AirSep Onyx Page 1 Instruction Manual Download

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Suggested List Price $25.00 (U.S.D.)

AirSep

Corporation

PSA Oxygen Generator
Onyx/Onyx+/Onyx Ultra

Instruction Manual

MN109-1 05/10 Rev.

AirSep

Corporation

260 Creekside Drive

Buffalo, NY 14228-2075 USA

Phone: 1-800-320-0303

Fax: 716-691-1255

www.airsep.com

Summary of Contents for Onyx

Page 1: ...U S D AirSep Corporation PSA Oxygen Generator Onyx Onyx Onyx Ultra Instruction Manual MN109 1 05 10 Rev AirSep Corporation x 260 Creekside Drive x Buffalo NY 14228 2075 USA Phone 1 800 320 0303 x Fax 716 691 1255 x www airsep com ...

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Page 3: ...ent record of your purchase PSA Oxygen Generator Model Number Serial Number Invoice Date Start up Date AirSep Representative Company Contact Address City Town State Zip Country Fax Phone Telex Before you attempt to install operate or repair the oxygen generator read and thoroughly understand this instruction manual Improper operation can result in severe bodily injury damage to the oxygen generato...

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Page 5: ...afety Publications 2 2 3 0 Generator Description 3 1 3 1 General 3 1 4 0 Components Description 4 1 4 1 External Components 4 1 4 2 Internal Components 4 3 5 0 Installation 5 1 5 1 Handling and Unpacking 5 1 5 2 Pre installation Operational Check 5 2 5 3 Installation Instructions 5 3 6 0 System Operation 6 1 6 1 Start up 6 1 6 2 Operation 6 1 6 3 Shutdown 6 1 6 4 Oxygen Purity Test 6 2 7 0 Mainten...

Page 6: ...truction Manual 8 0 Troubleshooting 8 1 8 1 Technical Support 8 1 8 2 Troubleshooting Chart 8 1 8 3 Procedures 8 6 A Appendix Technical Data Drawings A 1 B Appendix Warranty Returns B 1 C Appendix Parts List C 1 D Appendix Component Literature D 1 ...

Page 7: ...strations Figure 4 1 External Components Typical Oxygen Generator 4 1 Figure 4 2 Internal Components Typical Oxygen Generator 4 3 Figure A 1 Onyx Flow Schematic A 5 Figure A 2 Onyx Flow Schematic A 6 Figure A 3 Onyx Ultra Flow Schematic A 7 Figure A 4 Electrical Schematic A 8 ...

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Page 9: ...arranty information To ensure safe operation and proper maintenance of the oxygen generator AirSep Corporation recommends that you keep this instruction manual readily available for reference 1 2 Warnings Cautions and Notes As you read this instruction manual pay special attention to the WARNING CAUTION and NOTE messages They identify safety guidelines or other important information as follows Pro...

Page 10: ...ags or Labels This instruction 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 Refer to Chapter 4 for a description of the oxygen generator components ...

Page 11: ...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 avoid fire or an explosion keep gasoline kerosene oil grease cotton fibers paint and any other combustible material away from any part of the oxygen generator Do not smoke or use an open flame near the oxygen system Post NO SMOKING ...

Page 12: ...his instruction manual before you service the oxygen generator Disconnect power before servicing oxygen generator Do not disconnect protective earth 2 3 Safety Publications This section is not a complete summary of required safety procedures Review the following publications for additional information on the safe handling of oxygen Standard for Bulk Oxygen Systems at Consumer Sites NFPA No 50 Nati...

Page 13: ... in its adsorber vessels an inert ceramic material called molecular sieve to separate compressed air into oxygen and other gases The unique properties of molecular sieve allow it to attract or adsorb nitrogen physically from air under pressure This allows oxygen to exit the adsorbers as a product gas Each adsorber produces oxygen for approximately eight seconds Oxygen exits the adsorbers through a...

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Page 15: ... Refer to Appendix A of this instruction manual for general layout drawings and specifications 4 1 External Components Figure 4 1 below illustrates the external components Figure 4 1 External Components Typical Oxygen Generator The design of the AirSep Onyx Onyx and Onyx Ultra Oxygen Generators allows for easy access and removal of most components This allows you to perform scheduled maintenance r...

Page 16: ...he power cord connects the unit to a properly grounded electrical outlet to supply electrical power to the unit Gross Particle Filter The washable gross particle filter removes airborne particulate matter from the room air drawn into the unit Cabinet The cabinet protects the components inside the unit e g circuit board air compressor pressure switch and valves Hour Meter The hour meter indicates t...

Page 17: ... that adsorbs attracts nitrogen from compressed air and allows oxygen to pass through as the product gas Capacitor The capacitor stores additional electrical power to enable the air compressor to start Cooling Fan The cooling fan increases airflow inside the enclosure to cool the air compressor Air Compressor The air compressor pressurizes ambient air and delivers it to the adsorbers Capacitor Com...

Page 18: ...anual Circuit Board The circuit board controls the cycle time and sequence of each solenoid valve Valve Block The valve block houses the feed and waste solenoid valves Equalization Valve The equalization valve balances the pressure between the two sieve beds ...

Page 19: ...ng to facilitate future shipping and transporting of the unit 4 Place the unit in an upright position and thoroughly inspect the enclosure and all external components e g flowmeter for damage 5 Remove the side back and lower front panels and inspect the interior for loose or damaged parts To prevent electrical shock make sure the main power supply is disconnected when you remove the panels and ins...

Page 20: ...8 Rotate clockwise the knob on the flowmeter until it stops at the fully closed position Verify that the flowmeter indicates zero flow 9 Rotate counterclockwise the knob on the flowmeter until the flowmeter indicates 100 flow When nothing connects to the oxygen outlet the ball in the flowmeter should rise to the top of the flowmeter If this does not occur contact the AirSep Commercial Products Ser...

Page 21: ...tor Connect the unit to electrical power that continuously meets the specifications in Appendix A of this instruction manual 2 Place the oxygen generator in an upright position on a level surface 3 Connect the oxygen outlet to the inlet of your application Use only oxygen compatible materials for the hoses tubing and connections between the oxygen outlet and the inlet to your application If you us...

Page 22: ...rporation 5 4 Onyx Onyx Onyx Ultra Instruction Manual If a continuous supply of oxygen is critical to your application provide a backup source of oxygen to use if a power failure or equipment malfunction occurs ...

Page 23: ... the level mark 4 If your application requires the pressure of the product oxygen to differ from the pressure specified in Appendix A of this instruction manual contact the AirSep CPD Service Department Increasing the flow of the product oxygen above the flow specified in Appendix A of this manual results in reduced purity of the product oxygen On the Onyx standard specifications correspond to a r...

Page 24: ...the unit as specified in section 6 1 and does not exceed the capacity of the unit 4 Connect a calibrated oxygen purity analyzer to the oxygen outlet 5 Take oxygen purity readings every 60 seconds until the analyzer shows the same result for two consecutive readings 6 Disconnect the oxygen analyzer and reconnect your application Using the oxygen generator at flows higher than 15 above those specifi...

Page 25: ...er Clean the gross particle filter on the back of the oxygen generator enclosure every week or more frequently if site conditions warrant A clean filter allows the unit to cool properly Use the following procedure to clean the gross particle filter 1 Shut down the oxygen generator as described in Section 6 3 Shutdown Do not operate the unit without the gross particle filter in place 2 Remove the f...

Page 26: ...ean the enclosure Use the following procedure to clean the enclosure 1 Shut down the oxygen generator as described in Section 6 3 Shutdown 2 Disconnect the power cord from the electrical outlet 3 Use a dry lint free cloth on the enclosure taking care to wipe the enclosure clean Dry cloth clean only Do not apply liquid directly to the enclosure or use any petroleum based solvents or cleaning agents...

