Infinite O2 20L generator operators manual

Infinite O2 Oxygen Generator
Installation, Operation and
Maintenance Manual
Engler Engineering Corporation
1099 East 47th Street, Hialeah, Florida 33013
E-mail:infinite [email protected]
Website: www.englerusa.com
Manuals, Brochures, and How To: www.engler411.com
2010-9600 Rev A, Instruction Manual - Engler 20L Infinite O2
EEC974
10/30/2014
Page 1 of 24
Table of Contents
Topic
Page
Using this Manual
3
Initial Inspection
4
Warranty Information
4
Operating
5
Product Information
>
>
>
Features and Applications
6
PSA Technology
6
Components
7-10
>
>
Process Flow Diagram & Description
12-13
Specifications
14
Safety Precautions
15
Pre – Installation
16
Required Operating Conditions
17
Set-up, Installation
18
Operating Instructions
18
Troubleshooting Guide
19
Preventive Maintenance
20
Technical Service Assistance
21
Appendix
A
Spare Parts List
22-23
B
Maintenance Log
24
2010-9600 Rev A, Instruction Manual - Engler 20L Infinite O2
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Initial Inspection
The crates should be opened and inspected immediately upon delivery.
Unpack at once and perform a visual inspection to determine if the generator or tank
have been damaged.
Generator: Check to make sure the power cord is attached and that the control panel &
displays has not been damaged in any way during shipment.
Storage System: Confirm that the 30 gallon tank / control box, regulator, and pressure
relief valve have not been damaged and appear in order.
At Engler Engineering Corp. (EEC), we are committed to using shipping
companies with good reputations for taking care in the handling of freight and providing
excellent service in the event of damage. If damage is discovered, notify shipper and/or
refuse delivery. Document and photograph all damage for the claims process.
Warranty
The Engler Infinite O2 Oxygen system is warranted for one (1) year against
manufacturers defects.
Proudly made in the USA
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Operating
The Engler Infinite O2 Oxygen Generator is a self-contained system for the
production of high concentration oxygen. Although oxygen itself is not
combustible, it can be very dangerous. It greatly accelerates the burning of
combustible materials.
Precautions should be taken to avoid a fire in the area of the generator.
Smoking should not be permitted in the area where the generator is located.
All oxygen connections and hoses should be kept clean and free of grease,
oil and other combustible materials.
Valves controlling oxygen flow should be opened and closed slowly to avoid the possibility
of fires or explosions that can result from adiabatic compression.
Do not attempt to modify or enhance the performance of an oxygen generator in any way.
When bleeding a tank or line, stand clear and do not allow oxygen to embed itself within
clothing. A spark could ignite the clothing violently.
All devices manufactured and / or sold by Engler Engineering Corporation are built and tested to approved
standards. Any modification to the device, cables or hoses, initiated by others nullifies all warranty statements.
Engler Engineering Corporation will not be held liable for any loss, damage, injury or death due to nonauthorized service and / or improper installation and / or improper use or misuse of the device.
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Product Information
Features and Applications
The Engler Infinite O2 extracts oxygen from the atmosphere using Pressure Swing
Adsorption (PSA) technology. It concentrates oxygen up to 93% (± 3 %) purity which
can be applied in various ways.
Features
Easy to use
Just connect to an electrical outlet (2 separate dedicated 120VAC 20 Amp circuits are required),
turn the ON / OFF power switch to the ON position and set your desired flow.
Dependable
Its internal air compressors, filtration system, molecular sieve, storage tanks and flow control
system are designed for 24 / 7 operation.
Durable
With oxygen-clean brass tubing and valves, the Infinite O2 can operate even in environments
as described under the specifications page.
Safe
A built-in oxygen pressure regulator maintains oxygen tank pressure at 20 PSI (1.3 bar). Each
of the compressors on the Infinite O2 has 0.38 Hp and have a built-in safety relief valve to
prevent excessive pressures. The Infinite O2 has a built-in pressure switch to switch the unit to
standby if the pressure stays high for 5 minutes, indicating the filling system cycle has ended.
