The Next

Generation of
Oxygen Concentrator
Systems

UnivOx DOS Systems

F r e s h Ai 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.
Page 2
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.

Page 3

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.


Page 4

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.
Page 5
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
Page 6
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.



Page 7




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
Page 8
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
Page 9

Cycle Pressure
On / Off
Feed Air Pressure Auto / Manual Switch
Oxygen Receiver Pressure
Hourmeter Manual Drain Button
Page 10
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
Page 11
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.
Page 12





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


Page 13
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.
Page 14

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
Page 15

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
Page 16




Back
Pressure
Valve
Compressor
Cylinder
Access Plate
Cooling
Fans
Check
Valve
Discharge
Port
Discharge
Pressure Switch
High Pressure Compressor
--side view--
figure 1-7
Page 17




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
Page 18
OSS Control Panel & Calibration Bottles

OSS Control Panel
The OSS Control Panel contains the electrical and pneumatic components
utilized to perform the system oxygen analysis. For typical operations, the user
has no need to access the interior components. Control Panel access should be
limited to Service Personnel Only.

The Control Display is mounted on the front of the panel and functions as a
message display of system operations. During normal operation, the percent of
oxygen (O
2
%) being produced is displayed on the top line of the display and
warning/error messages are displayed on the bottom line. Warnings and errors
are annunciated in all display modes. The bottom line reads "Normal Operation"
when no errors exist and a green light is shown. The top line may interweave
status statements such as "SAMPLING O
2
CALGAS" with the "O
2
%" display
while that mode is enabled. Gauge message numbers can be entered into the
numeric keypad to read specific operational parameters (figure 1) but should be
reserved for Service Personnel Only.

Calibration Bottles
The calibration bottles are mounted vertically in the control stand in such a way
that the regulators are easily accessible and that the bottles will be retained
safely and can be quickly replaced. Connections of the cal-gas to the Control Box
and components within are made via color-coded inch flexible polyethylene
tubing and CPC connectors at the box entrance. The cal-gas bottles, two @
99.9% oxygen and two @ 99.9% nitrogen are to be fully open, upon connection,
so to have cal-gas available at system start-up and for scheduled calibration
intervals. (see Rela Dwg. # 00266-01620)



Oxygen Cal-Bottle
Bottle Rack
Latches
Nitrogen Cal-Bottle
Calibration Bottle Rack (tilt out position)
figure 1-9



Page 19






Status Lights Numeric Keypad
LCD Display
Function
Keys
FreshAir Oxygen System Control Panel
figure 1-10
Page 20
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.









Page 21

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
Page 22

Transfill Cylinder
Refilling
Instructions
Reset / Clear
Button
Transfill Status
Lights
Start Button
Power On
Keyswitch

Transfill Table - Controller
figure 1-12
Page 23
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.
Page 24

Manual
Isolation
Valve
Page 25

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
Document # 00266 00327 Colorado MEDtech, Inc. Page 27
Revision # 01 Date: 03/18/98
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
Document # 00266 00327 Colorado MEDtech, Inc. Page 28
Revision # 01 Date: 03/18/98