BioTector Oxygen Concentrator

USER MANUAL
Oxygen Concentrator
Type: PSA.
With integral compressor.

© Copyright BioTector Analytical Systems Ltd. 2008 (revision September 2009)

Read the instructions in this manual carefully before installing
or starting the BioTector Oxygen Concentrator.

BioTector Analytical Systems Ltd cannot accept liability for damages due to
non-observance of this manual. Use of spare parts not supplied by BioTector
Analytical Systems Ltd will invalidate the warranty. BioTector Analytical
Systems Ltd shall not be liable for omissions or errors contained herein or for
incidental or consequential damages in connection with the furnishing,
performance, or use of this material.

The information contained in this manual is subject to change without notice.

The information contained herein is protected by copyright. Reproduction,
adaptation, or translation of any part of this manual without prior written
permission is prohibited, except as allowed under the copyright laws.

Product names mentioned herein are for identification purposes only and may
be trademarks or registered trademarks of their respective companies.

Where manuals are translated into several languages, the source language
text is considered as the original.

Maintenance / operation should not be carried out unless personnel

Caution
have been fully trained in the operation of the BioTector Oxygen
Concentrator.
Prior to working on the inside of the analyser, the technician should
be grounded via an earth strap.

This manual refers to

BioTector Oxygen
Model
Concentrator

Serial No. 419-081494-04

 Index

Declaration of conformity 1

1. Cautions, warnings and Hazards 2

2. Introduction and Principal of Operation 3

3. Specifications and operating conditions 4

4. Installation: oxygen concentration modules

with integral compressor 5

5. Operation and process flow description 6

6. Trouble shooting 7

7. Warranty and Exclusions 8

8. Maintenance Schedule 9

Reference Document(s)

System Drawing list.

BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 1

BioTector Analytical Systems Limited

Raffeen House, Ringaskiddy, Co. Cork, Ireland.
Tel +353 21 4374237 Fax +353 21 4374236
e-mail: info@biotector.com

Manufacturer: BioTector Analytical Systems Ltd.

Address: Raffeen House,

Ringaskiddy,
Co. Cork,
Ireland.

Declares that the BioTector Oxygen Concentrator with integral compressor is in conformity with the following
directives:

EMC Directive (89/336/EEC)

Low Voltage Directive (73/23/EEC)
Simple Pressure Vessels Directive (87/404/EEC)

The following parts of the harmonised standards have been applied:

- Electromagnetic Electrical equipment for measurement, control and laboratory use,

EMC requirements, part 1: EN 61326, 1997 edition.
- Electromagnetic Compatibility-Part 3: Testing and measurement techniques,
Section 2: Harmonic current emissions test. EN 61000-3-2, 1995 edition.
- Electromagnetic Compatibility-Part 3: Testing and measurement techniques,
Section 3: Voltage fluctuation and flickers test. EN 61000-3-3, 1995 edition,
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 2: Electrostatic discharge immunity test, EN 61000-4-2, 1995 edition.
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 3: Radiated, radio frequency, electromagnetic field immunity test,
EN 61000-4-3, 1995 edition.
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 4: Electrical Fast Transient/burst immunity test, EN 61000-4-4, 1995 edition.
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 5: Surge Immunity test, EN 61000-4-5, 1995 edition.
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 6: Conducted Immunity test, EN 61000-4-6, 1996 edition.
- Electromagnetic Compatibility-Part 4: Testing and measurement techniques,
Section 11: Voltage Dips and Interruptions immunity test, EN 61000-4-11, 1994 edition.
- Limits and methods of measurement of radio disturbance characteristics of
information technology equipment, EN 55011, 1998 edition.
- Safety requirements for electrical equipment for measurement, control, and laboratory
use. Part 1: General requirements EN 61010-1: 1993 including Amendment 2, 1995.

Martin Horan
Managing Director
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 2

1. Cautions, Warnings and Hazards

Oxygen Concentrators are self-contained systems 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 concentrator.

- Smoking should not be permitted in the area where the concentrator 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.

- 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.

- Gasses under pressure may be present within the system. Valves should be opened and closed
slowly, and safety glasses and hearing protection should be worn at all times while gasses are being
vented.

- Ensure that the oxygen concentrator is installed in a well-ventilated area. If the location is occupied,
then sufficient ventilation must be provided to prevent the accumulation of low oxygen concentration
waste gas in the location. At least 6 air changes per hour are necessary.

- The installation must comply with local regulations for the installation of oxygen systems, and for the
installation of compressed air systems

- The system should only be used by qualified staff and for the purpose it is intended for. Do not
attempt to modify or enhance the performance of a Concentrator in any way. Pay attention to the
safety warnings at all times.
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2. Introduction and Principle of Operation:

Pressure Swing Adsorption (PSA) Technology.

The Oxygen Concentrator is an on-site oxygen-generating machine capable of producing oxygen on

demand, with output flows up to 200 LPH. Including the compressor, it requires about 350 Watts of electrical
power in its operation.

