OGSI MOGS - 100 Installation, Operation And Maintenance Manual

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MOGS – 100

Installation, Operation and

Maintenance Manual

Oxygen Generating Systems Intl. (OGSI)

814 Wurlitzer Drive, North Tonawanda, New York 14120 USA

Tel: (716) 564-5165 Toll Free: (800) 414-6474 Fax: (716) 564-5173

E-mail: ogsimail@ogsi.com

Website: www.ogsi.com

Part # 9000000.004

US$ 25.00

Effective 11/2010

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Summary of Contents for OGSI MOGS - 100

Page 1 MOGS – 100 Installation, Operation and Maintenance Manual Oxygen Generating Systems Intl. (OGSI) 814 Wurlitzer Drive, North Tonawanda, New York 14120 USA Tel: (716) 564-5165 Toll Free: (800) 414-6474 Fax: (716) 564-5173 E-mail: ogsimail@ogsi.com Website: www.ogsi.com Part # 9000000.004 US$ 25.00...
Page 3: Table Of Contents
Table of Contents Topic Page Number Using this Manual Initial Inspection Warranty Information and Liabilities Safety Guidelines  Handling  Operating Product Information 7-22  Features and Applications  PSA Technology  Components  Process Flow Description  Specifications Safety Precautions Pre –...
Page 5 Password to Access Touch Screen 647401 Please take appropriate measures to keep this password secure and prevent unauthorized access.
Page 7: Using This Manual
Using the Manual This manual is intended as a guide for operators of OGSI Oxygen Generators and Oxygen Generating Systems. It includes information on our warranty policy, features, functions, applications, proper set-up and installation, operation and maintenance of our products.
Page 8: Initial Inspection
OGSI shipping terms are Free On Board (FOB), North Tonawanda, NY USA. This means that once the equipment leaves our dock you are the owner of it. OGSI has no legal claim to make against any shipping company for damage.
Page 9: Warranty Information And Liabilities
(1) year from the date of delivery to the original user. OGSI will pay for shipping the Products to the original user as well as returning damaged/defective Products to OGSI.
Page 10 Products will be billed and due on receipt. Note: The warranties of OGSI as set forth herein shall also become null, void and not binding on OGSI if a defect or malfunction occurs in the Products or any part of the Products as a result of:...
Page 11: Safety Guidelines
Safety Guidelines Handling of Compressed Gas Cylinders Many of the following procedures for the handling, storage, and utilization of compressed gas in cylinders are taken from material furnished by the Compressed Gas Association, which complies with OSHA standards. Always ensure that compressed gas cylinders are securely strapped or chained in place to prevent tipping or falling.
Page 12: Operating
Operating OGSI Oxygen Generators 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 generator.
Page 13: Product Information
Product Information Features and Applications The OGSI model MOGS-100 is a self-contained oxygen generating system that uses Pressure Swing Adsorption (PSA) technology. It allows users to generate medical- grade oxygen (conforming to United States Pharmacopeia (USP) XXII oxygen 93% Monograph) to be used on-site. It concentrates oxygen up to 93% (± 3 %) purity.
Page 14 Applications The MOGS-100 can be used in various applications. A few examples are given below. EMS (Emergency Medical Services) Fire Departments Hospitals and Clinics Veterinary Centers Nursing Homes Effective 11/2010...
Page 15: Psa Technology
Pressure Swing Adsorption(PSA) Technology An OGSI Oxygen 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 it is provided and returns the nitrogen (78%) to the atmosphere through a waste gas muffler.
Page 16: Components
External Components Front View 1. Control Panel 2. Fill/Blast Containment Chamber 3. Side Access Door 4. Front Access Door 5. Frame Inlet Air Filter (Underside) Effective 11/2010...
Page 17 Rear View 1. Upper Auxiliary Oxygen Port (70/90 psi) 2. Lower Auxiliary Oxygen Port (1900/2200 psi) 3. Reserve Oxygen Cylinder Bank 4. Power Cord Effective 11/2010...
Page 18 MOGS-100 with Auxiliary Manifold and Cylinders 1. Auxiliary Cylinder Filling Manifold Shown with Copper Pigtails (Optional) 2. Extra Reserve Cylinders (Optional) Effective 11/2010...
Page 19 Control Panel 1. Oxygen Compressor Outlet Pressure Gauge 2. Reserve Bank Valve 3. Reserve Bank Pressure Gauge 4. Fill Chamber Pressure Regulator 5. Regulated Pressure to Containment Chamber 6. Emergency Stop Button 7. Valve – Fill Chamber # 1 8. Gauge – Fill Chamber # 1 9.
