount of care on a regularly
scheduled basis. A well-organized maintenance program aids dependable equipment operation
and reduces problems to a minimum. Routine checks help to detect general overall wear, and
replacement of parts can often be made before a problem occurs.
Understanding this, we have established minimum maintenance requirements listed below
that include routine inspections and the replacement of filters using preventative maintenance
kits available for the specific AIRSTAR model. Adherence to this recommended maintenance
schedule will ensure that the equipment will continue performing at its best with uninterrupted
service.
Routine Inspection - Monthly
Clean exterior surfaces.
Check for abnormal noises and air leaks.
Make sure that no ammable, corrosive, or combustible materials are stored in
the equipment room (especially in the area around the equipment).
Check operational range of pressure switch is between 85-115 psi.
Inspect the Moisture Monitor (Figure 4) for a color change:
Blue indicates that the air in the storage tank is dry.
Pink indicates a high level of humidity is in the storage tank. See TROUBLESHOOTING
page 11 to correct this situation.
Note: To comply with NFPA 99C, a 5-micron Filter is installed on the output of all AIRSTAR models.
Routine Inspection - Yearly
Refer to Figure 4 and check the Service Indicator on the 5-micron Outlet Filter.
Red indicates that the lter must be replaced P/N 87168.
Green indicates No service is required.
Figure 4.
Moisture Monitor and 5-Micron Filter Location
MAINTENANCE
Moisture
Monitor
5 Micron
Filter
Service
Indicator

13
MAINTENANCE
Important: In dusty environments, the Intake Filter, PN 89938, may need to be changed more often than
once a year.
Always dispose of the removed filter in accordance with local codes.
Filter Replacement - Yearly
Refer to Figure 5 for the location of filters to be replaced using the preventative mainte-
nance kit for the specific AIRSTAR mode listed below. Replace the filters and associated
O-rings in accordance with the instructions provided with the kit. .
Filter Replacement Kits Supplied Components
AirStar Model AS10 AS21 AS22 AS30 AS50 AS70
Kit Part No 87351 87352 87353 87354
Component Part No. Quantity Quantity Quantity Quantity
Compressor Air Intake Filter 89938 1 2 4 6
Top Membrane Filter 87366 1 1 1 2
Bottom Membrane Filter 87367 1 1 1 2
Top Cover O-ring 87368 1 1 1 2
Filter Bowl O-ring 87369 1 1 1 2
87369
87367
87366
87368
89938 - See Table
for Kit Quantities
Figure 5.
AirStar Filter Location
Membrane Dryer
Top Membrane Filter
P/N 87366
Bottom Membrane Filter
P/N 87367
Note: Top Cover O-ring, P/N 87368, is replaced
with the Top Membrane Filter.
See instructions provided with the kit.
Note: Bottom Cover O-ring, P/N 87369, is replaced
with the Bottom Membrane Filter.
See instructions provided with the kit.
Compressor
Air Intake Filters
P/N 89938
(1 each cylinder head)

14
OPTIONAL ACCESSORIES
Description Model Part Number
REMOTE AIR INTAKE KIT
AirStar 10
AirStar 21, 22, 30
AirStar 50
AirStar 70
85491
85492
85493
85494
REMOTE CONTROL PANEL
w/24 V switches
1-Switch Plate Kit
2-Switch Plate Kit
3-Switch Plate Kit
4-Switch Plate Kit
For all AirStars 53111
53251
53250
53133
SOUND COVER
AirStar 10
AirStar 21
AirStar 22
AirStar 30
AirStar 50
AirStar 70
85961
85962-1M
85962-2M
85963M
89523M
89574M
REPLACEMENT PARTS
Description Part No.
5 Micron Replacement Filter 87168
Filter Replacement Kits
AirStar Model Kit Part No.
AS10 87351
AS21 AS22 AS30 87352
AS50 87353
AS70 87354

15
PRODUCT SPECIFICATIONS
AirStar
10 AirStar 21 AirStar 22 AirStar 30 AirStar 50 AirStar 70
Horsepower/Kilowatts 0.75/0.56 1.5/1.1 1.5/1.1 1.5/1.1 3.0/2.2 4.5/3.3
Voltage Rating 115 115 208/230 208/230 208/230 208/230
Frequency (Hz) 60 60 60 60 60 60
Voltage Min./Max. (VAC) 105/125 105/125 200/250 200/250 200/250 200/250
CFM
(Cubic Ft./Min) @ 80 psi 2.5 5.0 5.0 5.0 10.0 15.0
Pump-up Time
85-115 PSI
2 minutes,
55 secs 3 minutes, 10 secs 3 minutes, 10 secs 3 minutes, 10 secs 2 minutes, 50 secs 2 minutes, 40 secs
Recovery Time
85-115 PSI 48 47 47 47 42 40
Tank Size
(cu. ft.)
(US Gal.)
0.8
6
1.6
12
1.6
12
1.6
12
2.7
20
4.0
30
Shipping Weight
(Approximate lbs)
No Sound Cover
With Sound Cover
170
215
200
240
200
240
240
285
290
335
430
N/A
Dimensions (inches)
No Sound Cover
H
W
D
28.50
25.00
19.75
30.50
29.00
20.00
30.50
29.00
20.00
30.50
29.00
20.00
33.50
35.50
20.50
35.00
47.75
21.75
With Sound Cover
H
W
D
30.00
25.00
22.50
32.00
31.00
22.25
32.00
31.00
22.25
32.00
31.00
22.25
33.50
36.50
22.75
N/A
Requirement
AirStar Model

AirStar is a registered trademark of Air Techniques, Inc.
© Copyright 2009 •P/N 87109, Rev. H •November 2013
www.airtechniques.com
Corporate Headquarters
1295 Walt Whitman Road |Melville, New York 11747- 3062 |Phone: [phone] |Fax: [phone]
Western Facility
291 Bonnie Lane, Suite 101 |Corona, CA 92880 - 2804 |Phone: [phone] |Fax: [phone]
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For over 50 years, Air Techniques has been a leading innovator and manufacturer of dental
products. Our priority is ensuring complete satisfaction by manufacturing reliable products
and providing excellent customer and technical support. Whether the need is digital imaging,
utility room equipment or merchandise, Air Techniques can provide the solution via our network
of authorized professional dealers. Proudly designed, tested and manufactured in the U.S., our
products are helping dental professionals take their practices to the next level.
Air Techniques’ family of quality products for the dental professional include: