Manual Docs-200

TECHNICAL MANUAL
OPERATION AND MAINTENANCE
DEPLOYABLE OXYGEN CONCENTRATION SYSTEM

(DOCS) 200 LITERS PER MINUTE
MODEL NUMBER: M.E.2 200-55

PART NUMBER: 796925-001 & -002
Pacific Consolidated Industries, LLC

12201 Magnolia Avenue
Riverside, California 92503-4820
Tel: 951-479-0860
Fax: 951-479-0861
http://www.pcigases.com
350124 Rev. D 17May 2012

RECORD OF REVISIONS
REVISION DATE DESCRIPTION DCN

NC 13 April 2009 Initial Release 2165
A 7 Jan 2010 Refer to DCN 2357 2357
B 30 Nov 2010 Refer to DCN 2895 2895
C 11 August 2011 Refer to DCN 3245 3245
Added: Coupling grease, VSA lid hardware, Booster coupling &
Blower Legacy to Table 5-1; Table 5-3 List of additional
consumables; Sections 5.4, 5.5, 5.8.7.1 & 5.8.7.2, 5.8.7.3,
5.8.7.4, 5.8.8, 5.8.9 & 5.8.10; Tables 5-5 & 5-6; Blower
Legacy to Section 5.6.7; Figures 5-14 - 5-16; Tables C-5 -
C-7
Revised: All illustrations showing the electrical enclosure; Table 5-1
D 17 May 2012 Tip Seals was: 3000-4000, is: 8000; Table 5-2 to Kit 3415
797409-002; Was: Table 5-3 Special Tools, is: Table 5-4
Necessary Tools; Section 5.3 was: Special Tools, is:
Tools; Oxygen Clean was: Section 5.3, is Section 5.6 with
Isopropyl alcohol; Maintenance Tools was: Section 5.3.1,
is: Section 5.7; Maintenance was: Section 5.4, is: Section
5.8; Tables C-1 - C-4 were: 797409 rev G, are: rev J;
Figures FO-3 was: rev H, is: rev J, FO-4 was: rev A, is: rev
B
Copyright  2012 by Pacific Consolidated Industries, LLC (PCI). This document contains confidential technical data,
including trade secrets, proprietary to PCI. Disclosure of this data is expressly conditioned upon your assent that its
use is limited to use within your company only (and does not include manufacture or processing uses). No part of this
document may be used or reproduced in any form or by any means or stored in a database or retrieval system without
written permission of PCI. Copying or directly reproducing any part of this manual for any purpose other than the
original owner’s personal use is a violation of the United States Copyright laws. For more information and assistance
in obtaining additional copies of this manual, contact Pacific Consolidated Industries, LLC, 12201 Magnolia Avenue,
Riverside, California 92503-4820.
This manual is presented as-is, without warranty of any kind, either expressed or implied, respecting its contents,
including, but not limited to implied warranties for the manual’s quality. PCI is not liable to the purchaser or any other
person or entity with respect to any liability, loss, or damage caused or alleged to have been caused directly or
indirectly by this manual. Pacific Consolidated Industries assumes no responsibility for the accuracy, completeness or
usefulness of this manual, or from any problems or conditions which may arise from the use of the information
contained herein or omissions from this manual. Pacific Consolidated Industries reserves the right to change and
update the information and specifications contained within this manual at any time without notice.
DOCS 200
M.E.2 200-55
TABLE OF CONTENTS
PARAGRAPH PAGE
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 INTRODUCTION
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Location and Description of Components (DOCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Theory of Operation (DOCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 System Operation (DOCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2 PREPARATION FOR USE
2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4.1 Access Panels and Door (DOCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4.2 Installation Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.3 Interconnect Plumbing Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.4 Interconnect Wiring Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Electrical Power Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3 OPERATION
3.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Calibration Gas Bottle Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Output Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Monitor the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.1 LCD Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.2 Remote Unit Diagnostics and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.2.1 Diagnostic Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.2.2 Discharge Pressure Adjustment (Laptop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5 Operation in Unusual and Harsh Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6 System Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.7 Emergency Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8.1 Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8.2 Automatic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.10 Unit IP Address Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
4 MANUAL OPERATION
4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Operator Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
350124D i
DOCS 200
M.E.2 200-55
PARAGRAPH PAGE
4.3.1 Monitor Sub-Assembly Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.2 VSA Blower (BL-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.3 Scroll (Booster (C-1)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3.4 Main Cooler (FX-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3.5 Purge Solenoid (SV-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.3.6 O2 Sample Solenoid (SV-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.3.7 Off-Spec Solenoid (SV-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.3.8 Solenoid (SV-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.3.9 Horn Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.3.10 RIX (HP Compressor) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.3.11 RIX1 (HP Compressor 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.3.12 RIX2 (HP Compressor 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.3.13 Alarm Relay (RLY-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.3.14 Running Relay (RLY-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.3.15 Save and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
5 MAINTENANCE
5.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 List of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.4 Spare Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.5 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.6 Oxygen Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.7 Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.8.1 Pre-Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.8.2 Filter (F-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5.8.3 Filter (F-4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5.8.4 Filter (F-3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.8.5 Product Blower (BL-100) Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.8.6 Product Blower Motor (MTR-1) Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.8.7 Blower (BL-100) Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.8.7.1 1000 Hour Coupling Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.8.7.2 4000 Hour Coupling Grease Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5.8.7.3 Blower (BL-100) Coupling Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5.8.7.4 Blower (BL-100) Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5.8.8 VSA Bed Lid Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5.8.9 Booster Compressor (C-1) Coupling SetSCrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.8.10 Booster Compressor (C-1) Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5.8.11 Booster Compressor (C-1) Lubrication and Tip Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5.8.11.1 Booster Compressor (C-1) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5.8.11.2 Booster Compressor (C-1) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5.8.11.3 Tip Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5.8.11.4 Tip Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5.8.11.5 Booster Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5.8.11.6 Booster Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
5.8.11.7 Booster Compressor (C-1) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
5.8.12 Post Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29
ii 350124D
DOCS 200
M.E.2 200-55
PARAGRAPH PAGE
5.9 Calibration Gas Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.9.1 Gas Bottle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.10.1 Error Codes and Common Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.10.2 Performance Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
6 SHIPMENT AND STORAGE PREPARATION
6.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Shipment Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.1 Electrical Power Disconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.2 Interconnect Wiring Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.3 Interconnect Plumbing Disconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.1 Electrical Power Disconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.2 Interconnect Wiring Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.3 Interconnect Plumbing Disconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.4 Storage Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Appendix A Foundation Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-1
Appendix B P&ID and Electrical Drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-1
Appendix C Spares Kits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C-1
350124D iii
DOCS 200
M.E.2 200-55
LIST OF ILLUSTRATIONS
FIGURE PAGE
1-1 Blower Module Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1-2 VSA Module Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
1-3 Distribution Box Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
2-1 Access Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
2-2 Typical Module Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
2-3 Unit Interconnect Plumbing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
2-4 Blower Module Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2-5 Electrical Enclosure Interconnect Wiring Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2-6 Electrical Enclosure (inside bottom) Interconnect Wiring - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2-7 Unit Power Cable Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2-8 Input Power Circuit Breaker (CB-1) Power Cable Connections - - - - - - - - - - - - - - - - - - - - - 2-8
3-1 Operator Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3-2 Blower (BL-100)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3-3 DOCS 200 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-4 Unit (front view) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-5 Normal Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-6 Setup Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-7 Pressure Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-8 TCPIP CONFIG Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
3-9 DIRECT IO Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
3-10 SETTINGS EXIT Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
3-11 Operator Panel Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9
3-12 E-Stop Button and Circuit Breaker (CB-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-12
3-13 O2 Cal Prep Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3-14 O2 Cal Sampling Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3-15 O2 Cal Checking Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3-16 O2 Cal Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-13
3-17 Cal Status Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-14
3-18 Setup Entry Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-15
3-19 Output Pressure Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-15
3-20 IP Configure Enter Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-15
3-21 DHCP Setting Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-16
3-22 Address Edit Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-16
3-23 Mask Edit Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-17
3-24 Gateway Edit Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-18
3-25 IP Exit Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-18
3-26 Direct IO Entry Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-18
3-27 Settings Exit Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-18
4-1 Setup Entry Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-2 Output Pressure Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-3 IP Configure Enter Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-4 Direct IO Entry screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-5 Direct IO Fault Input Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4-6 VSA Blower Forward Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4-7 VSA Blower Reverse Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
iv 350124D
DOCS 200
M.E.2 200-55
FIGURE PAGE
4-8 Scroll Forward Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4-9 Main Cooler Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4-10 Purge Solenoid Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4-11 O2 Sample Solenoid Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4-12 Off-Spec Solenoid Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4-13 Solenoid (SV-4) Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4-14 Horn Sink Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
4-15 RIX Fan Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
4-16 RIX1 Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-11
4-17 RIX2 Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4-18 Alarm Relay Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4-19 Running Relay Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4-20 Settings Exit Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4-21 Normal Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14
5-1 Normal Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
5-2 Distribution Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-5
5-3 Blower Module Filter (F-3)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5-4 Product Blower (BL-100) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
5-5 Product Blower Motor (MTR-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
5-6 Product Blower Motor Coupling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
5-7 Coupling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
5-8 Blower (BL-100) Coupling Screws - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
5-9 Coupling Element Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
5-10 Coupling Hub Spacing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
5-11 Blower Coupling Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
5-12 VSA Bed Lid Torque Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
5-13 Booster Coupling Motor Hub - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
5-14 Booster Coupling Compressor Hub - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-15 Booster Compressor Hub Alignment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
5-16 Booster Motor Hub Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
5-17 Booster Coupling Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18
5-18 Booster Compressor (C-1) Tubing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-19
5-19 Booster Compressor Fittings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-20
5-20 Booster Compressor (compressor end) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-20
5-21 Fixed Scroll LP Seal Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21
5-22 Fixed Scroll Dust Seal Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-21
5-23 Fixed Scroll Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
5-24 Orbital Scroll Seals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
5-25 Booster Compressor (C-1) Seal Kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
5-26 Orbital Scroll HP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
5-27 Orbital Scroll LP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24
5-28 Orbital Scroll LP Seal Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24
5-29 Fixed Scroll HP Seal Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24
5-30 Fixed Scroll LP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-25
5-31 Fixed Scroll Backup Tube Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-25
5-32 Fixed Scroll Dust Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-26
5-33 Booster Compressor Main Bearing Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-26
350124D v
DOCS 200
M.E.2 200-55
FIGURE PAGE
5-34 Booster Pin Crank Bearing Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-27
5-35 Booster Compressor (compressor end) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-27
5-36 Booster Compressor Fittings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-28
5-37 Booster Compressor (C-1) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-28
6-1 Input Power Circuit Breaker (CB-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
6-2 Electrical Enclosure (inside bottom) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
6-3 Blower Module Interconnect Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
6-4 Unit Interconnect Plumbing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4
FO-1. Unit Foundation Drawing (Sheet 1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-3
FO-2. Process and Instrumentation Drawing (P&ID) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-3
FO-3. Electrical Schematic (Sheet 1 of 3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-5
FO-4. VFD Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B-11
vi 350124D
DOCS 200
M.E.2 200-55
LIST OF TABLES
TABLE PAGE
1-1 Blower Module Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 VSA Module Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Distribution Box Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3-1 Operator Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 IP Addressing Button Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4-1 Direct IO Fault Input Fields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5-1 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2 List of Consumables Kit (797409-002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-3 List of Other Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-4 Necessary Tools Kit (797409-001). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-5 Specialty Tools Kit (797409-009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-6 Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-7 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-8 Common Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-9 Performance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
C-1 Necessary Tools SpareV Kit (797409-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-2 Consumables SpareV Kit (797409-002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-3 Capital Spares Kit (797409-003) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-4 On Hand Spares Kit (797409-004). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C-5 Specialty Tools Spares Kit (797409-009). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C-6 3 YR Consumables Spares Kit (797409-010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C-7 5 YR Consumables Spares Kit (797409-011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
350124D vii/(viii blank)

