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Summary of Contents for AirSep Onyx
- Page 1 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...
- Page 3 Ownership Data ® Please take a moment to note below important information about your AirSep Corporation PSA Oxygen Generator. Retain this instruction manual, along with your invoice, to serve as a permanent record of your purchase. PSA Oxygen Generator Onyx/Onyx+/Onyx Ultra...
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Page 5: Table Of Contents
Installation ..................5-1 Handling and Unpacking..............5-1 Pre-installation Operational Check ...........5-2 Installation Instructions ..............5-3 System Operation................6-1 Start-up .....................6-1 Operation ..................6-1 Shutdown..................6-1 Oxygen Purity Test ................6-2 Maintenance..................7-1 Cleaning the Gross Particle Filter .............7-1 Cleaning the Enclosure..............7-2 Onyx/Onyx+/Onyx Ultra Instruction Manual... - Page 6 ® AirSep Corporation Troubleshooting ................8-1 Technical Support................8-1 Troubleshooting Chart ..............8-1 Procedures ..................8-6 Appendix Technical Data & Drawings........... A-1 Appendix Warranty/Returns ............B-1 Appendix Parts List ................ C-1 Appendix Component Literature ........... D-1 Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 7 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 Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 9: Introduction
General This instruction manual provides description of the AirSep Corporation Onyx, Onyx+ and Onyx Ultra PSA Oxygen Generators, as well as instructions for their installation, operation, and maintenance. The Appendix of this instruction manual also includes pertinent specifications and warranty information. -
Page 10: References To Controls And Indicators With Tags 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. Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 11: Safety
Oxygen is an invisible gas that is colorless, odorless, and tasteless. To ensure your safety, thoroughly read and familiarize yourself with this entire section of the instruction manual. In addition, AirSep Corporation strongly recommends that you review this section periodically. -
Page 12: Safety Publications
9101; Quincy, Massachusetts 02269-9101 USA. “Oxygen;” Pamphlet G-4; Compressed Gas Association; 1725 Jefferson Davis Highway; Arlington, Virginia 22202-4102 USA. “Cleaning Equipment Oxygen Service;” Pamphlet G-4.1; Compressed Gas Association; 1725 Jefferson Davis Highway; Arlington, Virginia 22202-4102 USA. Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 13: Generator Description
Corporation Generator Description General The AirSep Corporation PSA Oxygen Generator is a self-contained unit that utilizes Pressure Swing Adsorption (PSA) technology to produce oxygen on site. The oxygen generator uses compressed air to produce oxygen. Air enters the Oxygen Generator through an external air intake gross particulate filter. This filtered air enters the compressor via a suction resonator, which quiets the compressor’s... -
Page 15: Components Description
Power Cord 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, repair, and replacement of parts with minimal time and effort. - Page 16 The cabinet protects the components inside the unit (e.g. – circuit board, air compressor, pressure switch, and valves). Hour Meter The hour meter indicates the total number of hours that the unit cycles. Circuit Breaker The circuit breaker protects the unit from power surges. Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 17: Internal Components
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. Onyx/Onyx+/Onyx Ultra Instruction Manual... - Page 18 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. Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 19: Installation
Installation Handling and Unpacking AirSep Corporation ships the oxygen generator in a heavy-duty cardboard carton with two cutout-carrying handles. The unit’s size and weight allow easy transport by manual lifting; the enclosure also has handles and casters for ease of mobility. -
Page 20: Pre-Installation Operational Check
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 Service Department. 10) Set the ON/OFF power switch to OFF. -
Page 21: Installation Instructions
Installation Instructions To ensure optimum 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. - Page 22 ® AirSep Corporation 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. Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 23: System Operation
50% level mark and for Onyx+ unit; the flowmeter must be set at 70% level mark. For Onyx Ultra, set the flowmeter at 90% level mark. For proper flowrate setting, ensure that top of the ball of the flowmeter is at the level mark. -
