AirSep AS-A User manual

Suggested List Price $75.00 (U.S.D.)
AirSep®Corporation
PSA Oxygen Generator
Models AS-A – AS-P
Instruction Manual
MN011-1 Rev A
AirSep®Corporation •260 Creekside Drive •Buffalo, NY 14228-2075 USA
Phone: [phone] •Fax: [phone] •www.airsep.com

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
AS-A—AS-P Series Instruction Manual i
Table of Contents
1.0 Introduction ..................................................................................... 1-1
1.1 General .............................................................................................1-1
1.2 Warnings, Cautions, and Notes ........................................................1-1
1.3 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 ...........................................................................2-2
3.0 System Description ......................................................................... 3-1
3.1 General .............................................................................................3-1
4.0 Components Description................................................................ 4-1
4.1 External Components .......................................................................4-1
4.2 Control Panel ....................................................................................4-3
4.3 Manifold Components.......................................................................4-4
4.4 Accessory Kits ..................................................................................4-8
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 ................................................................................6-3
6.5 Extended Shutdown..........................................................................6-4
6.6 Start-up after an Extended Shutdown...............................................6-4

AirSep®Corporation
ii AS-A—AS-P Series Instruction Manual
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..................................... 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..........................................................7-7
8.0 Troubleshooting ..............................................................................8-1
8.1 Technical Support.............................................................................8-1
8.2 Troubleshooting Chart ......................................................................8-1
AAppendix Technical Data ............................................................... A-1
BAppendix Warranty/Returns .......................................................... B-1
CAppendix Parts List ........................................................................ C-1
DAppendix Component Literature ................................................... D-1

AirSep®Corporation
AS-A—AS-P Series Instruction Manual iii
List of Illustrations
Figure 4.1: External Components — Front View ..................................... 4-1
Figure 4.2: Control Panel — AS-B and AS-D Models .............................. 4-3
Figure 4.3: Manifold Components — AS-B Model................................... 4-4
Figure 4.4: Manifold Components — AS-L Model ................................... 4-5
Figure 5.1: Typical Installation Arrangement........................................... 5-3
Figure 7.1: Interior View of AS-B Model ................................................... 7-3
Figure 7.2: Pressure Switch for AS-A – AS-D .......................................... 7-8
Figure A.1: Typical Pressure Profile and Valves Cycle Sequence...... A-17
Figure A.2: Typical Installation Arrangement ....................................... A-18
Figure A.3: General Arrangement Drawing – AS-A .............................. A-19
Figure A.4: Flow Schematic – AS-A....................................................... A-20
Figure A.5: Electrical Schematic – AS-A (120 V) .................................. A-21
Figure A.6: Electrical Schematic – AS-A (240 V) .................................. A-22
Figure A.7: General Arrangement Drawing – AS-B .............................. A-23
Figure A.8: General Arrangement Drawing – AS-D .............................. A-24
Figure A.9: Flow Schematic – AS-B and AS-D...................................... A-25
Figure A.10: Electrical Schematic – AS-B and AS-D (120 V) ............... A-26
Figure A.11: Electrical Schematic – AS-B and AS-D (240 V) ............... A-27
Figure A.12: General Arrangement Drawing – AS-D+ .......................... A-28
Figure A.13: Flow Schematics – AS-D+................................................. A-29
Figure A.14: General Arrangement Drawing – AS-E ............................ A-30
Figure A.15: Flow Schematic – AS-E..................................................... A-31

AirSep®Corporation
iv AS-A—AS-P Series Instruction Manual
Figure A.16: General Arrangement Drawing – AS-G ............................ A-32
Figure A.17: Flow Schematic – AS-G..................................................... A-33
Figure A.18: General Arrangement Drawing – AS-J ............................. A-34
Figure A.19: Flow Schematic – AS-J...................................................... A-35
Figure A.20: General Arrangement Drawing – AS-K ............................ A-36
Figure A.21: Flow Schematic – AS-K ..................................................... A-37
Figure A.22: General Arrangement Drawing – AS-L............................. A-38
Figure A.23: Flow Schematic – AS-L ..................................................... A-39
Figure A.24: General Arrangement Drawing – AS-N ............................ A-40
Figure A.25: Flow Schematic – AS-N ..................................................... A-41
Figure A.26: General Arrangement Drawing – AS-P............................. A-42
Figure A.27: Flow Schematic – AS-P ..................................................... A-43
Figure A.28: Electrical Schematic – AS-D+ thru AS-P - I...................... A-44
Figure A.29: Electrical Schematic – AS-D+ thru AS-P – II.................... A-45
Figure A.30: Electrical Schematic – AS-D+ thru AS-P – III................... A-46

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 1-1
1.0 Introduction
1.1 General
This instruction manual provides description of the AirSep Corporation PSA
Oxygen Generator Models AS-A, AS-B, AS-D, AS-D+ AS-E, AS-G, AS-J, AS-K,
AS-L, AS-N and AS-P, 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.

