AirSep AS-Q User manual

INSTRUCTION MANUAL
ALPHA SERIES
AS-Q – AS-Z
PSA Oxygen Generators

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

Tables 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 FILTER ASSEMBLY 18
4.4 PRESSURE SWITCH SUB-ASSEMBLY 19
4.5 PRODUCT OUTPUT SUB-ASSEMBLY 19
4.6 FEED AND WASTE MANIFOLD ASSEMBLY 21
4.7 EQUALIZATION AND PURGE MANIFOLD ASSEMBLY 22
4.8 CONTROL PANEL: INTERNAL COMPONENTS 22
4.9 CONTROL PANEL: EXTERNAL COMPONENTS 23
4.10 CONTROL PANEL: INTERNAL COMPONENTS 30
5.0 Installation
5.1 HANDLING AND UNPACKING 33
5.2 PRE-INSTALLATION GUIDELINES 34
5.3 INSTALLATION INSTRUCTIONS 35

6.0 Operation
6.1 GENERAL 39
6.2 INITIAL START-UP 40
6.3 OPERATION 42
6.4 SHUTDOWN 43
6.5 NORMAL START-UP 43
6.6 EXTENDED SHUTDOWN 44
6.7 START-UP AFTER AN EXTENDED SHUTDOWN 44
7.0 Maintenance
7.1 GENERAL 45
7.2 DAILY MAINTENANCE 45
7.3 SEMI-ANNUAL MAINTENANCE 46
7.4 ANNUAL MAINTENANCE 47
8.0 Troubleshooting
8.1 GENERAL 51
8.2 TECHNICAL SUPPORT 51
8.3 TROUBLESHOOTING CHART 52
A. Appendix Technical Data
A.1 SPECIFICATIONS 57
A.2 DRAWINGS AND SCHEMATICS 63
A.3 ELECTRICAL SCHEMATICS – AS-Q – AS-Z 71
B. Appendix Warranty/Returns
B.1 PRODUCT WARRANTY 75
B.2 LIMITS OF LIABILITY 76
B.3 RETURNING THE OXYGEN GENERATOR OR A COMPONENT
FOR SERVICE 76
C. Appendix Component Literature
C.1 PROGRAMMABLE LOGIC CONTROLLER 79

C.2 TOUCHSCREEN 96
C.3 FILTERS 104
C.4 PRESSURE TRANSDUCER 116
C.5 VALVES AND ACTUATORS 126
C.6 PRESSURE SWITCH 171
C.7 MAGNALUBE-G 174
C.8 MISCELLANEOUS 192
D. Appendix Decommissioning/Disposal
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: Typical Filter Assembly 18
Figure 4.3: Typical Product Output Sub-assembly 19
Figure 4.4: Typical Feed & Waste Manifold Assembly 21
Figure 4.5: Typical Main System Control Screen 23
Figure 4.6: HMI Navigation Layout 25
Figure 4.7: Typical Oxygen Generator Screen 26
Figure 4.8: Typical Parameters and Output Screen 27
Figure 4.9: Typical Bed Pressure Graphs Screen 27
Figure 4.10: Typical Bed Pressure Calibration Screen 28
Figure 4.11: Feed Air Pressure Transducer Assembly 28
Figure 4.12: Bed Pressure Transducer Assembly 29
Figure 5.1: Typical Oxygen Outlet Manifold on Oxygen Receiver 37
Figure 5.2: Oxygen Sample Control Panel Connection 37
Table 6.1: Manual Valve Position Chart 40
Table 7.1: Maintenance Chart 45
Table A.1: AS-Q Specifications 58
Table A.2: AS-R Specifications 59
Table A.3: AS-W Specifications 60
Table A.4: AS-Z Specifications 61
Table A.5: Typical System Set points 62
Figure A.1: Typical Pressure Profile and Valves Cycle Sequence 63
Figure A.2: Typical Installation Arrangement 64
Figure A.3: General Arrangement Drawing – AS-Q 65
Figure A.4: General Arrangement Drawing – AS-R 66
Figure A.5: General Arrangement Drawing – AS-W 67
Figure A.6: General Arrangement Drawing – AS-Z 68
Figure A.7: P&ID Drawing – AS-Q, AS-R, AS-W and AS-Z 69
Figure A.8: Electrical Schematic – Sheet 1 70
Figure A.9: Electrical Schematic – Sheet 2 71

Figure A.10: Figure A.10: Electrical Schematic – Sheet 3 72
Figure A.11: Electrical Schematic – Sheet 4 73

AS-Q—AS-Z Series Instruction Manual 11
AirSep Corporation
1.0 Introduction
1.1 GENERAL
This instruction manual provides a description of the AirSep Corporation PSA
Oxygen Generator Models AS-Q, AS-R, AS-W and AS-Z, 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-Q—AS-Z 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-Q—AS-Z 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 7 — 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 022699101 USA.
■“Oxygen;” Pamphlet G4; Compressed Gas Association; 1725
Jefferson Davis Highway; Arlington, Virginia 222024102 USA.
■“Cleaning Equipment For Oxygen Service,” Pamphlet G4.1;
Compressed Gas Association; 1725 Jefferson Davis Highway;
Arlington, Virginia 222024102 USA.

AS-Q—AS-Z 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-Q through
AS-Z 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-Q—AS-Z 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 concentration 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.
Adsorber Vessels
Equalization Manifold
Product o/p Manifold
Control Panel
Filter Assembly
Feed & Waste Manifold
Pressure Transducer
for Bed A (PT2)
Pressure Transducer
for Bed A (PT3)
Pressure Transducer
for Bed A (PT4)
Figure 4.1: External Components — Front View

18 AS-Q—AS-Z 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 FILTER ASSEMBLY
The lter assembly consists of two lters. The particulate lter, or pre-lter, removes
particulates from the feed air before the air enters the coalescing lter and the
coalescing lter removes condensed water, oil vapor, and other contaminants
from the feed air before the air enters the adsorbers.
V-1
V-D1
V-D2
Figure 4.2: Typical Filter Assembly
Particulate Filter Drain (V-D1)
This automatic valve removes moisture from the particulate lter.
Coalescing Filter Drain (V-D2)
This automatic valve removes moisture from the coalescing lter.
Manual Feed #1 Valve (V-1)
This manual valve (if available) controls the ow of feed air from the air
compressor to the lter assembly.

AS-Q—AS-Z Series Instruction Manual 19
AirSep Corporation
4.4 PRESSURE SWITCH SUB-ASSEMBLY
The assembly is located before the inlet ball valve (V-2) of the feed and waste
manifold (Section 4.6). It solves the purpose of monitoring the feed air pressure.
The assembly also regulates the ow of air through all the automatic valves.
Manual Valve to Pressure Switch
This manual valve controls the ow of air to the pressure switch on the oxygen
generator. The valve should not be closed at any circumstance while the unit is
running.
4.5 PRODUCT OUTPUT SUB-ASSEMBLY
The product output sub-assembly directs the oxygen ow to the oxygen receiver
and the pressure transducer (PT4).
Connects to Equalization
Manifold Outlet Outlet for Oxygen
Hose Connection
Manual Valve
for PT4
Manual Valve
for Calibration
of PT4
V-3
PT4
Figure 4.3: Typical Product Output Sub-assembly

20 AS-Q—AS-Z Series Instruction Manual
AirSep Corporation
Manual Product Valve (V-3)
This manual valve controls the ow of oxygen from the product manifold to the
oxygen receiver.
Manual Valve to Pressure Transducer (PT4)
This manual valve controls the ow of oxygen to the pressure transducer (PT4) on
the oxygen generator. The valve should not be closed at any circumstance while the
unit is running except for the purpose of calibration.