Page 24: Oxygen Purity Test
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. Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 25: Maintenance
Rinse the filter thoroughly and remove excess water with a soft, absorbent towel. Allow the filter to dry, and then store it in a clean location. Alternate the clean filter with the filter on the unit each time you perform this procedure. Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 26: Cleaning The Enclosure
Disconnect the power cord from the electrical outlet. 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. Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 27: Troubleshooting
Technical Support For assistance in troubleshooting or repairing the unit, or to order replacement parts, contact the AirSep Commercial Products Service Department by telephone Monday through Friday between 7:30 a.m. and 4:30 p.m. Eastern Time. In the USA or Canada, call 1-800-320-0303. Outside the USA or Canada, call (716) 691-0202. - Page 28 Unit operates, but air does Faulty electrical Disconnect main power not circulate into unit. connections to cooling fan. supply, and ensure that all electrical connections, including cooling fan leads, connect securely. Defective cooling fan. Replace cooling fan. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 29 Improperly set or defective Check regulator setting or pressure regulator. replace defective regulator. Defective solenoid valve(s). Repair or replace solenoid valve(s). Defective air compressor. Replace air compressor. Defective circuit board. Replace circuit board. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 30 Low voltage to valve(s). Make sure electrical power remains within specification in Appendix A of this instruction manual. If power at inlet to unit is correct but is low at valve(s), contact AirSep Commercial Products Service Department. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 31 Faulty electrical Make sure all electrical connections. connections are secure. Defective circuit board. Replace circuit board Circuit board has more than Defective circuit board. Replace circuit board. two lights lit at any given time. Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 32: Procedures
This depends upon the model of the compressor, stroke size, bore size, and cup seal condition. The cup seals form the seal between the piston and the cylinder wall. As the cup seals wear, the compressor’s output begins to gradually decrease. This reduction in Onyx/Onyx+/Onyx Ultra Instruction Manual... - Page 33 To install the compressor assembly, follow the steps listed below: 1. Perform the compressor removal procedure in reverse order. 2. Make sure to position the compressor’s lead wires behind the braided suction tube. 3. Leak test all connections. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 34 2. Remove both sides and back panels. 3. Remove the red cap from the appropriate valve with a slotted head screwdriver. 4. Lift off the solenoid coil. Correct direction of spring is required for proper valve function. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 35 Keep all openings to the sieve beds sealed. If replacement is necessary, you must replace both sieve beds at the same time. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 36 The cabinet fan for the oxygen generator is located in the back of the unit. To replace the cabinet fan, take the following steps: 1. Set the unit’s ON/OFF switch to the OFF position and unplug the power cord. 8-10 Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 37 Circuit Board Removal 1. Set the ON/OFF switch to the OFF position, and unplug the power cord. 2. Remove both sides and back panels. 3. Disconnect the main power 10-pin connector from the circuit board. Onyx/Onyx+/Onyx Ultra Instruction Manual 8-11...
- Page 38 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 panels. 8-12 Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 39 Appendix Technical Data & Drawings Specifications Data in this section refers 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.
- Page 40 220 V ~±10%, 60 Hz, Single Phase, 2.3A Other Specifications: Pollution Degree Installation Category Altitude 2000 m *SCFH (standard cubic feet per hour) gas measured at 1 atmosphere and 70°F. **Nm (normal cubic meters) gas measured at 1 atmosphere and 0°C. Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 41 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 specifications.
- Page 42 220 V ~±10%, 50 Hz, Single Phase, 3.0A Other Specifications: Pollution Degree Installation Category Altitude 2000 m *SCFH (standard cubic feet per hour) gas measured at 1 atmosphere and 70°F. **Nm (normal cubic meters) gas measured at 1 atmosphere and 0°C. Onyx/Onyx+/Onyx Ultra Instruction Manual...
