Jiangyin Dongpeng Purification Equipment Co.,Ltd.

DPO Serious PSA Oxygen Generator

Instruction Book

Jiangying Dongpeng Purification Equipment Co.,Ltd.

West Section of Furong Road, Xiagang Town, Jiangyin, Jiangsu, China

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Contents

1．Technical data
1.1 Designing data
1.2 Performance data
1.3 Utility facility

2. Safety
2.1 System specified use
2.2 Accident prevent rule
2.3 Dangerous source

3 .Function and system structure

3.1 Air separation by OMS
3.2 Pressure swing adsorption（PSA）
3.3 Processing step
3.4 Purification by compressed air
3.5 Air separation
3.6 N2 storage and supply

4. Installation
4.1 Installation requirement
4.2 Normal installation manner and electrical connection

5. Operation
5.1 Control system
5.2 Control processing
5.3 O2 analyzer

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Content
5.4 Starting up
5.5 Shut down

6. Maintenance
6.1 Daily maintenance and examination for oxygen generator
6.2 Handling method for normal question

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Technical data
1.Technical data
1.1 Designing data
Required compressed air
Capacity: ≥6Nm3/min
Outlet pressure: ≥0.8Mpa
Dew point of compressed air: ≤2℃- -40℃

1.2 Performance data

Requirement for finished O2:
（1） Capacity： 20 Nm3/h
（2） Purity： ≥90-95%

1.3 Utility facility

Power source： 220V/60Hz
Oxygen generator power： 200W
Dryer power： 1.5KW

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Safety

1.Safety
Please read the operation manual carefully and pay attention to the warning
of the manual before operation.

We are not responsible for any damage caused by wrong operation.

2.1 System specified use

The PSA oxygen generator is designed by the capacity and purity according to
1.2，below amendment be forbidden without the Formal Approval of
Jiangyin Dongpeng Purification Equipment Co.,Ltd.

·Amendment Setting over the scope limit of 1.2

·The change of hardware of system
Quality Assurance invalid if the above situation occurred.

The all articles of the instruction book are stated by the rule of National Legal
Department, which should be complied when operation.

2.3Dangerous source

Harm！
Due to the automatically operation function of system, the compressing procedure,
drying procedure and the PSA system will be started up automatically.

Please shut off the whole system and each system before maintenance.

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Personal injury！
The system pipe is stressful. When disassembling the pipe and system parts,
maybe cause personal injury directly or indirectly because of high pressure.
The system and pipe pressure should be release before maintenance.

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Function and System Structure

3. Function and System Structure
The oxygen gas be made by separation processing technology from the air
material.
3.1 Separation air by OMS
Oxygen Molecular Sieve

3－1 CMS

Air separation processing procedure。

3.2 Pressure Swing Adsorption（PSA）

As the drawing3-2，compressed air flow into absorption tower.

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3－2 Pressure Swing Adsorption processing procedure（PSA）

Function and System Structure

The OMS inside the absorption tower ,which can absorb the N2 when air passing
through, while the Oxygen flow out.

After some time, the OMS should be regenerated because of large quantity of N2
absorbed. The regenerated procedure realized by depressurization, which called
desorption.
For continuous Oxygen supply, the two absorption towers are circularly regenerated
and absorbed.

3.3Processing step
Three steps of oxygen generator process：
1. Purification of compressed air
2. Air separation
3. Oxygen storage and supply

The process chart and PLC control system drawing are attached.

3.4 Compressed air and purification

The compressed air（0.75Mpa）will be firstly oil , dustiness and water removed by air
dryer.
Secondly flow into the class1 filter, removing the dustiness and oil, and then into
class 3 filter.

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Function and System Structure

3.5 Air separation
Compressed air flow into the absorption towers by PC valve AV101、AV102or
AV103.
The absorption tower A and B are the main parts of oxygen generator, which
loaded OMS to finish the procedure of air separation.
The load and compact of OMS is adopted automatic compact device.(refer to the
detailed drawing of vessels)
The OMS should be added termly in order to guarantee the good operation.

The PSA process principle is controlled by eight valves of AV101- 108.

The following chart 3-1 describes the process.
Process Valve open Remark

Tower A absorption, AV101、AV102、AV105、 Air separation in tower A,

B desorption AV106、AV108 regeneration in the tower B
Pressure balance process AV102、AV103、AV106、 Pressure forcing in tower B
for tower A and B AV107、
Tower B absorption, AV101、AV103、AV104、 Air separation in tower B,OMS
A desorption AV107、AV108 regeneration in tower A
Pressure balance process AV102、AV103、AV106、 Pressure forcing in tower B
for tower A and B AV107、
3-1：processing step

The finished oxygen gas go through tower A and tower B, flowing into oxygen buffer
by PC valve AV106,AV107 and AV108.

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Function and System Structure

The blow back hand valves on the top of oxygen generator is used for fair adjustment
of first time. No need to adjust when later process.

3.6 oxygen gas storage and supply

Oxygen gas buffer tank
·Buffer pressure fluctuation caused by PSA process
·Ensure the the minimum pressure of adsorption tower A and B at the beginning of
the adsorption

Manual flow control valve manually adjust the oxygen flow according to the value of
the rate measurement of flow meter F101, then oxygen enter into customer’s system.
The flow meter shows the actual oxygen flow.

Note: The flow meter on the equipment shows the finished oxygen gas flow data.