Pressure Swing Adsorption (PSA) Technology
An Infinite O2 generator is an on-site oxygen generating machine capable of producing oxygen on
demand in accordance with your requirements. In effect, it separates the oxygen (21%) from the air and
returns the nitrogen (78%) to the atmosphere through a waste gas muffler. The separation process employs
a technology called Pressure Swing Adsorption (PSA). At the heart of this technology is a material
called Molecular Sieve (synthetic zeolite). This sieve is an inert, ceramic-like material that is designed to
adsorb nitrogen more readily than oxygen. Each of the two beds that make up each of the enrichers
contains this sieve. The process is described below.
Stage 1 Compressed air is fed into the first molecular sieve bed. Nitrogen is trapped, while oxygen is allowed to
flow through.
Stage 2When the sieve in the first bed becomes full of nitrogen, the airflow is then directed into the second bed.
Stage 3As the second bed separates the oxygen from the nitrogen, the first bed vents its nitrogen into the
atmosphere.
Stage 4Compressed air is once again fed into the first bed and the process is repeated continuously. A constant
flow of oxygen is produced
This air separation process is reliable and virtually maintenance-free.
The molecular sieve will last indefinitely, as long as it does not become contaminated with water or oil
vapors. This is why regular filter element replacement is crucial to trouble-free operation. The filter
elements are inexpensive and do require semi-annual maintenance.
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External Components Drawing
Front View
1.
Hour Meter
2.
Flow Meter
3.
Fuse
4.
Power Switch
5.
Control panel & display
6.
Oxygen Enricher Concentration Display
7.
Oxygen Outlet
8.
Oxygen Pressure
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External Components Drawing
Side Views
Left Side
Right Side
1
Handle
1.
Handle
2.
Filter Holder
2.
Filter Holder
3.
Power Cord
3.
Lockable Caster
4.
Lockable Caster
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External Components Description
Oxygen Concentration
Display
This display shows concentration of the output oxygen.
Flow Meter
This flow meter shows the output of the unit while it is operating. (It
should remain full open).
Hour meter
The hour meter shows how long the unit has been operating. This helps
indicate when service intervals are due. It is resettable to identify time
between service intervals, but the accumulated time cannot be modified.
Power Switch
This switch controls power to machine. It is illuminated when the switch is
in the ON position.
Unit Power Switches
These switches control each of the three units operating inside of the
Oxygen generator. If a problem exists with one of the three units it may
be turned off and the unit will continue to operate at a reduced output.
These membrane switches are located on the display.
Power Cord
The power cord used on 125 VAC / 60 Hz / 20 Amp electrical systems
comes with a three-pronged grounded Euro plug.
Reset Button
The reset button is actually a circuit breaker that opens if there is an electrical
overload in the system. The main system reset is on the front of the machine.
Oxygen (O2 Outlet)
The outlet fitting is a 1/4” female NPT pipe fitting.
Filter Holder
The filter holders are located on each side of the unit and the filter elements
should be cleaned every two weeks or sooner if in a dusty and dirty
environment.
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Internal Components Drawing
Inside View
1. Modular Bed (3)
9. Compressor Capacitor (3)
2. Pressure Regulator (3)
10. OCSI Display Board
3. Circuit Board (3)
11. Oxygen Storage Tank
4. PLC
12. Inlet Resonator (2)
5. Air Inlet Filter (2)
13. Pressure Switch
6. Product Filter (3)
14. Terminal Block
7. Air Compressor (3)
15. Cooling Fan (3)
8. Heat Exchanger/Moisure Separator (3) 16. Solenoid Valve
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Internal Components Description
Modular Bed
Pressure Regulator
These modular beds contain the molecular sieve that performs the air
separation process, as well as the process control valves and oxygen
storage tank. They are spring loaded to prevent settling and should never
need to be opened. If the sieve becomes contaminated, the beds can be
easily replaced.
The pressure regulator controls the pressure delivered to the oxygen
outlet. It should be set in a way so that the pressure does not exceed 20
PSI (1.3 bar).
Circuit Board
The circuit board controls the operation of the process control valves.
While one valve coil is energized, the other is not. It also monitors the
oxygen output to make sure it is at least 90% concentration.
