OGSI OG-75 Instruction manual

TM
OG-100
Oxygen Generating Systems International
814 Wurlitzer Drive
North Tonawanda, New York 14120
Telephone - [phone]
Fax - [phone]
Toll Free - [phone]
E-mail - [email protected]
Web Site - http://www.ogsi.com
Model OG-75 thru OG-750
Oxygen Generator
Installation, Operation &
Maintenance Manual

Table of Contents
Topic Page Number
General Information:
- Unpacking Instructions 1
- Technical Service and Assistance 2
-WarrantyPolicy 3
- Limits of Liabilities 4
-OperationalWarnings 4
- Safe Handling of Compressed Gas Cylinders 5
- Pressure Swing Adsorption (PSA) Technology 6
- OG-75 thru OG-750 Specifications 7
- Required Operating Conditions 8-9
- Typical Setup Diagrams 10
Operating Instructions:
- Pre-installation Check 11
- Sieve Re-packing Diagram 12
- Type 1 Switch Connection Diagram 13
- Type 2 Switch Connection Diagram 14
- Setup Instructions 15-16
- Safety Precautions 17
- Start Up Procedures 18-19
- Shut Down Procedures 20
- Troubleshooting Guide 21
- Detailed Warning Description 22
Component drawings/description:
- Process Flow Schematic 23
- Process Flow Schematic:Touchscreen Option 24
-ProcessFlowDescription 25
- External Components Drawing 26
- External Components Description 27-29
- Internal Components Drawing 30
- Internal Components Description 31-32
- Touchscreen General Introduction 33-34
- Individual Touchscreen Desriptions 35-46
-ManifoldDrawing 47
- Manifold Operating Procedures 48
Maintenance Instructions:
- Routine Maintenance 49
- Long Term Maintenance 49
- Filter Element Replacement Instructions 50

©2003, OGSI. All rights reserved. OGSI is a registered
trademark. This publication may not be reproduced in
part or whole without written permission of OGSI.

Effective April 2006
1
Unpacking Instructions
The crate should be opened and inspected immediately upon delivery. If the
exterior of the crate is noticeably damaged at the time of delivery, make a note on the
freight bill before signing it. 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.
Do not discard the shipping crate. If for any reason the unit should need to be
returned in the future the user will be responsible for packaging the unit to the same
degree that it was received from OGSI to ensure its undamaged arrival at OGSI.
If any damage is discovered during the initial visual inspection, call the Freight
Company immediately. This must usually be done within 24 hours of delivery.
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.
When you call OGSI for your Return Authorization Number please ask us about
preferred shipping companies.

Effective April 2006
2
Technical Service and Assistance
This manual is intended as a guide for operators of OGSI Oxygen Generators
and Oxygen Generating Systems. It includes information on our warranty policy, on
how the machines work, on proper set up and operation, and finally on how to maintain
them.
It is our intention to provide complete customer satisfaction. This manual is one
way in which we hope to provide you with technical assistance.
If you do not find what you need in this manual or you have other questions
about this equipment, please feel free to contact us directly. This can be done in a
number of ways that are listed below. We look forward to serving your oxygen needs
and invite your inquiries. We will respond to you as promptly as possible.
Technical service personnel are available at OGSI from 8:00 A.M. through 5:00
P.M. Eastern (U.S.) Standard Time which is Greenwich Mean Time minus 5 hours
(GMT - 5). You may reach OGSI personnel through the following means:
- By Telephone from within the United States two numbers may be used:
[phone] - our toll free number (from within the USA only)
[phone] - our direct number
- By Telephone from outside the United States you must dial:
Your local International Access Code (usually 0 or 00), followed by
The Country Code for the U.S. which is (1), followed by
Our Area Code and Number [phone]
-By Automated Voicemail:
at the numbers listed above -available 24 hours/day.
- By Fax from within or outside the United States as above at;
[phone] - available 24 hours/day
- By E-Mail or through our World Wide Web site at:
[email protected] - available 24 hours/day
http://www.ogsi.com - available 24 hours/day
- By Mail at:
OGSI
814 Wurlitzer Drive
North Tonawanda, New York 14120 USA
- By UPS, FedEx or Common Carrier at:(This address for return shipments)
OGSI
814 Wurlitzer Drive
North Tonawanda, New York 14120 USA
We also have a list of Distributors and Authorized Service Agents available upon
request.

