Airsep Corporation As-J-600-Hmfm Duplex Psa Oxygen System: Instruction Manual

AirSep® Corporation
AS-J-600-HMFM DUPLEX
PSA Oxygen System
Instruction Manual
Project# PSA18002 & PSA18003

ASSIST INTERNATIONAL
ETHIOPIA
AirSep® Corporation • 260 Creekside Drive • Buffalo, NY 14228-2075 USA

Phone: (716) 691-0202 • Fax: (716) 691-1255 • www.airsep.com
Ownership Data
Please take a moment to note below important information about your AirSep ® Corporation
PSA Oxygen System. Retain this instruction manual, along with your invoice, to serve as a
permanent record of your purchase.
PSA Medical Oxygen System
Model Number: AS-J-600-HMFM DUPLEX
Serial Number: PSA18002 & PSA18003
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 plant, read and
thoroughly understand this operating manual. Improper operation can
result in severe bodily injury, damage to the plant, or poor performance.
1.0 Introduction
1.1 General
This instruction manual provides description of the AirSep Corporation AS-J-600-
HMFM PSA Oxygen System as well as instructions for its installation, operation,
and maintenance. The Appendix of this operating manual also includes pertinent
drawings and component literature.
To ensure safe operation and proper plant maintenance, AirSep Corporation
recommends that you keep this operating 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.
AS-J-600-HMFM DUPLEX Instruction Manual 1-1

1.3 References to Controls and Indicators with
Tags or Labels
This operating 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). These numbers correspond to the labels on the process and
instrumentation diagram located in the Appendix of this operating manual.
Refer to chapter 4 for a description of all the components of the PSA oxygen
system.

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 our air by
volume. Although classified as a non-flammable gas, oxygen supports combustion.
As an active element, it combines directly or indirectly with all 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 this entire
section of this operating 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 system.
Do not allow smoking, open flame, or usage of
electronic devices that may generate sparks (e.g.,
cellular telephones near the oxygen system.
Post “NO SMOKING OR OPEN FLAMES” signs
conspicuously near the location of the oxygen system.
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

plant indoors, away from rain or any other type of
moisture.
Before you attempt to install, operate, or repair the

plant, read and thoroughly understand this operating
manual and the component manuals located in
Appendix of this operating manual. Improper
installation, operation, or repairs can result in severe
bodily injury, damage to the oxygen system, or poor
performance.
The interior of the oxygen system 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 operating manual
before you service the oxygen system of the plant.
Disconnect power before servicing oxygen generating

system.
Do not disconnect protective earth:

2.3 Safety Publications

The safety section of this operating 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.


3.0 System Description
3.1 General
The AirSep Corporation AS-J-600-HMFM DUPLEX PSA Oxygen System is a
self-contained system designed to continuously supply oxygen or to fill
oxygen cylinders with high-pressure oxygen at the design purity. Refer to the
process and instrumentation diagram, located in the Appendix of this
operating manual, for a flow schematic of the plant. Refer to the following
paragraphs for a general description of the operation of the plant:
The PSA system can be used to supply oxygen to the application at a
pressure of 65-70 psig or to fill cylinders at a pressure of 2200 psig using an
oxygen compressor. The general process of the PSA system begins as
atmospheric air enters the air compressor for pressurization and is then
stored in the air receiver tank. The air receiver tank delivers the air to the
oxygen generator. The oxygen generator separates the air into oxygen and
waste gases, and delivers feed oxygen to the oxygen receiver. The feed
oxygen flows from the oxygen tank to the oxygen compressor, which
increases the pressure of the product oxygen. Finally, the high-pressure
product oxygen flows to the oxygen cylinder filling station (mounted on the
oxygen compressor skid) to fill the oxygen cylinders.
A bypass piping is also provided to get the oxygen supply at 65-70 psig from
the oxygen generator directly without using the oxygen compressor. In this
case, a provision for backup supply of cylinders (filled before using the
continuous supply of the oxygen) is also available. The regulator (PR-3) for
the back-up supply cylinders is set for approximately 65 psig. (Refer to the
Process and Instrumentation diagram in the Appendix A) so in the event of
continuous oxygen supply pressure falling below 65 psig, the back up supply
cylinders starts supplying oxygen to the application for a limited period of
time.
A sample of the product oxygen flows from the oxygen receiver to an oxygen
analyzer inside the control panel of the AS-J, which continuously monitors
purity during operation.
The PSA Oxygen System can pressurize multiple oxygen cylinders
simultaneously. The plant operates automatically after start-up: When the
oxygen cylinders become full, the oxygen compressor shuts down to allow
removal of filled cylinders and connection of empty cylinders. At the same
time, the oxygen generator and the air compressor continue operation for a
certain time period to maintain the purity of the product oxygen within the
range specified in the Appendix of this operating manual. The system
behaves in a similar fashion when the application stops using continuous
supply of oxygen i.e. when the oxygen compressor is not used and the PSA
system is supplying oxygen to the customer’s application directly.


4.0 Components Description

All components function as integral parts of the Oxygen System. Maintain all
components as specified in their manuals, which are located in the Appendix of this
operating manual.
4.1 Main Breaker Panel

The main electrical connection to the system is made at the main breaker panel.
The main breaker panel provides electrical overload protection to each component
of the system. Refer to the power distribution diagram for all the electrical
connections for the plant.
4.2 Air Compressor – Kaeser ASD 60T

The air compressor draws ambient air through an inlet air filter and into the
compressor element. The air is then compressed to the desired pressure. The air
compressor also consists of an automatic drain valve. Refer to the appendix C for
the component literature of the air compressor.
Figure 4.1 – Air Compressor, Kaeser A

4.3 Air Receiver

The air receiver stores pressurized air for use by the oxygen generator. The
capacity of the air receiver tank is 120 gallons. The typical air receiver consists of a
ball valve on the inlet and outlet of the receiver, as well as an automatic
condensate drain valve. Please operate the manual drain valve few times daily to
ensure the proper functioning of the automatic drain valve
4.4 Oxygen Generator — AS-J AirSep

Corporation
The AirSep Corporation AS-J PSA Oxygen Generator is an on-site oxygen
generating unit that uses compressed air as a feed gas to produce oxygen. The
oxygen generator uses in its adsorber vessels an inert ceramic material called
molecular sieve to separate air into product oxygen and other gases. The entire
oxygen generating process is completely regenerative, which makes it both reliable
and virtually maintenance-free. Figure 4.2 shows the front of the AS-J. Not shown
in the figure below is the activated carbon filter included on this system.
Equalization Valve
Manual Product
Valve
Muffler
Feed Valve
Manual Air Inlet

Valve
Waste Valve
Feed Air Regulator

Particulate Filter
Coalescing Filter
Figure 4.2: AS-J Series Oxygen Generator

4.5 Oxygen Receiver Tank

The oxygen receiver stores the oxygen produced by the oxygen generator
for delivery to the oxygen compressor or main customer pipeline. The
oxygen receiver also provides stable flow and purity for short-term surges
of oxygen above the rated capacity of the oxygen generator. A solenoid
valve after the oxygen receiver provides automatic isolation of low purity
oxygen. A bacteria filter (FI-1) removes any bacteria from the gas stream.
Relief Valve (RV-2)
Pressure Indicator
(PI 10)
Manual Vent Valve

