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AirSep Topaz, Instruction Manual

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Page 1: ...0 AirSep Corporation PSA Oxygen Generator Topaz Topaz Topaz Ultra Instruction Manual MN012 2 03 12 Rev C 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: ...as a permanent record of your purchase PSA Oxygen System Model Name 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 or operate the oxygen generator read and thoroughly understand this instruction manual Improper operation can result in severe bodily injury damage to the oxygen system or...

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Page 5: ...onents 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 7 0 Maintenance 7 1 7 1 Cleaning the Gross Particle Filter 7 1 7 2 Cleaning the Enclosure 7 2 7 3 Solenoid Valves 7 2 7 4 Air Compressor 7 3 8 0 Troubleshooting 8 1 8 1 Technical Supp...

Page 6: ...rator External Components 4 1 Figure 4 2 Oxygen Generator Internal Components 4 3 Figure A 1 Flow Schematic Topaz A 5 Figure A 2 Flow Schematic Topaz A 6 Figure A 3 Flow Schematic Topaz Ultra A 7 Figure A 4 100 110 120 V 50 or 60 Hz Electrical Schematic A 8 Figure A 5 240 V 50 or 60 Hz Electrical Schematic A 9 ...

Page 7: ...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 the 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 preven...

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Page 9: ...l Improper operation can result in severe bodily injury damage to the unit or poor performance 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 avoid fire or an explosion keep gasoline kerosene oil grease cotton fibers paint and any oth...

Page 10: ...event fire or electrical shock locate the oxygen generator indoors away from rain or any other type of moisture 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 National Fire Protection Association 1 Ba...

Page 11: ...e 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 and flow into a mixing tank which maintains stable flow and purity of the product oxygen The product oxygen flows from the mixing tank through a pressure regulator that a...

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Page 13: ...for general layout drawings and specifications 4 1 External Components Left Side Right Side Figure 4 1 Oxygen Generator External Components Enclosure The enclosure protects the components inside the unit e g circuit board air compressor and valves Gross Particle Filter The washable gross particle filter removes airborne particulate matter from the room air drawn into the unit Enclosure Air Exhaust...

Page 14: ...utlet The B size adapter at the oxygen outlet connects to your application Air Exhaust Heat from the unit escapes through the air exhaust located on the left side of the enclosure Power Cord The power cord not shown and its grounded plug connect from a connection See Figure 4 1 on the unit to a properly grounded electrical outlet to supply electrical power to the unit l O Power Switch The l O powe...

Page 15: ...ts Front View Rear View Figure 4 2 Oxygen Generator Internal Components Cycle Pressure Gauge Pressure Regulator Air Compressor Cooling Fan Hour Meter Circuit Board Valve Block Capacitor Heat Exchanger Adsorbers Equalization Valve Mixing Tank Intake Resonator Terminal Strip Exhaust Muffler ...

Page 16: ... Heat Exchanger The heat exchanger cools the pressurized air from the air compressor Adsorbers Sieve Beds The adsorbers or sieve beds contain the molecular sieve that adsorbs attracts nitrogen from compressed air and allows oxygen to pass through as the product gas Cycle Pressure Gauge The cycle pressure gauge indicates the pressure inside the sieve beds The cycle pressure gauge does not indicate ...

Page 17: ...nk provides stable flow and purity for short term surge in oxygen demand Pressure Regulator The pressure regulator controls the delivery pressure of the product oxygen This regulator is factory set and should never be adjusted Changing the regulator setpoint in any way can potentially cause damage to the molecular sieve and will void the warranty Exhaust Muffler The exhaust muffler allows waste ga...

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Page 19: ...ior of the carton is severely damaged note it on the freight bill before you sign it 3 Unpack the unit and remove any protective wrapping and packaging Retain the carton and packaging 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 enclosure and ...

Page 20: ...gure 4 1 to l Verify that the green indicator light on the switch illuminates 6 Listen for the sound of the air compressor See Figure 4 1 in operation 7 Verify that exhaust air emits from the air exhaust See Figure 4 1 on the left side of the enclosure 8 Rotate the knob on the flowmeter See Figure 4 1 clockwise until it stops at the fully closed position Verify that the flowmeter indicates zero fl...

Page 21: ...timum performance of the oxygen generator and prevent damage not covered under the AirSep Corporation Product Warranty make sure location of the unit meets the following conditions Locate the unit in an area that is protected from the weather elements and where the ambient temperature remains within the specifications in the Appendix A of this instruction manual To enable adequate airflow to cool ...

Page 22: ...gen outlet the barb and fastener provided in the plastic bag shipped with the unit Insert the barb into the tubing connected to your application and clamp the tubing securely to the barb Clean your hands thoroughly before handling the barb and fastener Make sure the tools used to secure the connection between the oxygen outlet and your application does not contaminate the hoses tubing or connectio...

