OGSI MOGS - 100 User manual

Effective 11/2010
MOGS – 100
Installation, Operation and
Maintenance Manual
Oxygen Generating Systems Intl. (OGSI)
814 Wurlitzer Drive, North Tonawanda, New York 14120 USA
Tel: [phone] Toll Free: [phone] Fax: [phone]
E-mail: [email protected]
Website: www.ogsi.com
Part # 9000000.004
US$ 25.00

Effective 11/2010 Rev A
Table of Contents
Topic
Page Number
Using this Manual
1
Initial Inspection
2
Warranty Information and Liabilities
3
Safety Guidelines
5-6
Handling
5
Operating
6
Product Information
7-22
Features and Applications
7
PSA Technology
9
Components
10
Process Flow Description
21
Specifications
22
Safety Precautions
23
Pre – Installation
24
Required Operating Conditions
25
Set-up and Installation
26
Operating Instructions
27
Troubleshooting Guide
28
Touch Screen Overview
30
Manifold Design and Installation
44
Cylinder-Filling Procedure
46
Preventive Maintenance
49
Technical Service Assistance
51
Appendix
I-VII
Spare Parts List
I
Oxygen Cleaning Procedure
II
Oxygen Sensor Calibration Procedure
IV
Air Changes by Room Size
V
Units of Measurement
VI
Maintenance Log
VII

©2010, OGSI. All rights reserved. OGSI is a registered trademark.
This publication may not be reproduced in part or whole without written permission of OGSI.

Password to Access Touch Screen
647401
Please take appropriate measures to keep this password secure and prevent unauthorized access.

Effective 11/2010 1
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.
The following symbols are used throughout the manual:
Information
(Do not use product before
reading the manual)
Electrical Hazard
Sound Fire Hazard
No Smoking Warning
No Open Flames
Power ON/OFF
Flow Meter
Timer
No Oil Not Connected to Outlet

Effective 11/2010 2
The crate should be opened and inspected immediately upon delivery. Unpack the
unit at once and perform a visual inspection to determine if it is dented, bent or scratched.
Also check to make sure the power cord is attached and that the control panel has not been
damaged in any way during shipment.
If for any reason the unit should need to be returned in the future, the original
crate is the best way to ship it back to the manufacturer. Claims of damage due to freight
handling can only be filed by you, the consignee, as 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.
At OGSI, we are committed to using shipping companies with good reputations
for taking care in the handling of freight and providing service in the event of damage.
Initial Inspection

Effective 11/2010 3
Warranty
Oxygen Generating Systems Intl., being a division of Audubon Machinery
Corporation (hereinafter OGSI), provides a warranty on its products (the "Products")
against defects in material and workmanship, under normal use and operation, to the
extent set forth in this Warranty.
THIS WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY OF OGSI WITH
RESPECT TO THE PRODUCTS AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR
IMPLIED ALL OF WHICH ARE HEREBY DISCLAIMED TO THE FULLEST EXTENT PERMITTED
BY APPLICABLE LAW. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING
DISCLAIMER AND EXCEPT AS OTHERWISE SET FORTH IN THIS WARRANTY, OGSI
DISCLAIMS ALL WARRANTIES OF MERCHANTABILITY WITH RESPECT TO THE PRODUCTS
AND ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. THE WARRANTY OF
OGSI AS SET FORTH HEREIN IS FOR THE BENEFIT OF THE ORIGINAL USER OF THE
PRODUCTS AND IS NOT TRANSFERABLE WITHOUT THE PRIOR EXPRESS WRITTEN CONSENT
OF OGSI.
The OGSI Warranty provides the following:
1) OGSI shall repair or replace the Products free of charge to the original user where
defects in the material and/or workmanship are evident at the time of delivery.
Such replacement of the Products does not include damages incurred in shipping
the Products. If shipping damage is evident, the original user should contact the
shipper immediately. OGSI will pay for shipping the Products to the original user
as well as returning damaged/defective Products to OGSI. Once the Products are
repaired, OGSI will ship the Products back to the original user and cover all costs
incurred in shipping.
2) OGSI shall repair or replace the Products (excluding filter elements and sieve
material) free of charge to the original user where defects in material and/or
workmanship become evident between the time of delivery to the original user
and one (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. Once the Products are repaired, OGSI will ship the Products
back to the original user and cover all costs incurred in shipping. In no event
shall OGSI have any responsibility or liability for the cost of labor for the
removal of component parts or equipment that constitute part of the Products,
packaging of the component parts or equipment that constitute part of the
Products or the re-installation or replacement of the component parts or
equipment that constitute part of the Products.
3) The warranty provided by OGSI to the original user covers parts and equipment
specifically manufactured by OGSI and used as components or equipment that
constitute part of the Products. The warranty on parts or equipment manufactured
by third parties and included as part of the Products (e.g. air dryers, air
compressors, oxygen compressors, instrumentation, etc.) is limited to the
respective original warranties of such third parties.
Note: A Return Authorization Number must be obtained from OGSI prior to the return
shipment of the Product or any component parts or equipment of the Products.

