Instructions

The NextGeneration of

Oxygen ConcentratorSystems

UnivOx DOS Systems

F r e s h A i r T M

General Operating Instructions Fresh Air LTC Oxygen Concentrator System

Introduction The facility has chosen to implement the combination of a conventional nursing home oxygen distribution system, augmented with oxygen that is produced on site with a PSA oxygen separator. The basic technology used in the nursing home is identical to that used for making oxygen for individual use but the separator is scaled up to provide oxygen for many patients simultaneously. The larger unit can be designed more robustly to insure improved safety, reliability and oxygen purity. The system economics also justifies a transfill pump that permits refilling portable high-pressure cylinders from the low-pressure oxygen created. In this way, portable oxygen is available on site. The large device is more reliable because the service life of the separator and the low-pressure air compressor to drive the separator can be economically increased. The oxygen purity is assured because the system incorporates two high precision oxygen analyzers to monitor purity and an automatic control system to discontinue the oxygen production if the purity falls outside of USP limits. Safety is enhanced because in the event of a separator failure, the conventional oxygen distribution system takes over and an automatic alarm system notifies the system administrator. Process Description PSA Oxygen Separator PSA oxygen generation systems employ a pressure swing adsorption process, which removes nitrogen from the air to produce an oxygen product stream. The PSA oxygen unit uses two adsorbent vessels to achieve a continuous and constant flow of oxygen gas. Supply air is separated into oxygen and a nitrogen-rich waste stream as it flows through one of the vessels filled with the adsorbent. The adsorbent, trade named Molecular Sieve, attracts and traps the carbon dioxide, water, and nitrogen gas while allowing the oxygen to pass through. Any hydrocarbons existing in the air are also separated from the oxygen by the adsorbent and purged with the waste stream. The oxygen is separated from the supply air by adsorption at high pressure followed by a release of the adsorbed materials at low pressure. The process operates on an alternating cycle of adsorption and regeneration. While one bed is adsorbing, the other is regenerating. During the adsorption step, supply air flows through one of the adsorber vessels until the adsorbent is loaded with the impurities. The supply air is then switched to the second adsorber and the first adsorber is regenerated. Regeneration consists of depressurizing, purging of impurities at atmospheric pressure, and repressurizing. The sequencing of adsorption - regeneration steps among the two vessels is microprocessor controlled by two-way solenoid operated valves.

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A general representation of a PSA oxygen plant flow schematic identifying major components is shown in figure 1-1. Oxygen Storage Fresh Air has been designed to be of a size to meet the requirements of many nursing home facilities. The oxygen supply needs are determined by several factors but the National Fire Protection Association, NFPA, recommends a system having a supply consisting of two high-pressure banks lasting 24 hours each (NFPA 99c, 4-3.1.1.5) or a system with a primary, secondary, and reserve supply. The reserve is the minimum of three high-pressure tanks or at least 24 hours supply whichever is larger.

The typical facility installation will consist of the standard liquid system with 'H' tank backup. The 'H' tank and liquid cylinder manifold supply the peak flow demand and serve as the emergency reserve. The size of the emergency reserve is based on the requirement for 24 hours capability at the average flow rate of 60 lpm (liters per minute). A design for 60 lpm requires at least 13 'H' tanks to provide a 24-hour reserve. The Fresh Air design calls for 18 'H' tanks for the total reserve. The system should have liquid cylinders on the primary and secondary sides and a backup system consisting of 'H' tanks. The 'H' tanks will be configured into three banks; consisting of eighteen (18) standard tanks, with six (6) tanks as Primary, six (6) in Secondary, and six (6) in Reserve which is equipped to provide gas for transfilling small ambulatory cylinders. After the Fresh Air system is installed, it will provide the high-pressure oxygen for refilling the three (3) banks of 'H' tanks in the backup system.

Safety Considerations

The first safety requirements are addressed in NFPA 99c, Standard on Gas & Vacuum Systems. This publication specifies correct facility distribution plumbing configuration, materials, installation and the limits on oxygen storage in the facility. The distribution piping, manifold design, and alarm design and installation are the responsibility of the nursing home facility and it's contractors.