Page 23: ... be set at the specified flow rate Refer to Appendix A for the specified flow rates At the appropriate flowrate setting top of the ball of the flowmeter will be at the level mark Increasing the flow of the product oxygen above the flow specified in Appendix A of this instruction manual results in reduced purity of the product oxygen potential damage to the molecular sieve and the warranty will be ...

Page 24: ...ra Instruction Manual 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 ...

Page 25: ...shooting Table 7 1 Maintenance Chart 7 1 Cleaning the Gross Particle Filter Clean the gross particle filter on the right side of the oxygen generator enclosure See Figure 4 1 every two weeks 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 Sec...

Page 26: ...nclosure 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 7 3 Solenoid Valves Check the performance of solenoid valves once every month Rebuild or replace the solenoid valves as necessary Refer to Section 8 Troubleshooting for some possible faulty valve scenarios The typical preventive ...

Page 27: ...ventive maintenance interval for the air compressor is 15 000 hours Rebuild the air compressor if applicable after 15 000 hours If the air compressor for the unit you purchased does not come with a rebuild kit replace the air compressor if the maximum cycle pressure starts to go below 179 kPa 26 psig ...

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Page 29: ...4228 2075 USA Attention Commercial Products 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 Electrical shock hazard The interior of the oxygen generator contains electrical parts that can produce an electrical shock if not handled properly Disconnect the main power supply before removing t...

Page 30: ...r Circuit breaker on I O power switch tripped Reset the circuit breakers and set I O power switch to I to restart unit If circuit breaker immediately trips again check the wiring for any short circuit Also check I O power 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 ...

Page 31: ...exhaust muffler Defective solenoid valve s Repair or replace solenoid valve s Excess temperature inside enclosure due to inadequate ventilation outside enclosure high ambient temperature dirty gross particle filter blocked air intake or defective cooling fan Provide proper ventilation make sure ambient temperature does not exceed specification in Appendix A of this instruction manual clean filter ...

Page 32: ... as necessary Improperly set or defective pressure regulator Check regulator setting or replace defective regulator Relief valves release Refer to Popping sound indicates release of relief valves problem in troubleshooting chart Defective air compressor Rebuild or replace air compressor as applicable Popping sound indicates release of relief valves Obstructed exhaust muffler Replace exhaust muffle...

Page 33: ...er to the Topaz Topaz and Topaz 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 34: ...6 lb Power Requirements 100 V 10 50 or 60 Hz 5 5 A 120 V 10 60 Hz 5 0 A 240 V 10 50 or 60 Hz 2 5 A All the above are Single Phase Ventilation Do not install adjacent to heat source and allow a minimum of six inches around unit to provide adequate airflow Ambient temperature range 40ºC 104ºF maximum 4ºC 40ºF minimum Other Specifications Pollution Degree 2 Installation Category II Maximum altitude a...

Page 35: ... Weight 21 kg 46 lb Power Requirements 120 V 10 60 Hz 5 0 A 240 V 10 50 or 60 Hz 2 5 A All the above are Single Phase Ventilation Do not install adjacent to heat source and allow a minimum of six inches around unit to provide adequate airflow Ambient temperature range 40ºC 104ºF maximum 4ºC 40ºF minimum Other Specifications Pollution Degree 2 Installation Category II Maximum altitude above sea lev...

Page 36: ... D x H Weight 21 kg 46 lb Power Requirements 120 V 10 60 Hz 6 0 A 240 V 10 50 Hz 3 0 A All the above are Single Phase Ventilation Do not install adjacent to heat source and allow a minimum of six inches around unit to provide adequate airflow Ambient temperature range 40ºC 104ºF maximum 4ºC 40ºF minimum Other Specifications Pollution Degree 2 Installation Category II Maximum altitude above sea lev...

Page 37: ...AirSep Corporation Topaz Topaz Topaz Ultra Instruction Manual A 5 Figure A 1 Flow Schematic Topaz ...

Page 38: ...AirSep Corporation A 6 Topaz Topaz Topaz Ultra Instruction Manual Figure A 2 Flow Schematic Topaz ...

Page 39: ...AirSep Corporation Topaz Topaz Topaz Ultra Instruction Manual A 7 Figure A 3 Flow Schematic Topaz Ultra ...

Page 40: ...AirSep Corporation A 8 Topaz Topaz Topaz Ultra Instruction Manual Figure A 4 100 110 120 V 50 or 60 Hz Electrical Schematic ...

Page 41: ...AirSep Corporation Topaz Topaz Topaz Ultra Instruction Manual A 9 Figure A 5 240 V 50 or 60 Hz Electrical Schematic ...

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Page 43: ...pplicable 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 d...

