AirSep ALPHA Series User manual

INSTRUCTION MANUAL
ALPHA SERIES
AS-D+ – AS-P
PSA Oxygen Generators
(with touchscreen)

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/Postal Code
Country
Fax
Phone
Cell
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.

Symbols/Abbreviations
Symbols are frequently used on equipment in preference to words with the intention
of lessening any possibility of misunderstanding caused by language differences.
Symbols can also permit easier comprehension of a concept within a restricted
space.
The following table is a list of symbols and denitions that may be used with AirSep’s
AS Series Nitrogen Generator. These symbols are referenced from the appropriate
International Electro-technical Commission (IEC) standards:
Symbol Description Symbol Description
ON (power switch on) 0OFF (power switch off)
No smoking Do not disassemble
Date of manufacture Consult instructions for use
Warning – Describes a hazard or
unsafe practice that if not avoided
can result in severe bodily injury,
death or property damage
See Instructions
Caution – Describes a hazard or
unsafe practice that if not avoided
can result in minor bodily injury or
property damage
Complies with the 93/42/
EEC directive drawn up by the
approved organization No. 0029
Note – Provides information
important enough to emphasize
or repeat
Safety agency for CAN/CSA
C22.2 No. 601.1 M90 for medical
electrical equipment
Consult the accompanying
documents Keep unit and accessories dry
Use no oil or grease
Proper disposal of waste
of electrical and electronic
equipment required
Catalog number Do not expose to open ames
Safety agency for CAN/CSA
C22.2 No. 601.1 M90 for medical
electrical equipment
Keep in the vertical position
Fragile – handle with care Serial number
Manufacturer
EC REP
Authorized Representative in the
European Community

Table of Contents
1.0 Introduction
1.1 GENERAL 11
1.2 WARNINGS, CAUTIONS, AND NOTES 11
1.3 REFERENCES TO CONTROLS AND INDICATORS WITH TAGS
OR LABELS 11
2.0 Safety
2.1 GENERAL 13
2.2 POTENTIAL HAZARDS 13
2.3 SAFETY PUBLICATIONS 14
3.0 System Description
3.1 GENERAL 15
4.0 Components Description
4.1 EXTERNAL COMPONENTS 17
4.2 ADSORBERS 18
4.3 CONNECTIONS 18
4.4 MANIFOLD COMPONENTS 19
4.5 CONTROL PANEL: EXTERNAL COMPONENTS 21
4.6 CONTROL PANEL: INTERNAL COMPONENTS 28
4.7 ACCESSORY KITS 29
5.0 Installation
5.1 HANDLING AND UNPACKING 33
5.2 PRE-INSTALLATION GUIDELINES 34
5.3 INSTALLATION INSTRUCTIONS 35
5.4 INITIAL START-UP 38
5.5 OPERATION 40
5.6 SHUTDOWN 40
5.7 EXTENDED SHUTDOWN 41

5.8 START-UP AFTER AN EXTENDED SHUTDOWN 41
6.0 Maintenance
6.1 DAILY MONITORING 43
6.2 MONTHLY MONITORING 43
6.3 DEPRESSURIZING THE FILTERS 44
6.4 CHANGING FILTER ELEMENTS 45
6.5 DEPRESSURIZING THE OXYGEN GENERATOR 46
6.6 ADJUSTING THE FEED AIR REGULATOR 46
7.0 Troubleshooting
7.1 TECHNICAL SUPPORT 49
7.2 TROUBLESHOOTING CHART 49
A. Appendix Technical Data
A.1 SPECIFICATIONS 55
A.2 DRAWINGS AND SCHEMATICS 65
A.3 ELECTRICAL SCHEMATICS – AS-D+ – AS-P 83
B. Appendix Warranty/Returns
B.1 PRODUCT WARRANTY 87
B.2 LIMITS OF LIABILITY 88
B.3 RETURNING THE OXYGEN GENERATOR OR A COMPONENT
FOR SERVICE 88
C. Appendix Component Literature
C.1 PROGRAMMABLE LOGIC CONTROLLER 91
C.2 TOUCHSCREEN 108
C.3 FILTERS 116
C.4 REGULATORS 129
C.5 VALVES 133
A.1 MAGNALUBE-G 175
C.6 MISCELLANEOUS 193