The second major requirement is the oxygen purity to be delivered to the patient. The FDA requirement for medical oxygen is that it meets the USP standard. USP medical oxygen shall be 93% pure with an accuracy of 3%. A significant part of the operation that assures satisfaction of the FDA purity regulation is the incorporation into the system of two high precision oxygen analyzers that are always measuring the concentration of oxygen in the produced gas. If this purity should fall below 90%, the output of the separator to the distribution system is automatically turned off until the problem is resolved and the purity returns to above 90%.

For fire safety considerations, only a very small amount of oxygen is actually stored at the separator during the separation process. The accumulator or receiver tank is 60 gallons at 60 psi, which equals approximately 1000 liters of gaseous oxygen or about 30 cubic feet.

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CAUTION: NO SMOKING, OPEN FLAME, or SPARK PRODUCING DEVICES SHALL BE PRESENT WHEN OPERATING OXYGEN EQUIPMENT.

NOTE: Oxygen itself is non-flammable, and listed as an oxidizer, however, materials which burn in air will burn much more vigorously and at higher temperature in oxygen-enriched atmospheres. If ignited, some combustibles such as oil or grease burn in oxygen with explosive force. Some other materials, which do not burn in air, will burn in an oxygen-enriched atmosphere. Oxygen under pressure presents a hazard in the form of stored energy. Ignition temperatures are lower in oxygen-enriched atmospheres and accidents may result when not properly controlled.

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Labeling The labeling requirements for the FreshAir device, and the oxygen product it produces are very specific. Federal Code, sections 201.1 and 820.120. and the National Fire Protection Association, NFPA 99, Health Care Facilities, addresses the labeling and warning signs. The Fresh Air labels and signs shall be applied to the device and verified prior to shipping. Verification documents shall include the signature and date of the person(s) performing the examination and shall be documented in the device history record. Labeling and signage shall also be applied in the facility at the time of installation. Flowmeters, pressure-reducing regulators, and oxygen-dispensing apparatus shall be clearly and permanently labeled, designating the gas and percentage of concentration for which they are intended. All labeling and signage shall be durable and able to withstand repeated cleaning or disinfection. Precautionary signs, readable from a distance of 5 feet (1.4 m) shall be conspicuously displayed in the facility, at the site of equipment installation and at the transfill location in compliance with applicable national, state and local requirements. Examples of labeling are included in the FreshAir Transfill Operating Instructions, (# 00266-00327) and the Transfill Training Document, (# 00266-003260). Placement of facility labels and signs are included in the Installation Guide for the FreshAir system and are utilized by qualified system installers. Periodic inspection as to the condition, legibility, and accuracy of labels and signs shall be performed as a part of the preventative maintenance program and documented in the device history record.

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SYSTEM ASSEMBLIES & MODE OF OPERATION

The Fresh Air LTC Oxygen Concentrator System consists of three basic parts: The Oxygen Separator System (OSS), the Transfill Table, and the Distribution Manifold.

The main assembly of the Fresh Air system, the OSS, is fabricated on a skid that mounts the oxygen separator (SEP), an accumulator or receiver tank, and control panel and calibration cylinders. The high-pressure compressor (HPC), electrical panel, and separator manifold are mounted on an adjoining stand. This skid is located within the facility, in a room with adequate power and ventilation. The SEP unit receives clean oil-free air from a low pressure compressor (LPC) unit on site. It converts the air into high purity oxygen and fills the accumulator tank. The output of the accumulator tank connects to the Distribution Manifold via the separator manifold, which acts as a flow control device through a series of solenoids which can direct the high purity oxygen to distribution or re-direct any impure oxygen (less than 90%) to the atmosphere. The High Pressure Compressor (HPC) takes low pressure oxygen from the Distribution Manifold, converts it to high-pressure oxygen and returns it to the high-pressure manifold to be stored in the 18 'H' tanks, which make up the primary, secondary, and reserve banks. The reserve bank then is utilized to supply high-pressure oxygen to the Transfill Table for the refilling of ambulatory oxygen cylinders.