Effective April 2006
3
Warranty
Oxygen Generating Systems, International (hereinafter OGSI) provides a
warranty on its products against defects in material and workmanship, under normal use
and operation, as applicable in the statements below.
The OGSI Warranty provides the following:
a.) Free replacement of the product where defects in the material
and/or workmanship are evident at the time of delivery,
EXCLUSIVE of shipping damages. OGSI will pay shipping both
ways. (If shipping damage is evident, contact shipper
immediately).
b.) Free repair or replacement of product (excluding filter elements)
where defects in material and/or workmanship become evident
between the time of shipment and one (1) year from the date of
shipment. OGSI will pay shipping one (1) way.
Note - A Return Authorization Number must be obtained from OGSI prior to
return shipment of equipment
These warranties shall also become null, void and not binding on OGSI if a
defect or malfunction occurs in the product or any part of the product as a result of:
a.) A failure to provide the Required Operating Conditions (see page 9)
b.) Repair, Attempted Repair, Adjustment or Servicing by anyone other
than an authorized representative of OGSI
c.) External Causes
Molecular Sieve Replacement:
The breakdown of the molecular sieve inside the generator (dusting of the
sieve) only occurs if excess water/oil are entrained in the feed air stream.
Under no circumstances is molecular sieve covered under warranty by
OGSI. If sieve dusting occurs on your machine, check the air compressor,
air dryer and filter elements.
This warranty may be transferred to subsequent owners of a given machine only
with the prior approval of OGSI. The warranties above are given expressly in lieu of any
other warranty stated or implied and constitute the only warranties made by OGSI.

Effective April 2006
4
Limits of Liability
OGSI shall not be liable for any special, indirect, incidental or consequential
damages resulting from the use, or as a result of the malfunction of an Oxygen
Generator.
In the event the buyer or leasee chooses to use the OGSI oxygen generator for
medical or human life purposes, OGSI will not be liable for any special, indirect,
incidental, or consequential damages resulting from such use.
Operational Warnings
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.
•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.
•High-pressure gasses may be present within the system. Valves should be
opened and closed slowly, and safety glasses and hearing protection should be
worn at all times while gasses are being vented.
•Do not attempt to modify or enhance the performance of a Generator in any
way.

Effective April 2006
5
Safe 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.
•If visual inspection indicates obvious damage, the cylinder should be returned
to the supplier without any attempt at using the machine.
•If a 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.
•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.
•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.
•Always ensure that compressed gas cylinders be securely strapped or
chained in place to prevent tipping or falling. Do not store near elevators,
stairs, or passageways.
•Do not store oxygen cylinders with flammable gas cylinders. Stored oxygen
and fuel gas cylinders should be at least 20 feet 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, available by request at OGSI, or online at
http://www.iso.ch

Effective April 2006
6
Pressure Swing Adsorption
(PSA) Technology
The OGSI Oxygen Generator is an on-site oxygen-generating machine capable
of producing oxygen on demand in accordance with your requirements. It requires less
than 600 Watts of electrical power to control its operation.
In effect, it separates the Oxygen (21% of air) from the air it is provided and
returns the Nitrogen (78% of air) 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.
This Molecular 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
contain this sieve. As air is fed into one of the beds, the sieve in that bed holds the
Nitrogen to it and allows the Oxygen to flow through it and out to the surge tank as
product gas. Eventually the sieve becomes saturated with Nitrogen. When this occurs,
the feed air is directed to the other bed where the oxygen production/separation process
continues. While the second bed is being fed air, the first is depressurized and safely
releases the Nitrogen it has trapped through the waste gas muffler. This regenerates
the sieve in the first bed and prepares it to accept feed air again continuing the process.
The two beds continue to work in this alternating fashion to provide a continuous supply
of Oxygen.
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 critical to trouble
free operation. The filter elements are very inexpensive, semi-annual maintenance.