Page 44: ...IRSEP HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES AirSep oxygen generators are sold for use in industrial applications only Contact AirSep or an authorized AirSep representative before you use this unit for any medical application Returning the Oxygen Generator or a Component for Service Follow the procedure below to return the oxygen generator or a component for service or credit 1 Obtain...

Page 45: ...ssued by AirSep 3 Use the original packaging material to return item s Pack merchandise for a safe return AirSep 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 basis only ...

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Page 47: ...0 Threads 4 MO007 1 Regulator 0 10 PSI w Holes Non Relieving Norgren 1 RG022 1 Muffler 1 4 MPT Norgren 1 MU034 1 Flowmeter 6 LPM 1 FM080 1 Foam Acoustic Muffler 1 FO003 1 Foam Filter 4 X 4 X 1 2 Thk 15 PPI 1 FO015 1 Heat Exchanger 1 HX002 2 Hour Meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Beds Assy 3 DIA X 16 LG 1 BE036 2 Switch Rocker Green 1 SW004 1 Supplemental Equipment Analyzer Maxtec Max O2 plus...

Page 48: ...at Exchanger 1 HX002 2 Hour Meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Beds Assy 3 DIA X 16 LG 1 BE036 2 Switch Rocker Green 1 SW004 1 Supplemental Equipment Analyzer Maxtec Max O2 plus 1 AN005 1 Analyzer O2 Maxtec Handi Handheld 1 AN021 1 12 000 Hours Compressor Assy 220 60 1 CO076 3 Compressor Assy 220 50 1 CO076 2 Compressor Kit Compression 2660 Trigon 1 CO012 11 30 000 Hours Valve Solenoid 1 4 10...

Page 49: ... 1 FO015 1 Heat Exchanger 1 HX002 2 Hour meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Beds 8L Assy 18 long 1 BE176 1 Switch Rocker Green 1 SW004 1 Tank 8L Mixing Assy 1 TA110 1 Valve Check 1 4 barb X1 4 barb MPC 3001 MPCA975 2 VA006 1 Valve Check Acrylic Hose Barb 2 VA142 3 Gauge Dual Scale 1 1 2 0 30 psi 1 8 MPT w CLP 1 GA001 5 Supplemental Equipment Analyzer Maxtec Max O2 Plus 1 AN005 1 Analyzer O2 M...

Page 50: ...FO015 1 Heat Exchanger 1 HX002 2 Hour meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Beds 8L Assy 18 long 1 BE176 1 Switch Rocker Green 1 SW004 1 Tank 8L Mixing Assy 1 TA110 1 Valve Check 1 4 barb X1 4 barb MPC 3001 MPCA975 2 VA006 1 Valve Check Acrylic Hose Barb 2 VA142 3 Gauge Dual Scale 1 1 2 0 30 psi 1 8 MPT w CLP 1 GA001 5 Supplemental Equipment Analyzer Maxtec Max O2 Plus 1 AN005 1 Analyzer O2 Maxt...

Page 51: ...1 2 Hour Meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Foam Acoustic Muffler 1 FO003 1 Muffler 1 4 MPT Norgren 1 MU034 1 Regulator 1 4 FPT Norgren 100 psig 1 RG088 1 Switch Rocker Green 1 SW004 1 Mixing Tank 1 TA149 1 Valve Block Non Anodized SS Plugs 1 VA290 1 Circuit Breaker 8 Amps 1 CR001 1 Supplemental Equipment Analyzer Maxtec Max O2 Plus 1 AN005 1 Analyzer O2 Maxtec Handi Handheld 1 AN021 1 12 000...

Page 52: ... 2 Hour Meter LCD 100 270VAC 50 60 HZ 1 HM009 1 Foam Acoustic Muffler 1 FO003 1 Muffler 1 4 MPT Norgren 1 MU034 1 Regulator 1 4 FPT Norgren 100 psig 1 RG088 1 Switch Rocker Green 1 SW004 1 Mixing Tank 1 TA149 1 Valve Block Non Anodized SS Plugs 1 VA290 1 Transformer 220 110 N 68X 1 TR026 1 Circuit Breaker 4 Amps 1 CR001 6 Supplemental Equipment Analyzer Maxtec Max O2 Plus 1 AN005 1 Analyzer O2 Max...

Page 53: ... Industries 2660 Series Compressors CE32 CG32 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 CE50 Exploded View and Parts List Thomas Industries 2660 Series Com...

Page 54: ...pose Regulators Installation and Adjustment Instructions Valves ASCO Valve Inc Solenoid Valve Assembly Diagram ASCO Valve Inc U8016 US8016 Open Frame Solenoids Installation and Maintenance Instructions ASCO Valve Inc HV238915 Solenoid Valves Dwg 214639 107 General Installation and Maintenance Instructions ASCO Valve Inc 8262 8263 Series 2 way Direct Acting Solenoid Valves Installation and Maintena...

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