D. Appendix
D.1 OXYGEN GENERATOR DECOMMISSIONING AND DISPOSAL
GUIDELINE 195

List of Figures and Tables
Figure 4.1: External Components — Front View 17
Figure 4.2: Manifold Components — AS-L Model 19
Figure 4.3: Typical Main System Control Screen 22
Figure 4.4: HMI Navigation Layout 24
Figure 4.5: Typical Oxygen Generator Screen 25
Figure 4.6: Typical Parameters and Output Screen 25
Figure 4.7: Typical Bed Pressure Graphs Screen 26
Figure 4.8: Typical Bed Pressure Calibration Screen 27
Figure 4.9: Feed Air Pressure Transducer Assembly 28
Table 4.1: Description of the Parts included in the Starter Kits 29
Table 4.2: Additional Available Accessories 31
Figure 5.1: Typical Installation Arrangement 35
Table 5.1: Feed Air Connection Sizes and Hose Sizes 35
Table 5.2: Oxygen Outlet Connection Sizes 36
Figure 5.2: Oxygen Sample Control Panel Connection 37
Table 6.1: Maintenance Chart 43
Table A.1: AS-D+ Specifications 56
Table A.2: AS-E Specifications 57
Table A.3: AS-G Specifications 58
Table A.4: AS-J Specifications 59
Table A.5: AS-K Specifications 60
Table A.6: AS-L Specifications 61
Table A.7: AS-N Specifications 62
Table A.8: AS-P Specifications 63
Table A.9: Typical System Set points 64
Figure A.1: Typical Pressure Profile and Valves Cycle Sequence 65
Figure A.2: Typical Installation Arrangement 66
Figure A.3: General Arrangement Drawing – AS-D+ 67
Figure A.4: Flow Schematics – AS-D+ 68
Figure A.5: General Arrangement Drawing – AS-E 69

Figure A.6: Flow Schematic – AS-E 70
Figure A.7: General Arrangement Drawing – AS-G 71
Figure A.8: Flow Schematic – AS-G 72
Figure A.9: General Arrangement Drawing – AS-J 73
Figure A.10: Flow Schematic – AS-J 74
Figure A.11: General Arrangement Drawing – AS-K 75
Figure A.12: Flow Schematic – AS-K 76
Figure A.13: General Arrangement Drawing – AS-L 77
Figure A.14: Flow Schematic – AS-L 78
Figure A.15: General Arrangement Drawing – AS-N 79
Figure A.16: Flow Schematic – AS-N 80
Figure A.17: General Arrangement Drawing – AS-P 81
Figure A.18: Flow Schematic – AS-P 82
Figure A.19: Electrical Schematic – Sheet 1 83
Figure A.20: Electrical Schematic – Sheet 2 84
Figure A.21: Electrical Schematic – Sheet 3 85
Figure A.22: Electrical Schematic – Sheet 4 86

AS-D+—AS-P Series Instruction Manual 11
AirSep Corporation
1.0 Introduction
1.1 GENERAL
This instruction manual provides a description of theAirSep Corporation PSAOxygen
Generator Models 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 keeping 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.
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 identied by tags or labels. Numbers inside parentheses
(e.g., V-2) identify manually operated ow controls (e.g., manual valves). Refer to
Chapter 4 for description of the oxygen generator components for each model.

AS-D+—AS-P Series Instruction Manual 13
AirSep Corporation
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-fth of air by
volume. Although classied as a non-ammable 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 aame.
To reduce the risk of re or explosion, keep gasoline, kerosene, oil,
grease, cotton bers, wood, paint, and other combustible material
away from all parts of the oxygen generator.
Do not allow smoking, open ame, 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 re or explosion, oxygen clean all surfaces that can come in
contact with the product oxygen. Check all oxygen ttings for leaks
with an oxygen-compatible, leak-detecting solution.
To prevent re or electrical shock, locate the oxygen generator
indoors, away from rain or any other type of moisture.
Before attempting to install, operate, or repair the oxygen
generator, read and thoroughly understand this instruction manual
and the component manuals located in the Appendix C of this
instruction manual. Improper installation, operation, or repairs can
result in severe bodily injury, damage to the oxygen generator, or
poor performance.