In effect, it separates the Oxygen (21% of air) from the air it is provided with and returns the Nitrogen (78%
of air) to the atmosphere through a waste gas silencer. The separation process employs a technology called
Pressure Swing Adsorption (PSA). At the heart of this technology is a material called a Molecular Sieve.

The Molecular 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 the concentrator contains this sieve. As air is fed into one of the
beds, the sieve in that bed holds the Nitrogen, Water Vapour and Carbon Dioxide to it and allows the
Oxygen to flow through it and out to the surge tank as product gas. Eventually the sieve becomes saturated
with Nitrogen and other gasses. Before this occurs, the feed air is directed to the other bed where the
oxygen production/separation process continues. While the second bed is being fed air, the first is back-
purged and safely releases the Nitrogen and other gasses it has trapped through the waste gas silencer.
This regenerates the sieve in the first bed and prepares it to accept feed air again thereby repeating the
process. The two beds continue to work in this alternating fashion to provide a continuous supply of Oxygen.

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 and oil vapours. This is why the air
supply has to be free of water, oil and dust.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 4

3. Specifications and Operating Conditions.

Performance:
Oxygen volume and purity: 0-200 LPH at 93% +/- 3%, 0.6 bar.
See graph on previous page.
Oxygen dew point: -70°C.
Feed Air requirement: Integral compressor with 3.9 bar safety relief valve.
Start up time: 2 minutes.

Physical data:
Oxygen outlet fitting: Viton sleeve to HEPA filter.
Outlet HEPA filter: 0.2 microns.
Dimensions 400mm W x 725mm H x 370mm D.
Weight 25kg.

Power Requirements:
230V AC, 50Hz, Single Phase, 2 amps.
230V AC 60Hz, Single Phase, 2 amps (Special order only).
115V AC 60Hz, Single Phase, 4 amps.

Location of Concentrator:
The standard Oxygen Concentrator is intended for use indoors in a commercial or light industrial setting.

Feed Air Quality:

The useful life expectancy of any PSA Oxygen Concentrator is directly related to the air quality that is fed
into it. If the oxygen concentrator is located in a hot, humid, dirty, or oily location, then the feed air will
degrade the performance of molecular sieve. It is important that the humidity should be non-condensing
at all times. In order to preserve the effectiveness and extend the useful life of the concentrator, the air is
filtered through an air inlet filter located at the back of the concentrator. This must be kept clean at all times,
and it is recommended that this is replaced every month. Damage caused to the molecular sieve as a result
of poor feed air is not covered by warranty.

Ambient Air Temperature:

The concentrator is designed for use over a temperature range of 5°C to 40°C

Positioning:
The unit must be operated in an upright position only, with no obstruction blocking airflow around the unit.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 5

4. Installation – Oxygen Concentration Modules with Integral

Compressors.

Unpacking:
Unpack the unit, and remove the side, back and lower front panels. Inspect the interior and exterior for loose
or damaged parts. Re-install the panels before running.
Confirm that the air inlet filter is fitted in the back of the concentrator before running it.

Positioning:
The concentrator must be installed in an upright position!
Ensure that there is sufficient space around the Oxygen Concentrator - 300mm is recommended. Also
ensure that there are no restrictions around the outlets from the enclosure. A free flow of air around the
enclosure is essential.

Space available for oxygen concentrator:

If the oxygen concentrator is going to be located in a room that is small, (less than 25 cubic meters), that
room should be well ventilated with at least 6 air changes in the room per hour. This is important because
the concentrator will be discharging nitrogen into the atmosphere of the room, and a nitrogen build up could
be dangerous to people entering the room.

Electrical connections:
Connection to the electricity supply should only be carried out by a certified electrician, and should be in
accordance with local site regulations.

Connection to the BioTector:

The oxygen connection is by means of a ¼” Swagelok connection. This is the same size connection as used
in the BioTector TOC analyser. When the unit is connected to the BioTector, confirm that the flow-meter
knob is turned fully anti-clockwise.

Important: It is essential that oxygen systems are properly cleaned and inspected to insure that no
combustible material remains in the system.
Do not allow the free flow of oxygen from the oxygen concentrator or from any point in the oxygen system.
The installation must comply with local regulations for the installation of oxygen systems, and for the
installation of compressed air systems.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 6

5. Operation

Switch on

Prior to switching on the unit, confirm that Oxygen Concentrator is connected to the BioTector and that
oxygen will not leak into the atmosphere from the unit or the tubing system.

Turn the electrical supply on to the concentrator, and switch the concentrator on.
- Listen for the sound of the compressor in operation.
- Confirm that air emits from the lower exhaust panel under the left side of the concentrator.
- Confirm that the valves operate and the system discharges air (a hiss can be heard) every few
seconds.

The output pressure from the oxygen concentrator is 0.6 bar. In addition to supplying oxygen at this
pressure, this pressure is required so that the pressure swing absorption cycle (see introduction and
principle of operation) will operate effectively.