Page 20 (70 psi) oxygen compressor inside the machine must be switched OFF. If this capability is used, OGSI recommends that an additional oxygen storage tank be installed and located next to the left side of the cabinet. The lower port allows for the expansion of the reserve cylinder bank beyond the two (2) cylinders that are included in the frame of the machine.
Page 21 The power cord is designed for use at 230 VAC (single phase). Power Cord An electrician will need to wire this into a dedicated circuit with a disconnect/lockout. This valve allows the reserve bank to be isolated from the system for the purpose of trans-filling smaller cylinders in the containment Reserve Cylinder Valve chamber directly.
Page 22 Internal Components Front View 1. Power Distribution Panel 2. Inlet Air Filters 3. Programmable Logic Controller (PLC) 4. Back Pressure Regulator Gauge 5. Air Storage Tank 6. Air Compressors Bank (5) 7. Air Pressure Transducer 8. Oxygen Generator Bank (5) 9.
Page 23 Rear View 1. Heat Exchanger 2. Compressed Air Filter 3. Back Pressure Regulator 4. Oxygen Storage Tank 5. Refrigerant Dryer Effective 11/2010...
Page 24 Fill/Blast Containment Chamber 1. Fill Whip # 1 2. Fill Chamber # 1 3. Fill Whip # 2 4. Fill Chamber # 2 Effective 11/2010...
Page 25 Internal Components Description The terminal board distributes electrical power to the different components of Power Distribution Panel the system. The air filter keeps dust and dirt from entering the compressor and needs to be changed twice a year in normal environments to maintain the unit‟s Inlet Air Filter performance.
Page 26 The (RIX) oxygen compressor boosts the oxygen pressure from the oxygen storage tank to 2200 psi (152 bar). It is a two-stage compressor with a self-contained motor, starting capacitor, pressure switch, pressure relief Oxygen Compressor valve, and check valve. This is a complex machine and comes with its own Service Manual.
Page 27: Process Flow Description
Process Flow Description The incoming air enters the machine through a filtered opening in the floor of the machine frame. This opening is protected by a furnace filter type element, which is 12” x 16” x 1”. The air is drawn into the air compressor bank after being filtered through one of two additional inlet air filters on the feed air manifold.
Page 28: Specifications
Unit Specifications Performance 0 – 100 SCFH (3 Nm Oxygen Volume 0 – 47 LPM High Pressure: Up to 2200 psi (152 bar) Oxygen Pressure Low Pressure: Up to 70 psi (4.8 bar) Oxygen Purity United States Pharmacopeia (USP) XXII oxygen 93% Monograph ...
Page 29: Safety Precautions
Safety Precautions It is very important that you read the precautions below and make yourself aware of 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.
Page 30: Pre-Installation
Pre-Installation Before installing the OGSI MOGS-100 unit, it is necessary to consider the location, space available and power supply for the generator. 1) Locating the MOGS-100: The oxygen generator should be located in an area that is indoors and remains between 40 F (5 C) and 100 F (38 C).
Page 31: Required Operating Conditions
38 C). Since hot air has the ability to hold 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 not be warranted by OGSI. Electrical Power: On U.S.
Page 32: Set-Up And Installation
15 minutes. If this does not occur, check to make sure that none of the hose connections have come loose. Call OGSI Technical Service Department at (800) 414-6474 (toll free number in USA and Canada) or (716) 564-5165 if no loose connections are found and trouble persists.
Page 33: Operating Instructions
Operating Instructions Start-up Once the system has been installed in accordance with the set-up and installation instructions, it may be energized and cylinder filling may begin. It is highly recommended that the user read the „Touch Screen Overview‟ section (Pages 30-43) prior to operating the system.
Page 34: Troubleshooting Guide
Troubleshooting Guide Problem Sign Cause Solution No power Blank touch Circuit breaker has Ensure that power is available screen display tripped from 230 VAC supply. Loose wires Check the Emergency-Stop button. If this button is pushed in, it secures all power to the system.
Page 35 Warning Signs Thermal Switch Warning The appropriate thermal overload switch must be reset (by pressing it) and the „CLEAR WARNING‟ button must be pressed. Normal operation can then be resumed. 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.
Page 36: Touch Screen Overview