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Page 43: Figure A-1: Onyx Flow Schematic
® AirSep Corporation Figure A-1: Onyx Flow Schematic Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 44: Figure A-2: Onyx+ Flow Schematic
® AirSep Corporation Figure A-2: Onyx+ Flow Schematic Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 45: Figure A-3: Onyx Ultra Flow Schematic
® AirSep Corporation Figure A-3: Onyx Ultra Flow Schematic Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 46: Figure A-4: Electrical Schematic
® AirSep Corporation Figure A-4: Electrical Schematic Onyx/Onyx+/Onyx Ultra Instruction Manual... -
Page 47: B Appendix Warranty/Returns
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. - Page 48 EXPRESSLY UNDERSTOOD THAT THE SOLE AND EXCLUSIVE REMEDY FOR ANY DEFECT IN PARTS OR WORKMANSHIP IS LIMITED TO ENFORCEMENT OF AIRSEP’S OBLIGATIONS AS SET FORTH ABOVE, AND AIRSEP SHALL NOT BE LIABLE TO ORIGINAL PURCHASER OR ANY OTHER PARTY FOR LOSS OF...
- Page 49 Corporation. 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.
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Page 51: C Appendix Parts List
Parts List Use the following lists to order parts for 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 Feed and Waste Valve Coil VA054-1 Equalization Valve Replacement VA003-9 Equalization Valve Coil VA052-1 Capacitor CC006-3 Circuit Breaker CR001-1 Rebuilt Sieve Bed Assembly Onyx (2 Beds) BE036-1 Supplemental Equipment Oxygen Analyzer AN009-2 Replacement Sensor (MedR-17) AN014-2 On-Off Switch, rocker, two pole SW114-1 Regulator...
- Page 53 Feed and Waste Valve Coil VA119-1 Equalization Valve Replacement VA003-10 Equalization Valve Coil VA117-1 Capacitor CC006-6 Circuit Breaker CR001-5 Rebuilt Sieve Bed Assembly Onyx (2 Beds) BE036-1 Supplemental Equipment Oxygen Analyzer, Model AX-300 AN009-2 Replacement Sensor(MedR-17) AN014-2 On-Off Switch, rocker, two pole SW114-1 Regulator...
- Page 54 ® AirSep Corporation Onyx+ Spare Parts List (115V generators) Item Part # 12,000 Hour /2 yr New compressor or Rebuild Existing Compressor 115/60, Compressor Only CO240-9 Compressor 115/60, Complete Assby, Mtd CO006-18 Compressor, Rebuild Kit 2660 CO012-11 30,000 Hour Kit/ 4 Year...
- Page 55 ® AirSep Corporation Onyx+ Spare Parts List (220V generators) Item Part # 12,000 Hour /2 yr New compressor or Rebuild Existing Compressor, 220/50,Compressor Only CO240-7 Compressor, 220/60,Compressor Only CO240-8 Compressor, 220/50,Complete Assby Mtd CO006-19 Compressor, Rebuild Kit 2660 CO012-11 30,000 Hour Kit/ 4 Year...
- Page 56 ® AirSep Corporation Onyx Ultra Spare Parts List (115V generators) Item Part # 12,000 Hour /2 yr New compressor or Rebuild Existing Compressor 115/60, Compressor Only CO305-1 Compressor, Rebuild Kit 2660 CO012-11 30,000 Hour Kit/ 4 Year Feed and Waste Valve Rebuild Kit...
- Page 57 ® AirSep Corporation Onyx Ultra Spare Parts List (220V generators) Item Part # 12,000 Hour /2 yr New compressor or Rebuild Existing Compressor, 220/50,Compressor Only CO337-1 Compressor, Rebuild Kit 2660 CO012-11 30,000 Hour Kit/ 4 Year Feed and Waste Valve Rebuild Kit...
- Page 59 Wiring Diagram Thomas Industries 2660 Series, Compressors CE36 Troubleshooting Guide Thomas Industries 2660 Series, Compressors CS37 Exploded View and Parts List Thomas Industries 2660 Series, Compressors CS37 Wiring Diagram Thomas Industries 2660 Series, Compressors CS37 Troubleshooting Guide Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 60 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 Regulator Installation and Maintenance Instructions Onyx/Onyx+/Onyx Ultra Instruction Manual...
- Page 61 ® AirSep Corporation Valves ASCO Valve Inc. U8016 & US8016, Valves Open-Frame Solenoids Installation and Maintenance Instructions Onyx/Onyx+/Onyx Ultra Instruction Manual...
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