DOCS 200
M.E.2 200-55
FOREWORD
PARTS AND SERVICE INFORMATION
Before contacting Pacific Consolidated Industries (PCI) for service and support, make sure you have the following
information about your equipment:
Equipment Name/Nomenclature
Part Number
Serial Number
Date of Manufacture
All of this information is found on the Equipment Data Plate installed on the equipment.
When requesting information and availability for specific parts, make sure you have the following information:
PCI Part Number
Drawing Number (if available)
Item Number on Drawing (if available)
OEM Part Number (if available)
CONTACT PCI FOR PARTS AND SERVICE
For PCI parts, service, warranty and field support contact Product Support, by phone or fax, with the following
telephone numbers:
Toll Free: (800) 309-9185
Voice: (951) 479-0860
Fax: (951) 479-0864
Or contact PCI on the internet with the Support web page at: http://www.pcigases.com.
350124D ix/(x blank)

DOCS 200
M.E.2 200-55
SAFETY SUMMARY
This safety summary contains general safety warnings that must be understood and applied during operation and
maintenance of this equipment. Failure to obey these precautions could result in serious injury or death to personnel
and damage to the equipment. When first aid is required refer to OSHA Standard 1910.151.
These are the safety and hazardous material icons used within the manual:
Highlights an essential operating or maintenance procedure,

practice, condition, statement, etc. which, if not strictly observed,
could result in injury to, or death of, personnel or long term health
hazards.

practice, condition, statement, etc. which, if not strictly observed,
could result in damage to, or destruction of, equipment or loss of
mission effectiveness.
NOTE

condition or statement.
Make sure you read the information in the warning, caution and notes carefully. Consult someone, experienced in
handling oxygen equipment, about any issues that are unclear. Warnings shall precede cautions, which in-turn shall
precede notes. Warnings and cautions precede the step for which they are intended, and notes follow the step.
Additional safety guidelines related to specific components of the unit are described in the correct sections.
ELECTRICAL SAFETY AND LOCK-OUT/TAG-OUT PROCEDURES
Follow all lock-out/tag-out requirements and obey all electrical safety precautions and procedures. Danger still exists
when the power control is set to OFF.
 Remove power, discharge and ground a circuit before touching it.
 When possible, work in pairs, preferably with a Basic Life Support (BLS) qualified personnel.
 Personnel working with or near dangerous voltage shall be trained in modern methods of resuscitation.
FINGER RINGS/JEWELRY
Remove rings, watches and other metallic objects, which can cause shock or burn hazards. Unless specifically
allowed by shop safety procedures, remove finger rings during all maintenance activity.
350124D xi
DOCS 200
M.E.2 200-55
PERSONAL PROTECTIVE EQUIPMENT
Eye protection, hearing protection and Personal Protective Equipment (PPE) are selected based upon the task being
done and should be approved by a specialist before operating, maintenance, service and repair of the unit.
Use proper ear protection as high decibel noise can cause permanent hearing loss through prolonged exposure.
OXYGEN SYSTEMS
The oxygen system must be cleaned and inspected in accordance with Compressed Gas Association (CGA)
pamphlet G 4.1. Make sure no combustible materials remain in the connecting piping and fittings.
NOTE
If you are not familiar with oxygen cleaning procedures contact the
CGA or PCI before putting oxygen into your piping and distribution
system. The CGA web site is www.cganet.com.
Oxygen is a powerful oxidizing agent that can cause a fire or explosion. Obey strict cleanliness procedures when
fabricating and connecting the oxygen piping.
OXYGEN LUBRICATION AND CLEANING COMPOUNDS
Do not lubricate any oxygen component or connection with petroleum-based grease, oil, Vaseline (petroleum jelly),
hydraulic fluid or other petroleum compounds. This includes cylinder connections, valve adjustment stems, internal
seal lubricants (i.e.used during assembly), fittings, etc. Only use inert, oxygen-certified lubricants.
Do not clean oxygen components or parts in petroleum-based cleaning solvents that can leave a residual film,