Page 27: ...roducts Service Department E mail cpdservice airsep com 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 oxygen generator Electrical shock hazard The interior of the oxygen generator contains electrical parts that can produce an electrical shock if not handled properly Disconnect the...

Page 28: ... ON OFF switch circuit board capacitor and air compressor Replace all defective components Air compressor stops unexpectedly or does not operate when cooling fan operates Restricted air flow to air compressor Clean gross particle filter or remove obstruction Extreme cold ambient temperature Allow temperature of unit to increase above 4ºC 40ºF Thermal shutdown activated on air compressor Allow air ...

Page 29: ...mbient temperature does not exceed specification in Appendix A of this instruction manual clean filter remove obstruction or replace cooling fan Defective circuit board Replace circuit board Contaminated adsorbers Replace adsorbers Obstructed exhaust muffler Replace exhaust muffler Defective solenoid valve s Repair or replace solenoid valve s Flowmeter fluctuates or flow rate of product oxygen cha...

Page 30: ... Leak in unit Pressurize unit set ON OFF power switch to OFF and disconnect main power supply Remove panels and make sure tubing remains connected to fittings Use soapy water to check all hoses tubing and fittings in unit Most leaks are audible when area is quiet Repair leaks as necessary Contaminated adsorbers Replace adsorbers Defective solenoid valve s Repair or replace solenoid valve s Defecti...

Page 31: ...fewer than two lights lit at any given time Defective solenoid Replace solenoid coil Faulty electrical connections Make sure all electrical connections are secure Defective circuit board Replace circuit board Circuit board has more than two lights lit at any given time Defective circuit board Replace circuit board ...

Page 32: ...ase These parts were specially designed and formed They should never require replacement under normal use Caster Replacement Remove the cabinet panels to expose the caster nut Remove the caster nut with a 9 16 inch socket Use an extension for the two front caster nut removals Install the new caster and washer and tighten the nut Reconnect the cabinet panels 8 3 2 Compressor The compressor is the p...

Page 33: ...ve the compressor assembly for exchange follow the steps listed below 1 Set the unit s ON OFF switch to the OFF position and unplug the power cord 2 Remove both sides and lower front panels 3 Disconnect the suction tube 4 Disconnect the blue compressor lead at the terminal strip and the brown lead at the temperature switch 5 Disconnect the two leads to the capacitor and remove if necessary 6 Disco...

Page 34: ...nd one equalization Each valve has an open energized and closed de energized position As the unit operates two valves are always energized The solenoid valves of the unit require no scheduled maintenance If a valve becomes noisy you can easily replace the internal valve parts To identify the noisy valve observe which green circuit board light illuminates at the time of the noise The lighting matri...

Page 35: ...F position and unplug the power cord 2 Remove both sides and back panels 3 Remove the red cap from the appropriate valve with a slotted head screwdriver 4 Disconnect the solenoid leads and lift off the solenoid coil 5 Replace with the new coil 6 Press the red cap back on top of the coil and reconnect the solenoid leads 7 Reconnect the back and side panels 8 3 4 Sieve Beds Do not expose molecular s...

Page 36: ...re in reverse order It is very important to tighten all tubes to eliminate leaks However do not over tighten To check for leaks take the following steps 1 Plug in the unit 2 Set the unit s ON OFF switch to ON for three minutes with the flowmeter closed to pressurize the system 3 Set the unit s ON OFF switch to OFF and unplug the power cord 4 Apply soapy water around the sieve bed tube connections ...

Page 37: ... configuration of the Oxygen generator Two green lights should always illuminate and rotate cycle during normal operation A green light that fails to illuminate indicates a disconnected or faulty solenoid coil or an electrical malfunction in that valve circuit The Printed Circuit Boards PCBs contain components that are sensitive to electrostatic discharge ESD and can damage the board if not handle...

Page 38: ...d to the circuit board If applicable 6 Remove the circuit board Handle the new circuit board only by the edges to prevent electrostatic damage to the unit 8 3 6 2 Circuit Board Installation 1 Push the circuit board onto the support tabs 2 Firmly plug in the 10 pin connector 3 Reconnect If applicable any tubing disconnected during the circuit board removal procedure 4 Reconnect the back and side pa...