(V-16)
Manual Oxygen
Sample Valve (V-15)
Manual Oxygen Outlet

Valve (V-14)
Bacteria Filter (FI-1)

Automatic Low Purity
Oxygen Shutdown
Manual Inlet Valve Valve (V-17)
(V-13)
Manual Outlet Valve to Pressure Regulator

Compressor (V-19) (PR-1)
Manual Outlet Valve to Pressure Regulator

Bypass Supply (V-18) (PR-2)
Figure 4.3: Typical Oxygen Receiver (layout may vary)

4.6 Oxygen Compressor — Rix Industries 2V3B

The oxygen compressor pressurizes oxygen from the oxygen receiver and delivers
the pressurized oxygen to the oxygen cylinder-filling manifold on the oxygen cylinder-
filling station. High-pressure oxygen cylinders connect to the oxygen cylinder-filling
manifold and are filled to the set pressure. Refer to the component manual for a
labeled diagram of the compressor.
4.7 Oxygen Cylinder Station

The oxygen cylinder station consists of an oxygen cylinder manifold, a cylinder
rack, and a vacuum pump. The oxygen cylinder manifold supplies high-pressure
product oxygen to the oxygen cylinders. The cylinder rack holds multiple oxygen
cylinders to be pressurized with high-pressure product oxygen at design purity from
the oxygen cylinder manifold.
Vacuum Pump
Connections and
Connections and Pressure Gauge
Pressure Gauge for for Backup Oxygen
Export Oxygen Cylinders
Cylinders
Oxygen Cylinder
Rack
Figure 4.4: Typical Oxygen Cylinder Filling Station
4.8 Vacuum Pump System — Thomas/617BCD22

The vacuum pump system, located on the oxygen cylinder station, uses a
vacuum pump to evacuate any contaminants that may remain in the
oxygen cylinders after use.

Vacuum Gauge
On/Off Switch
Connection Ports
for Cylinder
Evacuation Hoses
Figure 4.5: Typical Vacuum Pump
4.9 Control Panel: External Components

Schneider Electric Touch Screen
The touch screen on the oxygen generator control panel uses a series of screen
pages to perform the following functions:
◼ Provides a normal start-up system
◼ Monitors and controls the operation of the process valves
◼ Monitors signals coming from pressure transducers
◼ Provides an alarm system to indicate malfunctions in the PSA Oxygen
Generating System
◼ Provides a fail-safe shutdown in the event of loss in product
concentration
The main Human/Machine Interface (HMI) consists of the Schneider Electric
Magelis Touch screen. The Magelis has a 5.7” screen, which is touch-sensitive.
In order to make the software simple to use, the various screens follow a
consistent template design. Each screen consists of two components: the title bar
and the information display.

Title Bar
Local
Message
Display
Maintenance
Screen
Figure 4.3: Typical Main System Control Screen
The title bar serves two purposes. It identifies the screen that is currently being
displayed. It also acts as the main navigational tool.
No matter which screen is being currently displayed, touching the AirSep logo will
display the Main System Control screen.
The “Information Display” changes depending on the screen currently displayed.
However, they all share three basic components: Monitoring Devices, Message
Displays, and Interface Mechanisms. Monitoring Devices are components that are
used to relay real-time information about the system, like pressure graphs. Message
Displays are used to relay information pertaining to the system in a text format.
These displays are also used to present help pages that can be used to better
understand the unit. Interface Mechanisms are screen items that can be used to
interface directly with the system. These are in the form of buttons, switches, or
icons.
The Main System Control Screen is the primary source for information on the whole
unit. In the top left corner of the information display are the buttons that will start and
stop the oxygen generator.
Every time an alarm or shutdown condition is displayed on the ‘Local Message
Display’ (Refer to Figure 4.3), rectify the cause and press the ‘Alarm Reset’ icon to
bring the system into normal mode before starting.
The ‘Local Message Display’ icon displays the different status of the generator
namely Stopped, Running, Standby, and Alarm. This display will also show the
recent alarms if you push and hold.

This window will populate with the most recent, highest priority message of the
system. The priorities are listed here, from highest to lowest:
Priority List
I. Runtime Power Loss
II. Emergency Stop
III. Stopped
IV. Shutdown: High Bed Pressure
V. Shutdown: Low Instrument Air
VI. Shutdown: Low Oxygen
VII. Standby
VIII. Stop Sequence Activated
IX. Alarm: High Bed Pressure
X. Alarm: Low Oxygen Concentration
XI. Running
The icons ‘Oxygen Generator’ and ‘Output Parameters’ take the user to
dedicated screens described later in this section. Lastly, by touching ‘Screen
Cleaning’ icon at the bottom right corner of the information display, a blank
screen for cleaning purpose is displayed and the ‘Maintenance’ icon will
display a screen that provides guidelines for the general maintenance of the
unit. The ‘Silence Horn’ icon bypasses the horn for 10 minutes during an
alarm or shutdown condition.
Figure 4.4 below shows the layout of all the screens in HMI for easy navigation.
Oxygen Generator
Bed Pressure Graphs

Main System Control
Output Parameters Output Pressure Graphs
Bed Pressure Calibration
Receiver Calibration
Figure 4.4: HMI Navigation Layout
Permanent Purity
The ‘Oxygen Generator’ Screen (Figure 4.5) is the and primary source of
information pertaining to the actual oxygen generation process. The adsorber
Horn Bypass
vessels (also called beds – Bed A is the bed on your left while facing the
control panel and Bed B is on your right while facing the control panel) are
shown in the center of the screen and the oxygen receiver vessel is shown
on the right hand side of the screen. The receiver has a numeric pressure
display. Additionally, the diagram shown will animate to indicate which valves
are currently being actuated. The ‘AUTO/MAN’ icon selects the operating

mode for the oxygen generator. In the AUTO position, the oxygen generator
cycles on and off to meet oxygen demand.
When the pressure in the product output manifold increases to approximately the
maximum pressure specified in the Appendix A, the oxygen generator stops oxygen
production after a timed delay and enters standby mode. To prevent short cycling
and maintain concentration, the oxygen generator continues to operate for five
additional cycles after increased pressure in the product output manifold. This five-
cycle delay to shutdown functions only in the AUTO mode.
When the pressure in the product output manifold decreases to approximately the
minimum pressure specified in the Appendix A, the oxygen production begins.
In the MANUAL position, the oxygen generator cycles continuously. The symbol
‘A’ at the right side of the ‘AUTO/MAN’ switch appears only when the oxygen
generator is in AUTO mode.
The ‘MANUAL DRAIN’ icon activates the drain valve when pressed.
Figure 4.5: Typical Oxygen Generator Screen
The ‘Parameters and Output’ Screen (Figure 4.6) is the main location to observe
the several parameters of the oxygen generator. The bed pressures, oxygen
receiver pressure, oxygen concentration, and the number of working hours are all
displayed here via Message Displays.