14 AS-D+—AS-P Series Instruction Manual
AirSep Corporation
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 servicing the oxygen generator.
AirSep oxygen generators are sold for use in commercial
applications only. Contact AirSep Corporation, or an authorized
AirSep representative, before using this unit for any medical
application.
Disconnect power before servicing oxygen generator.
Do not disconnect protective earth
Cet appareil produit de l’oxygène à concentration élevée,
favorisant une combustion rapide. Ne pas permettre de fumer ou
des ammes nues dans la même chambre: (1) cet appareil ou (2)
tout accessoire contenant de l’oxygène. Ne pas utiliser de produits
à base d’huile, de graisse ou de pétrole sur ou à proximité de
l’unité. Déconnecter le cordon d’alimentation de la prise électrique
avant de nettoyer ou de faire l’entretien de l’unité.
Risque de choc électrique.Seuls votre fournisseur d’équipement ou
un technicien de service qualié devrait faire l’entretien de l’unité.
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.
■“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-D+—AS-P Series Instruction Manual 15
AirSep Corporation
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 ows through
a lter assembly before the air enters the adsorber vessels. A particulate lter
removes condensed water, oil, dirt, scale, etc. from the feed air and then a separate
coalescing lter (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-D+ through
AS-P models. Refer to the illustrations, located in the Appendix A, for the detailed
ow diagram, electrical schematic, and the general arrangement drawings of the
oxygen generator models referenced in this instruction manual.

AS-D+—AS-P Series Instruction Manual 17
AirSep Corporation
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 the Appendix for general layout drawings and
specications 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 ow 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 the external components viewed from the front of the
oxygen generator.
Adsorbers
Control Panel
Alarm Horn
Oxygen Sample
Regulator
(Set at 1 psig)
AS-G Series Model
Figure 4.1: External Components — Front View

18 AS-D+—AS-P Series Instruction Manual
AirSep Corporation
4.2 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.
4.3 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.
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 lters (not applied for all the models).

AS-D+—AS-P Series Instruction Manual 19
AirSep Corporation
4.4 MANIFOLD COMPONENTS
Figure 4.2 below illustrates the manifold components of the oxygen generator. The
location and the presence of components may vary between the various models of
the generator.
Bed A
Feed Valves Mufers
Particulate Filter
Feed Air Regulator
Coalescing Filter
Filter Drain Valve
Manual Air Inlet
Valve (V-2)
Manual Air Inlet
Valve (V-1)
Waste Valve
Bed B
Equalization
Valve
Check
Valves
Pressure
Transducer
PI-2
Pressure
Transducer
PI-3
Pressure
Transducer
PI-1
Manual Product
Valve (V-3)
Figure 4.2: Manifold Components — AS-L Model

20 AS-D+—AS-P Series Instruction Manual
AirSep Corporation
Manual Air Inlet Valve (V-1)
This manual valve controls the ow of feed air from the air compressor to the lter
assembly. It is named manual feed # 1 valve (V-1).
Particulate Filter
The particulate lter, or prelter, removes particulates from the feed air before the
air enters the coalescing lter and then the adsorbers.
Coalescing Filter
The coalescing lter 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. It controls the maximum
oxygen generator cycle pressure. The setting of the regulator is customized as per
the demand of oxygen for your application. Please ensure that the feed air regulator
setting is not changed before consulting AirSep Corporation.
Setting the feed air regulator to a value such that the maximum
oxygen generator cycle/bed pressure is 80 psig or more can cause
severe damage to the molecular sieve in the adsorbers which will
not be covered under AirSep’s warranty.
Filter Drain Valve
This automatic valve removes moisture from the lters through tubing connected to
an outlet of the lters.
Manual Filter Outlet Valve (V-2)
This manual valve controls the ow of feed air from the feed air regulator after the
lters to the automatic feed air valves. It is named manual feed # 2 valve (V-2).
Automatic Feed Air Valves
The automatic feed air valves control the ow of the feed air as the air enters the
adsorbers.
Automatic Waste Valves
The automatic waste valves control the ow of waste gas as it exits the adsorbers.
Pneumatic Equalization Valve
The pneumatic equalization valve enables the pressure in the adsorbers to equalize
after the product oxygen exits from one of the adsorbers.