Oxygen Separator (SEP) and Accumulator Tank

Functional Description

The SEP, (Rela part # 00266-00313), consists of a commercial PSA oxygen separator capable of delivering 160 SCFH of 90-95% oxygen. This oxygen generator is designed to accept compressed air, filter it via a pre-filter and coalescing filter, and then direct the air into one of two absorbers containing molecular sieve. The molecular sieve attracts and adsorbs nitrogen while leaving the oxygen to pass through. This oxygen is transferred into the accumulator or receiver tank and through a 0.3 micron filter before delivering it to the separator manifold. The Accumulator/Receiver Tank, (Rela part # 00266-00313), stores oxygen produced by the generator. It is utilized to provide stable flow and purity for short term surges of oxygen above rated capacity of the generator (SEP). A pressure relief valve assembly at the tank input prevents the build up of excessive pressure. A pressure regulator is not used at the tank output as it is regulated at the distribution manifold. The 60 gallon tank vessel design is pressure rated at 150 psi, which is greater than the 70 psig regulated pressure of the separator. The inlet/outlet connections from the tank are made via a 300 psig hose.

Operation Pressures

The operating pressures of the SEP are controlled below the operating pressure of the adsorption cylinders by an internal pressure regulator set to 65-70 psig, and protected by pressure relief valves on each tank. The tank input pressure

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and the accumulator pressure are visible on mechanical pressure gauges on the SEP front panel. (see AirSep Instruction Manual, AS-160)

Mode of Operation

The Fresh Air LTC Oxygen Concentrator System is intended to be operated in the AUTOMATIC MODE, which is set at the time of system installation by placing the MAN/AUTO switch into the AUTOMATIC position. In this mode the SEP will cycle on & off as a function of product oxygen demand. This mode is preferred when oxygen usage is variable. The process is controlled by a pressure switch tied to high pressure oxygen tank pressures. This pressure switch has two set points, a high and low. The high set point is the maximum oxygen tank pressure. At low or no oxygen demand, the pressure in the oxygen tank reaches the high set point of the pressure switch, the switch will open and the process cycle will stop. The air (LPC) and oxygen compressors (HPC) will unload and all the automatic process valves will close. This will restart the process cycle. This mode of operation will limit oxygen production to an amount not greater than what is being consumed. In this mode, the pressure in the high pressure oxygen tank will fluctuate between the high and low pressure set points of the pressure switch. This pressure range is set such that the low pressure set point is higher than the minimum pressure required by the customer. A pressure regulator installed between the oxygen storage tank and the use point, maintains a constant oxygen delivery pressure.

The MAN setting corresponds to the MANUAL mode of operation. In this mode, the system is on continuously, regardless of oxygen consumption. Manual mode is generally selected when it is desirable to keep then oxygen pressure in the oxygen tank(s) at maximum. This mode is not intended to be used at the facilities or for the applications served by the Fresh Air LTC Oxygen Concentrator System.

General User Instruction

As in the case of the mode setting described above, all of the various settings and controls for the Fresh Air system are adjusted to establish correct system operation at the time of installation and are not intended to be changed by facility personnel. System integrity and performance are checked continuously by monitoring the purity of the output oxygen. In the event that this purity falls below specified levels, the separator output flow will be diverted to exhaust to the atmosphere, a visual indicator will alert the nurses station and available backup oxygen supplies will take over.

The prescribed action by facility personnel in such a situation is to contact Fresh Air Service immediately. Fresh Air technical personnel will conduct an initial assessment of the situation at that time and schedule appropriate corrective action in a timely manner.

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Separator Adsorber Vessels

System Control Panel

High Pressure

Compressor

System Monitor (cmed

personnel only)

Oxygen Separator

Control Panel

Accumulator / Receiver Tank

Calibration Bottles & Rack System Circuit

Breaker Panel

FreshAir System --Transfill table not shown--

figure 1-2

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Operation / Start-Up Procedure

A) Electrical Connection

Observe that the ON/OFF switch is in the OFF position and power indicator light is on. If light is off, check that 10 amp circuit breaker in load center panel is On and power is present. If Ok, check internal fuse.