Compressor Inlet Filter
The compressor inlet filter keeps dust and dirt from entering the
compressor and needs to be changed twice a year in normal
environments to maintain performance. In especially dirty and oily
areas, it should be changed more often. Four times a year is
recommended.
Air Compressor
The air compressor supplies the feed air to the sieve beds. It should
work as designed for a minimum of 10,000 hours and may last 20,000
hours in some cases. It is suspended by four springs to dampen vibration
that should not require replacement.
Heat Exchanger /
Moisture Separator
The heat exchanger moisture separator delivers the feed air from the air
compressor to the modular bed. Significant moisture removal occurs
before the air enters the sieve beds, improving performance.
PLC
The Programmable Logic Controller (PLC) provides the logic that
operates the unit.
Terminal Strip
Assembly
The terminal strip distributes electrical power as required to the
compressors and control components of the machine.
Oxygen Purity Display
The oxygen display board monitors the output of the unit and
displays the purity on the front cabinet.
Oxygen Pressure Switch
The oxygen pressure switch shuts the unit down after
continuous operation when the unit is dead headed for a
period of 15 minutes..
Oxygen Storage Tank
The oxygen storage tank, provides a small buffer to allow the unit to
operated smoothly on high demand applications, it provides product
equal to approximately 30 seconds of operation.
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Process Flow Diagram
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Generator Process Flow Description
There are three independent subsystems providing oxygen to the outlet. Each one
functions on it’s own, and if one system were to fail the other two will continue to provide oxygen
but at a reduced output. In each system, once the incoming air is filtered and compressed in the
Infinite O2 unit, it is directed into one of the two sieve beds, within the modular bed. As the air
enters the bed, the nitrogen is adsorbed by the sieve and the oxygen passes through as product gas
to the storage tank. Each bed produces oxygen until the sieve in that bed is saturated with
nitrogen. When this occurs, the feed airflow is directed to the other bed, which continues the
production process. While the second bed is producing oxygen, the first bed is releasing the
nitrogen it adsorbed, into the atmosphere, under very low pressure through a waste gas muffler.
The oxygen product gas passes from the storage tank in the modular bed, through a
factory set orifice, then, an OCSI monitor. If the concentration is above 90% then it will flow into
a small receiver tank. This receiver tank serves as a reservoir for the oxygen prior to entering flow
meter. The oxygen product gas is then delivered to the oxygen storage tank at up to 20 PSI (1.3
bar). From the storage tank the oxygen passes through a second OCSI monitor where a digital
display of the concentration is produced. The system will automatically go on standby when the
maximum pressure is reached and does not drop for 5 minutes.
OCSI Display Board:
The OCSI board monitors the output of the machine to make sure the oxygen concentration is
within acceptable conditions. Output of the machine will be up to 20 LPM of dry oxygen at 20
PSI (1.3 bar) discharge pressure. The board will use an ultrasonic sensor to determine the purity
of the oxygen as it exits the sieve beds. The board will monitor the purity level and alarm if the
purity falls below 90%.
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Unit Specifications
Performance
Oxygen Volume/Pressure
42 SCFH @ 20 PSI
20 LPM or @ 1.3 bar
Oxygen Purity
93% (± 3%)
[United States Pharmacopeia (USP) XXII oxygen 93% Monograph]
Oxygen Dew point
- 60° F (-51° C)
Feed Air Requirement
None, compressors included
Response Time
Approximately 5 minutes to attain maximum purity after
initial start-up or extended shut-down
Physical
Oxygen Outlet Fitting
¼” NPT Female or DISS
Sound Levels
68 dBA @ 1 m
Dimensions
36 x 22 x 42 in (W x D x H)
92 x 56 x 107 cm (W x D x H)
Weight
275 lb (125 kg)
Power Requirement
Standard
120VAC, 60 Hz, Single Phase 20 Amps each unit
Oxygen Flow Rate
42 SCFH @ 20 psi
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Safety Precautions
It is very important that you read the precautions below and make yourself familiar
with the hazards of oxygen in general. While it can be handled and used very safely, it
can also be mishandled or applied incorrectly causing dangerous situations.