AirSep®Corporation
1-2 AS-A—AS-P Series Instruction Manual
1.3 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 description of the oxygen generator components for each model.

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 2-1
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 air by
volume. Although classified as a non-flammable gas, oxygen supports combustion.
As an active element, it combines directly or indirectly with all the 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 the 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)
near 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.

AirSep®Corporation
2-2 AS-A—AS-P Series Instruction Manual
Before you attempt to install, operate, or repair the oxygen
generator, read and thoroughly understand this instruction
manual and the component manuals located in the 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
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:
"Installation of 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.

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 2-3
"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.

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 3-1
3.0 System Description
3.1 General
Air Contains 21 % oxygen, 78% nitrogen, 0.9% argon, and 0.1% other gases.
AirSep PSA Oxygen units separate oxygen from compressed air through a unique
Pressure Swing Adsorption (PSA) process. 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, and then, a
separate coalescing filter (mounted on most of the models) 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 the 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.
This instruction manual serves as the guidelines for the standard AS-A thru AS-P
models. Refer to the illustrations, located in the Appendix A of this instruction
manual, for the detailed flow diagram, electrical schematic, and the general
arrangement drawings of the oxygen generator models referenced in this
instruction manual.

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 4-1
4.0 Components Description
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 of this instruction manual for
general layout drawings and specifications for all the 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.
AS-B Series Model AS-E Series Model
Figure 4.1: External Components — Front View
A
dsorbers
Control Panel
Enclosure

AirSep®Corporation
4-2 AS-A—AS-P Series Instruction Manual
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). It is present only in AS-A thru AS-
D models. The control system components are inside the control panel in the AS-
D+ thru AS-P models.
Disconnect power before opening and/or removing enclosure.
Power Cord
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. In the event of different type electrical connection, 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-D+ through AS-P series 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 Connections
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.

AirSep®Corporation
AS-A—AS-P Series Instruction Manual 4-3
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 (not applied for all the models).
4.2 Control Panel
The control panel on the oxygen generator contains the controls needed to operate
the oxygen generator and monitor its operation. An example of a typical control
panel is shown in Figure 4-2. Not all components are available on every generator.
On the AS-D+ through AS-P models, the gauges are mounted directly on the
manifolds and the hour meter is inside the control panel.
Figure 4.2: Control Panel — AS-B and AS-D 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 the oxygen
demand. In the MANUAL position, the oxygen generator cycles continuously. The
yellow 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.
A
uto/Manual
Switch
Oxygen
Receiver
Pressure
Gauge
Manual Drain
Button
Feed Air
Pressure Gauge
On/Off Switch
Hour Meter
Cycle Pressure
Gauge

AirSep®Corporation
4-4 AS-A—AS-P Series Instruction Manual
Hour Meter (Not available on AS-A models)
The hour meter indicates the total number of hours the oxygen generator cycles.
FEED AIR PRESSURE Gauge (Not available on AS-D+ — AS-P 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-D+ — AS-P 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-D+ — AS-P models only)
The adsorber pressure gauges indicate the pressure in the two adsorbers.
OXYGEN RECEIVER/PRODUCT OXYGEN PRESSURE Gauge
The OXYGEN RECEIVER/PRODUCT OXYGEN PRESSURE gauge indicates the
oxygen pressure at the oxygen receiver/product manifold outlet.
4.3 Manifold Components
Figures 4-3 and 4-4 below illustrate the manifold components of the oxygen
generator. The location and the presence of components may vary between the
various models of the generators.
Figure 4.3: Manifold Components — AS-B Model
Manual Air Inlet
Valve
Filter Drain Valve
Particulate Filter
Coalescing Filter
Feed Air Regulator
Manual Filter Outlet Valve
Muffler
Flow Controller
Feed Air Valves
Equalization Valves
Pressure Switch
Waste Valves