AirSep Topaz User manual

Suggested List Price: US $25.00
AirSep Corporation
PSA Oxygen Generator
Topaz/Topaz+/Topaz Ultra
Instruction Manual
MN012-2 03/12 Rev. C
AirSep®Corporation x260 Creekside Drive xBuffalo, NY 14228-2075 USA
Phone: [phone] xFax: [phone] xwww.airsep.com

Topaz/Topaz+/Topaz Ultra
Ownership Data
Please take a moment to note below important information about your portable PSA Oxygen
Cylinder Filling System. Retain this instruction manual, along with your invoice, to serve as a
permanent record of your purchase.
PSA Oxygen System
Model Name:
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 or operate the oxygen generator, read and
thoroughly understand this instruction manual. Improper operation can
result in severe bodily injury, damage to the oxygen system, or poor
performance.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual i
Table of Contents
1.0 Introduction...............................................................................................................1-1
1.1 General.................................................................................................................1-1
1.2 Warnings, Cautions, and Notes............................................................................1-1
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 Internal Components ............................................................................................4-3
5.0 Installation ................................................................................................................5-1
5.1 Handling and Unpacking ......................................................................................5-1
5.2 Pre-installation Operational Check.......................................................................5-2
5.3 Installation Instructions.........................................................................................5-3
6.0 System Operation.....................................................................................................6-1
6.1 Start-up.................................................................................................................6-1
6.2 Operation..............................................................................................................6-1
6.3 Shutdown .............................................................................................................6-1
7.0 Maintenance.............................................................................................................7-1
7.1 Cleaning the Gross Particle Filter.........................................................................7-1
7.2 Cleaning the Enclosure ........................................................................................7-2
7.3 Solenoid Valves....................................................................................................7-2
7.4 Air Compressor ....................................................................................................7-3
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
ii Topaz/Topaz+/Topaz Ultra Instruction Manual
List of Illustrations
Figure 4.1 - Oxygen Generator External Components........................................................4-1
Figure 4.2 - Oxygen Generator Internal Components.........................................................4-3
Figure A.1 - Flow Schematic - Topaz................................................................................. A-5
Figure A.2 – Flow Schematic – Topaz+ .............................................................................. A-6
Figure A.3 – Flow Schematic – Topaz Ultra ....................................................................... A-7
Figure A.4 – 100/110/120 V, 50 or 60 Hz Electrical Schematic .......................................... A-8
Figure A.5 – 240 V, 50 or 60 Hz Electrical Schematic ........................................................ A-9

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 1-1
1.0 Introduction
1.1 General
This instruction manual provides a description of the AirSep PSA Oxygen
Generators – Topaz/Topaz+/Topaz Ultra as well as instructions for
installation, operation, and maintenance. The Appendix of this instruction
manual also provides 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 the 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.
Provides information that can prevent minor bodily
injury or property damage.
Provides information important enough to emphasize
or repeat.

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Topaz/Topaz+/Topaz Ultra 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, it forms about one-fifth of our
air by volume. Although oxygen is classified as a non-flammable gas, it
supports combustion. As an active element, it combines directly or
indirectly with all elements except the rare gases. It is an invisible gas that
is colorless, odorless, and tasteless.
To ensure your safety, thoroughly read and familiarize yourself with this
section of the manual. AirSep Corporation strongly recommends that you
review this section periodically.
2.2 Potential Hazards
Before you attempt to install, operate or repair the oxygen generator, read
and thoroughly understand this manual. Improper operation can result in
severe bodily injury, damage to the unit, or poor performance.
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 avoid fire or an explosion, keep gasoline,
kerosene, oil, grease, cotton fibers, paint, and any
other combustible material away from any part of the
oxygen generator.
Do not smoke or use an open flame near the oxygen
generator.
Post “NO SMOKING OR OPEN FLAMES” signs in the
area where the oxygen generator is located. AirSep
Corporation STRONGLY recommends that only
individuals trained and experienced in the safe handling
of oxygen operate this unit.
Take extreme care to keep all oxygen piping and
vessels clean. To avoid fire or an explosion, oxygen-
clean all surfaces that can come in contact with
oxygen. Check all oxygen fittings/joints for leaks with
an oxygen-compatible leak-detecting solution.