Touch Screen Overview The touch screen is the main interface between the operator and machine, and incorporates all controlling mechanisms within its display. Listed below are the Main Operator Features incorporated within the touch screen: Language selection Password protection Energize/de-energize the machine Monitor the operating condition of valves and compressors Monitor all system pressures and oxygen purity Hours meter and real time clock to monitor service intervals...
Page 37 Language Screen The language screen enables the user to choose the language – English, French or Spanish. After choosing a language, select MAIN MENU. Effective 11/2010...
Page 38 Password Screen This screen prompts the user to enter the password supplied by the manufacturer.  Select PASSWORD AREA  Enter the password using the numeric keypad displayed on the screen.  Select ENTER The password will be verified and the screen will change to the CONTROL screen when the password is accepted.
Page 39 Main Menu Screen This screen allows the user to navigate through the program from screen to screen and it will get you where you need to go inside the program. (Note: A notification will appear at the top of the screen only if the machine has the timer set and is turned ON.) Effective 11/2010...
Page 40 Control Screen The CONTROL screen is used to operate the machine. The mode of operation – AUTOMATIC or MANUAL is selected here and the system status can also be viewed here.  Power In AUTOMATIC mode, the machine will start running when the button is in the ON position.
Page 41  Air Compressor This feature monitors the operational condition of the air compressors. When the air compressors are de-energized, it will display STANDBY and will toggle to RUNNING when they are energized.  Oxygen Compressor This feature monitors the operational condition of the oxygen booster compressor. When the oxygen compressor is de-energized, the feature will display STANDBY and will toggle to RUNNING when it is energized.
Page 42 Advanced Settings Screen  Timer Setup If there are particular hours of the day you want the machine to run, you can enter the hour and minutes (military time) you want into the starting and ending time inputs.  Setting Timer This button activates the timer.
Page 43 Gauge Screen The GAUGE screen displays the instantaneous reading of the four primary variables during system operation. These are described below:  Oxygen Purity This feature displays the percentage of oxygen present which is typically about 93% (±3%). The system will shut down automatically if low oxygen purity (less than 90%) is produced for more than a short period of time and an alarm will be activated.
Page 44 Graph Screen This screen shows the graph based on the readings on the GAUGE screen. 60 minutes are displayed at a time and 24 hours are stored in memory. If power to the machine is lost (Emergency-Stop button is pushed in, machine is unplugged, etc.), the chart memory will be lost.
Page 45 Alarm Screen This feature displays warnings when any of the following faults occur: Oxygen pressure has fallen below acceptable limits (This fault does not de-energize the machine) Oxygen purity has fallen below acceptable limits Air compressor thermal switch has tripped Oxygen compressor thermal switch has tripped Air compressor has been running one hour, and the purity has not yet reached an acceptable level...
Page 46 This warning is usually indicative of a contamination of the molecular sieve inside one or more of the oxygen generators. Warning *Contact OGSI if this warning occurs.* These warnings must be cleared after following the instructions on the displayed warning indicator. For certain alarms, the machine will not operate until the „CLEAR WARNING‟...
Page 47 Information Screen This screen displays information pertinent to the system, and manufacturer contact information. The Model Number of the Machine and its Serial Number are displayed along with the Date of Completion. The software versions for both the Programmable Controller and Touch Screen are also shown. During the course of normal maintenance, the company may offer to upgrade the software packages on the machine as improvements and modifications to it become available.
Page 48 Troubleshooting Screen The TROUBLESHOOTING screen was designed to test each set of sieve beds individually to see if one is out of purity in the system. It is important to note that once you enter this troubleshooting mode the system will not continue to operate normally. Once the troubleshooting has been completed the system can be re-started again.
Page 49 Correcting Missing or Irregular Touch Screen Color Scheme Ensure that the machine is not in CYCLING mode and leave the machine in the ON position. Touch both the top left corner and the bottom left corner of the touch screen at the same time.
Page 50: Manifold Design And Installation
