V A C U U M A N D P R E S S U R E T E C H N O L O G Y

OPERATING MANUAL

ULTRAOX
MODELS: 3, 8, 12, 30, 50, 70, 90, 100, 120, 180, 260, 370, 440, 560

PLEASE READ THIS MANUAL CAREFULLY BEFORE USING

ULTRAOX® IT CONTAINS VITAL INFORMATION FOR THE
CONSERVATION AND SAFETY OF THE DEVICE.
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- Index –

1. GENERAL INFORMATION ........................................................... 3

2. ULTRAOX FEATURES ............................................................... 7
3. INSTALLATION INSTRUCTIONS ................................................. 13
4. QUICK REFERENCE GUIDE ....................................................... 17
5. MAINTENANCE ..................................................................... 19
6. COMPRESSOR AND AIR DRYER INSTRUCTIONS FOR USE .................. 25
7. LAYOUT ............................................................................. 29
8. ELECTRIC DIAGRAM ............................................................... 30
9. VALIDATION ........................................................................ 32
10. DECLARATION OF CONFORMITY.............................................. 34

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1. GENERAL INFORMATION
ULTRA-CONTROLO - Projectos Industriais, Lda., was founded in 1987 and is a Portuguese leader
company in Vacuum systems, Pressure producing and Air treatment technologies in Portugal.
ULTRAOX® is ULTRA-CONTROLO's specifically designed plant for medical use.
The extensive scientific knowledge gained from early in the departments of research and development
of its principals and by the research department of the ULTRA-CONTROL, knowledge of international
law, standards and technical rules led to the creation of certified devices intended for medical use,
namely MEDIAR ®, ULTRAAR ®, ULTRAVAC ®, ULTRASEG ® and now ULTRAOX ®.

COPYRIGHT:
This manual contains text, images, diagrams and other illustrations that are protected by
copyright. No part of this document may be reproduced without the written permission of the
Manufacturer. Any violation will be punished by law. All rights reserved.
ULTRA-CONTROLO, reserves the right to make modifications to this operating manual without
prior notice.

1.1. MANUFACTURER
ULTRA-CONTROLO PROJECTOS INDUSTRIAIS, LDA.
PARQUE INDUSTRIAL QUINTA LAVI, ARMZ.8
ABRUNHEIRA
2710-089 SINTRA PORTUGAL

Phone: +351 219154350

Fax: +351 21 9259002
e-mail: info@ultra-controlo.com

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1.2. SAFETY INFORMATION

USERS MUST READ THIS MANUAL CAREFULLY BEFORE USING THE DEVICE. IT CONTAINS VITAL
INFORMATION FOR THE CONSERVATION AND SAFETY OF THE DEVICE.
OBSERVE THE WARNINGS SHOWN IN ORDER TO PREVENT MALFUNCTIONS OR RISK OF PERSONAL
INJURY.
ENSURE THAT THE OPERATING INSTRUCTIONS ARE ALWAYS ACCESSIBLE FOR INSPECTION NEAR
THE DEVICE.

ULTRA-CONTROLO IS NOT LIABLE FOR ANY DAMAGE OR INJURY RESULTING FROM THE
NON-OBSERVANCE OF THESE SAFETY INSTRUCTIONS OR NEGLIGENCE OF THE USUAL CARE AND
ATTENTION REQUIRED DURING HANDLING, OPERATION, MAINTENANCE OR REPAIR, EVEN IF THIS
IS NOT EXPLICITLY MENTIONED IN THESE OPERATING INSTRUCTIONS.
IF ANY OF THE REGULATIONS CONTAINED IN THESE INSTRUCTIONS - ESPECIALLY WITH REGARD
TO SAFETY - DOES NOT CORRESPOND TO THE LOCAL LEGAL PROVISIONS, THE STRICTER OF BOTH
SHALL PREVAIL.
THESE SAFETY REGULATIONS ARE GENERAL AND VALID FOR VARIOUS TYPES OF MACHINES AND
EQUIPMENT. IT IS THEREFORE POSSIBLE THAT SOME REFERENCES DO NOT APPLY TO THE UNIT(S)
DESCRIBED IN THESE INSTRUCTIONS.
IN ADDITION TO THE OPERATING INSTRUCTIONS, ALL OTHER GENERALLY APPLICABLE LEGAL AND
OTHER MANDATORY REGULATIONS RELEVANT TO ACCIDENT PREVENTION AND ENVIRONMENTAL
PROTECTION MUST BE ADHERED TO AND PASSED ON TO OTHERS!
THESE COMPULSORY REGULATIONS MAY ALSO DEAL WITH THE HANDLING OF HAZARDOUS
MATERIALS OR THE ISSUING/WEARING OF PERSONAL PROTECTIVE EQUIPMENT, OR TRAFFIC
REGULATIONS.

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1.3. INTRODUCTION TO ULTRAOX

Ultra-Controlo knows that, in most cases, healthcare facilities around the world oxygen storage is secured by
suppliers of oxygen that produce oxygen locally, with oxygen generation devices, and then proceed to its
distribution for medical use in pressure vessels, not few times without the implementation of necessary
procedures needed to assure the product quality.
ULTRAOX® is a medical device certified by Directive 93/42/CEE and in compliancy with ISO 10083:2006 - Oxygen
concentrator supply systems for use with medical gas pipeline systems which, among others issues, sets a
minimum standard for the quality of oxygen for medical use.
ULTRAOX® assures the continuous supply of medical quality oxygen, at the desired flow rate, by constantly
monitoring the quality of the produced oxygen through a digitally controlled oxygen sensor, whenever the
quality of the produced oxygen falls below the factory pre-set default standards, supply to the medical gas
pipeline system is shut off, the produced air is rejected into the atmosphere and the secondary or reserve
source of supply take over the medical pipeline system.
Some of ULTRAOX®'s benefits:
 Total control of medical oxygen quality supplied to the medical pipeline system;
 Total control of medical oxygen quality produced and stored as secondary or reserve source of supply;
 Total control of production costs with local production at lower prices;
 Total independence from market prices variations referring to oxygen volume unit price, pressure vessels
rental and handling;
 Total independence from logistic problems, transport, storing, etc.
Whenever liquid oxygen supply is not possible, the use of Medical Oxygen System ULTRAOX is indispensable.

ULTRA-CONTROLO manufactures not only conventional but also facilities to the needs of its customers. This
ability to design, planning and execution, made the ULTRA-CONTROL pioneer in many areas of technology of
compressed air and vacuum as well as treatment and filtration of gases in Portugal, with a long and successful
series of innovative systems that will mark its definitive presence in this millennium.
In ULTRAOX ®, the oxygen is produced by pressure swing adsorption and the quality is monitored by a oxygen
sensor before supplying the medical pipeline system.
Each ULTRAOX ®, is tested in an intensive test under the most adverse conditions. These conditions are much
more severe than those required in most medical applications. This test also includes a full simulation of faults,
alarms, a leak test and verification of the conditions of installation on site.
Along with this operating instructions, please read the instructions for use specific to the vacuum pumps.

When operating with ULTRAOX, we recommend the use of PPE, namely ear protector
and face shield.

1.4. MEDICAL DEVICE CLASSIFICATION

Medical Oxygen System ULTRAOX, is designed and constructed in accordance with the essential health and safety
for medical devices of Class IIb.

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1.5. LABELLING
On the side of the control panel of the plant is affixed the CE marking of the equipment, which is
composed of the information presented below.

1.6. WARRANTY

ULTRA-CONTROLO covers warranty for the period of one year, depending on the models.
Signal lamps, fuses and sensors are not covered.
This warranty period of one (1) year counts from the date of issue of the invoice to the device, under normal
conditions of use and operation, in respect of defects in materials and manpower.
The warranty is not extendable to any component if the defect or malfunction results from improper use or
misuse of the device, such as ambient temperature out of limits, nonconforming installation site, compressed air
in poor conditions and preventative maintenance at fault.
The warranty will be considered void if the plant has been repaired or modified by another entity other than
ULTRA-CONTROLO or its authorized agent.
For other warranty conditions, please see warranty certificate.
Medical Oxygen System is warranty

1.6.1. Warranty Procedure

For warranty requirements, the following information must be provided to ULTRA-CONTROLO or its authorized
agent.
 Plant model
 Plant serial number
 Invoice date
Ultra-Controlo reserves the right to evaluate and approve or reject, after verification of the equipment on its
site. The warranty when approved is assured at factory (Sintra - Portugal).

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2. ULTRAOX FEATURES

2.1. INTENDED USE

The Oxygen production plant ULTRAOX is intended to produce Medical Oxygen to be supplied to the
medical gas pipeline systems of healthcare facility, with quality according to the European parameters.

The medical conditions will be those require respiratory treatment with higher concentration of Oxygen
Should not be used for any other purposes since it is classified as a medical device class IIb.

2.1.1 Intended user

Authorized hospital professionals that needs to connect to oxygen hospital network in order to administer oxygen
to patients.
The responsibility of the use of Medical Gases belongs to the hospital professional personal
(doctors/pharmacist), who should decide to whom to it will be used and on what medical conditions and its
contra-indications.

2.1.2 Intended patient population:

All people who need respiratory treatment with higher concentration of Oxygen

2.2. PERFORMANCE CLAIM

Performance claim for ULTRAOX® should be:

Pressure
Capacity O2
Inlet Outlet
Model (per unit)
(AC) (O2)
l/min m3/h bar bar
3 5,3 0,318 7,5 6
8 13 0,777 7,5 6
12 17,9 1,072 7,5 6
30 51,7 3,1 7,5 6
50 76,7 4,6 7,5 6
70 108,3 6,5 7,5 6
90 133,3 8 7,5 6
100 158,3 9,5 7,5 6
120 206,7 12,4 7,5 6
180 303,3 18,2 7,5 6
260 436,7 26,2 7,5 6
370 608,3 36,5 7,5 6
440 725 43,5 7,5 6
560 928,3 55,7 7,5 6

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2.3. DESCRIPTION: MAIN COMPONENTS

ULTRAOX ® main components as follows:

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STANDARD ULTRAOX® SYSTEM IS BUILT UP OF THE FOLLOWING COMPONENTS:

2.3.1. Compressor
Each ULTRAOX ® is equipped with one, or several high technology compressors with the following main
characteristics:
 Inlet air filter
 Ensures continuous operation

2.3.2. Fridge dryer

Each ULTRAOX ® is equipped a aluminum cooling technologies compressed air dryer with one high efficiently
cooling module with direct effect on reducing energy consumption and pressure drop. The main advantages are:
low pressure drop even with load variances and a constant pressure Dew Point with differing load conditions.
The components of the air dryer from refrigerant to materials of construction have been selected with maximum
respect for the environment and their ability to be recycled.
Main characteristics:
 Precise and accurate by-pass valve  Energy saving design.
 CFC free refrigerants.  Limited acoustic emission
 CFC free insulation parts.

2.3.3. Oxygen Concentrator

ULTRAOX ® oxygen concentrator applies an optimized Pressure Swing Adsorption process for the separation of
the oxygen in ambient air from the other gases. ULTRAOX ® oxygen concentrator contains either two single
adsorption vessels (Twin-Tower systems) or a series of modules of two adsorption vessels (Modular systems),
where each vessel is filled with an appropriate zeolite molecular sieve.
The oxygen production process starts by pressurizing one of the adsorption vessels with clean compressed dry
air. Before the equilibrium load is reached at the top of the adsorption bed, the feed air supply will be
interrupted to prevent a break-through.
The adsorption vessels are alternatively loaded in order to guarantee a continuous oxygen flow. If one
adsorption vessel is loaded, simultaneously the other one is regenerated by a pressure decrease (desorption).
The depressurization required for regeneration is obtained by simply venting to the atmosphere.
Prior to the subsequent adsorption and desorption phase, a pressure equalization will take place between the
adsorption vessels in order to preload the regenerated vessel by a gas rich in oxygen.
ULTRAOX ® oxygen concentrator is able to produce oxygen at very stable purities at 94% (+/- 1%)

2.3.4. Electric Control Box

The used electrical control box consist of certified components being the box itself also certified. Connections
are made in accordance with applicable law.
The electrical control box commands, surveys, controls alarm signals and protects all electrical components of
ULTRAOX, namely the compressor, refrigerating air drier, oxygen concentrator and cyclone separator.

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Note: The electric control box can vary according to the type of plant and
the needs of each configuration according to the type of compressor
control and air treatment units.
Optical signals given by the control box:

Information Color Symbol

Compressor ON Green H1
Compressor failure Red H2
Compressor maintenance Yellow H3
Oxygen concentrator failure Red H4
Compressed and dried air vessel pressure failure Red H5
Presence of voltage Yellow H6
Sound alarm (optional) shut off Red S1

Information available for remote monitoring through the terminal free voltage:
 Presence of voltage  Compressor maintenance
 Compressor failure  Oxygen concentrator failure

2.3.5. Pressure vessels

Note: Check local legislation and rules for equipment’s under pressure
The pressure vessels as well as safety accessories are subject of periodic verifications and
validations.

2.3.5.1. Pressure vessel for air

ULTRAOX ® air pressure vessel comes equipped with standard safety and surveillance equipment
namely, pressure gauge, pressure release valve, shut down ball valves and a manually operated ball
valve to drain condensate from the pressure vessel.

2.3.5.2. Pressure vessel for oxygen

ULTRAOX ® oxygen pressure vessel comes equipped with standard safety and surveillance
equipment namely, pressure gauge, pressure release valve, shut down ball valves and a manually
operated ball valve to drain condensate from the pressure vessel. Has been submitted to a special
inner coating treatment and cleaning for oxygen storage.

2.3.6. Filter Set

A filter set of dust, micro and activated carbon filters are fitted in order to minimize contaminants
delivered downstream.

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2.4. PLANT INTENDED USE MISUSE

Do not change any constructive part of the installation!
Constructive changes in the installation can only be performed by the manufacturer or
with his written consent. Any type of constructive change you wish to make, you must
have a written approval provided by the manufacturer.

Very important notes!

 ULTRAOX® produced medical oxygen is only available for medical application. All other
uses are prohibited.
 In no event shall ULTRAOX ® work to weather or come in contact with water, the plant
cannot be installed in outdoors locations or locations where ambient temperature can fall
below 10˚C or raise above 30°C range nor where relative humidity can be above 60%.
 In adverse conditions water can freeze inside the pipeline and stop the flow or condensate
inside the electromechanical elements leading to system failure.
 Electric elements are not suited to cope with such duty conditions.

 The plant is not ready to work in potentially explosive environments. Please contact the
manufacturer should such a need arise.

 Must be careful when transporting the components of the plant. Always use a forklift or
pallet trucks, pallet components must be belted (figure above). Apply the forks in the
appropriate places.

2.5. WORKING PRINCIPLE

ULTRAOX® working principle is as follows:
ULTRAOX® Oxygen Concentrator Supply System provides the medical gas pipeline systems at the requested
oxygen purity and flow rate through continually monitoring of the oxygen purity.
It compresses and dries ambient air, usually with a 21% oxygen volume concentration, and through the
pendulum swing adsorption process increases the oxygen purity to the desired level initiating the delivery to
the oxygen storage vessel.
Once the oxygen storage vessel(s) reaches the intended pressure, ULTRAOX® delivers the specified flow
rate to the medical pipeline system.
Beyond the protection of components for short circuit or thermal overload, the main electric switchboard
provides vital information such as potential free contacts for monitoring from a distance indicating the
normal state or malfunctions of the plant and may also provide additional information for the technical
staff.
Other functional and automation solutions available upon request.