B) Supply Air Pressure and Connection

Turn on compressed air supply. Observe that Supply Air Pressure Gauge is in 90-150 psig range. If not, check for proper air supply connection.

C) Power On

Turn ON/OFF switch ON. Air will exhaust for 3-5 seconds from filter drain port on the left rear bottom of the cabinet. This is normal. It ensures removal of any condensate that may be present in the filter bowls before air is fed into the adsorbers. Observe that exhaust from filter drain port is clear of water or oil. If not, manually press Drain push button until exhaust is clear of liquid. Under normal operating conditions, air should exhaust from filter drain port for 3-5 seconds every 10 minutes.

Turn AUTO/MANUAL switch to AUTO position for normal operation and observe Supply Air Pressure Gauge and Cycle Pressure Gauge for one complete cycle (approximately 2 minutes). As the unit cycles (amber cycle indicator light on), supply air pressure should not fall below 70 psig and peak cycle pressure should not go above 70 psig. If it does, contact qualified Service Personnel.

With the selector switch in the AUTO position, observe the oxygen receiver pressure gauge. When the pressure reaches approximately 55 to 60 psig the amber light will go off indicating oxygen production has stopped. When oxygen is used and receiver pressure falls to approximately 45 the amber light will come on and oxygen production will resume. Readjustment of the pressure switch should not be necessary, but if required, contact qualified Service Personnel.

The unit should normally be operated in the AUTO position.

Shut-Down Procedure

A) Turn off supply air compressor or discharge valve at compressor tank. Observe that Auto/Manual switch is in the AUTO position and allow separator unit to continue to cycle until amber indicator light is off. This allows the receiver tank to fill completely with oxygen for immediate use when next required. It also allows the unit to shutdown at the proper point in the cycle.

B) Turn the generator ON/OFF switch OFF.

Installation, Maintenance, Troubleshooting & Parts

See Air Sep Oxygen Generator Instruction Manual, Model AS 160

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Cycle Pressure On / Off

Feed Air Pressure Auto / Manual Switch

Oxygen Receiver Pressure

Hourmeter Manual Drain Button

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Oxygen Separator Control Panel figure 1-3

Filter Outlet Ball Valve

Prefilter

Regulator

Coalescing Filter

Air Inlet Ball Valve

Oxygen Separator Components (cover removed) figure 1-4

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Separator Manifold Functional Description The Separator Manifold input is from the outlet of the Receiver Tank and consists of a pressure transducer, a O-2 sampling outlet to supply SEP generated oxygen to the analyzers and process controls via inch flexible polyethylene tubing, two (2) independent purity shut-off solenoid valves, a purity dump valve, flowmeter, pressure gauge and output check valve. (see Rela Dwg. # 00266-01002 ASSY, DIST. section) Shutoff Valve #1 Shut off solenoid valve #1, (SN1DIS), is electrically connected to #1 processor control PLC (see Detailed Electrical Design) and is deactivated (closed) when the purity level is low so as to not distribute low purity oxygen into the system. When purity has been reestablished, the solenoid valve opens to redirect the oxygen flow back into the system. Shutoff Valve #2 Shut off solenoid valve #2, (SN3DIS), is electrically connected to #2 processor control PLC (see Detailed Electrical Design) and is deactivated (closed) when the purity level is low so as to not distribute low purity oxygen into the system. When purity has been reestablished, the solenoid valve opens to redirect the oxygen flow back into the system. Dump Valve The purity dump valve, (SN2DIS), is electrically connected to both processor control PLC #1 & 2 (see Detailed Electrical Design) and is activated (opened) when the purity level is low and to dump the low purity oxygen to the atmosphere to allow the system to recover. When purity has been reestablished, the solenoid valve closes to redirect the oxygen flow back into the system. Flowmeter A 0-300 SLM flowmeter, (FM1DIS), monitors output flow to the system. It is electrically connected to monitor flow and to prevent the HPC from operation when the flow rate is greater than 60 lpm. Pressure Gauge A mechanical pressure gauge, (SG1DIS), monitors output pressure to the system. Range 0 3000 psig. The gauge is located at the outlet of the SEP manifold. Check Valve A check valve, (CV1DIS), at the SEP manifold outlet connection, prevents backflow of oxygen into the manifold, receiver tank, or oxygen separator. Output Filter A filter, (F1DIS), is installed at the output of the Separator Manifold to capture any particulate that may have entered the manifold or been produced by repeated actuation of the valves.