MOGS-100 Filling Manifold Design & Installation (Optional) Effective 11/2010...
Page 51 Design The MOGS-100 oxygen generating system manifold serves two purposes: To connect the MOGS-100 to each bottle for filling To connect the bottles to one another for equalizing during trans-filling (filling smaller bottles from larger ones) A shut off valve is located at the end of the manifold, downstream of the K-type storage cylinders.
Page 52: Cylinder-Filling Procedure
70 psi (4.8 bar) port at the same time. A low output pressure will result if this is attempted. If this capability is used OGSI recommends that an additional oxygen storage tank be installed and located next to the left side of the cabinet.
Page 53 3, 4, etc. additional cylinders. These additional high pressure reserve manifolds along with extra cylinders are available from OGSI. See drawing below for suggested layout.
Page 54 MOGS machine. Then connect the manifold to the Lower Auxiliary Oxygen port on the left side of the MOGS unit using the high pressure interconnecting line provided by OGSI or your manifold supplier. Make sure the cylinder valves on the two (2) reserve cylinders already connected are closed and that the manifold line is de-pressurized when you begin to make use of this connection.
Page 55: Preventive Maintenance
This filter element is accessed by reaching under the front of the machine and pulling it forward. While these can be supplied by OGSI as part of a spares kit, the easiest way to get replacements is by going to any hardware store and buying 16”...
Page 56 The most common failure mode is molecular sieve contamination due to high moisture content. These units can be re-built at OGSI or new units can be installed in the field. Replacement in the field is possible and takes about 20 minutes per generator.
Page 57: Technical Service Assistance
Technical service personnel are available from 8:00 AM to 5:00 PM EST (GMT - 5). We also have a list of Distributors and Authorized Service Agents available upon request. Customer Satisfaction Survey Help us serve you better. Please take our Customer Satisfaction Survey at www.ogsi.com Effective 11/2010...
Page 59 Appendix...
Page 61: Spare Parts List
Spare Parts List PART NAME PART NUMBER QUANTITY " NC Direct Acting Solenoid Valve 1510009.CD3 " Check Valve 1530001.G02 25A Motor Contactor 1810107.003 100 psi Air Pressure Transducer 1910001.100 " Compressor Inlet Filter (Change every 6 months) 2180001.E01 Replacement Air Compressor Assembly 7030004.R04 Double Solenoid Valve 230VAC 1510007.220...
Page 62: Oxygen Cleaning Procedure
Scope This procedure sets forth the cleaning requirements for parts that are used in the construction of OGSI oxygen systems and are in the gaseous oxygen product stream including but not limited to valves, tubing, fittings, manifolds and pipes. Objective The objective of this procedure is to provide personnel with clear directions and an understanding of how parts are to be cleaned and why that is important.
Page 63 among others. For parts that have an internal cavity that is not directly observable by the naked eye, a lint free cloth that is first soaked in water can be inserted into the part and withdrawn for evidence of contamination. No part failing inspection shall be used in any assembly. Pre-Cleaning Pre-cleaning methods include soaking parts in a water based solution with an aqueous detergent, using a wire brush or thread pick, holding it under a wire brush grinding wheel or...
Page 64: Oxygen Sensor Calibration Procedure
Oxygen Sensor Calibration The oxygen sensor is located at the bottom of the right side cabinet access door. The „Zero‟ adjustment screw is shown below as viewed from the right side of the open door. The sensor is a Model 120J OxyAlert 2-Gas Sensor with ±1% accuracy. It is made by Douglas Scientific (Compass Controls).
Page 65: Air Changes By Room Size
OG-650 22.5 OG-750 22.5 OG-1000 OG-1250 OG-1500 CFP-15+/15M MOGS-100 Notes: 1. NR means that the models indicated are not recommended for rooms of this size. 2. For air changes requirements for models OG-2000 and above, please contact OGSI. Effective 11/2010...
Page 66: Units Of Measurement
Units of Measurement U.S. Pound Horsepower Pound-force per Square Inch Kilowatt Kilowatt hour Cubic Feet Volts Alternating Current Hertz SCFH Standard Cubic Foot per Hour SCFM Standard Cubic Foot per Minute Liter Per Minute 1 bar 1.45 x 10 Decibel (A scale) Ampere Watt °C...
Page 67: Maintenance Log
Maintenance Log Authorized Service Date Part Reason for Maintenance Technician Signature Effective 11/2010...

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