Effective 11/2010 4
The Return Authorization Number must be visibly written on the outside of the package
of the returned Products, component parts or equipment as applicable or OGSI will not
accept the return.
Note: A Credit Certificate will be created for all Warranty Exchange transactions.
OGSI will provide the Credit Certificate with an invoice at the time of shipment to the
original user. The Credit Certificate must be included in the package to OGSI with the
returned products within 30 days of the date of the invoice. Failure to return Warranty
Exchange Products to OGSI within 30 days will make the Warranty Exchange process
void and payment for 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:
a) A failure to provide the Required Operating Conditions for the Products
(See Page 25)
b) Repair, attempted repair, adjustment or servicing of the Products, or any
component parts or equipment that constitutes part of the Products by anyone
other than an authorized representative of OGSI. The authorized service
representative must obtain prior approval from OGSI‟s Service Manager before
performing any warranty work.
c) External Causes (e.g. flood, hurricane, tornado, fire, any natural disaster, or any
event deemed an act of God).
Molecular Sieve Replacement:
The breakdown of the molecular sieve inside the generator (dusting of the sieve)
only occurs if excess water/oil is entrained in the feed air stream. Under no circumstances
is the molecular sieve covered under any warranty by OGSI. If sieve dusting occurs on
your machine, check the air compressor, air dryer and filter elements.
Other Matters:
OGSI is not liable for any special, indirect, punitive, economic, incidental or
consequential losses or damages including without limitation, loss of use, malfunction of
OGSI products, replacement oxygen charges, delays or lost savings related to the
Products or otherwise even if OGSI shall have been advised of the possibility of such
potential losses or damages.
Limits of Liability
OGSI Oxygen Generator products shall not be used for breathable or medical oxygen
applications, unless they are assembled with the appropriate support equipment, tested, and
operated in compliance with either American, Canadian or ISO norms for hospital oxygen
systems.

Effective 11/2010 5
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. Do not store near elevators, stairs, or passageways.
Do not place cylinders in a position where they might become part of an electric circuit.
When electric welding is taking place, precautions should be taken to prevent accidental
grounding of cylinders, permitting them to be burned by electric welding arc.
If visual inspection indicates obvious damage, the cylinder should be returned to the
supplier without any attempt at using the machine.
If cylinder leaks, other than normal venting, and the leak cannot be corrected by tightening a
valve gland or packing nut, the valve should be closed and a tag attached stating that the
cylinder is not serviceable. Remove the cylinder outdoors to a well-ventilated or open area,
notify the supplier, and follow the supplier's instructions for the return of the cylinder.
Keep the cylinder valve closed at all times except when in active use. When removable caps
are provided for valve protection, they should not be removed except for active use.
Remember to replace removable caps when not in use.
Cylinders should not be dropped or permitted to strike each other or any other surface.
Do not drag or slide cylinders; use a suitable hand truck, fork truck, roll platform or similar
device, firmly securing the cylinders for transporting.
Do not store oxygen cylinders with flammable gas cylinders. Stored oxygen and fuel gas
cylinders should be at least 20 ft apart; preferably separated by a fire resistant partition.
For additional information refer to the CGA publications that can be found at http://www.cganet.com
See also ISO publication 10083 that can be found online at http://www. iso.org