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Installation

4．1 Installation requirement

1) Clean and dry compressed air
2) Power source 220V/60HZ

4．2 Normal installation method

Oxygen generator should be placed on fixed location, which is plain ground and
ventilated.
Avoiding big difference of temperature place.
If the equipment should be placed inside house, the discharged N2 and
unqualified O2 should be discharged outside.

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Operation
5．Operation
5.1 Control system
The PSA system consist of PLC of SIMENS ，O2 analyzer, flow meter and
auxiliary circuit.
The control system send signal according to certain order, controlling the open
and close of 11 pieces of program valves. Oxygen analyzer will check the
oxygen content on line, if the content exceed alarm value, the controller will send
the interlocking signal ， to let the gas discharge directly and prevent the
unqualified gas flow into next step.

5.2 Control procedure

·Main control procedure
1. Program control procedure
The program control procedure consists of PLC, solenoid and pneumatic valve,
opening and closing according to the order of previously setting. Thus to complete
the PSA procedure, which is absorption, voltage-sharing and desorption.

2. Concatenate alarm system for unqualified O2

Concatenate alarm system for unqualified O2 consists of oxygen analyzer , PLC
sequencing valve AV109 and AV11. Oxygen analyzer will check the O2 content on
line，if the O2content under the setting data will cause the alarm and start up the
AV109 and AV110 valve, discharging gas on the condition of PSA system normally
running.

·Control cabinet:
Control cabinet consists of oxygen analyzer, touch screen for program, open and
close button etc.
1．Oxygen analyzer (alarm for lower purity of O2)

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Analyzer will check the O2 content on line, showing the figure on the surface. When
the O2 content under the setting date, it means the O2 purity is lower, will cause the
alarm automatically to make the valve AV110 open and AV109 close, thus the
unqualified O2 will be discharged directly.

2. Starting switch
Starting switch is the simply operation button which on-off controls PLC system, that
means the PSA system is starting up.

3.Stop button
The oxygen generator will immediately stop operation when pressing stopping
button.
The gas inside tower A and B will be evacuated totally.

4. Page turning button

When pressing page turning button, the touch screen will show the next page,
which will be checked the program and operation data.

5.3 oxygen analyzer

Supervise the O2 content when operation

5.4 Starting up
1. check if the compressed air outlet pressure attains to 0.75Mpa
2. Press the starting button on the surface of oxygen generator, checking if tower A
and B are operating normally according to the pressure swing of two towers.
3. Regeneration tower pressure should be 0 and when pressure-sharing, pressure
should be half of original pressure of operation tower.
4. Power on O2 analyzer, adjust the flow control valve, feeling if any gas out at the
end of exit. The gas flow should not be large. Then check the O2 purity.

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5. Adjust the outlet valve to control the O2 purity and flow: slowly opening the
discharge globe valve, let the flow data to be the half of rated flow. When the
purity attain to the required data, slowly open O2 outlet globe valve to let the flow
be the required data, then close the discharge globe valve, and machine to be
operated smoothly.

5.5 Shut down

1) Close the O2 outlet valve and sample connection valve.
2) Shut down air dryer and the inlet valve of compressed air.
3) Press stop button on oxygen generator, shut down the power source.

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Maintenance

6.1Daily examination and maintenance for nitrogen generator

Examination Examination
Examination method Normal value
content period

Filter
Filter Check if any discharges through
Every day
discharge outlet
Cleaning for
Remove discharge valve,
discharge Every week
cleaning with neutral solution
valve of filter
Filter element Replacement be
replacement made half a year

Compressed air buffer tank

Pressure Check if pressure be in the
Every day
meter normal scope

Bottom
Check if any discharges Every two
discharge
through outlet hours
valve

PSA system
Check sample gas and pressure, Feeling if gas out
O2 analyzer Every day
make some adjustment if needed. 0.1Mpa

Flow meter Check oxygen flow meter 20Nm3/h Every day

Pressure Check each pressure meter if

Every day
meter operation normally.

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indictor will be
move up and
Valve
Check yellow indicator on valve down when
operation Every day
driver valves operation
condition
opening and
closing.

Complete pipeline
Oxygen Every three
Chase leaks.
pipelines months

Note：Air compressor and dryer maintenance refer to separate instruction book.

Specially reminding: Oxygen generator should be stop operation when air

dryer and filter are out of order.

6.2 Handling method for normal problem when operation

phenomenon reason Handling method

O2 flow too high Check flow meter setting

O2 alarm
O2 analyzer setting
Check O2 analyzer setting point
point out of control
Check the light on or not through the output
1. PLC problem of the PLC. If light not on means PLC
broken. Should make replacement.
Check if gas pressure more than 4bar, if not
please increase pressure or check any leaks
2. gas pressure too
Pneumatic on connections of tube and copper pipes. If
low
valve can not the connections don’t work please make
be open replacement.

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If none of any problems, detach the copper

connections of pneumatic head to check if
any gas inside the copper pipe. If with gas
3. valve rod locked
means the rod locked. Please remove the
pneumatic head, force the rod to move by
hand.
If none of any problems, check the solenoid
inside electric cabinet to see if any loose
4. solenoid winding
connection of wire, if so, fasten the wire.
burning out
While if the coil was burning up or spool leak
the solenoid should be replaced.
Black ash on
muffler or on OMS leaking Contact with us.
flow meter

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