Figure 4.6: Typical Parameters and Output Screen
The ‘Bed Pressure Graphs’ icon takes to the Bed Pressure Graphs Screen as
shown.
Figure 4.7: Typical Bed Pressure Graphs Screen
The ‘Output Parameter Graphs’ icon takes to the screen that displays the graphs
between oxygen pressure Vs time and the oxygen concentration Vs time. The

‘Next Pen’ icon changes the scale of the ordinate to suit the respective displayed
pressure.
The ‘Calibrate Pressure Transducers’ icon displays a screen dedicated to the
pressure transducers calibration and settings as shown below.
Figure 4.8: Typical Bed Pressure Calibration Screen
The pressure transducers for the beds and the product oxygen pressure are
factory calibrated and should not require any calibration for a long period.
However, if the need arises, follow the procedure below for calibration.
1. The three-way valve (V-A) (Figure 4.9) handle shows the direction of flow path.
In Figure 4.9, direction of flow path is from oxygen generator to pressure
transducer. Close this manual three-way valve (V-A), so that the flow path is
from the atmosphere to the pressure transducer.
2. Take out the plug, if any, from the port A (Figure 4.9) and attach a manual air
pump having an accurate pressure gauge.
3. Press the ‘Calibrate 0 psig’ icon when the gauge on the manual air pump reads
0 psig.
4. Manually pump the air so that the pressure reading on the gauge is 100 psig.
5. At this point, press the ‘Calibrate 100 psig’ icon on the calibration screen to
finish the calibration procedure.
6. Press and hold the “SET” button until it pops back out. This will save the
calibration.
7. Release pressure and check a few points in the range and ensure the reading
is close. If it is off return to step 3.

Direction of flow
path shown from
oxygen generator
to pressure
transducer
Oxygen
Generator Port A (shown open
Manifold to atmosphere
unless calibrating)
Connection
V-A
Figure 4.9: Feed Air Pressure Transducer Assembly
8. Disconnect the manual air pump from the port A and put the plug, if any, back
to the port A.
9. Open the manual three-way valve (V-A), so that the flow path is from the
oxygen generator to the pressure transducer as shown in Figure 4.9.
Press the ‘NEXT’ icon to navigate the calibration screen for Bed B and the oxygen
receiver pressure transducer.
4.10 Control Panel: Internal Components

The internal layout of the control panel mainly consists of programmable logic
controller (PLC), oxygen purity board (optional), HMI, circuit breakers, transformers
and an alarm horn.
Programmable Logic Controller

The programmable logic controller (PLC) contains the logic for the oxygen
generator operation.
Oxygen Purity Monitoring Board
This board monitors the purity of the product oxygen. A sample of product oxygen
flows from the oxygen receiver to this board through a regulator. Ensure that the
regulator is set for ~2 psig for accurate readings.

Human Machine Interface (HMI)

The HMI acts as an interface between the operator and the oxygen
generator.

5.0 Installation
5.1 Unpacking
To unpack the PSA Oxygen Generating System, follow these guidelines:
1) Inspect the shipping container, and open it immediately upon receipt.
2) If the exterior of the container is severely damaged, note it on the
freight bill before you sign it.
3) Unpack the system, and remove and discard the protective wrapping
and packaging from all the components.
4) Thoroughly inspect each component for damage.
5) Open each component cabinet, and inspect the interior for loose or
damaged parts.
6) Inspect all wiring to ensure that no wires are broken and no
connectors are off their terminals.
If a wire is disconnected, refer to the respective component manual,
located in the Appendix of this operating manual, to reconnect the wire.
You must submit a damage claim within 24 hours of

delivery. A claim can be filed only by the consignee.
5.2 Installation Instructions

To install the PSA Oxygen Generating System, follow these guidelines:
Locate the system in an indoor environment where the ambient
temperature ranges between 4°C (40°F) and 44°C (111°F). The area
must be dry and the floor must be of sufficient strength to support the
weight of the system.
If the ambient temperature at the location of the system exceeds 44°C
(111°F), install ventilation to remove the air compressor exhaust from the
room.

Make sure the area that surrounds the system is well

ventilated, and there is sufficient space around each
component to allow for cool airflow as well as to allow
safe operation and maintenance.
To prevent fire or electrical shock, locate the system

away from rain or any other type of moisture.
Place the PSA oxygen system in the designated place.
It is advisable to have the electrical conduits laid out

below the hosing connections.
All the necessary electrical connections that have to be made are tagged.
Make the appropriate electrical connections for the power supply to
the oxygen system. Refer to the power distribution diagram given in
the Appendix A of the operating manual.
Connect the main power supply to the main breaker panel.

Connect all the hoses to the respective components (if not connected).
Similar to the electrical connections all the hoses that has to be
connected are tagged. The job is to match the tags for hose
connections.
Move the cylinder manifold assembly one space to the right as indicated
on the tag.
Mount the PR-3 regulator assembly on the cylinder manifold.
Make sure the fluid levels are adequate. Perform the

fluid checks before the initial start-up and during daily
maintenance.

Provide proper voltage to the plant. Improper voltage

causes damage not covered under the AirSep
Corporation Product Warranty.
You must connect an earth and an electrical ground

wire to the ground bus in the circuit breaker panel.
5.3 Voltage Check

Check the voltage to all three-phase electrical connections, including the
main buses, using these guidelines:
Check the voltage to the main buses first.
1) Provide electrical power from the main power supply.

2) Obtain a voltmeter rated for the voltage specified in the Appendix of
this operating manual, and set it to AC.
When measuring high voltage, use a high-quality

voltmeter rated for safe measurement of the voltage
specified in the Appendix of this operating manual.
3) Locate the three main buses.

4) Connect the two leads on the voltmeter to any two of the three
buses.
5) Make sure the voltmeter reading matches the phase-to-phase
voltage requirements specified in the Appendix of this operating
manual.
6) Repeat step 5 for all possible combinations of the three main buses.

Check all possible combinations of the three main

buses with the voltmeter leads to ensure consistent
phase-to-phase voltage.
7) Locate the ground bus.

8) Connect one lead from the voltmeter to the ground bus, and connect
the other lead to one of the three main buses.
9) Make sure the voltmeter reading matches the phase-to-ground
voltage requirement.
10) Repeat step 8 for the two other main buses.
Check all three main buses with the voltmeter leads to

ensure consistent phase-to-ground voltage.
11) Locate the neutral bus.

12) Connect one lead from the voltmeter to the neutral bus, and connect
the other lead to one of the three main buses.
13) Make sure the voltmeter reading matches the phase-to-neutral
voltage requirement.
14) Repeat step 11 for the two other main buses.
Check all three main buses with the voltmeter leads to

ensure consistent phase-to-neutral voltage.
15) Connect one lead from the voltmeter to the ground bus, and connect
the other lead to the neutral bus. Make sure the voltmeter reading
indicates zero voltage between the ground and neutral buses.
5.4 Motor Rotation Checks
Check the direction of rotation of the motor on the air

compressors and the oxygen compressor before initial
start-up to prevent damage not covered under the
AirSep Corporation Product Warranty.