Effective 11/2010 6
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.
Smoking should not be permitted in the area where the generator 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.
Do not attempt to modify or enhance the performance of an oxygen generator in any way.
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.

Effective 11/2010 7
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.
Features
Durable
MOGS-100 unit has a PLC controller with a UL® listed electrical panel.
It has a sound attenuating enclosure with slam-action latches and lift-off
hinges.
Economical
The MOGS-100 unit reduces oxygen supply costs by 80% or more in most
cases. It consumes less than 1 kWh of energy to fill one „M‟ size oxygen
cylinder. It eliminates all delivery and handling charges from oxygen
suppliers.
Dependable
Having a MOGS-100 unit assures care providers that their oxygen supply
chain will not be disrupted in the event of a disaster. The system itself can be
transported for use at a disaster site. It can be moved by truck and fits easily
through a standard 36”wide doorway.

Effective 11/2010 8
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 9
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. The separation process employs a
technology called Pressure Swing Adsorption (PSA). At the heart of this technology is
a material called Molecular Sieve (Zeolite). This 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 generator contains this sieve. The process is described below.
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
vapors. This is why regular filter element replacement is crucial to trouble-free operation.
The filter elements are inexpensive and require semi-annual maintenance.
Stage 1
Compressed air is fed
into the first molecular
sieve bed. Nitrogen is
trapped, while oxygen is
allowed to flow through.
Stage 2
When the sieve in the
first bed becomes full
of nitrogen, the airflow
is then directed into the
second bed.
Stage 3
As the second bed
separates the oxygen
from the nitrogen, the
first bed vents its
nitrogen into the
atmosphere.
Stage 4
Compressed air is once
again fed into the first
bed and the process is
repeated continuously.
A constant flow of
oxygen is produced.

Effective 11/2010 10
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 11
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 12
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 13
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. Valve – Fill Chamber # 2
10. Gauge – Fill Chamber # 2
11. Touch Screen Pad

Effective 11/2010 14
External Components Description
Control Panel
This feature is the operator interface area for normal control of the
machine. Each of the components of the control panel and its operation
will be described in more detail below.
Fill/Blast Containment
Chamber
The cylinders are loaded and connected for refill at this chamber.
The purpose of this chamber is to protect the operator in the unlikely
event of a cylinder explosion.
Side Access Door
The side door provides access to the oxygen generator bank and many
of the other components of the system.
Front Access Door
The front door provides access to many of the system components.
Frame Inlet Air Filter
Maintains the air flow through the enclosure and only allows air to pass
through the bottom of the machine. This filter can be accessed by
reaching under the machine from the front and pulling it forward.
Upper Auxiliary Oxygen Port
(70 psi)
The upper port allows for bypassing the high pressure oxygen
compressor inside the MOGS and delivering oxygen at 70 psi (4.8 bar)
directly to a clinic, hospital or other application. In order to do this, the
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.
Lower Auxiliary Oxygen Port
(2200 psi)
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.
From this port an auxiliary high pressure manifold can be connected,
increasing the size of the reserve bank by 3, 4, etc. additional cylinders.
These additional high pressure reserve manifolds along with extra cylinders
are available from OGSI.
Reserve Cylinder Bank
The system is shipped with a reserve bank of two (2) H /K size (244 ft3
capacity) steel cylinders, rated at 2200 psi. These are located on the
back side of the machine and used to trans-fill smaller D, E or M size
cylinders in the blast containment chamber. These cylinders come fully
connected and leak checked and should not have to be removed or
serviced until they need to be re-certified.