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2-2 Topaz/Topaz+/Topaz Ultra Instruction Manual
Electrical shock hazard. Only trained personnel may
open the oxygen generator. The interior of the
oxygen generator contains electrical parts that can
produce an electrical hazard if not handled properly.
Connect the oxygen generator power cord to a
properly grounded wall outlet on a circuit that cannot
be accidentally turned off. Do not use extension
cords. Do not position the generator in an area that
makes it difficult to disconnect the power.
To prevent fire or electrical shock, locate the oxygen
generator indoors away from rain or any other type of
moisture.
2.3 Safety Publications
This section is not a complete summary of required safety procedures.
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.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 3-1
3.0 System Description
3.1 General
The AirSep Corporation PSA Oxygen Generator is a self-contained unit
that uses Pressure Swing Adsorption (PSA) technology to produce
oxygen on site. The PSA process extracts oxygen from ambient air to
deliver product oxygen continuously to an application that requires feed
oxygen.
The oxygen generator uses compressed air from its internal air
compressor as a feed gas to produce the product oxygen. Ambient air
enters the air intake, passes through a gross particle filter to remove large
airborne particulate matter, then flows into the internal air compressor.
The air compressor pressurizes the feed air and delivers the feed air to a
heat exchanger for cooling. The cooled, pressurized air then enters one
of the adsorber vessels.
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 and flow into a mixing tank,
which maintains stable flow and purity of the product oxygen. The product
oxygen flows from the mixing tank through a pressure regulator that
allows the delivery pressure to be set as required for your application.
Finally, the product oxygen flows through a flowmeter, which allows you to
set the flow rate required for 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 Appendix A of this instruction manual for a detailed flow
diagram, an electrical schematic, and specifications for the oxygen
generator.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 4-1
4.0 Components Description
The drawings in this section illustrate the location of the main components of the
Topaz/Topaz+/Topaz Ultra oxygen generators. All models include similar
components unless noted otherwise. Refer to Appendix A of this instruction
manual for general layout drawings and specifications.
4.1 External Components
Left Side Right Side
Figure 4.1 - Oxygen Generator External Components
Enclosure
The enclosure protects the components inside the unit (e.g., circuit board,
air compressor, and valves).
Gross Particle Filter
The washable gross particle filter removes airborne particulate matter
from the room air drawn into the unit.
Enclosure
A
ir Exhaus
t
Flowmete
r
Oxygen
Outlet
Circuit
Breaker
Power Cord
Connection
I/O Power
Switch
Oxygen
Pressure
Gauge
Gross
Particle Filte
r
Fuse

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4-2 Topaz/Topaz+/Topaz Ultra Instruction Manual
Oxygen Pressure Gauge
This gauge indicates the delivery pressure of the product oxygen.
Flowmeter
The flowmeter allows you to view and adjust the flow rate of the product
oxygen. The flowmeter should never be adjusted beyond the setpoint
designated for the unit in Appendix A.
Increasing the flowmeter beyond the setpoint
designated for the particular model can potentially
cause damage to the molecular sieve and will void the
warranty.
Oxygen Outlet
The ‘B’ size adapter at the oxygen outlet connects to your application.
Air Exhaust
Heat from the unit escapes through the air exhaust, located on the left
side of the enclosure.
Power Cord
The power cord (not shown) and its grounded plug connect from a
connection (See Figure 4.1) on the unit to a properly grounded electrical
outlet to supply electrical power to the unit.
l/O Power Switch
The l/O power switch starts and stops the operation of the unit. When you
set the switch to l, the green indicator light illuminates.
Circuit Breaker
Use the circuit breaker button to reset the unit after an electrical overload
shutdown.
Fuse
For the 240 V units, an additional fuse safety is provided as per the CE
regulations.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 4-3
4.2 Internal Components
Front View
Rear View
Figure 4.2 - Oxygen Generator Internal Components
Cycle Pressure
Gauge
Pressure
Regulator
A
ir Compresso
r
Cooling Fan
Hour Meter
Circuit Board
Valve Block
Capacitor
Heat Exchanger
A
dsorbers
Equalization Valve
Mixing Tank
Intake Resonator
Terminal Strip
Exhaust Muffler