Arrow labels inside the air compressors and the

oxygen compressor cabinet/enclosure indicate the
proper direction of rotation of the motor. (Refer to the
component manual, located in the Appendix of this
operating manual, for additional information.)
To check the rotation of the motor, follow these guidelines:

1) Provide electrical power to the compressor.
2) Check the supplied voltage to the compressor. (Refer to Section 5.3
— Voltage Check.)
3) While you observe the motor on the compressor, start the
compressor to determine the direction of rotation of the motor, and
then quickly stop the compressor.
The motor on the compressors should rotate as little

as possible during this procedure. To prevent damage
to the motor, do not allow the motor to attain full
operating speed at this time.
If the motor rotates in the incorrect direction, proceed to Section 5.5 —

Motor Rotation Correction.
If the motor on the compressor rotates in the correct direction, proceed to
Section 6.0 to start up the system.
5.5 Motor Rotation Corrections

If the motor on the compressor rotates in the incorrect direction, follow
these guidelines:
1) Disconnect, tag, and lockout electrical power from the main power
supply.
2) Reverse any two of the three-phase wire connections at the MAIN
breaker.
3) Provide electrical power to the compressor.
4) Confirm the proper direction of rotation of the motors on the
compressor. (Refer to Section 5.4 — Motor Rotation Check.)
When the compressor motor rotates in the correct direction, the system is
ready for start-up.


6.0 System Operation
6.1 General
This section of this instruction manual provides the procedures for initial start-
up, normal operation, and shutdown of the system. The Appendix of this
instruction manual includes specific operating instructions and maintenance
procedures for each major component. Read and thoroughly understand all
component manuals before you attempt to start the system.
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 the oxygen

cylinder connections and hoses free of oil, grease, cotton
fibers, and any other combustible material.
Do not allow smoking, open flame, or usage of electronic
devices that may generate sparks (e.g., cellular
telephones) near the system.
Post “NO SMOKING OR OPEN FLAMES” signs
conspicuously near the location of the system.
6.2 Start-up — Initial
1) Many components on the system contain automatic controls. To prevent an

unexpected start of these components, refer to the following chart to set the
position of the manual controls on the components before supplying
electrical power.
Normal
Start-up Operating
Component Manual Control Position Position
Air Compressor Emergency stop button Depressed Released
from
depressed
position
Oxygen compressor Hand/Off/Auto Switch Off Auto
Table 6.1 - Pre-start Manual Control Settings Chart

2) Provide electrical power from the main power supply to the MAIN breaker in
the main breaker panel.
3) Set the MAIN breaker to I (ON).
4) After the above two steps set the rest of the circuit breakers to I (ON), one at
a time.
5) Make sure all electrical components receive electrical power.
6) Refer to the following chart to set the position of the manual valves before
initial start-up. Make sure each valve is fully open or fully closed, as
indicated in the chart.
Normal
Valve Start- Operating
Component Valve Description No. up Position
Positio
n
Air Compressor Manual Outlet valve V-8 Open Open
Air Receiver Manual Inlet Valve V-9 Open Open
Manual Drain Valve V-10 Closed Closed
Manual Outlet Valve V-12AB Closed Open
Oxygen Generator Manual Inlet Valve# N/A Open Open
1 and 2 (V-1) and
(V-2)
Manual Product N/A Closed Open
Valve (V-3)
Oxygen Receiver Manual Inlet Valve V-13 Open Open
Manual Oxygen V-15 Open Open
Sample Valve
Manual Vent Valve V-16 Closed Closed
Manual Outlet Valve V-14 Open Open
Customer Supply V-20 Closed Variable
Valve
Manual Valve to V-19 Closed Variable
Oxygen Compressor
Hospital Piping Manual Outlet Valve V-35 Closed Variable
Table 6.2 - Pre-start Manual Valve Position Chart

6.3 Air Compressor/Air Receiver Start-up

(Refer to Table 6-1: Pre-start Manual Control Settings Chart and Table 6-2: Pre-
start Manual Valve Position Chart to confirm the proper position of the manual
controls and valves on the air compressor and air receiver.)
An improperly maintained air compressor adversely affects the

operation of the oxygen generator and can cause excessive
wear on the compressor mechanism.
1) Check the oil level in the air compressor, and add oil if necessary.
2) Ensure all the shipping brackets have been removed.
3) Pull outward or rotate fully counterclockwise the emergency stop button on
the air compressor control panel to release the button from the depressed
position.
4) Start the air compressor.
Refer to the air compressor manual, located in the Appendix of

this operating manual, for additional information about the air
compressor.
6.4 Oxygen Generator/Oxygen Receiver Start-up

To start the oxygen generator for the first time or after an extended or unexpected
shutdown, follow the steps below:
1) Ensure that the oxygen generator receives the power supply. Make sure the
power circuit cannot be turned off accidentally.
If the power is turned off unexpectedly, the unit will stop cycling.
If your application is using oxygen when the power is off, the
oxygen receiver will depressurize.
2) Open the manual valve (V-12) on the air receiver.

3) Provide feed air to the oxygen generator that meets the specification for your
model.

4) If the oxygen purity monitoring board is provided then ensure that all the
manual valve on the oxygen sample line are open and the pressure regulator
at the inlet of the purity monitoring board is set at ~1 psig. The regulator is set
from factory and should not require any further adjustment. The oxygen
sample is typically taken from the oxygen receiver.
5) Press the ‘ALARM RESET’ icon on the Oxygen Generator Control Screen (if
visible). The generator will only start if there is no shutdown condition
existing. However, during start-up, a low purity alarm may exist. If a shutdown
condition exists, pressing the ‘ALARM RESET’ will not reset the system. The
‘ALARM RESET’ icon disappears once all the alarm and shutdown conditions
have been rectified.
Please note that during initial start-up or start-up after a long period, the
oxygen purity can be lower than the low purity alarm and/or shutdown
setpoint and a ‘low purity’ alarm may exist. However, the oxygen
generator ignores the oxygen purity shutdown setpoint for the first 60
minutes after start-up. If the oxygen purity after 60 minutes of operation
is still below the low purity shutdown setpoint, the oxygen generator
shuts down.
The low purity cut-off valve (V-17) will only open when the oxygen purity is
above the shutdown set point to allow the product oxygen to flow to your
application.
6) Set the AUTO/MAN icon on the ‘Oxygen Generator Screen’ to manual mode.
7) Press the ‘START’ icon on the ‘Main System Control Screen’.
8) Close the manual product valve (V-3) (refer to Figure 4.2 for location of
valve). The manual product valve on these units has been configured to
enable a predetermined amount of flow through the valve when closed. This
allows the product pressure to build up even when the valve is closed.
9) Press the manual drain button and make sure the exhaust from the filter drain
does not contain water or oil. If the exhaust contains water or oil, press and
hold the manual drain button on the control panel until the exhaust no longer
contains liquid.
10) Allow the oxygen generator to operate until the oxygen receiver pressure on
the ‘Parameters and Output’ screen (Figure 4.9) registers approximately 45
psig and then fully open the manual product valve (V-3).
11) To purge oxygen at less than design purity from the oxygen receiver, while
the oxygen generator is running in manual mode, open the manual vent valve
(V-16) on the oxygen receiver to vent gas.
While venting oxygen, do not allow smoking or open flame. Do

not allow venting oxygen to come in contact with clothing or
hydrocarbon-based materials.

