Air Techniques AirStar AS10 User manual

Installation and Operation Manual
DENTAL AIR SYSTEM

Page 3Air Techniques, Inc.
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
FIGURE TITLE PAGE
1 AirStar Parts Location ....................................... 6
2 Overall Site Requirements .................................... 9
3 Left and Right Head Assembly Installation ........................10
4 Left and Right Head Assembly Motor Connections .................11
5 AirStar Electrical Connections .................................13
6 Moisture Monitor and 5 Micron Filter Location .....................17
7 AirStar Filter Location........................................18
8 Service Timer ..............................................19
TABLE OF CONTENTS
LIST OF ILLUSTRATIONS
SECTION PAGE
Congratulations .......................................................4
Safety Instructions .....................................................5
Key Parts Identification .................................................6
Sizing Guide .........................................................7
Operating Information ..................................................7
Site Requirements .....................................................8
Installation Information ................................................ 10
Troubleshooting ...................................................... 15
Maintenance ........................................................ 17
Replacement Parts ................................................... 20
Optional Accessories .................................................. 20
Product Specifications ................................................. 21
Warranty ........................................................... 22
On-Line Warranty Registration .......................................... 22

Air Techniques, Inc. Page 4
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
Your AIRSTAR generates 100% oil-less, ultra-dry dental air which protects valuable hand-
pieces 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 envi-
ronment 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
Uninterrupted Compressor Availability
Maximum Dryness with Quadruple Filtered Air
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.
CONGRATULATIONS

Page 5Air Techniques, Inc.
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
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
Air Techniques, Inc.
1295 Walt Whitman Road
Melville, New York, USA 11747- 3062

Air Techniques, Inc. Page 6
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
Figure 1. AirStar Parts Location
KEY PARTS IDENTIFICATION
View A. Front View
View C. Input Power Connection Detail View
Power Line Cord
Control
Box
View D. Tank Outlet Assembly Detail View
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
Service
Timer
View B. Right -Side View
Cooler
Membrane
Dryer
Membrane Dryer
Drain Valve

Page 7Air Techniques, Inc.
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
AS10, AS12, 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, AS40, AS50, AS70 and AS100
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
AS12 1 - 2 1 1
AS21 2 - 3 2 1
AS22 2 - 3 2 1
AS30 3 - 4 2 2
AS40 4 - 5 3 2
AS50 5 - 7 4 2
AS70 7 - 10 6 3
AS100 10-14 8 2
SIZING GUIDE

Air Techniques, Inc. Page 8
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
SITE REQUIREMENTS
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 in3or more than 100 ft. of 1/2" diameter
pipe, a pressure regulator should be installed between the main tank and the distribution
piping. Set pressure to pressure switch cut in value (factory set at 85 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.
Storage and Transport:
Temperature, -18 to 65°C (0 to 150°F).
Relative Humidity, 0 to 90%.
IEC 60601-1 Classification:
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):
- All Modes Except AS100: Continuous
- AS100 Only: 50% Duty Cycle; Maximum
Continuous ON Time of 20 Min

Page 9Air Techniques, Inc.
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
SITE REQUIREMENTS
Site Electrical Requirements
AS10 AS12 AS21 AS22 AS30 AS40 AS50 AS70 AS100
Nominal Supply Voltage (VAC, see note) 120 220 120 220 220 220 220 220 220
Frequency (Hz) 60 60 60 60 60 60 60 60 60
Full Load Amps 8 4 15 8 8 12 16 24 20
Minimum Panel Breaker Rating (Amps) 20 10 30 20 20 20 30 40 30
Minimum. Wire Size (AWG) 12 16 10 12 12 12 10 8 10
Requirement
AirStar Model
Note: Install a buck or boost transformer if actual facility service is above or below the
supply voltage fluctuation of ±10% of nominal voltage ratings listed.
Figure 2. Overall Site Requirements
Remote 24 Volt Switch with
Pilot Light (sold separately)
3/8” FNPT End fitting
1/2” Copper Main Air Line
Control Cable 18 Gauge 4 Conductor
Connect to Pressure Switch.
See 24 Volt Circuit Connections.
13” max
Building Power
Supply Panel
Buck/Boost
Transformer
(optional)
Remote Air Intake Kit Manifold - Kit
includes 2 inch PVC Pipe and flexible
hose with 70 inches of clear tubing for
connection to the air intake of each
compressor. See Note 1.
Type Style
AS10 5-20R
NEMA*
AS21
AS12
6-20R
NEMA*
AS22
AS30
AS40
AS50 Hard
Wired**
See Figure 3
for Connection
Details.
AS70
AS100
Green
Dot
Green
Dot
OUTSIDE AIR PIPE
2-Inch Pipe for Air Intake.
Must be protected from rain and animals
Shroud &
Screen
Screen
Rear Clearance
12 inches minimum
from wall
Drip Leg with Drain Valve
See Note 2
36 Inch
Maximum
Height
Maximum 24
inches from
main air line
Membrane Dryer
Drain Valve
See Note 3
Notes:
1. Remote Air Intake Kit Manifold - Refer to the
Optional Accessories listing, page 18, for the kit part number
corresponding to the AirStar model.
2. Remote Air Intake Drip Leg & Valve - A drip leg
with drain valve must be installed at lower end of the
remote air intake pipe to collect condensation during
operation. Attach a drain tube to the drip leg valve to allow
drainage into oor drain/sink.
3. Membrane Dryer Drain Valve - See Key Parts
Identification, page 6, and install the Drain Tube found in
either accessory kit P/N 87133 or P/N 87134 used to drain
moisture collected in the Membrane Dryer.
Side
Clearance
12 inches
*Use Hospital Grade
Receptacle Only
** Only AS100 Models
use 3-Phase Power.
Disconnect Needed
when Servicing.

Air Techniques, Inc. Page 10
AS10, AS12, AS21, AS22, AS30,
AS40, AS50, AS70, & AS100
INSTALLATION INFORMATION
AS100 ASSEMBLED at the SITE
Installing Left and Right Head Assemblies
All AIRSTAR models, except the AS100, are shipped assembled and can be installed upon
delivery by following the installation guidelines for plumbing and electrical connections provided
by pages 12 & 13. The AS100 is shipped as separate assemblies that must be assembled
during installing the system at the site
Place the tank assembly in the installation space; then perform the following procedure to
install the left and right head assemblies onto the AS100 tank assembly.
Left head installation.
Move air hose A and B to make sure they are not damaged during installation.
Orient the left head with its electrical box on the right side.
Align the 4 screw holes of the mounting plate with the 4 left shock mounts.
Install the head assembly onto the 4 left shock mounts and secure with 4 nuts
provided with the head assembly accessory kit.
Right head installation.
Move air hose A and B to make sure they are not damaged during installation.
Orient the right head with its electrical box on the left side.
Align the 4 screw holes of the mounting plate with the 4 right shock mounts.
Install the head assembly onto the 4 right shock mounts and secure with 4 nuts
provided with the head assembly accessory kit.
Each assembly (tank and
heads) weighs over 100 pounds
and requires two people to lift.
Figure 3. Left and Right Head Assembly Installation
Facing Electrical
Connection
Boxes Mounting
Plate
Mounting
Plate
Left Head
Assembly
Right Head
Assembly
Left
Shock
Mounts
Air
Hose A
Air
Hose B Right
Shock
Mounts
Front
Membrane
Dryer
Front
Cooler
Rear
Membrane
Dryer
Rear
Cooler