Oxygen is a fire hazard. It can be very dangerous as it vigorously accelerates the
burning of combustible materials. To avoid fire and / or the possibilities of an explosion,
oil, grease or any other easily combustible materials must not be used on or near the
oxygen generator. DO NOT SMOKE NEAR THE UNIT. The unit should be kept
away from heat and flames. Individuals who have experience handling oxygen systems
should become the designated operators of the oxygen generator within your facility.
In sensitive applications, it is important to have a backup supply of oxygen since the
generator does not come with any reserve storage tank and requires electrical power to
operate. Therefore, during power outages, oxygen will not be produced.
Do not use extension cords to bring power to the generator. The current drawn into the
unit is high and could overheat some extension cords. It is also important to use only a
properly grounded outlet.
High pressure oxygen may present a hazard. Always follow proper operating
procedures, and open valves slowly. Rapid pressurization may result in personal injury.
Safety glasses and hearing protection are required when venting oxygen under high
pressure.
Ensure that the oxygen outlet stream is not directed toward anyone’s clothing.
Oxygen will embed itself in the material and one spark or hot ash from a cigarette
could ignite the clothing vigorously.
All devices manufactured and / or sold by Engler Engineering Corporation are built and tested to
approved standards. Any modification to the device, cables or hoses, initiated by others nullifies
all warranty statements. Engler Engineering Corporation will not be held liable for any loss,
damage, injury or death due to non-authorized service and / or improper installation and / or
improper use or misuse of the device.
2010-9600 Rev A, Instruction Manual - Engler 20L Infinite O2
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Pre-Installation
Before installing the Engler Infinite O2 generator, it is necessary to consider the
location, space available and power supply for the generator.
1) Locating the Infinite O2 System:
The oxygen generator should be located in an area that is indoors and remains
between 40 F (5 C) and 100 F (38 C). Setting the machine outdoors or in an
area that is not normally within this temperature range will void the
Warranty.
There should be a distance of at least 8 in (20 cm) between the unit and any side
wall in the room. It should also not be located any closer than 24 in. (60 cm) from
the discharge of any other operating units. This ensures proper airflow into the
generator and minimizes any restriction.
2) Space Available for the Infinite O2 System:
If the unit is going to be set up in a room that is small, (less than 2000 ft3or 56.6
m3), that room should be well ventilated (at least 8 air changes in the room per
hour). The generator will be discharging nitrogen into the atmosphere of the room
and a nitrogen build up could be dangerous to people entering the room. If the
generator is placed in a small closet, the air in that closet will become enriched
with nitrogen. As the generator continues to run, it would become more and more
difficult for it to separate the oxygen from the air because oxygen will make up a
smaller and smaller fraction of the air that is fed into the enricher.
3) Power Supply for the Infinite O2 System:
The oxygen generator should be positioned within 8 ft (2.2 m) of the electrical
outlet that will power it. The reason for this is that the motor draws a large current
during the first few seconds of start-up. It is also very important for this reason
NOT to use any extension cords with the unit. They could overheat and melt,
possibly causing a fire.
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Required Operating Conditions
Location of the Generator:
The Infinite O2 System is intended for indoor use only. The enclosure meets NEMA 1
protection guidelines, which provides a degree of protection against dust and falling dirt.
Feed Air / Ambient Air Quality:
The life of any PSA oxygen generator is directly related to the air quality that is fed into it.
Hot, humid, dirty, oily air deteriorates and degrades the performance of the molecular sieve.
In order to preserve the effectiveness and extend the life of the generator, precautions must be
taken to ensure that the air provided is cool, dry, clean, and oil-free. Changing the inlet air
filter is a simple and easy way to provide the unit with some protection. It is advisable to
position the unit in an air-conditioned, well-ventilated area. The room should also be free of
toxic gases and high concentrations of hydrocarbons, especially carbon monoxide. Installation
in humid, oily, dusty areas should be avoided as much as possible.
Ambient Air Temperature:
The machine is designed for use over a temperature range of 40 F to 104 F (5 C to 40 C).
Since hot air has the ability to hold much more water in the form of humidity than cool air,
operating the units in hot areas will reduce the effective life of the molecular sieve.
Note: Operation outside of this temperature range will void the warranty.