including paint thinner, mineral spirits (standard solvent), lacquer thinner, kerosene, gasoline, etc. Only use oxygen-
certified cleaning solutions and solvents.
Petroleum products can cause a fire and an explosion hazard when in contact with oxygen.
OXYGEN EQUIPMENT SAFE PRACTICES
High purity oxygen can be hazardous and supports combustion. A material which will not burn in air can burn in high
purity oxygen. Follow all comprehensive guidelines and training for safe oxygen handling. These are general
guidelines for minimizing the chance of fire:
 Do not allow smoking within 50 feet of oxygen equipment.
 Store oxygen in clean dry locations away from direct sunlight.
 Make sure any cleaning, repair or transfilling of oxygen equipment is done by qualified correctly trained
personnel.
 Do not work on oxygen equipment with ordinary tools. Designate special tools, clean and store them for Use
with Oxygen Equipment Only.
 Use plugs, caps and plastic bags to protect equipment from dust and dirt while not in use.
 Make sure staff using oxygen equipment are adequately trained in its operation, in oxygen safety and have
knowledge of the manufacturer’s instructions for use.
xii 350124D
DOCS 200
M.E.2 200-55
HIGH OXYGEN CONCENTRATION
Oxygen concentrations in excess of 25% significantly increase the hazard exposure to personnel and equipment.
Those materials, which burn in air, will burn more violently and sometimes explosively in oxygen.
Personnel must be familiar with the hazards of oxygen and safe practices for oxygen systems in order to operate and
maintain the system.
Hydrocarbons can spontaneously combust in the presence of enriched oxygen. In some cases the elevated oxygen
levels can linger even after the source has been shut off. Clothing can become saturated for extended periods of time
with enriched oxygen and significantly increase the likelihood of ignition in the presence of sparks, heat or flame.
Personnel who work with enriched oxygen should not smoke until changing out of their work clothes.
All areas exposed to enriched oxygen atmospheres should be continually monitored for fire loading practices. Fire
loading is good house keeping. Flammable items shall not be stored near enriched oxygen sources. Some materials
will burn in the presence of pure (or near pure) oxygen that would not otherwise burn.
To prevent unwanted combustion, make sure there is adequate ventilation, prevent enriched oxygen component
contamination and avoid fire loading.
Enclosed areas with enriched oxygen can explode and burn violently when exposed to spark or flame. Do not place
an enclosed tent around the unit without proper ventilation.
If there is insufficient ventilation, personnel can begin to suffer from enriched oxygen induced problems such as
nausea, vomiting, twitching or seizures, disorientation, chest pains, prolonged night vision adaptation, loss of
consciousness and possible death.
LOW OXYGEN CONCENTRATION ASPHYXIATION
An oxygen concentration of less than 19% can cause asphyxiation, including loss of life. Do not operate the unit in an
enclosed non-ventilated area.
The purpose of this unit is to separate oxygen from air and make the oxygen available at low pressures. The waste
gas (vented exhaust) produced is nitrogen-rich. Nitrogen, while inert, does not sustain life. If allowed to collect, it will
cause hypoxia and asphyxiation to exposed personnel.
If the vented exhaust is allowed to accumulate in a closed, non-ventilated area, the air in the area could be oxygen
depleted sufficiently to produce asphyxiation, resulting in unconsciousness or death. If the unit is to be located
indoors, additional ventilation must be provided.
HIGH TEMPERATURES
Certain areas of the unit can become hot to the touch. Some areas include the heat exchangers and interconnecting
piping. The blower and silencer are other sources of heat. Use caution when servicing the equipment and allow the
equipment to cool before doing maintenance.
ROTATING EQUIPMENT
The unit must be operated with the doors closed and the panels installed. Rotating parts can cause severe injury.
Never attempt adjustments while the unit is running unless otherwise specified by the service procedure. Keep body
parts and objects away from all moving parts and obey all safety precautions.
350124D xiii/(xiv blank)