12) Allow the oxygen generator to operate until the designed purity level is
reached. Fully close the manual vent valve (V-16) if the low purity oxygen gas
no longer discharges from the receiver.
13) Set the AUTO/MANUAL icon on the ‘Oxygen Generator’ screen to auto
mode.
14) Observe the oxygen receiver pressure on the ‘Parameters and Output’
screen (Figure 4.9). When the pressure in the oxygen receiver increases to
approximately the auto-standby upper setpoint pressure, the oxygen
generator runs for five more cycles (approx. 15 min.) and then enters
standby. When delivery of product oxygen reduces the pressure in the
oxygen receiver below auto standby lower setpoint pressure, the oxygen
generator begins to cycle.
15) After the oxygen receiver pressurizes and the oxygen generator enters the
standby mode, the generator is ready to deliver oxygen to your application.
16) After the oxygen receiver pressurizes and the oxygen generator enters the
standby mode, the generator is ready to deliver oxygen. At this stage, load
the oxygen cylinders for filling.
Refer to the oxygen generator manual, located in the Appendix

of this operating manual, for additional information about the
oxygen generator.
6.5 Cylinder Loading Start-Up

Handle oxygen cylinders with extreme care. Protect cylinders
from physical damage, and store them in a cool, dry area in an
upright, firmly secured position. Do not allow cylinder storage
area temperature to exceed 130°F (54°C). AirSep Corporation
STRONGLY recommends that only individuals experienced in
the safe handling of high pressure oxygen cylinders operate
this equipment.
AirSep Corporation strongly recommends the use of cylinders

cleaned for oxygen service to ensure that purity remains within
specifications.
1) Use the vacuum pump system to evacuate the contents of the cylinders to be
filled. (Refer to Section 6.8 Evacuating Cylinders.)

2) Place the empty oxygen cylinder(s) to be filled in the cylinder rack, and chain
them in place. (Refer to Section 4 — Oxygen Cylinder Filling Station.)
3) Connect a cylinder filling hose to each oxygen cylinder, and tighten.
4) Slowly open fully (rotate handle counterclockwise) the manual valves on the
cylinder filling manifold to each oxygen cylinder.
5) Slowly open fully the manual valve on each oxygen cylinder.
The time required to fill the oxygen cylinders depends on the

volume of the cylinders, the pressure of the oxygen, and the
number of cylinders connected to the oxygen cylinder filling
manifold.
6.6 Oxygen Compressor Start-Up
Make sure the set point of the discharge pressure switch on the
oxygen compressor does not exceed the pressure rating of the
cylinders being filled.
1) Make sure the pressure gauge on the product oxygen receiver registers 65-
75 psig. (Refer to Section 4 —Oxygen Generator.)
2) Fully open the manual inlet valves (V-19) to the oxygen compressor.
3) Make sure the pressure gauge on the oxygen compressor pressure
regulator (PR-1) registers the pressure as specified in the Appendix A.
4) Press the START button on the oxygen compressor to begin to fill empty
cylinders. Make sure HAND/OFF/AUTO switch is in AUTO mode.
5) When the cylinders in the rack become fully pressurized, the oxygen
compressor automatically shuts down.
The SUCTION gauge on the oxygen compressor may indicate

a pressure decrease when the oxygen compressor starts.

During initial start-up, allow the oxygen compressor to begin to

pressurize the cylinder filling manifold, cylinder filling hoses,
and oxygen cylinders, then apply soapy water to the manifold,
hoses, and connections to check for leaks. Repair or replace
leaking item(s), or reconnect fittings as necessary.
Refer to the oxygen compressor manual, located in the

Appendix of this operating manual, for additional information
about the oxygen compressor.
6.7 Remove Filled Cylinders

1) Slowly close fully each manual valve on the oxygen cylinder filling manifold.
(Refer to Section 4 — Oxygen Cylinder Filling Station.)
2) Fully close the manual valve on each oxygen cylinder.
3) Make sure that the oxygen compressor is stopped before proceeding.
4) Carefully disconnect the cylinder filling hose from each oxygen cylinder on
the filling side only.
5) Unchain the filled oxygen cylinders and remove them from the cylinder rack.
6) To reload cylinders, repeat Cylinder Loading Start-Up, steps 1–5.
If electrical power is interrupted during the filling process,

repeat the entire start-up procedure to ensure cylinders contain
oxygen at design purity and pressure.
16)
The PSA oxygen generating system can also be used for a regulated supply of
oxygen at 65-70 psig using the bypass to the oxygen compressor. Following
procedure describes the oxygen supply from the bypass piping after filling the back
up cylinders.
- Fill up the back up cylinders (cylinders that get attached to the manual
valve assembly of the cylinder filling station not having check valves)
as described above.
- Allow the oxygen compressor to stop when the back up cylinders fully
pressurized. Set the HAND/OFF/AUTO switch to OFF to ensure
safety.
- At this stage, open the valve (V-20) and then the valve (V-35) to start
a regulated flow of oxygen at 65-70 psig to the customer application.

The pressure regulator PR-3 is set such that if the pressure in the bypass piping
drops below 65 psig, it allows the constant flow of the oxygen through the back up
cylinders for a certain period of time.
6.8 Evacuating Cylinders
Handle oxygen cylinders with extreme care. Protect cylinders

from physical damage, and store them in a cool, dry area in an
upright, firmly secured position. Do not allow the temperature of
the cylinder storage area to exceed 130°F (54°C). AirSep
Corporation STRONGLY recommends that only individuals
experienced in the safe handling of high pressure oxygen
cylinders operate this equipment.
1) Place the oxygen cylinder to be evacuated in the cylinder rack below the
vacuum pump, and secure it in place.
2) Connect cylinder evacuation hose to an empty, depressurized oxygen
cylinder and open the connection port ball valve.
3) Slowly open fully the manual valves on the oxygen cylinders.

4) Lift the switch on the side of the vacuum pump to the up position to start
the pump. Allow the pump to run until its pressure gauge consistently
registers 25–27 inches of mercury.
If the pressure does not decrease to 25–27 inches of mercury,

check for leaks in the connections.
5) Fully close the manual valves on the oxygen cylinders.

6) Lower the switch on the vacuum pump to the down position to stop the
pump.
7) Disconnect the cylinder evacuation hoses from the closed oxygen
cylinders.
8) Keep the manual valves on the oxygen cylinders fully closed until the
oxygen cylinders connect to the cylinder filling hoses on the oxygen
cylinder filling manifold.

6.9 Shutdown
The procedure in this section to shut down the system protects components that
use automatic controls and isolates the oxygen in the vessels and piping to
maintain the purity of the oxygen and facilitate the subsequent restart of the
system.
If the cylinders are not full, start the oxygen compressor and fill the cylinders. When
the oxygen compressor stops, the oxygen generator runs for few more minutes
(approx. 10-20 min.) and then enters standby mode. When the oxygen generator
stops producing oxygen, the air receiver pressurizes and the air compressor
unloads.
1) Allow the oxygen compressor to stop when the high pressure oxygen
cylinders are full, then fully close the manual valve on the oxygen receiver
(V-20).
2) Put HAND/OFF/AUTO switch in OFF mode.
3) Close the valves on all cylinders as well as all manifold valves.
4) Make sure the AUTO/MANUAL icon on the HMI of the oxygen generator is
set to AUTO.
5) Allow the oxygen receiver to re-pressurize fully. When the oxygen receiver
re-pressurizes, after a time delay of five cycles, the oxygen generator stops
cycling and enters the standby mode.
6) Press the STOP icon on the ‘Main System Control Screen’
7) Close the manual valve for the oxygen sample (V-15) to the oxygen purity
monitoring board.
Fully close the manual oxygen sample valve (V-15) on the

oxygen receiver to prevent oxygen from flowing out of the
receiver while the system is shut down.
Allow the oxygen generator to enter standby during shutdown

to ensure that the oxygen receiver contains oxygen at design
purity during the subsequent restart and also ensure that the
unit shuts down at the proper point in the cycle. Failure to wait
until the oxygen generator enters standby results in temporarily
reduced purity oxygen during the subsequent restart.