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Pressure Switch Manual

Isolation Valve

Dump Solenoid

High Temperature

Solenoid

Manual Dump Valve

Sight Pressure Gauge

Purity Shutoff

Solenoid Flowmeter

Separator Manifold Components

figure 1-5

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High Pressure Compressor (HPC) Functional Description The High Pressure Compressor (HPC), (Rela part # 00266-00315), is an oxygen specific compressor, with a rated flow of 60-120 SCFH at 2250 psig, used to supply high pressure oxygen to the facilitys Reserve bank of oxygen storage cylinders, which primary use is to supply oxygen for the Transfill operation. The compressor is a two-stage type employing two oil-free single-acting cylinders on a vertical opposed design crankcase. Heat exchangers, crankcase and compression cylinders are air-cooled. The free floating second stage piston allows the piston and rings to be easily changed. Built-in safety features, which automatically shut down the compressor if the input pressure is too low or excessive pressure is reached in the second stage discharge line, are included in the system. A safety shroud is installed to cover the motor/pump belt and pulley. All external plumbing connections use high-pressure flexible hose. (see RIX Instruction Manual, Model 2PS2B-.85) Safety Valves Pressure relief valves, internal to the HPC, are provided after each stage. These valves prevent an over-pressurization of the system. The first stage relief valve is set for 700 psig; the second stage is set for 2500 psig. The relief valves are mounted behind their respective gauges. There is an inlet relief valve, set at 75 psig. Pressure Switches The compressor will automatically shutdown on high discharge pressure. The high-pressure switch, internal to the HPC, is factory set to trip if the discharge pressure reaches 2200 psig. The pressure switch may be adjusted to any pressure between 1600 and 2200 psig. The compressor will automatically shutdown if the inlet pressure becomes too low. The low-pressure switch, internal to the HPC, is set to trip if the inlet pressure falls below 30 psig. Pressure Gauges Pressure gauges, internal to the HPC, measure the inlet pressure and the first and second stage discharge pressures. Inlet: 30-70 psig; First Stage: 350-600 psig; Second Stage: 1500-2200 psig. Back Pressure and Check Valves The Back Pressure valve is factory set at 1500 psi. and is adjustable if necessary. It is located in the discharge piping prior to the check valve. The Check valve prevents any reverse flow of oxygen back into the compressor. It is located at the discharge outlet. Both valves are factory installed and internal to the HPC. Inlet Solenoid Valve A solenoid valve is provided at the compressor inlet. This opens when the compressor is running and closes when it stops. The function is to prevent the continuous leakage of oxygen from the oxygen reserve supply or the piped distribution lines when the compressor is not being operated.

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Mode of Operation Controller (start / stop) The compressor is controlled by a three position, HAND-OFF-AUTO selector switch (HOA). It will normally be operated in the automatic mode. In the manual mode, it is necessary to push the start button to start the compressor. It will run until the low inlet pressure switch or the high discharge pressure switch trips, (30 and 2200 psig respectively), at which time it will shut down and not restart. In the automatic mode, the compressor will start as soon as the HOA switch is turned to the AUTO position. It will continue to run until either the low inlet or high discharge pressure switches trips (open). The compressor will then stop, and re-start automatically when the pressures at the inlet and discharge are adequate to re-close both switches.