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2.6. APPLIED SYMBOLS DESCRIPTION

Label Equipment Label Equipment

C1 Compressor F3 Activated Carbon Filter

SC Cyclonic Separator GO Oxygen Concentrator

S1 Refrigerating Air Dryer R2 Oxygen Pressure Vessel

F1 Pre-Filter F4 Dust Filter

R1 Compressed and Dried Air Pressure Vessel F5 Sterilization Filter

F2 Micro Filter SO# Shut off valves

Read Operator's Manual Danger

Before Using Equipment Machine Starts Automatically

Electrical Hazard Warning Danger Hot Surfaces

MD reference MD Serial number

Manufacturing date (year) Manufacturer

Notified Body 0120:

SGS United Kingdom, Ltd.
Worle 202B, Parkway, Weston-Super-Mare, 6WA BS22 United Kingdom

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3. INSTALLATION INSTRUCTIONS

3.1 INSTALLER’S DUTIES

Once the plant is used for medical applications, installer must follow the following notes:
 Arrange the right installation of the complete plant according to the manufacturer instructions, assuring
the continuous supply of the oxygen
 Verify that the site of installation is suitable for the kind of application, compatible to the produced gas
(ex. by using for the network, only copper degreased pipes, compatible with oxygen, etc). In particular
the quality of the produced gas, the user safety and the environmental conditions shall be considered;
 Assure that the oxygen network is appropriate for the use of oxygen, according to local law and
 Assure that the final test / commissioning of the complete System of Supply is in accord with the
manufacturer instruction.

3.2 INSTALLATION PLACE

BEFORE INSTALLING, READ THIS COMPLETE MANUAL CAREFULLY.

DAMAGES RESULTING FROM DISREGARD BY ALL INDICATED SAFETY RULES ARE NOT COVERED
BY THE EQUIPMENT WARRANTY.

 Plant must be placed in a plain, clean, dry, well ventilated and protected area, in absence of sparks or
naked flames, inflammable substances (gas, vapour, dusts) that can be fire or explosions cause.
 Rooms or areas for supply systems should be dedicated and not used for any other purposes.
ONLY NOMINATED PERSONS SHOULD BE AUTHORIZED TO OPERATE AND ATTEND THE
SUPPLY EQUIPMENT.
The air compressor and the air dryer can be placed in the same room together with the
concentrator.
 Environmental temperature must be between 5° and 40° C.
In case the ambient temperature falls below + 10°C, the installation should be equipped with an
auxiliary heating device to guarantee a frost free working conditions.
 One group of filled cylinders sufficient for one side of a manifold may be stored in the same room or
area. Empty cylinders disconnected from the supply equipment may be stored pending their removal.
Full and empty cylinders should be segregated and their respective storages areas should be labeled.
 Services or containers of combustible gases or liquids should not be permitted within, adjacent to, the
supply system location.
 All electrical fittings in supply rooms should be located in fixed positions or protected to minimize the
risk of physical damage.
 Clean the area before a definitive placement of the equipment’s that compose the plant.
 There should be a minimum distance of 0,8 meters from walls or other obstacles for future
maintenance and parts replacement.

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 Main access must have a distance of 1,0 meters in order to remove components for factory
Technical Assistance Centre major overhauls.
 Access to manifold rooms and storage vessels should be level and kept clear.
All doors should be capable of being opened from the inside, at any time, without a key, and should
open outwards.
The doors or gate rooms or enclosures containing the source of supply should be capable of being locked.
At least one emergency exit, which should be free from obstructions at all times and should lead into the
open air or another safe location, should be provided.

 A heating system may be used to heat supply system enclosure or storage areas, provided that no part of
the heating system in contact with the air within the room can exceed a temperature of 225˚C and that
cylinders are prevented from coming into contact with the heating system.
 Fire-fighting equipment should be provided.
 The room or enclosure should be well lit.
o Enclosures (interior or exterior) for supply systems should conform to the following:
o when an enclosure is located near a source of heat such as a furnace, incinerator, or boiler room,
its construction should prevent the cylinder temperature from exceeding 40 ˚ C
o An enclosure should not be located within 3 m of open electrical conductors or transformers
o an enclosure should not be adjacent to oil storage tanks
o an enclosure should comply with local building codes
o an enclosure should have concrete floors
o fences and walls should be of a height no less than 1,75 m

 A warning notice should be displayed on both sides of each door, examples:

 WARNING - OXYGEN  NO OIL OR GREASE

 NO SMOKING  NO COMBUSTIBLE MATERIAL TO
 NO OPEN FLAMES OR SPARKS BE PLACED WITHIN 5 m

3.3. GENERAL INSTALLATION

 The concentrator air filters drainage shall be collected to a wasting system according to local law in force.
The size of the pipes should be matching the size detect on the concentrator itself.
 The owner of the installation should follow the local rules regarding pressure vessels.
 Whenever there is a need for the main components to be placed near a wall it is convenient to leave an
appropriate slack in electric cable and flexible hoses in order to allow movement for better access to the
compressor.

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3.4 ELECTRICAL INSTALLATION

ELECTRICAL CONNECTIONS MUST BE MADE ONLY BY LICENSED ELECTRICIANS.
THE PLANT MUST ALWAYS BE TURNED OFF VIA THE ON-OFF BUTTON, AND NEVER BY
DISCONNECTING THE WIRE.
OPERATION AND MAINTENANCE OF THE PLANT MUST ALWAYS BE CARRIED OUT WITH THE
PLANTS ELECTRICAL CONNECTION SWITCHED OFF.
DO NOT START THE PLANT WITHOUT ALL ELECTRICAL AND PNEUMATIC CONNECTIONS ARE
PROPERLY INSTALLED.
EQUIPMENT MUST ALWAYS BE CONNECTED TO A NETWORK WITH THE SPECIFICATION AND
PROTECTIONS PROVIDED BY THE MANUFACTURER.
ATTENTION! DAMAGES RESULTING FROM THE INFRIGEMENT OF THE ABOVE SAFETY RULES ARE
NOT COVERED BY THE EQUIPMENT WARRANTY.