DOCS 200
M.E.2 200-55
CHAPTER 1
INTRODUCTION
1.1 SCOPE
This manual has instructions for the operation and maintenance of the Deployable Oxygen Concentration
System (DOCS), Model Number M.E.2 200-55 (here after called DOCS or the unit), part number 796925-
001. The DOCS is manufactured by Pacific Consolidated Industries, LLC (PCI).
1.2 PURPOSE
The DOCS is an oxygen generator delivering United States Pharmacopoeia (USP) grade 93% ± 3% oxygen
for supplemental oxygen use.
1.3 LEADING PARTICULARS
The modular design has two modules (Blower and VSA) mounted on separate skids. The basic model
(M.E.2 200-55) module particulars are listed followed by the other models specific particulars.
Environmental Characteristics:
Operating temperature 0 to 120°F (-18 to 49°C)
Storage temperature 0 to 140°F (-18 to 60°C)
Noise Level (average) 76 dBA at 20 feet (6 m)
Noise Level (peak) 85 dBA at 20 feet (6 m)
Input Power Requirements:
 380 Vac, 3-phase, 50 Hz, 42 FLA
 460 Vac, 3 phase, 60 Hz, 35 FLA
Performance Characteristics (at standard condition of 70°F, 14.7 psia (21°C, 1 bar)):
Low Pressure Discharge 10 - 100 psig (0.69 - 6.9 bar)
Low Pressure Flow 200 Lpm (7 scfm)
Media USP grade Gaseous Oxygen
Oxygen Purity 93% ± 3%
Discharge and Calibration Ports
Discharge 3/8 inch, 37° Flare, Tube, Compression Fitting
Calibration 1/4 inch, Tube, Compression Fitting
Blower Module:
Height 72 inch (183 cm)
Width 68 inch (173 cm)
Depth 26 inch (66 cm)
Exterior Volume 74 cubic ft (2.1 cubic m)
Lift Capabilities Forklift slots
VSA Module:
350124D 1-1
DOCS 200
M.E.2 200-55
Blower and VSA Modules on single skid:

Weight 3046 lbs (1382 kg)
1.4 LOCATION AND DESCRIPTION OF COMPONENTS (DOCS)
Figure 1-1. and Table 1-1. show and list the blower module major components.
Table 1-2. on page 1-3 and Figure 1-2. on page 1-4 list and show the VSA module major components.
Figure 1-3. and Table 1-3. on page 1-5 show and list the distribution box major components.
6
3
4 7
10
Figure 1-1. Blower Module Major Components
Table 1-1. Blower Module Major Components
ITEM COMPONENT DESCRIPTION

Primary Heat Exchanger Fan
1 One horse power motor directly coupled to the cooling fan (FX-100)
Motor (MTR-2)
Primary Heat Exchanger Fan
2 Pushes cooling air through the heat exchanger (HX-100) and the enclosure
(FX-100)
Product Intake Heat Exchanger
3 Cools the air routed to the VSA chamber
(HX-100)
4 Product Blower Motor (MTR-1) Twenty-five horse power motor coupled directly to the blower (BL-100)
1-2 350124D
DOCS 200
M.E.2 200-55
Table 1-1. Blower Module Major Components (Continued)

5 Interconnect Piping Plumbs the compressor module to the VSA module
6 Inline Silencer (S-200) Muffles a percentage of the noise made by the blower (BL-100)
7 Blower/Motor Coupling Directly couples the motor (MTR-1) drive to the Blower (BL-100)
A low-pressure, rotary lobe type blower sending pressurized air to the VSA bed (C-
8 Product Blower (BL-100) 300) during the pressure cycle. Reverses direction pulling vacuum to remove
contaminants from the adsorber bed during the vacuum cycle
9 Intake Silencer (S-100) Muffles a percentage of the noise made by the Blower (BL-100)
10 Air Supply Filter (F-3) A five micron filter removes air particles from the air going to the VSA module
Table 1-2. VSA Module Major Components

1 Purge Solenoid Valve (SV-1) Opens to use purge oxygen to clean the VSA chamber during the vacuum phase
2 Circuit Breaker (CB-1) Main power circuit breaker, applies Vac power to the Unit
3 Operator Control Panel Operator interface to the unit; has the controls for the unit operation
4 Emergency-Stop Switch (SW-1) Removes control power from the Unit; does not remove Vac power
VSA Outlet Pressure Transducer
5 Monitors the output pressure/vacuum of the VSA chamber (C-300)
(XT-2)
6 Product Check Valve (CV-1) Prevents back flow from the buffer tank (C-400) to the VSA bed (C-300)
7 VSA Chamber (C-300) Contains the sieve material adsorbing the gases in air to give high purity oxygen
8 Distribution Box Houses the booster package for discharge pressures 10 - 100 psig
Buffer Tank Out Pressure Safety Pressure shunt valve set to 16 psig; limits the buffer tank discharge pressure to
9
Valve (PSV-1) 16 psig
Buffer Tank Outlet Check Valve
10 Prevents back flow from the booster compressor (C-1) to the buffer tank (C-400)
(CV-3)
11 Buffer Tank (C-400) Buffer tank with internal strainers (inlet & outlet)
12 Electrical Enclosure Contains the electronics required to operate the unit
350124D 1-3
DOCS 200
M.E.2 200-55
5
2
6
3
4 7
12
10
11
Figure 1-2. VSA Module Major Components
1-4 350124D
DOCS 200
M.E.2 200-55
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
Figure 1-3. Distribution Box Major Components
Table 1-3. Distribution Box Major Components