WARNING Discharge pipes, fittings, and port areas can be HOT and cause burns if touched. Always exercise caution around the compressor components when it is running or has recently been running. Operating Start-Up Procedure A) Electrical Connection Observe that HOA (Hand-Off-Auto) switch is in the OFF position. Check that 15 amp circuit breaker in load center panel is ON and power is present. B) Inlet Pressure Verify inlet pressure on inlet gauge. A slight hissing may occur as inlet gas escapes past the compressor rings. C) Power On Turn HOA switch to AUTO position. Compressor should start. If operated in the Manual mode, switch to the HAND position and press the START button. A brief knocking sound lasting less than 10 seconds may occur. Observe 1st and 2nd stage pressure gauges are rising.

The unit should normally be operated in the AUTO position. Shut-Down Procedure A) Turn HOA switch to the OFF position. Installation & Operation See RIX Operation & Maintenance Manual, Model 2PS2B-.85 Maintenance, Troubleshooting & Parts See RIX Operation & Maintenance Manual, Model 2PS2B-.85

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Pressure

Relief Valves

Pressure Gauges

Cooling Fan

Motor

Hourmeter

HPC Control Panel

Manual Start

Button

Selector Switch Hand-Off-Auto

Run Light

High Pressure Compressor --front view--

figure 1-6

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Back Pressure

Valve

Compressor Cylinder

Access Plate

Cooling Fans

Check Valve

Discharge Port

Discharge Pressure Switch

High Pressure Compressor --side view--

figure 1-7

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Pressure

Transducer 2nd Stage Cylinder

Filter

Filter

Beltguard Back Pressure

Valve

Check Valve

Discharge Port

Discharge Pressure Switch

Solenoid Valve

Inlet Pressure Switch Inlet Port

High Pressure Compressor --rear view--

figure 1-8

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OSS Control Panel & Calibration Bottles OSS Control Panel The OSS Control Pa components utilized to perform th erations, the user has no need to accelimited to Service Pe The Control Displaymessage display of oxygen (O2 %) beingwarning/error messaare annunciated in awhen no errors exisstatus statements suwhile that mode is enumeric keypad to rreserved for Service Calibration Bottles The calibration bottlthat the regulators asafely and can be qand components wittubing and CPC con99.9% oxygen and tso to have cal-gas aintervals. (see Rela

Bottle Rack Latches

nel contains the electrical and pneumatice system oxygen analysis. For typical op

ss the interior components. Control Panel access should be rsonnel Only.

is mounted on the front of the panel and functions as a system operations. During normal operation, the percent of produced is displayed on the top line of the display and ges are displayed on the bottom line. Warnings and errors ll display modes. The bottom line reads "Normal Operation"

t and a green light is shown. The top line may interweave ch as "SAMPLING O2 CALGAS" with the "O2 %" display

nabled. Gauge message numbers can be entered into the ead specific operational parameters (figure 1) but should be Personnel Only.

es are mounted vertically in the control stand in such a way re easily accessible and that the bottles will be retained uickly replaced. Connections of the cal-gas to the Control Box hin are made via color-coded inch flexible polyethylene nectors at the box entrance. The cal-gas bottles, two @ wo @ 99.9% nitrogen are to be fully open, upon connection, vailable at system start-up and for scheduled calibration Dwg. # 00266-01620)

Oxygen Cal-Bottle

Nitrogen Cal-Bottle

Calibration Bottle Rack (tilt out position) figure 1-9

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Status Lights Numeric Keypad