8) Fully close the manual outlet valve (V-12) on the air receiver, then allow the
receiver to pressurize fully.
9) When the air receiver fully pressurizes, the air compressor will first unload.
Press the O (stop) button on the air compressor control panel to stop the air
compressor.
6.9.1 Extended Shutdown

For an extended shutdown, complete all the steps in Section 6.10 —
Shutdown, then perform the following steps:
1) Fully close the inlet and outlet valve on the oxygen receiver.
2) Set all circuit breakers to O (OFF), one at a time.
3) Set the MAIN breaker to O (OFF).
Using the oxygen generator at flows higher than 15% above

those specified in Appendix A of this manual, will result in the
likely contamination of the molecular sieve beds. This damage
is not covered under the standard warranty.

7.0 Maintenance
7.1 General
The PSA Oxygen Cylinder-Filling System requires only minimal
maintenance. Use the following charts as guides to provide preventive
maintenance at the specified intervals. Please note that the tables below
are summary of scheduled maintenance required on the components.
Please, refer to the component manuals, located in the Appendix of this
operating manual, for detailed information on how to maintain each
component.
Before you perform service on any of the components,

set all circuit breakers to OFF (O) and discontinue the
main power supply to the MAIN breaker. (Refer to
Section 4 — Circuit Breaker Panel.)
The system operates with air, oxygen, coolant, and oil

under pressure. Shut down the system, and slowly
relieve all air, oxygen, coolant, and oil pressure
before removal of valves, caps, plugs, fittings, bolts,
connections, gauges, hoses, piping, or filters. Also,
press the emergency button.
To maintain the system properly, make sure all

components thoroughly drain any excess moisture
that may accumulate during normal operation.

7.2 Daily (up to 24 Hours) Maintenance

Hours/
Component Maintenance
Period
Air Compressor Daily Check operation of air compressor. Make
sure readings remain normal. Listen for
unusual noises.
Daily Check oil level.
Oxygen Generator Daily Check operation of oxygen generator.
Make sure readings remain normal.
Listen for unusual noises.
Daily Use MANUAL DRAIN button to drain
excess fluid from the coalescing filter.
Oxygen Compressor Daily Check operation of oxygen compressor.
Make sure readings remain normal.
Check for unusual noises and vibrations.
Daily Check interstage gas pressures against
normal operating pressures.
7.3 Weekly–Monthly (25–700 Hours) Maintenance

Hours/
Period
Oxygen Generator Monthly Check performance of oxygen generator
and operation of automatic valves.
Oxygen Compressor Weekly Verify compressor starts and stops
correctly.

7.4 Monthly–Semi-annual (700–4,000 Hours)

Maintenance
Hours/
Period
Air Compressor 3-monthly Check coolers. Clean if necessary.
3-monthly Remove and inspect air filter element.
Clean or replace as necessary.
3-monthly Check condenser of dryer. Clean if
necessary.
4,000 Check for leaks.
4,000 Replace oil filter and separator.
4,000 Clean compressor.
4,000 If Atlas Copco Roto-inject fluid is used,

change oil.
Oxygen Generator Six Replace prefilter elements*.
months
Oxygen Compressor 1,000 Check for leaks (Do not use any
flammable solution for leak testing).
3,000 Replace 2nd stage piston rings and check
cylinder liners for excessive wear.
3,000 Clean or replace the discharge filter.
4,000 Inspect compressor valves.
* Prefilter element should be changed if found very dirty even if six

months time period is not elapsed.

7.5 Semi-annual to Annual or Longer

(4,001–8,000+ Hours) Maintenance
Hours/
Period
Air Compressor 8,000 Check all restrictors for cleanliness. Clean
as required.
8,000 Test safety valve(s).
8,000 Inspect all flexible material (e.g., hoses).
Replace as required.
8,000 Test temperature shut down function
Oxygen Generator 8,000 Replace coalescing filter elements*.
8,000 Check operation of automatic valves.
Repair or replace as required.
Oxygen Receiver 8,000 Check the bacteria filter element, replace
if necessary.
8,000 Check operation of solenoid valve. Repair
or replace as required.
Oxygen Compressor 4,500 Replace 1st stage piston rings and check
cylinder liners for excessive wear.
4.500 Inspect compressor valves.
8,000 Adjust the tension of the Drive-belt
8,000 Test the pressure relief valves.
* Coalescing filter element should be changed if found very dirty even if

one-year time period is not elapsed. This includes the activated carbon
filter on this model.

8.0 Troubleshooting
8.1 Technical Support

For assistance in troubleshooting or repairing the system, or to order
replacement parts, contact the AirSep Commercial Products Service
Department by telephone Monday through Friday between 7:30 a.m. and
4:30 p.m. Eastern Time. In the USA or Canada, call 1-800-320-0303.
Outside the USA or Canada, call (716) 691-0202. Send fax inquiries
anytime to (716) 691-1255. Address written inquiries to:
AirSep Corporation
260 Creekside Drive
Buffalo
NY 14228-2075 USA
Attention: Commercial Products Service Department
Visit www.airsep.com to know about our complete range of standard
Oxygen Generators.
8.2 Troubleshooting Chart

Use the following chart as a guide to troubleshoot the system and its components.
For additional information about the components, refer to the manufacturers’
manuals located in the Appendix of this operating manual.
Automatic controls may cause equipment to begin operation at

any time. Disconnect from the power source, tag, and lockout
the system, or any of its components, before you work on the
system or component.
The system operates with air, oxygen, and oil under pressure.
Shut down the system and slowly relieve the pressure of the air,
oxygen, and oil before removal of valves, caps, plugs, fittings,
bolts, hoses, connections, gauges, sensors, or filters.

Air Compressor
Problem Probable Cause Solution
Air compressor does not No electrical power to air Provide electrical power to
start. compressor. main breaker panel, and set
MAIN breaker and air
compressor circuit breaker
to l (ON).
Emergency stop button Pull outward or rotate
locked in depressed position. counterclockwise
emergency stop button to
release it from depressed
position.
Air compressor malfunction. Refer to air compressor
manual, located in Appendix
of this operating manual, for
additional information.
Air compressor does not Leak(s) in piping, Use soapy water to check
stop within 30 minutes of connections, or hoses. piping, connections, and
oxygen generator shutdown. hoses for leaks. Repair or
replace leaking item(s), or
reconnect fittings as
necessary.
additional troubleshooting
information.
Air Compressor (continued)
Air compressor produces Air compressor malfunction. Refer to air compressor
feed air at incorrect manual, located in Appendix
pressure. of this operating manual, for
Air compressor unloads and Obstruction(s) in feed air Locate and remove
remains unloaded. piping. obstruction(s).
Manual valves on feed air Fully open manual valves
piping or air receiver closed
or not fully open.
Air compressor stops Electrical power loss. Provide electrical power to
unexpectedly. main breaker panel, and set
MAIN breaker and air
to l (ON).