1 Compressor Motor (MTR-3) Three horse power motor coupled directly to the compressor (C-1)
2 Output Heat Exchanger (HX-200) Cools the booster compressor (C-1) discharge
Pressure shunt valve set to 105 psig; limits the booster compressor (C-1) discharge
3 Output Safety Valve (PSV-2)
pressure to 105 psig
4 Output Check Valve (CV-4) Prevents back flow from the discharge port to the booster compressor (C-1)
5 Product Particulate Filter (F-1) 0.01 micron filter for the oxygen product routed to the discharge port
SCroll Out Pressure Transducer
6 Monitors the output of the booster compressor (C-1) discharge pressure
(XT-1)
7 Booster Compressor (C-1) Compresses oxygen product for a 10 - 100 psig product discharge at the output port
8 Inlet Filter (F-4) 0.01 micron filter for the inlet of the booster compressor (C-1)
Filter Inlet Pressure Transducer
9 Monitors the inlet of the booster compressor (C-1) inlet pressure
(XT-3)
Three-way valve routes out-of-spec oxygen to atmosphere or routes 93% ± 3%
10 Off-Spec Solenoid Valve (SV-3)
oxygen to the discharge port
11 Off-Spec Orifice (OR-2) Off-spec product port; maintains system pressure during off-spec vent
Sample/Calibration Solenoid Three-way valve routes oxygen product to oxygen analyzer (AE-1) or connects
12
Valve (SV-2) calibration connection port (CC-1) to the inlet of oxygen analyzer (AE-1)
Oxygen Analyzer Pressure Pressure regulator valve set to 13 psig; limits the pressure to oxygen analyzer
13
Regulator (PRV-1) (AE-1) to 13 psig
14 Low Pressure Discharge Port Product discharge port for oxygen at 55 psig (nominal)
Calibration Connection Port
15 Oxygen analyzer (AE-1) calibration port; connector for calibration oxygen bottle
(CC-1)
350124D 1-5
DOCS 200
M.E.2 200-55
1.5 THEORY OF OPERATION (DOCS)
The air separation capability is based on the principle of adsorption.

The surface of the molecular sieve material (sieve) causes specific gases in the air mixture to adhere to its
surface separating the gas mixture. Gases other than oxygen contained in the air; nitrogen, water vapor and
carbon dioxide adhere to the sieve while oxygen passes through. Adsorption of these gases is achieved at
higher pressure; lowering the pressure desorbs these gases.
The adsorption process begins when air is forced through the sieve at high pressure, and the nitrogen, water
vapor and other undesirable elements adsorbs onto the sieve while the oxygen passes through and is
collected downstream of the sieve bed in high concentrations. After a while, the sieve will become saturated
with the contaminants.
The direction of flow through the sieve bed is then reversed, lowering the bed pressure. The sieve releases
the gases adsorbed on the sieve and some of the concentrated oxygen is introduced in the reverse flow
stream. This portion of the cycle is called desorption and purge.
When all the unwanted gases have been removed, the adsorption process starts again. This process is
called Vacuum Swing Adsorption (VSA).
1.6 SYSTEM OPERATION (DOCS)
Refer to the Process and Instrumentation Diagram (P&ID) and Electrical Schematics in Appendix B.
On start-up, the VSA blower motor (MTR-1) drives the VSA blower (BL-100) in the vacuum direction of the
cycle. When pressure transducer (XT-2) detects the maximum vacuum set point, solenoid valve (SV-1)
opens for a short time flushing the VSA chamber with oxygen. Solenoid valve (SV-1) closes and the blower
(BL-100) reverses direction starting the pressure function of the cycle. Ambient air is drawn-in through filter
(F-3) and silencer (S-100). The blower accelerates the air, forces it through silencer (S-200), heat exchanger
(HX-100) and into the VSA chamber (C-300). The oxygen is not adsorbed and moves through check valve
(CV-1) into the buffer tank (C-400). The blower reverses direction and the vacuum function of the cycle
starts over again. This vacuum/pressure cycle is continually repeated.
When the unit is started, the vacuum/pressure cycle builds the booster inlet pressure to 18.7 psia before the
booster compressor runs. When transducer (XT-3) detects the correct pressure; the booster compressor
(C-1) runs drawing the oxygen through an inlet filter (F-4) and discharging through a heat exchanger
(HX-200) and filter (F-1). Transducer (XT-1) detects the booster compressor (C-1) output pressure. Solenoid
valve (SV-2) routes the oxygen product to the oxygen analyzer (AE-1). Until the correct purity of oxygen is
detected through the oxygen analyzer (AE-1), the off-spec oxygen is vented to atmosphere through solenoid
valve (SV-3). When purity is greater-than or equal-to the set point, solenoid valve (SV-3) shifts and product
is routed to the discharge port.
1.7 ACRONYMS AND ABBREVIATIONS
FLA . . . . . . . . . . . Full Load Amperage