Effective April 2006
7
OG-75 Thru OG-750 Oxygen
Generator Specifications
Model Oxygen Output Air Required Power
*SCF/Hour **NM³/Hour SCF/Minute NM³/Minute Watts/Hour
OG-75 75 2.0 17 0.45 120
OG-100 100 2.6 22 0.58 120
OG-175 175 4.6 32 0.84 120
OG-250 250 6.6 45 1.18 120
OG-375 375 9.9 68 1.78 120
OG-500 500 13.1 88 2.31 120
OG-650 650 17 118 3.10 120
OG-750 750 19.7 133 3.50 120
Model Dimensions (D x W x H) Weight
Inches Centimeters Pounds Kilograms
OG-75 21 x 21.5 x 67 53 x 54 x 170 310 141
OG-100 24 x 24 x 69 61 x 61 x 175 500 227
OG-175 25 x 26 x 72 64 x 66 x 183 775 351
OG-250 26 x 32 x 72 66 x 81 x 183 1100 499
OG-375 30 x 36 x 84 76 x 91 x 213 1350 612
OG-500 36 x 48 x 83 91 x 122 x 211 1800 816
OG-650 48 x 55 x 83 122 x 140 x 211 2400 1625
OG-750 38 x 52 x 88 97 x 132 x 224 2600 10888
The Oxygen Purity Specification is 93% (±3%) for all models.
The Minimum Feed Air Pressure Required is 90 PSIG (621 kPa) for all models.
The Minimum Oxygen Pressure Delivered is 45 PSIG (310 kPa) for all models.
For domestic models the Power Configuration is 110 VAC/60 Hz, for export models 220
VAC/50 Hz.
* - A Standard Cubic Foot (SCF) is a cubic foot of gas at 14.7 psia (sea level atmospheric pressure) and 60 degrees
Fahrenheit
** - A Normal Cubic Meter (NM3) is a cubic meter of gas at 760 mm-Hg (sea level atmospheric pressure) and 0
degrees Celsius

Effective April 2006
8
Required Operating Conditions
Location of Machine: The standard Oxygen Generator is intended for use indoors.
It comes with a NEMA 12 enclosure box, which provides a degree of protection against
dust, falling dirt and non-corrosive liquids. A NEMA 4X enclosure package is optionally
available if outdoor location is required. The NEMA 4X package will provide a degree of
protection against corrosion, windblown dust and rain and splashing or hose-directed
water.
Feed Air/Ambient Air Quality: The useful life expectancy of any PSA Oxygen
Generator is directly related to the air quality that is fed into it. Hot, humid, dirty, oily air
deteriorates and degrades the performance of molecular sieve. In order to preserve the
effectiveness and extend the useful life of the generator, all precautions should be taken
to insure that Cool, Dry, Clean, Oil-Free air is provided to it.
Changing the inlet air filter is a simple and easy way to provide the unit with
some protection. Where possible, it would be advantageous to locate the unit in an air-
conditioned space, or at least a well-ventilated area. The room should also be free of
toxic gases and high concentrations of hydrocarbons, especially carbon monoxide.
Additionally, to the degree possible, humid, oily areas should be avoided as installation
sites.
Ambient Air Temperature: The machine is designed for use over a temperature
range of 40°F to 100°F (5°C to 38°C). Since hot air has the ability to hold much 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.
Feed Air Requirements:
The pressure of the incoming feed air supply should be at least 90 PSIG
(620 kPa). Pressure below this level will not allow the machines to run at the oxygen
purity, production capacity and efficiency levels they were designed to meet.
The compressed air that is fed into the Oxygen Generator should be no
hotter than 100 ° F (38 ° C). Air temperatures higher than this will immediately reduce the
efficiency of the machines and can damage the molecular sieve over time. Hot air is
also able to hold much more water than cool air and water ruins sieve.
The use of aftercoolers on feed air compressors and refrigerated air dryers
between the air compressor and the oxygen generator is highly recommended
and will improve the performance and lifetime of the oxygen generator.