After 2 minutes the system will have reached its optimal generating capacity.

Process Flow Description

The normal flow of air through the oxygen concentrator is shown in drawing 81104041 in the drawing list.

The incoming air is drawn in through the air inlet filter by the fan. The compressor then draws the filtered air
in through the suction resonator, and pumps this through the heat exchanger. The air is then directed into
one of the two sieve beds. As the air enters the bed, the nitrogen is adsorbed by the sieve and the oxygen
passes through as product gas to the oxygen tank. Each bed produces Oxygen until the sieve in that bed is
almost saturated with Nitrogen, Water Vapour and Carbon Dioxide. When that occurs, the feed airflow is
directed to the other bed, which continues the production process. While the second bed is producing
oxygen the first is venting the Nitrogen and other gasses it adsorbed to the atmosphere through a waste gas
silencer.

From the oxygen tank, the oxygen pressure is regulated, filtered in the HEPA filter, and is then ready for
connection to the BioTector, through the ¼” Swagelok fitting.

Shutdown
To shutdown the oxygen concentrator, turn the ON / OFF switch off.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 7

6. Trouble shooting

Unit does not operate:

- Confirm that the electrical power is connected to the concentrator.
- Confirm that the circuit breaker has not tripped.

Compressor does not run:

- Thermal overload open, confirm that the fan is running and there is an unrestricted airflow over the
compressor.
- Defective capacitor, replace the capacitor.

Low Oxygen Purity:

- Leak in unit
- Defective compressor.
- Defective PCB.
- Contaminated sieve beds.
- Defective solenoid valves.

Popping sound indicating lifting of safety relief valve:

- Defective PCB.
- Contaminated sieve beds.
- Defective solenoid valves.

Chattering or buzzing noise from solenoid valves:

- Defective solenoid valves.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 8

WARRANTY AND EXCLUSIONS

Coverage of Oxygen Concentrator Warranty

The BioTector Oxygen Concentrator comes with a standard 1 year warranty for agreed applications. The
warranty is against manufacturing defects only. The warranty does not cover service / consumable items
and consequential damage.

Validity of Warranty
For the warranty to be valid, regular 6th Monthly and 12th Monthly servicing must be carried out using
BioTector Analytical Systems Ltd supplied Service Parts. The recommendations on Maintenance &
Servicing given in this manual should, as a general rule, be followed. However, it is understood that service
needs will vary from site to site.

Exclusions
The following standard service items are not covered under the BioTector Analytical Systems Ltd warranty:
- Air filter element.
- HEPA filter.
- Sieve beds and associated controls and valves if contaminated by dirty, wet or oily air.

Limitations
BioTector Analytical Systems Ltd liability with respect to certain moving parts (e.g., valves) will be limited to
the manufacturer's specified lifetimes.

Procedure for Warranty Repair / Replacement

Prior to returning any item under warranty, a Returned Merchandise Authorization (R.M.A.) number must
first be requested from BioTector Analytical Systems Ltd. The R.M.A. number must be quoted on all
correspondence.

Shipping Costs
The cost of transporting the parts to be repaired or replaced under warranty from the end-user to BioTector
Analytical Systems Ltd shall be borne by the end-user; the transport costs from BioTector Analytical
Systems Ltd back to the distributor shall be borne by BioTector Analytical Systems Ltd.

Method of delivery shall be at the sender’s discretion. BioTector Analytical Systems Ltd will use the lowest
cost service (including regular post) available. If the distributor requires goods returned on an urgent basis,
the distributor may nominate his preferred means of transport but shall then be liable for shipping costs.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 9

7. Maintenance Schedule

Maintenance depends on local environmental conditions such as temperature and atmospheric conditions.

The maintenance schedule detailed on the following pages is typical, but some additional maintenance may
be required depending on site conditions. In general, the oxygen concentrator should operate for over 5
years with only the maintenance listed in the following pages required.
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 10

Maintenance Schedule

BioTector Oxygen Concentrator.

Serial No: ______________________________

Voltage: ______________________________
Shipping date: ______________________________
Installation date: ______________________________

Every month:
Replace air inlet filter.

Year 1: 6 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 1: 12 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 2: 18 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 2: 24 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Rebuild compressor.
Rebuild 4 feed and waste valves.
Rebuild equalization valve.
Replace product outlet valve.
Notes:
BioTector Oxgyen Concentrator User Manual type PSA with integral compressor Page 11

Year 3: 30 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 3: 36 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter
Notes:

Year 4: 42 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 4: 48 months after installation.

Confirm filters in filter pack are clean (red warning indicators not showing), replace if dirty.
Replace HEPA filter
Replace compressor.
Rebuild 4 feed and waste valves.
Rebuild equalization valve.
Replace product outlet valve.
Notes:

Year 5: 54 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter.
Notes:

Year 5: 60 months after installation.

Confirm operation of oxygen concentrator.
Replace air filter (part of monthly maintenance).
Replace HEPA filter
Notes: