Service, Maintenance &

Troubleshooting
Presented by: Peter Knotko
Service Engineer
Oxymat-Slovakia, s.r.o.

Worldwide Manufacturer of PSA Generators

 Preventive maintenance

Monitoring the operation of the And what is necessary to service ?

unit and Preventive Maintenance • Air compressor – all PM according to
(PM) on a regular basis is the best manufacturer’s manual
way how to ensure a long life for
your PSA Generator. • Filter elements – coal tower incl.
• Dryer – according to manufacturer’s
How often? manual
• Drain system - Oxymat manual
Daily • PSA generator - Oxymat manual
Weekly
Biannualy • High pressure equipment as RIX, Haug
Annualy or Bauer compressor – according to
Every 5 years manufacturer’s manual
Complete line
 Daily maintenance

Daily inspection consist of:

• Every day simply observe the
operation of the unit
• Check purity and product
consumption
• Verify what is the dew point of
feed air or displayed temperature
on the refrigeration dryer
• Make sure that the drain system is
functioning properly – press test
button
!!! Plugging off
the drain systems will cause water/oil
carry-over into the adsorbent vessels, and
will cause severe damage to the adsorbent
which is not covered under the
manufacturer's warranty
 Weekly maintenance

Air compressor flow

Weekly inspection consist of: diagram

Do observe your Air Supply system

basis

• Check operation conditions of the

air compressor (oil level, oil
temperature, noise etc...)

• Check filters – clogging /

diferential pressure indicators
must not be in red area at any
time of operation
 Weekly maintenance

Clean procedure
plus:
• With an air jet (max. 2 bar / 30 psig)
blowing from inside towards outside blow
• Air compressor – cleaning
out the dust
procedure of oil after-cooler +
• Repeat this operation blowing in the
oil level check
opposite way
• Air Dryer – cleaning
procedure of cooler

• PSA control cabinet – !!! Be careful not to damage the

cleaning procedure of dust aluminium fins of the cooling
filter package.
 Biannualy maintenance

The biannualy inspection of the

PSA unit consists of:

1. Service of air compressor

according to supplier manual
(filters and oil replacement, etc...)
2. Service of air dryer according
to supplier manual (drain and
strainer cleaning, etc...)
3. Replace pre-filter element
1μm and micro-filter element
0,01μm
 Annual maintenance
The Annual PM of the unit consist
from the points of biannualy
PM, plus:
1. Coal-Tower PM: Replacement of
coal, oil indicator and micro-filter
element is recommended Oil indicator and
micro- filter

2. Air Tank PM:

• Inspection of drain system
• Each non-return valve has to be
Coal tower
cleaned and checked for damage
(replace if needed) Non-return

• Axial drain valve has to be cleaned

valve
Air tank

and properly re-greased Axial drain

valve

3. Inline filter for gas analyzer:

. Replacement of inline filter
 Annual maintenance

3. PM of PSA generator :
• all system has to be inspected for
function, damage, leakage (solenoid
valve block, hose/pipe connection,
safety valves, etc...)
• process VIP valves has to be
cleaned and properly re-greased (for
O2 application oxygen grease has to
be used)
• strainer and main regulator has to be Omal axial VIP
valve
cleaned
• gas analyzer has to be checked with
calibration gas and calibrated if
needed Omed upgrade filters placed
behind the receiver tank

4. PM of receiver tank:
• active-carbon and bacterial/sterile
filter elements has to be replaced
Annual maintenance :

How to lubricate process valves

Every 2 years maintenance :

Recommended replacement of all process valves.

Every 2 years maintenance :
Top brass filters and O-rings for each column.
Every 3 years maintenance :
Recommended replacement parts :

HDMI valve block.

O2 Analyzer.