Effective April 2006
9
Pipe scale, oil carryover from the compressor and water vapor should all
be minimized to ensure long and trouble-free Oxygen Generator operation. These
things can be accomplished with a few regular procedures. First, it is important to
recognize that the air compressor is a critical component in the Oxygen Generating
process. It needs to be maintained in accordance with the instructions provided in its
operating manual. Second, condensation needs to be removed from the air receiver
tank and air distribution lines at regular intervals to keep it from flowing into the
generator. Finally, as already mentioned in a few areas, the filter element inside the
Oxygen Generator needs to be replaced every six months.
Electrical Power: On U.S. models, the power for the control circuitry of the Oxygen
Generator is a single-phase electrical supply of 120 Volts AC and less than 1 Amp at a
frequency of 60 Hz. This equates to fewer than 120 Watts of power.
On Export models, the power for the control circuitry of the Oxygen Generator is
a single-phase electrical supply of 220 Volts AC and less than 500 milliAmps (0.5
Amps) at a frequency of 50 Hz. This also equates to less than 120 Watts of power.
Positioning: The unit must be operated in an upright position only, with no obstruction
blocking airflow around the unit.

Effective April 2006
10
Typical Setup Diagrams
Shown immediately below is a sample drawing that depicts how a typical system
could look when connected.
G
22
OISG
22
G
IOGS
OISG
22
G
Occasionally a user may choose to maintain a liquid or cylinder backup and keep it
connected to his system for critical applications. This is a precaution that ensures
uninterrupted oxygen flow if the power supply should be lost or the compressor or
generator malfunction.
22
GG
22
SGO I
GSIOGSIO
G
22

Effective April 2006
11
Pre-Installation Check Instructions
Although every Oxygen Generator is thoroughly tested and checked before it is
shipped from our factory, the following checks are necessary to insure that none of
the internal components have been damaged in shipment. This check should take
less than five minutes to perform.
1.) Make a visual inspection of the machine and make sure all parts are properly
attached.
2.) Sieve settles during shipment, therefore it is important to re-pack the supplied
sieve to the top of the sieve beds making sure no empty voids are left in the beds.
The sieve can be harmed by exposure to air and caution must be taken to keep the
sieve in the oxygen generator & the container sealed as much as possible. (See
page 12 for diagram.)
3.) The ON/CONTINUOUS/AUTO switch will need to be attached to the enclosure
door. (See page 13 or 14 for a diagram depending on the type of switch you have.)
4.) These checks are for machines with the touchscreen option:
a. Ensure the touch screen is powered, and a display is visible. Consult the
troubleshooting guide in this manual (see page 14) for any problems
encountered.
b. After selecting a language and entering a password, start the machine by
pressing both the OPERATING MODE (Automatic), and then the ON/OFF
pushbuttons.

Effective April 2006
12
Sieve Re-packing Diagram

Effective April 2006
13
Type 1 Switch Connection Diagram
SWITCH ASSEMBLY INSTRUCTIONS
1-TAKE #1 AND PUSH THROUGH #7
2-NOW TAKE #1 & #7 AND PUSH THROUGH THE
FRONT OF THE ENCLOSURE DOOR
3-NEXT TAKE #6 AND PUSH ONTO #1 FROM THE
BACKSIDE OF THE ENCLOSURE DOOR
4-NOW HAND TIGHTEN #5 ONTO #1 FROM THE
BACKSIDE OF THE ENCLOSURE DOOR
5-AFTER THIS PUSH #3 INTO #1 FROM THE
BACKSIDE OF THE ENCLOSURE DOOR
6-NOW PUSH #4 INTO THE LOCKED POSITION
(SEE FRONT VIEW)
7-NOW TAKE #2 AND PUSH ONTO #4 TO SECURE
IT IN THE LOCKED POSITION

Effective April 2006
14
Type 2 Switch Connection Diagram
SWITCH ASSEMBLY INSTRUCTIONS
1-TAKE #1 AND PUSH THROUGH #4
2-NOW TAKE #1 & #4 AND PUSH THROUGH THE
FRONT OF THE ENCLOSURE DOOR
3-PUSH #2 ONTO #1 AND TURN IT TO LOCK THEM
TOGETHER
4-NOW MAKING SURE THE ASSEMBLED PARTS ARE
STRAIGHT TAKE A SCREW DRIVER AND TIGHTEN BOTH #3's

Effective April 2006
15
Setup Instructions
These instructions are intended as a general guideline for a typical system
installation. If you feel you have an unusual situation or would like additional assistance
in determining the appropriateness of a particular setup, please do not hesitate to
contact us. See Page 2 for details on how that can be done.
1.) Connect a Ball Valve Between Your Air Supply and the Feed Air (Black) Hose
Provided -
This valve will be used to shut off the air supply to the generator for filter
replacement. If you do not have a valve on hand at this time, skip this step as
one can be installed at this point at a later date.
OGSI does stock valves that can be used for this purpose. If you need one you
can reach our sales department at [phone].
2.) Connect the Feed Air to the Ball Valve Mentioned Above (or directly to) Your Air
Supply and to the Left Side of the Generator -
On systems this size, a hose is not included as installation setups vary greatly.
The left side of the generator has a fitting that is labeled ‘Air In’. This fitting will
be either a 37°-flared JIC fitting or a male pipe thread depending on which model
you have. Connections to these are readily available worldwide through the
Parker distribution network or from OGSI.
3.) Unroll and Direct the Filter Drain (Clear) Hose into a Bucket or Floor Drain (if
available) -
This drain hose is provided with each unit and can be used to alleviate the
potential problem of having water and material trapped by the filter blown directly
on to the floor. If this hose is not going to be used it should be disconnected from
the machine and discarded.
4.) Connect the Oxygen (Green) Hose to the Oxygen Outlet Connection on the Right
Side of the Generator and to the Oxygen Storage Tank -
The green hose is the Oxygen hose. The Oxygen Outlet Connection is on the
right hand side of the machine and is Labeled ‘O2Out’. This Oxygen Hose has
threaded fittings that swivel on each end of it. Either side can be connected to
the generator, as the fittings are the same on each end.
If your storage tank was purchased from OGSI, it will have an appropriate fitting
in place for this connection. It will be attached to the same tee fitting that holds
the safety relief valve. If the tank was not purchased from OGSI, you must insure
that it has the appropriate size fitting to accept this hose assembly.
OGSI can provide these fittings, if necessary.

Effective April 2006
16
5.) Connect Your Oxygen Hose to the Oxygen Pressure Regulator on the Oxygen
Storage Tank -
If you are using an Oxygen Manifold as in one of the previous drawings, we
recommend another ball valve between the hose that is connected to the Oxygen
Regulator and the Oxygen Manifold. This Ball Valve can then be used as your
primary supply or shut off valve between the generator and your application.
Closing this valve nightly before turning the generator off will ensure that the
storage tank is full the next day.
As before, this Oxygen Hose and Ball Valve are not included with the generator
because the connections used from location to location can vary greatly. We can
provide these Ball Valves and Hose Assemblies, if required, but intentionally do
not include them with every machine so that we may provide you with the best
price for the basic package.
6.) Plug the Electrical Cord into an Outlet -
It is preferable that the outlet used be one that cannot be accidentally turned off.
Generators shipped within North America can be plugged into any typical 110
Volt outlet while those shipped outside North America will typically be wired to
accept a single phase 220 Volt supply.
Once connected you should be ready to begin to produce your own Oxygen.

Effective April 2006
17
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.
1.) Oxygen is a fire hazard. It can be very dangerous as it vigorously
accelerates the burning of combustible materials. To avoid fire and/or the
possibilities of an explosion, oil, grease or any other easily combustible materials
must not be used on or near the oxygen generator. Smoking, heat and open
flames are also not recommended near the unit. Individuals who have
experience handling oxygen systems should become the designated operators of
the oxygen generator within your facility.
2.) Ensure that the oxygen outlet stream is not directed toward anyone’s
clothing. Oxygen will embed itself in the material and one spark or hot ash from
a cigarette could ignite the clothing vigorously.
3.) In critical applications it is important to have a backup supply of oxygen, as it
should be remembered that the generator does not come with any reserve
storage tank and it does require electrical power to operate. Therefore during
power outages oxygen will not be produced.
4.) As previously mentioned, do not use extension cords to bring power to
the generator. The current draw into the unit is high and could overheat some
extension cords. It is also important to use only a properly grounded outlet.
5.) High Pressure Oxygen may present a Hazard. Always follow proper
operating procedures, and open valves slowly. Rapid pressurization may result
in personal injury. Safety glasses and hearing protection are required when
venting oxygen under high pressure.