Page 39: ...fers to standard Onyx Onyx and Onyx Ultra oxygen generators Consult your sales representative to determine whether your oxygen generator requires modifications for your application Provide proper voltage from a grounded outlet to the oxygen generator Main power supply voltage fluctuation must not exceed 10 of the nominal supply voltage ...

Page 40: ...x H Approximate weight 54 lb shipping weight 61 0 lb 25 kg shipping weight 28 kg Power requirements 100 V 10 50 60 Hz Single Phase 5 5A 120 V 10 60 Hz Single Phase 5 0A 220 V 10 50 Hz Single Phase 2 3A 220 V 10 60 Hz Single Phase 2 3A Other Specifications Pollution Degree 2 Installation Category II Altitude 2000 m SCFH standard cubic feet per hour gas measured at 1 atmosphere and 70 F Nm3 normal c...

Page 41: ...uirements 120 V 10 60 Hz Single Phase 5 0A 220 V 10 50 Hz Single Phase 2 3A 220 V 10 60 Hz Single Phase 2 3A Other Specifications Pollution Degree 2 Installation Category II Altitude 2000 m If you have purchased a Onyx 120 V 60 Hz with the flowmeter calibrated in lpm scale instead of percentage please ensure that top of the ball of the flowmeter touches the 6 5 lpm marked line for standard specifi...

Page 42: ...n W x D x H 40 x 36 8 x 72 4 cm W x D x H Approximate weight 58 lb shipping weight 65 0 lb 26 kg shipping weight 30 kg Power requirements 120 V 10 60 Hz Single Phase 6 0A 220 V 10 50 Hz Single Phase 3 0A Other Specifications Pollution Degree 2 Installation Category II Altitude 2000 m SCFH standard cubic feet per hour gas measured at 1 atmosphere and 70 F Nm3 normal cubic meters gas measured at 1 a...

Page 43: ...AirSep Corporation Onyx Onyx Onyx Ultra Instruction Manual A 5 Figure A 1 Onyx Flow Schematic ...

Page 44: ...AirSep Corporation A 6 Onyx Onyx Onyx Ultra Instruction Manual Figure A 2 Onyx Flow Schematic ...

Page 45: ...AirSep Corporation Onyx Onyx Onyx Ultra Instruction Manual A 7 Figure A 3 Onyx Ultra Flow Schematic ...

Page 46: ...AirSep Corporation A 8 Onyx Onyx Onyx Ultra Instruction Manual Figure A 4 Electrical Schematic ...

Page 47: ...able 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 n...

Page 48: ... sold for use in industrial applications only Contact AirSep Corporation or an authorized AirSep Corporation representative before you use this unit for any medical application Returning the Oxygen Generator or a Component for Service If the oxygen generator or a defective part requires service contact your distributor If instructed by your distributor to contact AirSep Corporation follow the proc...

Page 49: ...r written authorization was issued by AirSep Corporation 3 Return item s in their original packaging material Pack merchandise for a safe return AirSep Corporation assumes no responsibility for damage that occurs in transit Any damage to the oxygen generator or a component because of failure to follow this procedure is the sole responsibility of the customer Return item s on a freight prepaid basi...

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Page 51: ...r the oxygen generator To order please contact your distributor If instructed by your distributor to contact AirSep Corporation contact the AirSep Commercial Products Service Department Section 8 1 Technical Support If the list does not contain the part you require please provide a precise description of the part when you call ...

Page 52: ...ompressor Rebuild Kit 2660 1 CO012 11 30 000 Hour Kit 4 Year Feed and Waste Valve Rebuild Kit 4 VA034 1 Equalization Valve Replacement 1 VA003 9 Emergency Kit PC Board 1 CB004 1 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA054 1 Equalization Valve Replacement 1 VA003 9 Equalization Valve Coil 1 VA052 1 Capacitor 1 CC006 3 Circuit Breaker 1 CR001 1 Rebuilt Sieve Bed Asse...