OXY Z - zirconia cell

OXY F - fuel cell
OXY FS - fuel cell
Inlet pressure regulator. (ppm)
OXY P - paramagnetic
Example when regular or proper
maintenance is not performed!
PSA generator types :
 5 years maintenance – every 40 000 wh

PM of PSA generator every 5

years consist of:

• Molecular sieve replacement Top brass filter

is recommended
• Top brass filter replacement
• Vessel inspection

Bottom stainless steel filter

!!! Be carefull not to damage

the bottom stainless steel
filters during moleculare sieve
replacement
 Replacement of filter elements

Poor quality of compressed air could affect filter period [y] period [h]
the operation of your PSA generator. 1μm 1/2 year 4,000
The filter element(s) supplied with each unit
have been selected by manufacturer based 0.01μm 1/2 year 4,000
upon the units feed air requirements.
active carbon 1 year 8,000

Replacement of filter element step by step: bacterial/sterile 1 year 8,000

• Close the air inlet for filter.

• Carefully remove 4/6 mm tube below
filter.
• Remove filter element by Replacement of active coal in coal tower:
counterclockwise turn. • Once per year (recommended)
• Remove one-way valve from old
element and mount it to the new one. • Otherwise: when oil indicator gets red
• Install new element with one-way valve.
• Plug-in the 4/6mm tube to filter element.
• Perform leak test.
 Safety valves

Visual inspect safety relief valves

and other safety devices for dirt or
damage.

If there is debris in the valve seat,

scavenge the valve as follows:

1. Pressurize vessel and loosen

the top screw one turn. This
should remove debris from the
valve.

2. Retighten the top screw

 Pressure vessel maintenance
• External and internal inspection
of vessels and other pressurized
equipment must be carried out
according to local regulations.
• When your Oxymat or Nitromat
Generator is installed and
operated according to the
prescribed conditions, it is not
needed to do internal inspection
of generator vessels on regular
basis
• If molecular sieve is replaced inspect
vessels for corrosion or other damage
(replace if needed)
• Refer to molecular sieve material
safety data sheet for handling and
safety instructions of sieve.
• Receiver vessel should be inspected
internally every 4 years or according to
local regulations.
 Leak test procedure
1. Safely shut down the application /
consumption
2. Let the plant run in auto mode,
until generator will automatically
stop by pressure.
3. Close the feed air supply.
4. If fitted with purity monitoring
probe close of the pressure
reduction valve on probe inlet.
5. Read and note the pressure P1 in
oxygen receiver, column 1, column
2, coal tower and feed air tank.
6. Let the plant stand still (rest) and
isolated in pressurized condition for
an hour.
• After an hour read and note the pressure P2
in oxygen receiver, column 1, column 2 and
feed air tank.
• Then determine an eventually pressure drop
as the difference between P1 and P2 for
each component.
• The Leak Test is OK, if the pressure drop
after one hour is less than 0.1 bar.
• If a leak is detected, a suitable device must
be used to locate the leaking component
(leak tester in spray or soap water)
• If closed, reset the pressure reduction valve
on probe inlet
 Required tools For valve lubrication:
• Paint brush
• Grease (for O2 application oxygen grease
has to be used-Kluebertemp YV 93-
Safety warning: 92),N2 application –SuperLube.
Always wear personal protection • 2 spanners (according to size of the
equipment for ears, hands, eyes etc... valve).
• spare valve
Installation: For filter element replacement:
• Plastic tubes 4/6/8 mm • spanner of proper size
• spare valves, regulator • belt pliers
• pliers, screwdriver, spanner, etc. • PTFE tape
• Connecting fittings for tubes • filter element
• reductions Vessel inspection:
• spare indicators • spanner of proper size
• PC with installed software • battery light
• Design Review Certificate
 Troubleshooting

Most common operation failure is
insufficient product purity due to:
1. Generator is overflowed !
2. Low quality of feed air !
3. Valve block error !
4. Process valve error !
5. Gas analyzer error or
misreading !
Solution:
1. Check system for leaks ,fastenings and
product consumption.
2. Check filters, drain system, air
compressor temperature, dryer
temperature, ambient air temperature.
3. Check air signals from solenoid valve
block to process valves (replace if
needed).
4. Re-grease or replace valve if needed.
5. Calibration or replacement if needed.
6. Otherwise contact OXYMAT A/S.
• Service check list

• recommended to use on
daily(weekly,anually) basis to
avoid failure
and prevent possible breakdown.
 Oxymat A/S
Fasanvej 18-20
DK-3200 Helsinge
Denmark

Questions…

www.oxymat.com