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4-4 Topaz/Topaz+/Topaz Ultra Instruction Manual
Intake Resonator
The intake resonator reduces noise from the air compressor (See Below).
Air Compressor
The air compressor pressurizes ambient air and delivers it to the
adsorbers (See Below).
Cooling Fan
The cooling fan increases airflow inside the enclosure to cool the air
compressor. The models without enclosures do not have a fan installed.
Capacitor
The capacitor stores additional electrical power to enable the air
compressor to start.
Heat Exchanger
The heat exchanger cools the pressurized air from the air compressor.
Adsorbers (Sieve Beds)
The adsorbers, or sieve beds, contain the molecular sieve that adsorbs
(attracts) nitrogen from compressed air and allows oxygen to pass
through as the product gas.
Cycle Pressure Gauge
The cycle pressure gauge indicates the pressure inside the sieve beds.
The cycle pressure gauge does not indicate the
pressure set by the pressure regulator. The oxygen
pressure gauge on the right side of the enclosure
indicates the pressure set by the pressure regulator.
Valve Block
The valve block houses the solenoid valves.
Equalization Valve
The equalization valve balances the pressure between the two sieve
beds.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 4-5
Circuit Board
The circuit board controls the cycle time and sequence of each solenoid
valve.
Terminal Strip
The terminal strip provides a connection point for the wiring to the circuit
board and the air compressor.
Mixing Tank
The mixing tank provides stable flow and purity for short-term surge in
oxygen demand.
Pressure Regulator
The pressure regulator controls the delivery pressure of the product
oxygen. This regulator is factory set and should never be adjusted.
Changing the regulator setpoint in any way can
potentially cause damage to the molecular sieve and
will void the warranty.
Exhaust Muffler
The exhaust muffler allows waste gas to exit the adsorbers.
Hour Meter
The hour meter indicates the total number of hours that the unit cycles.

AirSep®Corporation
Topaz/Topaz+/Topaz Ultra Instruction Manual 5-1
5.0 Installation
5.1 Handling and Unpacking
AirSep Corporation ships the oxygen generator in a heavy-duty cardboard
carton with two cutout carrying handles. The unit’s size and weight allow
easy transport by manual lifting; however, the enclosure does not
provide handles or wheels because it is intended for stationary operation.
To facilitate transport of the oxygen generator, place the unit in the carton
and use the handles on the carton to lift the package. Use a hand cart to
transport the unit safely to a different location.
To unpack the oxygen generator, follow these guidelines:
1) Inspect the shipping carton, 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.
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., flowmeter) for
damage.
5) Remove the enclosure, and inspect the interior for loose or
damaged parts.
Only trained personnel may open the oxygen
generator. To prevent electrical shock, make
sure the main power supply is disconnected
when you remove the enclosure and inspect
the internal components.
6) Inspect all wiring to ensure that no wires are broken and no
push-on connector is off its terminal.
You must submit a damage claim within 24
hours of delivery. A claim can be filed only
by the consignee.
7) After inspecting the interior of the enclosure, re-install the
enclosure on the unit.

AirSep®Corporation
5-2 Topaz/Topaz+/Topaz Ultra Instruction Manual
8) Locate the plastic bag that contains the instruction manual, extra
gross particle filter, and a barb connection for the oxygen outlet.
Be sure to read the entire manual before installing and operating
the unit.
5.2 Pre-installation Operational Check
Although every oxygen generator is tested thoroughly after it is
manufactured, perform the following test to ensure that no damage
occurred during shipping and handling:
1) Make sure the enclosure fastens securely to the unit.
2) Make sure the gross particle filter (See Figure 4.1) completely
covers the air intake.
3) Make sure the power cord connects securely to the power cord
connection (See Figure 4.1) on the unit.
4) Connect the power cord to a properly grounded electrical outlet.
5) Set the l/O power switch (See Figure 4.1) to l. Verify that the
green indicator light on the switch illuminates.
6) Listen for the sound of the air compressor (See Figure 4.1) in
operation.
7) Verify that exhaust air emits from the air exhaust (See Figure
4.1) on the left side of the enclosure.
8) Rotate the knob on the flowmeter (See Figure 4.1) clockwise
until it stops at the fully-closed position. Verify that the flowmeter
indicates zero flow.
9) Rotate the knob on the flowmeter counterclockwise until the
flowmeter indicates the flow specified in Appendix A for the
particular model of oxygen generator with nothing connected to
the oxygen outlet. The ball in the flowmeter should rise and the
oxygen pressure gauge should register 62 kPa (9 psig) for
Topaz and 138 kPa (20 psig) for Topaz+ and Topaz Ultra. If
this does not occur, contact the AirSep Commercial Products
Service Department.
10) If flowmeter setting is disturbed during shipping, adjust the
flowmeter to the flow rate specified. Refer to Appendix A for the
specified flow rates.
11) Set the l/O power switch to O.