Electrical Power:
The power for the control circuitry of the oxygen generator is a single-phase electrical supply
of nominal 120 VAC and about 17 or 18 Amps at a frequency of 60 Hz. This equates to
approximately 2000 W of power. A dedicated 20 Amp circuit is required for each Infinite O2
unit installed. Additionally, the unit must be connected to this circuit using only the supplied
power cord, and without additional extension cords.
Positioning:
The unit must be operated in an upright position only, with no obstruction blocking airflow
around the unit.
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Set-up, Installation, and
Operation
Although every Infinite O2 unit is thoroughly tested and checked before it is
shipped from our facility, the following checks are necessary to ensure that
none of the internal components have been damaged in shipment. This check
should take less than five minutes to perform. (Refer to ‘Initial Inspection’
on Page 2 before reading the instructions below)
Make a visual inspection of the machine and make sure all parts are properly attached. (Refer
to ‘Components’ section)
Connect the unit into a dedicated electrical outlet. A receptacle plug of local configuration
will need to be attached first if the supplied NEMA 5-20 (125V) is not acceptable. Please
note that this system will only work with nominal 120 VAC 60 Hz.
To test the Infinite O2 Generator unit, turn the Power Switch to the ON (up) position and
make sure that the Display unit illuminates. After a few seconds the hour glass indicator
disappears and the unit will begin to operate. Each of the three units should cycle on, one
at a time. The generator will begin operating, and after about one minute the Oxygen
output will open.
Listen for the sound of the three compressors to start operating one at a time
(staged in to reduce start-up current draw), if you do not hear it within ten
minutes, shut the machine down immediately and call EEC for assistance.
Turn the power switch off after testing.
The oxygen flow meter should indicate a flow increase after each of
the individual units cycle on and meets minimum purity requirements.
If this does not occur, check to make sure that none of the hose
connections have come loose. If the trouble persists, Call the EEC
Technical Service Department at +1(800))445-8581.
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Troubleshooting Guide
Problem
Sign
Machine not starting
Cause
Solution
Machine not
plugged in
Ensure that machine is
plugged in.
Machine not
turned on
Ensure that switch is in the
ON position.
No power to the
machine
Ensure that there is power
supply to the machine.
Circuit breaker has
tripped
Push in the reset button on the
right hand side of the cabinet.
Compressor under
pressure
Remove the head pressure that
exists in the compressor outlet
stream.
Loose wire
Check that all wiring
connections are secure.
Pressure Switch not
Working
Machine not
turning ON /
OFF at target
press res
Faulty switch
Remove switch and return for
replacement.
Low Oxygen Pressure
This may be a result of a
leak in the system.
Use a leak testing solution to locate
and repair any leaks.
Oxygen purity has fallen
below acceptable limits
This may be a result of a
leak in the system.
Use a leak testing solution to locate
and repair any air leaks.
Beds Are Hydrated
Replace Beds
Dirty Filters
Replace Filters
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Preventive Maintenance
Air Filter Cleaning
The air filter elements should be removed and cleaned in soapy water every two weeks or 20 hours of
operation to reduce the dust and dirt contamination inside of the unit.
Compressor Filter Element Replacement:
The air filter element provided with the Infinite O2 system must be replaced every six (6)
months on an average and more frequently in dusty environments. This element helps to
maintain the quality of the feed air supply, preserve the molecular sieve, and extend the life
of the air compressor.
Failure to replace the filter element on schedule will invalidate the warranty.
Cabinet & Power Cord:
The cabinet and power cord should be wiped down occasionally with a sponge or clean rag
and some soapy water. Avoid the use of ammonia or other strong chemical based cleaning
solvents. This prevents dust and dirt from building up on the machine.
Air Compressor:
The air compressors are a very important part of your oxygen generating system. In addition
to changing the air filter element, maintenance is relatively simple. The fans on either end
should remain free of debris / dust. The air compressors should last five (5) to six (6) years or
longer under normal operating conditions. Eventually, however, it will need to be rebuilt or
replaced. Oxygen purity and flow rate along with feed air pressure delivered to the sieve beds
will all be indicators that the air compressors has expended its life. Replacement in the field is
possible, but returning the unit to Engler Engineering Corp. is recommended.
