Air separators and related methods

An air separator system comprising:

• a first charging tower comprising a body with an upper end and a lower end defining an interior comprising a bed of carbon molecular sieve elements and a second charging tower comprising a body with an upper end and a lower end defining an interior comprising a bed of carbon molecular sieve elements, the first charging tower and the second charging tower are in constant fluid communication with one another at an outlet manifold for moving gas therebetween during a charging phase and a purging phase;
• a first manifold comprising a body having two or more ports to direct gas flow connected to a second manifold, said second manifold comprising a plurality of ports;
• a regulator and control system located downstream of the first manifold and comprising a manifold, a pressure step-down regulator, and a gas molecule sensor to sense gas molecule percent purity from the first charging tower and the second charging tower, wherein a value representative of the gas molecule percent purity is displayed on a control panel;
• a storage tank for storing gas discharged from the first charging tower and the second charging tower;
• and
• a controller to control a plurality of control valves to direct gas discharged from the first charging tower, the second charging tower, or both to the storage tank;
• wherein the controller is configured to activate the plurality of control valves when a predetermined gas molecule percent purity is sensed by the gas molecule sensor;
• wherein the predetermined gas molecule percent purity is adjustable using the control panel;
• and
• wherein the first manifold has a first outlet port connecting gas flow to the second manifold, a second outlet port connecting gas flow to the regulator and control system, and an inlet port for receiving pressurized inlet gas.

An air separator system comprising:

• a first charging tower comprising a body with an upper end and a lower end defining an interior comprising a bed of carbon molecular sieve elements and a second charging tower comprising a body with an upper end and a lower end defining an interior comprising a bed of carbon molecular sieve elements;
• the first charging tower and the second charging tower are attached to an outlet manifold having a unitarily formed body and the first and second charging towers are in constant fluid communication with one another through passages formed in the outlet manifold for moving gas therebetween during a charging phase and a purging phase, wherein a first outlet port in fluid communication with the first charging tower and a second outlet port in fluid communication with the second charging tower are located in the unitarily formed body of the outlet manifold;
• a first manifold comprising a body having two or more ports to direct gas flow connected to a second manifold, said second manifold comprising a plurality of ports;
• a regulator and control system located downstream of the first manifold and comprising a manifold, a pressure step-down regulator, and a gas sensor to sense gas molecule percent purity from the first charging tower and the second charging tower;
• a storage tank for storing gas discharged from the first charging tower and the second charging tower;
• and
• a controller to control a plurality of control valves to direct gas discharged from the first charging tower, the second charging tower, or both to the storage tank;
• and
• wherein a bypass header is attached to an exterior of the outlet manifold and connected to the first outlet port and the second outlet port of the outlet manifold.