LCD Display

Function Keys

FreshAir Oxygen System Control Panel figure 1-10

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Transfill Table Functional Description The Transfill Table is a station where small O-2 ambulatory cylinders or bottles can be evacuated and refilled with oxygen. This system consists of self contained table that can fill up to five pairs of bottles, a control processor, a transfill manifold, evacuation pump and associated high pressure piping, pressure switches, valves and solenoid. The transfill accepts high-pressure oxygen from the Reserve Tanks of the Distribution Manifold System. This oxygen has a pressure of 1600 to 2200 psi and is delivered via high pressure piping within the facility to the Transfill Table where it is then regulated to 1900 psig. The transfill controls the fill rate to 200psi/minute; therefore, the bottles should achieve their service pressure of 1900 in approximately 10 minutes. The Transfill Table has a Controller that accepts inputs from pressure switches and controls the evacuation and filling sequence. It displays information about the filling process through a set of 12 LEDs located on the front panel of the controller.(see Rela Dwg. # 00266-00324 and # 00266-00325) Transfill Manifold The Transfill Manifold, (Rela part # 00266-02110) is a pre-manufactured unit designed for oxygen transfilling and pressure rated at 3000 psig. It consists of a brass header, five manual valves with flow restrictors, and five pigtails with CGA oxygen specific (DISS) connectors. Vacuum Pump The Vacuum Pump (CO # 23) is utilized for the evacuation of any remaining oxygen in the ambulatory bottles and must draw a vacuum on these bottles to the equivalent of 25 Hg (at sea level). A vacuum rated hose supplies connection from the Transfill Manifold Vacuum Regulator to the pump. The Vacuum Pump is mounted onto a mounting plate on the underside of the bottom shelf via bolt and nut. Electrical power is supplied via cord and plug to a local A/C wall outlet. Vacuum Regulator and Gauge The Vacuum Regulator and Gauge (CO # 16) is attached to the end of the Manifold Header. The vacuum hose and a tee outlet for the vacuum switch tubing connect at the outlet of the regulator. Vacuum Switch A Vacuum Switch (CO # 18) is installed within the Control Box and flexible polyethylene tubing is connected to the vacuum line.

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TransfillControl Panel

Manifold Header Input Connection

Vacuum Regulator

Manual Isolation Valve

Cylinder Pigtails & Yoke

Vacuum Hose

Refillable Ambulatory Cylinders Vacuum Pump

Transfill Monitor (cmed personnel only)

Transfill Table - Front View

figure 1-11

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Transfill Cylinder Refilling

Instructions

Reset / Clear Button

Transfill Status Lights Start Button

Power On Keyswitch

Transfill Table - Controller

figure 1-12

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High Pressure Piping System The supply oxygen from the Reserve distribution bank feeds the Transfill operation via 3/8inch stainless steel, 3000 psi high-pressure piping at the facility. When this high-pressure gaseous oxygen reaches the Transfill Table, it is controlled via the control box and a series of valves, switches and regulator to complete the transfill operation. This section only addresses the piping system at the Transfill Table. (see Rela Dwg. # 00266-00325) Piping The high pressure piping on the Transfill Table is installed between the high-pressure distribution piping of the facility, via a high-pressure (3000 psi) hose, and the Transfill Manifold. This piping is 3/8 inch stainless steel, rated at 3000 psi, (Rela part # 00266-01902). Pressure Gauge A pressure gauge (CO # 8) is installed at the inlet of the Transfill Table to indicate that supply pressure is available. Gauge range is 200 3000 psig. Pressure Relief Valves This pressure relief valve (CO # 27) set at 1500 psi, and acts to prevent the transfill operation if adequate pressure is not available for a transfilling operation to commence. The proportional relief valve serves the purpose to prevent draining the Reserve Tanks in the case of a malfunction of the transfill table solenoid. Pressure relief valve (CO # 36) set at 2500 psi, acts as a safety relief in case of over pressurization. Check Valve A Check Valve (CO # 3) is installed to prevent the backflow of oxygen into the facilities distribution piping. This check valve is rated 3000 psi, crack pressure 100 psi. Input Pressure Switch This pressure switch (CO # 14) senses adequate input pressure from the Reserve distribution bank to support transfill operation.. Input Regulator The Input Regulator (CO # 12) will regulate the pressure of the supply oxygen to 2000 psig. The service pressure of the ambulatory bottles is 2015 psi. Transfill Solenoid Valve The transfill is controlled by one Solenoid Valve (CO # 13). The valve is connected between the high-pressure input from the Distribution Manifold to the Transfill Manifold. The valve is a normally closed 2-way valve. The valve must safely support the maximum system pressure and it must also provide adequate flow to the ten bottles during the refilling operation. Tankset Pressure Switches The Controller is electrically connected to a set of five pressure switches, which are then connected to the transfill header valve assembly with high-pressure, 3000 psi flexible hose. These switches (CO # 2) are set to trip at 1600 psi and are not adjustable.