Electric connection should be done adopting:

 Protective bonding circuit.
 Automatic, co-ordinated with equipotential bonding circuit, electric power breaking system, to guarantee the
appropriate automatic break of electrical power.
 Before connecting the plant to the main electric power, verify the voltage and other main data, labelled on
the plant.
 Connect a supplementary wire to the earth from the metal structure of the concentrator, to the pipelines
and to the receivers.
 Electric connections are to be made to electric control box with cable of appropriate cross section.
 The power cable to the Main Electric Switchboard must be fixed with clamps and glands of good quality,
meeting the rules of sound construction.

Before beginning work on the unit or facility, the following measures should be taken:
 Switch off the power.
 Take the necessary precautions to prevent it being switched on again.
 Make sure that there is voltage.
 Ground and short circuit.
 Cover or protect neighboring components under electric voltage.
If possible connect the Electric Control Box directly to your General Framework with the supplied cable.
Alternatively, take advantage of the flexible cable that is supplied and place a junction box between the
General Framework and the Electric Control Box with terminal blocks with appropriate section, or install a cable
directly between the two frames.
Make electrical connections in the electrical panel with suitable power cable for the location where ULTRAOX ®
will be installed, should contain three phase conductors, neutral conductor and protective conductor (H07VV-F
5G2,5).
The power cable to the Electric Control Box must be fixed with clamps and glands of good quality, meeting the
rules of sound construction.
The General Board shall have a four-pole circuit breaker curve D 6 or 10 A.
Other operating and automation solutions are possible to apply upon request.

DO NOT MAKE ANY CHANGE IN PARAMETERS AND CONNECTIONS MADE AT THE FACTORY. IF IN
DOUBT CONTACT YOUR SUPPLIER.

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3.5 INSTRUCTIONS FOR ULTRAOX STARTUP AND TESTING

Intended for authorized installer - not available to the user
Parameterization made in the factory - do not need no adjustment at the installation site
If in doubt contact the manufacturer (contact details described on point 1.1 of this manual)

3.6. STORAGE CONDITIONS

The environment must meet the following conditions to prevent damage caused by the arrest and / or storage:
 Dry
 Dust-free,
 Low vibration (Veff ≤ 2.8 mm / s).
 Ambient temperature: min. -30 ° C / max. 40 ° C

3.7. STARTUP AFTER PROLONGED STOPPAGE:

Before putting the unit back into operation after a prolonged stop, measure the resistance of the motor
insulation. The winding resistance should read above 1 kΩ/V, at least 1MΩ.
If in doubt contact the manufacturer (contact details described on point 1.1 of this manual)

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4. QUICK REFERENCE GUIDE

PLEASE READ THIS MANUAL CAREFULLY BEFORE USING ULTRAOX®

IT CONTAINS VITAL INFORMATION FOR THE CONSERVATION AND SAFETY OF THE DEVICE.

SELECTION AND QUALIFICATION OF PERSONNEL; BASIC RESPONSIBILITIES

WORK ON/WITH THE MACHINE/UNIT MUST BE CARRIED OUT BY RELIABLE PERSONNEL ONLY.
ENSURE THAT ONLY AUTHORIZED PERSONNEL WORK ON OR WITH THE MACHINE!

FOR A CORRECT USE OF THE PLANT, PLEASE FOLLOW THE FOLLOWING INSTRUCTIONS:

ATTENTION:
THE INTER CONNECTIONS OF THE MAIN COMPONENTS HAVE TO BE MADE ACCORDING TO
THE LABELS INDICATED IN THE FLEXIBLES / CABLES EVENTUALLY SUPPLIED.

The ULTRAOX® consists of the following main parts:

 One or more air compressor

 One or more air treatment chains
 One, two or more compressed air receivers
 One or two oxygen concentrators
 two or more compressed oxygen receivers
 One electrical control panel

CHECK THE FOLLOWING CONDITIONS BEFORE STARTING THE PLANT OR PUT INTO OPERATION:

ATTENTION:
NEVER PLACE ANY BODY PART, INCLUDING HANDS, AT THE ENTRANCE OF ANY VALVES,
YOU CAN HURT YOURSELF IRREMEDIABLY.

Note that at the first starting up, the oxygen pressure vessel is empty and contains air with an oxygen
concentration of 21%, so that the filling up time of the pressure vessel will be longer and some purging time will
be required.

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STARTING UP PROCEDURES:

 Connect the electric control box to the ULTRAOX ® components according with diagram;

 Power connect the electric control box;

 Check emergency push-down button of compressor;

 Power on the refrigerating air drier and wait until dew point of 2 - 3 ˚C is reached;

 Open if shut off valve between the compressor and the air drier;

 Open shut off valve between the air drier and the compressed and dried air pressure vessel;

 Close shut off valve outlet from compressed and dried air pressure vessel;

 Power ON the compressor;

 Confirm by reading the pressure gauge on compressed and dried air pressure vessel until the compressor
stops;

 Open shut off valve from compressed and dried pressure vessel to oxygen concentrator and wait until the
green light turns solid and purity level reaches 95%;

 Open shut off valve from oxygen concentrator to oxygen pressure vessel and wait until the pressure
gauge on oxygen pressure vessel reaches 6 bar, yellow light blinking;

 When yellow light becomes solid, open shut off valve from oxygen pressure vessel to oxygen
concentrator;

 Open the shut off valve from oxygen concentrator to the medical gas pipeline system;