Page 53: ... Kit 2669190 1 CO012 9 Compressor Rebuild Kit 2660 1 CO012 11 30 000 Hour Kit 4 Year Feed and Waste Valve Rebuild Kit 4 VA034 1 Equalization Valve Replacement 1 VA003 10 Emergency Kit PC Board 1 CB004 2 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA119 1 Equalization Valve Replacement 1 VA003 10 Equalization Valve Coil 1 VA117 1 Capacitor 1 CC006 6 Circuit Breaker 1 CR00...

Page 54: ... 1 Equalization Valve 1 VA003 9 Emergency Kit PC Board 1 CB068 3 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA054 1 Equalization Valve Replacement 1 VA003 9 Equalization Valve Coil 1 VA052 1 Capacitor 1 CC006 3 Circuit Breaker 1 CR001 1 Sieve Bed Assembly Onyx 2 Beds 1 BE155 1 Supplemental Equipment Oxygen Analyzer Model AX 300 1 AN009 2 Replacement Sensor MedR 17 1 AN0...

Page 55: ... Rebuild Kit 4 VA034 1 Equalization Valve 1 VA003 10 Emergency Kit PC Board 1 CB068 7 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA119 1 Equalization Valve Replacement 1 VA003 10 Equalization Valve Coil 1 VA117 1 Capacitor 1 CC005 9 Circuit Breaker 1 CR001 5 Sieve Bed Assembly Onyx 2 Beds 1 BE155 1 Supplemental Equipment Oxygen Analyzer Model AX 300 1 AN009 2 Replacemen...

Page 56: ... 1 VA003 9 Emergency Kit PC Board 1 CB068 9 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA054 1 Equalization Valve Replacement 1 VA003 9 Equalization Valve Coil 1 VA052 1 Capacitor 1 CC006 3 Circuit Breaker 1 CR001 1 Sieve Bed Assembly Onyx 2 Beds 1 BE186 1 Supplemental Equipment Oxygen Analyzer Model AX 300 1 AN009 2 Replacement Sensor MedR 17 1 AN014 2 On Off Switch ro...

Page 57: ... VA003 10 Emergency Kit PC Board 1 CB107 1 Feed and Waste Valve Rebuild Kit 1 VA034 1 Feed and Waste Valve Coil 1 VA119 1 Equalization Valve Replacement 1 VA003 10 Equalization Valve Coil 1 VA117 1 Capacitor 1 CC005 9 Circuit Breaker 1 CR001 5 Sieve Bed Assembly Onyx 2 Beds 1 BE186 1 Supplemental Equipment Oxygen Analyzer Model AX 300 1 AN009 2 Replacement Sensor MED R 17 1 AN014 2 On Off Switch r...

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Page 59: ...s Industries 2660 Series Compressors CE32 CG32 CG36 CHI37 and CHI42 Troubleshooting Guide Thomas Industries 2660 Series Compressors CE36 Exploded View and Parts List Thomas Industries 2660 Series Compressors CE36 Wiring Diagram Thomas Industries 2660 Series Compressors CE36 Troubleshooting Guide Thomas Industries 2660 Series Compressors CS37 Exploded View and Parts List Thomas Industries 2660 Seri...

Page 60: ...Troubleshooting Guide Thomas Industries 2660 Series Compressors CHI56 Exploded View and Parts List Thomas Industries 2660 Series Compressors CHI56 Wiring Diagram Thomas Industries 2660 Series Compressors CHI56 Troubleshooting Guide Fans Sunon Inc SP Series Fans Specification Sheet Sunon Inc SP Series Fans Model Numbering System Regulator Norgren R07 Series Regulator Data Sheet Norgren R07 Series R...

Page 61: ...AirSep Corporation Onyx Onyx Onyx Ultra Instruction Manual D 3 Valves ASCO Valve Inc U8016 US8016 Valves Open Frame Solenoids Installation and Maintenance Instructions ...

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