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Manual Isolation

Valve

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Transfill Table - Rear View

figure 1-13

Tankset Pressure Switches

Tankset Pigtails

Proportional Pressure

Relief Valve

Check Valve

Supply Pressure Switch

Pressure Relief Valve

High Pressure Oxygen

Regulator

High Pressure Solenoid

Vacuum Pump

Mode of Operation The Transfill Table is operated on an as needed basis and is ONLY to be operated by Qualified Personnel, who have received tranfill training and possess a key to power the transfill controller. System Alarms An alarm panel is located at the nurse's station ....

Document # 00266 00327 Colorado MEDtech, Inc. Page 26 Revision # 01 Date: 03/18/98

Low Pressure Compressor (LPC) (optional) The optional Low Pressure Compressor (LPC), (Rela part # 00266-00322), is a 100% oil-free air source supplying pressurized air to the Fresh Air oxygen separator. The air compressor consists of three 5 Hp scroll compressors with motors, mounted on a horizontal 120 gallon receiver tank. It is operated by a custom designed controller with PLC monitoring capability. The air provided is clean and 100% oil-less to meet the needs of the separator, but is not medical air or a medical air system and not for direct human consumption. Functional Description The Low Pressure Compressor (see figure 2), consists of all the parts and modules necessary to deliver clean 100% oil-free air to 125 psig max. The 120 gallon horizontal tank-mounted air compressor system is a single stage, dual belt-driven, oil-less rotary scroll, air-cooled compressor(s) with aftercoolers. This scroll compressor(s) are of the oil-less design using no lubricant within the compressor chamber. The volume of air output per pump shall not be less than 15 SCFM at 100 psig. The (LPC) is a triplexed unit each powered by a 5 HP electric motor mounted atop each pump. The intake ambient air is filtered to prevent particulate contamination of 5 micron size or larger. Installed between each compressor and the receiver tank is an isolation valve, check valve, and pressure relief valve to permit servicing of each compressor without disrupting operation. The 120 gallon, ASME 200 psi working pressure receiver tank has both a manual drain and an electric drain with Y-strainer mounted and wired. Major maintenance of the compressor(s) shall require only re-greasing the accessible bearings every 5000 hours of operation and replacement of the tip seals every 10,000 running hours. LPC Controller The electrical control panel (controller), mounted on the front of compressor, is utilized to start/stop and monitors the compressor functions. The front panel controls, (shown in figure 1), include a main circuit breaker with interlocking through-the-door handle. Individual Hand-Off-Auto (HOA) start/stop switches for each compressor/motor. Power On (available) indicator and individual Run and Overload indicator lights. A through-the-door Reset switch for each compressor and hourmeters to log the run time of each compressor/motor. A pressure gauge is installed to indicate receiver tank and discharge pressure. The internal controller features include a Power Monitor relay to detect low voltage, phase loss, and phase reversal. A switching relay to alternate the lead unit start-up after each shutdown cycle so that all compressor/motor run times are approximately equal. A surge capacitor for electrical surge protection and contacts for remote indication of compressor running and overload. Three current


transformers for power monitoring and a 208/120 step down transformer with fused primary and secondary circuits. Additionally, a PLC is installed and powered using the internal 120vac, to provide a remote monitor capability for compressor functions. The PLC (Programmable Logic Controller) is a 9 slot base size, with a 120vac power supply, and Ethernet interface card in lieu CPU. I/O modules were selected to monitor LPC functions as follows: (3) motor current via current transformers, (3) motor on/running, (3) dry contact overload trip, (3) bearing temperature, (1) ambient temperature, and (1) low pressure. Mode of Operation The Low Pressure Compressor will normally be operated in the AUTO MODE ONLY. The Main circuit breaker should be in the On position and the individual HOA (Hand-Off-Auto) switches are set to the AUTO position.

Main Breaker Reset-Off-Trip-On

Power On Light

Run Lights Hand-Off-Auto

Switches

Overload Lights Hourmeters

Pressure Gauge Reset Buttons

PowerEx Control Panel

figure 1-13


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