1. Service, Maintenance & Troubleshooting
Presented by: Peter Knotko
Service Engineer
Oxymat-Slovakia, s.r.o.
Worldwide Manufacturer of PSA Generators

2. Preventive maintenance
And what is necessary to service ?
Air compressor – all PM according to manufacturer’s manual
Filter elements – coal tower incl.
Dryer – according to manufacturer’s manual
Drain system - Oxymat manual
PSA generator - Oxymat manual
High pressure equipment as RIX, Haug or Bauer compressor – according to manufacturer’s manual
Monitoring the operation of the unit and Preventive Maintenance (PM) on a regular basis is the best way how to ensure a long life for your PSA Generator.
How often?
Daily
Weekly
Biannualy
Annualy
Every 5 years

3. Complete line

4. Daily inspection consist of:
Daily maintenance
Daily inspection consist of:
Every day simply observe the operation of the unit
Check purity and product consumption
Verify what is the dew point of feed air or displayed temperature on the refrigeration dryer
Make sure that the drain system is functioning properly – press test button
!!! Plugging off
the drain systems will cause water/oil carry-over into the adsorbent vessels, and will cause severe damage to the adsorbent which is not covered under the manufacturer's warranty

5. Weekly inspection consist of:
Weekly maintenance
Air compressor flow diagram
Weekly inspection consist of:
Do observe your Air Supply system basis
Check operation conditions of the air compressor (oil level, oil temperature, noise etc...)
Check filters – clogging / diferential pressure indicators must not be in red arrea at any time of operation

6. Weekly maintenance Clean procedure
With an air jet (max. 2 bar / 30 psig) blowing from inside towards outside blow out the dust
Repeat this operation blowing in the opposite way
plus:
Air compressor – cleaning procedure of oil after-cooler + oil level check
Air Dryer – cleaning procedure of cooler
PSA control cabinet – cleaning procedure of dust filter
!!! Be careful not to damage the aluminium fins of the cooling package.

7. The biannualy inspection of the PSA unit consists of:
Biannualy maintenance
The biannualy inspection of the PSA unit consists of:
Service of air compressor according to supplier manual (filters and oil replacement, etc...)
Service of air dryer according to supplier manual (drain and strainer cleaning, etc...)
Replace pre-filter element 1μm and micro-filter element 0,01μm

9. Annual maintenance . Replacement of inline filter
The Annual PM of the unit consist from the points of biannualy PM, plus:
Coal-Tower PM: Replacement of coal, oil indicator and micro-filter element is recommended
Air Tank PM:
Inspection of drain system
Each non-return valve has to be cleaned and checked for damage (replace if needed)
Axial drain valve has to be cleaned and properly re-greased
3. Inline filter for gas analyzer:
. Replacement of inline filter
Oil indicator and micro- filter
Coal tower
Non-return valve
Air tank
Axial drain valve

10. Annual maintenance 3. PM of PSA generator :
all system has to be inspected for function, damage, leakage (solenoid valve block, hose/pipe connection, safety valves, etc...)
process VIP valves has to be cleaned and properly re-greased (for O2 application oxygen grease has to be used)
strainer and main regulator has to be cleaned
gas analyzer has to be checked with calibration gas and calibrated if needed
4. PM of receiver tank:
active-carbon and bacterial/sterile filter elements has to be replaced
Omal axial VIP valve
Omed upgrade filters placed behind the receiver tank

11. Annual maintenance :
How to lubricate process valves

12. Every 2 years maintenance :
Recommended replacement of all process valves.

13. Every 2 years maintenance :
Top brass filters and O-rings for each column.

14. Every 3 years maintenance :
Recommended replacement parts :
HDMI valve block.
O2 Analyzer.
OXY Z - zirconia cell
OXY F - fuel cell
OXY FS - fuel cell (ppm)
OXY P - paramagnetic
Inlet pressure regulator.

15. Example when regular or proper maintenance is not performed!
Example when proper maintenance is not performed

16. PSA generator types :

17. 5 years maintenance – every 40 000 wh
PM of PSA generator every 5 years consist of:
Molecular sieve replacement is recommended
Top brass filter replacement
Vessel inspection
!!! Be carefull not to damage the bottom stainless steel filters during moleculare sieve replacement
Top brass filter
Bottom stainless steel filter

18. Replacement of filter elements
period [y]
period [h]
1μm
1/2 year
4,000
0.01μm
1/2 year
active carbon
1 year
8,000
bacterial/sterile
Poor quality of compressed air could affect the operation of your PSA generator.
The filter element(s) supplied with each unit have been selected by manufacturer based upon the units feed air requirements.
Replacement of filter element step by step:
Close the air inlet for filter.
Carefully remove 4/6 mm tube below filter.
Remove filter element by counterclockwise turn.
Remove one-way valve from old element and mount it to the new one.
Install new element with one-way valve.
Plug-in the 4/6mm tube to filter element.
Perform leak test.
Replacement of active coal in coal tower:
Once per year (recommended)
Otherwise: when oil indicator gets red

19. Safety valves
Visual inspect safety relief valves and other safety devices for dirt or damage.
If there is debris in the valve seat, scavenge the valve as follows:
Pressurize vessel and loosen the top screw one turn. This should remove debris from the valve.
Retighten the top screw

20. Pressure vessel maintenance
If molecular sieve is replaced inspect vessels for corrosion or other damage (replace if needed)
Refer to molecular sieve material safety data sheet for handling and safety instructions of sieve.
Receiver vessel should be inspected internally every 4 years or according to local regulations.
External and internal inspection of vessels and other pressurized equipment must be carried out according to local regulations.
When your Oxymat or Nitromat Generator is installed and operated according to the prescribed conditions, it is not needed to do internal inspection of generator vessels on regular basis

21. Leak test procedure Safely shut down the application / consumption
Let the plant run in auto mode, until generator will automatically stop by pressure.
Close the feed air supply.
If fitted with purity monitoring probe close of the pressure reduction valve on probe inlet.
Read and note the pressure P1 in oxygen receiver, column 1, column 2, coal tower and feed air tank.
Let the plant stand still (rest) and isolated in pressurized condition for an hour.
After an hour read and note the pressure P2 in oxygen receiver, column 1, column 2 and feed air tank.
Then determine an eventually pressure drop as the difference between P1 and P2 for each component.
The Leak Test is OK, if the pressure drop after one hour is less than 0.1 bar.
If a leak is detected, a suitable device must be used to locate the leaking component (leak tester in spray or soap water)
If closed, reset the pressure reduction valve on probe inlet

22. Required tools For valve lubrication: Paint brush
Grease (for O2 application oxygen grease has to be used-Kluebertemp YV 93-92),N2 application –SuperLube.
2 spanners (according to size of the valve).
spare valve
For filter element replacement:
spanner of proper size
belt pliers
PTFE tape
filter element
Vessel inspection:
battery light
Safety warning:
Always wear personal protection equipment for ears, hands, eyes etc...
Installation:
Plastic tubes 4/6/8 mm
spare valves, regulator
pliers, screwdriver, spanner, etc.
Connecting fittings for tubes
reductions
spare indicators
PC with installed software
Design Review Certificate

23. Troubleshooting Solution: Most common operation failure is
Check system for leaks ,fastenings and product consumption.
Check filters, drain system, air compressor temperature, dryer temperature, ambient air temperature.
Check air signals from solenoid valve block to process valves (replace if needed).
Re-grease or replace valve if needed.
Calibration or replacement if needed.
Otherwise contact OXYMAT A/S.
Most common operation failure is
insufficient product purity due to:
Generator is overflowed !
Low quality of feed air !
Valve block error !
Process valve error !
Gas analyzer error or misreading !

24. • Service check list
• recommended to use on daily(weekly,anually) basis to avoid failure
and prevent possible breakdown.

25. www.oxymat.com Questions… Oxymat A/S Fasanvej 18-20 DK-3200 Helsinge
Denmark
Questions…