Feed Air Conditions

Feed air pressure less than Manual valves on feed air Fully open manual valves
pressure specified in piping not fully open. on feed air piping.
Appendix of this operating
manual.
Manual drain valve on air Fully close manual drain
receiver not fully closed. valve on air receiver.
Leak(s) in piping, Use ‘soapy water’ to check
connections, or hoses. piping, connections, and
hoses for leaks. Repair or
replace leaking item(s), or
reconnect fittings as required.
Obstruction(s) in piping, Locate and remove
connections, or hoses. obstruction(s).
Air compressor malfunction. Refer to the air compressor
Oxygen Generator
Oxygen generator does not No electrical power to Provide electrical power to
cycle. oxygen generator. main breaker panel, and set
MAIN breaker and oxygen
generator circuit breaker to l
(ON).
Oxygen generator is in Allow oxygen receiver to
standby mode and oxygen depressurize during normal
receiver fully pressurized. operation, or fully open
manual vent valve (V-16) on
oxygen receiver.
‘START’ icon not pressed. Press the ‘START’ icon.
Oxygen generator Refer to oxygen generator
malfunction. manual, located in Appendix
Oxygen generator does not Oxygen receiver not fully Allow Oxygen receiver to
stop cycling in AUTO mode. pressurized. repressurize fully. Note: You
may need to fully close
manual outlet valve and
manual oxygen sample
valve.
Manual vent valve on Fully close manual vent
oxygen receiver not fully valve on oxygen receiver.
closed.
Oxygen compressor Shut down oxygen
continues to use oxygen compressor according to
from oxygen receiver. Section — Shutdown and

fully close manual outlet

valve on oxygen receiver to
check the functionality.
Leak(s) in oxygen hoses or Use ‘soapy water’ to check
connections. hoses and connections for
leaks. Repair or replace
leaking item(s), or
necessary.

Oxygen Generator (continued)

Oxygen generator operates Inadequate feed air Refer to “feed air pressure
incorrectly. pressure. less than…” problem in
troubleshooting chart.
Contaminants from feed air Check oxygen generator
in oxygen generator filters and drain for proper
adsorbers. operation. Replace filter
element(s) or repair as
necessary.
additional troubleshooting
information.
Oxygen generator stops Oxygen generator has Allow oxygen receiver to
cycling. entered the standby mode depressurize during normal
and oxygen receiver fully operation, or fully open
pressurized. manual vent valve on
receiver to check the
functionality.
Electrical power loss. Provide electrical power to
main breaker panel, and set
generator circuit breaker to l
(ON).
Shutdown condition exists Read the shutdown cause
on the Main screen of HMI
and rectify the cause.

Oxygen Conditions
Automatic low purity Low purity oxygen in low Refer to start-up procedure
shutdown occurs/low pressure oxygen receiver in Section— Start-up —
oxygen purity. not vented completely Initial.
during start-up.
Inadequate sample flow to Fully open manual oxygen
oxygen analyzer board. sample valve on low
pressure oxygen receiver
and ensure that the sample
oxygen regulator (mounted
below the control panel) is
set at 1 psig.
Oxygen analyzer board Replace the board.
malfunctions.
Incorrect feed air pressureRefer to “feed air pressure
to oxygen generator. less than…” problem in
malfunctions. manual, located in Appendix
Inadequate pressure in Manual vent valve (V-16) Fully close manual vent
oxygen receiver. not fully closed. valve.
Leak(s) in oxygen hoses or Use ‘soapy water’ to check
connections. hoses and connections for
leaking item(s), or
necessary.
Oxygen receiver overdrawn. Check oxygen pressure and
flow to oxygen compressor.

Oxygen Compressor
Oxygen compressor does No electrical power to Provide electrical power to
not start. oxygen compressor. main breaker panel, and set
to l (ON).
Inadequate pressure in low Refer to “inadequate
pressure oxygen receiver. pressure in oxygen
receiver…” problem in
Automatic low purity oxygen Refer to “automatic low
shutdown prevents oxygen purity shutdown occurs/low
delivery to oxygen oxygen purity” problem in
compressor. troubleshooting chart.
Cylinders are full. Replace the filled cylinders
with evacuated empty
cylinders.
Oxygen compressor Refer to oxygen compressor
Oxygen compressor Leak(s) in oxygen hoses or Use ‘soapy water’ to check
operates continuously. connections. hoses and connections for
leaking item(s), or
necessary.

Oxygen Compressor (continued)

Oxygen compressor stops Electrical power loss. Provide electrical power to
unexpectedly. main breaker panel, and set
to l (ON).
High discharge pressure Locate and remove
due to obstruction(s) in or obstruction(s) or replace
damage to high pressure damaged high pressure
oxygen hose. oxygen hose.
Inadequate pressure in Refer to “inadequate
oxygen receiver. pressure in oxygen
receiver…” problem in

A Appendix: Technical Data

Specifications
AirSep PSA
Oxygen System: AS-J-600-HMFM DUPLEX
Oxygen output:
Flowrate: 600 SCFH
Oxygen purity: 93% +/- 3%
Site conditions:
Ambient operating temperature: 40°C (105°F)
Ambient operating relative humidity: 95%
Elevation:
Power requirements: Voltage 400 VAC

Frequency 50 Hz
3 Phase
Single Phase 230V/50Hz
Instrumentation Set Points

Air Compressor:
Loading Pressure 108 psig

Unloading Pressure 116 psig
Chiller:
Temperature Setting 15.2° C

Differential 4° C
AS-J-600-HMFM DUPLEX Instruction Manual A-1

Oxygen generator:
Feed Air Regulator 80 psig
High Bed Pressure 83 psig
Oxygen Receiver 68 - 78 psig
Oxygen Compressor: 2V3B-4.1V—P1C
Inlet Suction Pressure 30 psig

Maximum Outlet Pressure 2250 psig
Oxygen Analyzer:
Alarm and Shutdown Setpoint 89%,85%
Pressure Regulator Settings

PR-1: 40 psig
AS-J-600-HMFM DUPLEX Instruction Manual A-2

B Appendix: Warranty/Returns
Product Warranty
AirSep Corporation (“AirSep”) warrants to the party purchasing from AirSep (the
“original purchaser”) the AS-J-600-HMFM DUPLEX PSA Oxygen System to be free
from defect in parts and workmanship for one year from the date of start-up, not to
exceed eighteen (18) months from the date of shipment to the original purchaser,
under normal use, maintenance and operation*. TO THE EXTENT PERMITTED
UNDER APPLICABLE LAW, ALL WARRANTIES WITH RESPECT TO SUCH UNIT
SHALL ONLY EXTEND TO AND BE FOR THE BENEFIT OF THE ORIGINAL
PURCHASER AND SHALL NOT BE ASSIGNABLE TO, EXTEND TO OR BE FOR
THE BENEFIT OF ANY OTHER PARTY. AirSep’s obligations under this warranty
are limited, at AirSep’s option, to the repair, replacement or refunding the purchase
price of any such system of equipments (or part thereof) found by AirSep to be
defective in parts or workmanship; provided, however, that AirSep shall have no
obligation hereunder with respect to a defective part unless it receives written
notice of such defect prior to the expiration of the applicable warranty period as
referenced above.
Each unit of equipment for which a warranty claim is asserted shall, at the request
of AirSep, be returned on a prepaid basis with proof of purchase date to the AirSep
factory specified by AirSep at the expense of the original purchaser. Replacement
parts shall be warranted as stated above for the unexpired portion of the original
warranty. This warranty does not extend to any unit or part subjected to misuse,
accident, improper maintenance or application, or which has been repaired or
altered outside of the AirSep factory without the express prior written authorization
of AirSep.
Notwithstanding anything to the contrary contained herein, during the applicable
warranty period, as specified above, AirSep will pay the cost of return freight
charges to the original purchaser, provided an authorized AirSep representative
approved return of the unit or parts, for any equipment found by AirSep to be
defective. For warranty repairs performed during the first 90 days from the date of
invoice, AirSep will pay freight both ways. After the applicable parts warranty
period has expired, the original purchaser is responsible for freight both ways.
* Please refer to the appropriate product documentation for applicable installation and operating
requirements.
AS-J-600-HMFM DUPLEX Instruction Manual B-1

Limits of Liability
THE FOREGOING WARRANTY IS THE ONLY WARRANTY MADE BY AIRSEP
WITH RESPECT TO THE SYSTEM (OR ANY PART THEREOF) AND IS IN LIEU
OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, IN FACT OR IN LAW,
INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR ANY PARTICULAR PURPOSE. IT IS EXPRESSLY
UNDERSTOOD THAT THE SOLE AND EXCLUSIVE REMEDY FOR ANY DEFECT
IN PARTS OR WORKMANSHIP IS LIMITED TO ENFORCEMENT OF AIRSEP’S
OBLIGATIONS AS SET FORTH ABOVE, AND AIRSEP SHALL NOT BE LIABLE
TO ORIGINAL PURCHASER OR ANY OTHER PARTY FOR LOSS OF USE OF
THE EQUIPMENT, LOST PROFITS OR FOR ANY OTHER SPECIAL, INDIRECT,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES (EVEN IF AIRSEP HAS BEEN
ADVISED OF THE POSSIBILITY OF SUCH DAMAGES).
Returning the Oxygen System or a Component for Service

Follow the procedure below to return a defective part for service:
1) Obtain a Return Goods Authorization (RGA) number from the AirSep
Commercial Products Service Department. Before you call for service
assistance, have the following information readily available:
◼ Model number of the component
◼ Serial number of the component
AirSep Corporation issues no credit for any warranted

replacement item(s) until you present the model and the serial
number of the component.
2) Write the RGA number clearly on the outside of the shipping container.
AirSep Corporation accepts no item(s) for service or credit

unless prior written authorization was issued by AirSep
Corporation.
3) Pack merchandise for a safe return. AirSep Corporation assumes no

responsibility for damage that occurs in transit. Any damage to a part

because of failure to follow this procedure is the sole responsibility of the

customer.
Return item(s) on a freight prepaid basis only.


C Appendix: Component Literature

Air Compressor
ASD60T 1 Kaeser
ASD60T
Operator Manual (compressor and controller)
Oxygen Generator
AS-J 1 AirSep Corporation
AS-D+ – AS-P Oxygen Generator With HMI
Instruction Manual
Oxygen Compressor
2V3 1 Rix Industries
2V3
Operating Instructions and Parts List
Vacuum Pump 607CD22 1 Thomas Industries 607 Series Single Cylinder

Oil-less WOB-L® Piston Compressors and
Vacuum Pumps
Operating Instructions
AS-J-600-HMFM DUPLEX Instruction Manual 5

Airsep Corporation As-J-600-Hmfm Duplex Psa Oxygen System: Instruction Manual

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AirSep® Corporation

Project# PSA18002 & PSA18003

AirSep® Corporation • 260 Creekside Drive • Buffalo, NY 14228-2075 USA

PSA Medical Oxygen System

Model Number: AS-J-600-HMFM DUPLEX

Serial Number: PSA18002 & PSA18003

City/Town: State: Zip:

1.2 Warnings, Cautions, and Notes

Provides information that can prevent severe bodily

Cautions against the risk of electric shock.

Provides information important enough to emphasize

AS-J-600-HMFM DUPLEX Instruction Manual 1-1

AS-J-600-HMFM DUPLEX Instruction Manual 1-2

2.2 Potential Hazards

Oxygen vigorously accelerates the burning of

Take extreme care to keep all oxygen piping and

AS-J-600-HMFM DUPLEX Instruction Manual 2-1

To prevent fire or electrical shock, locate the oxygen

Before you attempt to install, operate, or repair the

The interior of the oxygen system control cabinet

Disconnect power before servicing oxygen generating

Do not disconnect protective earth:

AS-J-600-HMFM DUPLEX Instruction Manual 2-2

2.3 Safety Publications

AS-J-600-HMFM DUPLEX Instruction Manual 2-3

AS-J-600-HMFM DUPLEX Instruction Manual 2-4

3.0 System Description

AS-J-600-HMFM DUPLEX Instruction Manual 3-1

AS-J-600-HMFM DUPLEX Instruction Manual 3-2

4.0 Components Description

4.1 Main Breaker Panel

4.2 Air Compressor – Kaeser ASD 60T

Figure 4.1 – Air Compressor, Kaeser A

AS-J-600-HMFM DUPLEX Instruction Manual 4-1

4.3 Air Receiver

4.4 Oxygen Generator — AS-J AirSep

Manual Air Inlet

Feed Air Regulator

Figure 4.2: AS-J Series Oxygen Generator

AS-J-600-HMFM DUPLEX Instruction Manual 4-2

4.5 Oxygen Receiver Tank

Relief Valve (RV-2)

Manual Vent Valve

Manual Oxygen Outlet

Bacteria Filter (FI-1)

Manual Outlet Valve to Pressure Regulator

Manual Outlet Valve to Pressure Regulator

Figure 4.3: Typical Oxygen Receiver (layout may vary)

AS-J-600-HMFM DUPLEX Instruction Manual 4-3

4.6 Oxygen Compressor — Rix Industries 2V3B

4.7 Oxygen Cylinder Station

Figure 4.4: Typical Oxygen Cylinder Filling Station

4.8 Vacuum Pump System — Thomas/617BCD22

AS-J-600-HMFM DUPLEX Instruction Manual 4-4

Figure 4.5: Typical Vacuum Pump

4.9 Control Panel: External Components

AS-J-600-HMFM DUPLEX Instruction Manual 4-5

Figure 4.3: Typical Main System Control Screen

AS-J-600-HMFM DUPLEX Instruction Manual 4-6

Bed Pressure Graphs

Output Parameters Output Pressure Graphs

Bed Pressure Calibration

AS-J-600-HMFM DUPLEX Instruction Manual 4-7