 As soon as the oxygen purity level reaches 92%, oxygen can be used in the healthcare facility;

 From this point on, the plant stays in autonomous oxygen production regime;

ATTENTION:
IF YOU NOTICE ANY NOISE OR VIBRATION, OR ANY DOUBT PERSISTS, PLEASE
IMMEDIATELY CONTACT OUR TECHNICAL SERVICES (INDICATED ON POINT 2.9 OF THIS
MANUAL)

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5. MAINTENANCE
PLEASE READ THIS MANUAL CAREFULLY BEFORE USING ULTRAOX. IT CONTAINS VITAL
INFORMATION FOR THE CONSERVATION AND SAFETY OF THE DEVICE.
THE SCHEDULED TASK TIME GAPS CAN EVENTUALLY BE CHANGED DEPENDING ON THE
CONDITIONS OF SERVICE IF THEY SO REQUIRE.
THE MAINTENANCE AND SERVICE TIME INTERVALS SHOWN ARE FOR NORMAL OPERATION.
THE INSPECTION PERIOD MAY DIFFER SLIGHTLY FOR DIFFERENT OPERATING CONDITIONS,
SUCH AS HIGH TEMPERATURE AND/OR HUMIDITY. IF THE OPERATING CONDITIONS ARE SEVERE
AND/OR UNSATISFACTORY, REDUCE THE INSPECTION TIME INTERVALS.

INSPECTIONS & MAINTENANCE MUST BE CARRIED OUT BY QUALIFIED TECHNICIANS

BEFORE PERFORMING ANY MAINTENANCE OPERATION, SHUT DOWN THE MAIN POWER TO
COMPRESSOR AND CLOSE THE COMPRESSOR SHUT OFF VALVE. DAMAGES CAUSED BY USE OF
NON-AUTHORIZED PARTS ARE NOT COVERED BY WARRANTY.

5.1. ULTRAOX - MAINTENANCE SCHEDULE

A B C D E F G
Observe Inspect Clean Tighten Replace Tighten Request validation

Maintenance must be carried out by qualified technicians (exceptions A e C).

Schedule Daily Weekly Monthly Semiannual Biennial Triennial

ULTRAOX room A(2) C

Pressure Vessel A(10,11)
Electric Control Box B(3) B(4,9) F(5)
Accumulated dust C(6)
Condensate bottle C(7)
Operating Manual A
Silencer filter element E
Admission and exaust silencers E
Oxygen Sensor E
Validation by the manufacturer G(12)
(7) – Removal of liquids and solids accumulated
(1) – Oil Level
(8) – Oil separators changing date
(2) – Room Temperature
(9) - Voltage reading and necessary adjustments to the Electric
(3) – Electric Control Box
Control Box
(4) – Physical state of the electric elements of the Electric
(10) - Maximum and minimum Pressure
Control Box
(11) - Check for leakage
(5) – Electric terminals of the Electric Control Box
(12) - Request manufacturer to validate plant operationally
(6) – Air venting grids, hoses, labels, QCC, signal indicators,
switches and selectors

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5.1.1 ULTRAOX - COMPRESSOR MAINTENANCE SCHEDULE

5.1.1.2 COMPRESSOR – ULTRACECO SC

Maintenance and Inspection Time Interval
Item Observations
Daily 500h 4.000h 8.000h 16.000h
Scroll V Check noise and vibration
Inlet filter V Replace a dirty or clogged filter
Safety valve V
Non return valve V
After cooler V Cleaning
Compressor fan* V *For canopied versions , clean
Bearings V Grease or replace the bearing
Transmission belts V Check correct tensioning
Service Kit 4.000h:
- Inlet filter
- Transmission belts R
- Safety valve
- Non return valve
Service Kit 8.000h:
- Inlet filter
- Transmission belts
- Safety valve
R
- Non return valve
- Scroll skid maintenance kit
Service kit 16.000h:
Scroll Block Unit
R
V Inspections and eventual replacement in case of need R Replacement To be performed by manufacturer technicians

5.1.1.2 COMPRESSOR - ULTRASCREW

Maintenance and Inspection Time Interval
Maintenance to be performed
3.000 6.000 9.000 12.000 15.000 18.000 21.000 24.000
Oil filter replacement x x x x x x x x
Panel filter replacement x x x x x x x x
Air filter replacement x x x x x x x x
Belt tension control /adjustment x x x x x x x x
Loose power connection check x x x x x x x x
Oil/air leak check x x x x x x x x
Radiator cleaning (with air) x x x x x x x x
Replacement of separator x x x x
Oil replacement x x x x x x x x
Air filter service kit replacement x x x x
Dryer maintenance x x x x x x x x
Intake valve service kit replacement x x x x
Multiblock service kit replacement x x x x
Air tank hydrostatic TEST Once per year, by an authorized organization
Belt replacement x x x x
Oil/air circuit hoses replacement x
Screw control / revision (if required) x x
Screw element revision x
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5.1.2. ULTRAOX - REFRIGERATING AIR DRYER MAINTENANCE SCHEDULE

 DAILY
 Verify that the Dew Point displayed on the electronic instrument is correct.
 Check the proper operation of the condensate drain systems.
 Verify the condenser for cleanliness.

 EVERY 200 HOURS OR MONTHLY

 With an air jet (max. 2 bar / 30 psig) blowing from inside towards outside
 Clean the condenser; repeat this operation blowing in the opposite way; be careful not to damage
the aluminum fins of the cooling package.
 Close the isolation valve for the condensate drain, remove the mechanical filter and clean it with
compressed air and a brush. Reinstall the filter, make sure it is secure, and open the isolation valve.
 At the end, check the operation of the machine.