OCSI Display Board
The OCSI board should never require calibration and cannot be calibrated in the field.
Calibration can be verified periodically if needed. Remove the back of the unit and
disconnect the hoses from the sensor on the large board. Supply the board with calibration
quality oxygen (99.99%) and check the display. If the display reads 90.2% +/- 3% then it is
within the calibration specifications. If it is outside that range it should be replaced. Contact
EEC for further instructions.
Notice
Using the Engler Infinite O2 generator / storage system in any manner inconsistent with it’s labeling
will void any warranty or liability from Engler Engineering Corp. Engler Engineering Corp. will not
be responsible for any malfunction, injury or death due to unauthorized modification or alteration of
any part or component. Only parts or assemblies supplied by Engler Engineering are permitted as
acceptable replacement parts.
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Technical Service Assistance
It is our intention to provide complete customer satisfaction. This manual is one way in which
we hope to provide you with technical assistance.
If you do not find what you need in this manual or you have other questions about this
equipment, please feel free to contact us directly. We look forward to serving your oxygen
needs and invite your inquiries. We will respond to you as promptly as possible.
You can reach EEC through the following means:
By Telephone (Outside the United States):
Your local International Access Code (usually 0 or 00), followed by
the Country Code for the U.S. which is (1), followed by our Area
Code and Number (305) 688-8581
Domestic Toll Free: 800-445-8581
By Fax (Within or outside the United States): +1(305) 685-7671
By E-Mail or Website:
[email protected]
http://www.englerusa.com
By Mail:
Engler Engineering Corp.
1099 East 47 Street
Hialeah, Florida 33013 USA
By UPS, FedEx or Common Carrier: (Address to return shipments)
Engler Engineering Corp.
1099 East 47 Street
Hialeah, Florida 33013 USA
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Appendix A
Spare Parts List
PART NAME
PART NUMBER
QUANTITY
Power Cord 12-3 (125V) NEMA 5-20
9600-1058
1
Strain Relief for Power Cord
9600-1080
1
Hour meter – Re-settable
8400-5028
1
Master On - Off Switch
9251-1809
1
20 A Fuse (115V)
9600-1066
1
15 A Thermal O / L button (230V)
9600-1023
1
Pressure Switch
9600-1083
1
Programmable Logic Controller
9600-1500
1
HMI Display Unit
9600-1505
1
Subsystem OCSI Board
8400-1310
3
Main OCSI system with Display
9251-1810
1
24VDC Power Supply Board
9600-1510
1
24VDC Control Relay
9600-1011
3
Modular Bed Control Valve
8400-1200
3
Inline Check Valves
9600-1081
2
Oxygen Pressure Regulator
8400-2060
3
Compressor Assembly (115 VAC, 60 Hz)
9251-1615
3
Thomas Compressor Rebuild Kit
7355-3670
1/8" NPT 3-Way Isolation Valve 24VDC
9251-1804
1/4" OD Blue Oxygen Polyurethane Tubing - Per Foot
7854-6109
1/4" ID Braid Reinforced PVC Tubing - Per Foot
7854-6105
3/8" OD Green Nylon Tubing - Per Foot (Low Temp Air)
7854-6107
PART NAME
PART NUMBER
3/8” OD Clear FEP Tubing - Per Foot (High Temp Air)
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QUANTITY
7854-6106
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Inlet Air Filter
9600-1053
2
Exhaust Fan 115V V
9300-1024
3
Exhaust Fan 115 V
9300-1023
3
Air Compressor filter (Change every 6 months)
9600-1012
2
Compressor Capacitor (115V)
9251-1647
3
Flow meter
9600-1026
1
Product Filter
9250-1053
3
Caster
9600-1016
4
Moisture Separator
9251-1911
3
Compressor Outlet Fitting
9251-1052
3
Moisture Separator Inlet Fitting
9250-1163
3
Moisture Separator Outlet Fitting
9250-1167
3
Inline Orifice
9600-1018
3
Front Panel Gauge
9600-1082
1
Replacement Set of Sieve Beds
8400-8021
3
Manual-Available Free on Website
2010-9600
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Appendix B
Maintenance Log
Date
Part
Reason for Maintenance
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Authorized Service
Technician Signature
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