 EVERY 1.000 HOURS OR YEARLY

 Verify for tightness all the screws of the electric system and that all the “Faston” type connections
are in their proper position, inspect unit for broken, cracked or bare wires.
 Inspect refrigerating circuit for signs of oil and refrigerant leakage.
 Measure and record amperage. Verify that readings are within acceptable parameters as listed in
specification table.
 Inspect condensate drain flexible hoses, and replace if necessary.
 At the end, check the operation of the machine.

5.1.3. FILTER SET MAINTENANCE SCHEDULE

 EVERY 1.000 HOURS

 Replace air filter elements

 EVERY 3.000 HOURS

 Replace oxygen treatment filter elements

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5.2. MAINTENANCE INSTRUCTIONS

ANYONE INVOLVED WITH ASSEMBLY, COMMISSIONING, HANDLING, CONSERVATION, MAINTENANCE,
REPAIR OR THE LIKE SHOULD HAVE PRIOR KNOWLEDGE AND UNDERSTANDING OF THE OPERATING
MANUAL, NAMELY SAFETY INSTRUCTIONS. IN CASE ANY DOUBTS ARISE PLEASE CONTACT THE
MANUFACTURER, SEE CONTACTS ON POINT 1.1 OF THIS MANUAL.

MAINTENANCE AND CONSERVATION TASKS MUST BE CARRIED OUT BY AUTHORIZED AND QUALIFIED
PERSONNEL.

MAINTENANCE AND CONSERVATION WORK MUST BE SCRUPULOUSLY CARRIED OUT ACCORDING TO

THE MAINTENANCE SCHEDULING PLAN, OTHERWISE THE MANUFACTURER DECLINES ALL
RESPONSIBILITY WITH THE PERFORMANCE OF THE EQUIPMENT.

THE PLANT IS SUBJECT TO WEAR AND DEGRADATION FROM THE START OF OPERATION SO THAT IT
STATUS MUST BE EVALUATED EVERY TWO YEARS BY ULTRA-CONTROLO TECHNICIANS, AND ITS
MAINTENANCE PLAN MUST BE SCRUPULOUSLY RESPECTED

IN ORDER TO AVOID THE RISK OF SOMEONE INADVERTENTLY STARTING THE PUMP WHILE IT IS
BEING REVIEWED OR INSPECTED, WHICH COULD CAUSE SERIOUS DAMAGE TO THE MAINTENANCE
STAFF, THE POWER SUPPLY TO THE ENGINE SHOULD BE COMPLETELY DISCONNECT. UNLESS THE
PUMP IS CLOSED AND FULLY ASSEMBLED, IT CANNOT BE OPERATED.

NEVER HANDLE A COMPRESSOR THAT IS STILL HOT OR NEAR ITS WORKING TEMPERATURE. YOU
CAN BURN YOURSELF WITH VERY HOT PARTS.

FOLLOW THE RECOMMENDATIONS FOR THE PROPER LEGAL DESTINATION OF THE PARTS, SUPPLIES
AND CLEANING PRODUCTS USED FOR PREVENTIVE MAINTENANCE INTERVENTIONS.

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5.3. ULTRAOX PREVENTIVE MAINTENANCE SHEET

Concentrator
Ai treatment

O2 treatment
Compressor

Air dryer
Date Parts List Task Description Operator
Signature

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5.4. PARTS REPLACEMENT NEEDED DUE TO WEAR

Preventive Maintenance

 Time Overhaul Kits

 Filters
 Compressor Oil
 Electric components kit
 Transmission belt

5.5. TROUBLE SHOOTING

Please contact the manufacturer should any problem arise.
We recommend you to read the manual as well as the electric diagrams equipping ULTRAOX

ON SITE OPERATIONS:
IN ORDER TO AVOID THE RISK OF SOMEONE INADVERTENTLY STARTING THE PUMP WHILE
IT IS BEING REVIEWED OR INSPECTED, WHICH COULD CAUSE SERIOUS DAMAGE TO THE
MAINTENANCE STAFF, THE POWER SUPPLY TO THE ENGINE SHOULD BE COMPLETELY
DISCONNECT.

It is advisable that all technical staff working with ULTRAOX should get in touch with the manufacturer, the
representative or authorized dealers.
Address and contact of the nearest Technical Assistance Service can be provided on request.

5.6. ENVIRONMENTAL PROTECTION

Waste resulting from installation and maintenance activities must be disposed of in an environmentally friendly
manner and in accordance with the applicable legislation.
The plant, at the end of its life, should be disposed of in an environmentally friendly manner and in accordance
with current regulations.

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6. COMPRESSOR AND AIR DRYER INSTRUCTIONS FOR USE

The operator must enforce all relevant safety measures, including those mentioned in this manual.

6.1. COMPRESSOR

ULTRACECO SC

1 ADMISSION FILTER
2 SCROLL ROTOR
3 STATIC SCROLL
4 COMPRESSED AIR OUTLE

ULTRASCREW

1 COOLING RADIATOR
2 INTAKE FILTER
3 OIL DRAINING VALVE
4 SCREW UNIT
5 OIL TANK
6 MOTOR

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6.1.2 First commissioning

Please follow chapter 2 – Quick Start Guide

MAKE SURE BEFORE COMMISSIONING THAT NOBODY IS IN THE DANGER ZONE OF THE SCROLL
COMPRESSOR.
ONLY OPERATE THE SCROLL COMPRESSOR WITH CLOSED ACCESS PANELS.

Important!
Although this compressor has been subjected to a test run at the factory and has again been thoroughly
inspected before shipment, damage during shipment cannot be excluded. For this reason, every compressor
should be checked once again for damage before being commissioned. In addition, it should be observed
during the first operating hours.

If the compressor is newly connected to a power supply, check the direction of rotation of the drive motor!

ALL ELECTRICAL AND PNEUMATIC CONNECTIONS SHOULD BE CARRIED OUT BY ACCREDITED

TECHNICIANS.

Turn the main switch ON, quickly turn On and OFF the compressor in order to verify the motor correct rotation
direction.

6.1.3 Routine commissioning

DANGER!
MAKE SURE BEFORE COMMISSIONING THAT NOBODY IS IN THE DANGER ZONE OF THE MOTOR COMPRESSOR.
AFTER COMPLETION OF WORK: VERIFY THAT ALL SAFETY DEVICES HAVE BEEN REFITTED AND THAT ALL
TOOLS HAVE BEEN REMOVED.
ONLY OPERATE THE COMPRESSOR UNIT WITH CLOSED ACCESS PANELS.

6.1.4 Working lifetime

Check the working hours and comply with the maintenance schedule.

6.1.5 Commissioning after malfunction

DO NOT SWITCH THE COMPRESSOR ON REPEATEDLY WITHOUT HAVING RECTIFIED THE
MALFUNCTION, SINCE THIS MAY CAUSE CONSIDERABLE DAMAGE TO THE MACHINE.

6.1.6 End of Life

Shut off the connection to the main pipeline. Shut off the main power.

6.1.7 Service and maintenance

Please check Chapter 5 – Maintenance.

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6.2 AIR DRYER

6.2.1. Air Dryer First Commissioning

This procedure should be followed on initial start-up, after periods of extended shutdown or
following maintenance procedures.
Qualified personnel must perform the start-up.

Sequence of operations:

 Ensure that the connection to the compressed air system is correct and that the piping is suitably
fixed and supported.

 Ensure that the condensate drain pipe is properly fastened and connected to a collection system or
container.

 Ensure that the by-pass system (if installed) is open and the dryer is isolated

 Ensure that the manual valve of the condensate drain circuit is open.

 Ensure that the cooling water flow and temperature is adequate (Water-Cooled).

 Remove any packaging and other material which could obstruct the area around the dryer.

 Activate the mains switch.

 Turn on the main switch - pos. 1 on the control panel.

 Ensure that the electronic instrument DMC14 is ON.

 Ensure the consumption matches with the values of the data plate.

 Ensure the fan work properly - wait for its first interventions (Air-Cooled).

 Allow the dryer temperature to stabilize at the pre-set value.

 Slowly open the air inlet valve.

 Slowly open the air outlet valve.

 Slowly close the central by-pass valve of the system (if installed).

 Check the piping for air leakage.

 Ensure the drain is regularly cycling - wait for its first interventions.

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6.2.2. START-UP AND SHUT DOWN

START UP:

 Check the condenser for cleanliness (Air-Cooled).

 Ensure the cooling water flow and temperature is adequate (Water-Cooled).

 Verify that the system is powered.

 Activate the main switch - pos. 1 on the control panel.

 Ensure that electronic controller DMC14 is ON.

 Wait a few minutes; verify that the DewPoint temperature displayed on electronic instrument DMC14
is correct and that the condensate is regularly drained.

 Switch on the air compressor.

SHUT DOWN:

 Verify that the DewPoint temperature displayed on electronic controller DMC14 is correct.

 Switch OFF the air compressor.

 After a few minutes, switch off the main switch on the control panel of the dryer (pos. 1).

NOTE:
A Dew Point within 0°C and +10°C displayed on the electronic controller is correct according to the possible
working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.).

During the operation, the refrigeration compressor will run continuously.

The dryer must remain on during the full usage period of the compressed air, even if the air compressor works
intermittently.

The number of starts must be no more than 6 per hour. The dryer must stop running for at least 5 minutes
before being started up again. The user is responsible for compliance with these rules. Frequent starts may
cause irreparable damage.

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7. LAYOUT

7.1 SPECIFICATION

The diagram represents the pneumatic flow within Medical Oxygen System ULTRAOX.
The plant consists of one compressor, one refrigerating air drier, one compressed and dried air pressure vessel,
one oxygen concentrator, one oxygen pressure vessel, one cyclonic separator filter, one pre-filter, one micro-
filter, one activated carbon filter, one sterilization filter, pressure gauges, pressure relief valve, non-return
valves and shut off valves
A oxygen sensor measures the percentage in volume of oxygen to be fed to the medical gas pipeline.

7.2 PNEUMATIC DIAGRAM

C1=Compressor
S1=Fridge Dryer
F#=Filter
R1=Compressed Air Vessel
GO=Oxygen Generator
R2=Oxygen Pressure Vessel
SO#=Shut off valves

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8. ELECTRIC DIAGRAM

8.1 SAMPLE - ESQ. 116/12

Electric Control Box Label

Information Color Symbol

Compressor ON Green H1
Compressor failure Red H2
Compressor maintenance Yellow H3
Oxygen concentrator failure Red H4
Compressed and dried air vessel pressure failure Red H5
Presence of voltage Yellow H6
Sound alarm (optional) shut off Red S1

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9. VALIDATION

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10. DECLARATION OF CONFORMITY

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