FNPT . . . . . . . . . . Female National Pipe Thread
MNPT. . . . . . . . . . Male National Pipe Thread
N/A. . . . . . . . . . . . Not Applicable
NEC . . . . . . . . . . . National Electrical Code
NOM . . . . . . . . . . Nominal
P&ID . . . . . . . . . . Process and Instrumentation Diagram
SCFM. . . . . . . . . . Standard Cubic Feet per Minute
SCMM . . . . . . . . . Standard Cubic Meters per Minute
VSA . . . . . . . . . . . Vacuum Swing Adsorption
W . . . . . . . . . . . . . Wide
W/ . . . . . . . . . . . . With
1-6 350124D
DOCS 200
M.E.2 200-55
CHAPTER 2
PREPARATION FOR USE
2.1 SCOPE
This chapter has the procedures to prepare the unit for use. These procedures have instructions for:
 Site and location requirements
 Access panel information
 Installation configuration
2.2 SITE REQUIREMENTS
 The area must not have smoking, open flames or other ignition sources within 50 feet of the unit.
 The area must be free of trash and debris that can cause a fire hazard, a trip hazard or accumulate
on the cooling vents and filters.
 The area, including any tarps, tents or enclosures must not reduce the air circulation around the unit,
or trap oxygen or nitrogen being vented.
 The area must be protected with free access limited to authorized personnel only.
 The area must have sufficient space around the equipment to provide access for operation and
maintenance tasks (refer to Appendix A).
 The equipment must be located away from motor pools, fuel farms, diesel generators and other
similar hydrocarbon and exhaust emitting areas to prevent ingestion of fumes.
 The unit must be operated on a relatively level surface, not on a slope or incline.
 The unit must be operated in an area free of standing water and not in areas that might be prone to
flooding.
 The unit must be protected from blowing dust, dirt, sand, rain, sleet and snow.
 The unit must be shaded from direct sunlight.
 The unit should be placed in an area where equipment noise is not objectionable.
 The site must have an electrical source of power 380/460 Vac, 3-phase, 50/60 Hz @ 42/35 Amps.
 The site must have ventilation equivalent to 2000 cfm of fresh air turn over.
2.3 EQUIPMENT LOCATION
Put the DOCS no more than 15 ft. (5 m) from the system requiring oxygen supply. The unit can be placed
outside in an area closest to the expected highest demand requirement.
2.4 EQUIPMENT INSTALLATION
1. Remove the wooden shipping crate, or other packing materials, as applicable.

2. Check indicators, tubing and operator panel for damage.
2.4.1 ACCESS PANELS AND DOOR (DOCS)
The access panels and door are used for maintenance access and should be closed during operation.
Figure 2-1. and Table 2-1. on page 2-2 show and list the access panels and door.
350124D 2-1
DOCS 200
M.E.2 200-55
Figure 2-1. Access Panels
Table 2-1. Access Panels
ITEM DESCRIPTION COMPONENTS ACCESSED
Primary Heat Exchanger Fan Motor (MTR-2), Primary Heat

1 Blower Top Access Panel Exchanger Fan (FX-100) and Product Intake Heat Exchanger
(HX-100)
2 Blower Rear Access Panel Blower Motor (MTR-1), Blower (BL-100) and Filter (F-3)
3 Distribution Box Access Panel Booster Compressor (C-1) and Filters (F-1 & F-4)
4 Electrical Enclosure Door All the electronic devices used to control the unit
2-2 350124D
DOCS 200
M.E.2 200-55
2.4.2 INSTALLATION CONFIGURATION
Figure 2-2. shows the typical module configuration for the maximum oxygen delivery.
NOTE
The Blower Module can be rotated in a half circle around the

Interconnect Plumbing. Refer to Appendix A.
VSA MODULE
BLOWER
MODULE
INTERCONNECT
PLUMBING
Figure 2-2. Typical Module Configuration
2.4.3 INTERCONNECT PLUMBING CONNECTION
The unit mounted on a single skid has the interconnect plumbing installed. The unit mounted on two
separate skids requires connecting the interconnect plumbing before operation.
REQUIRED CONSUMMABLE
O2 Lubricant {Krytox grease} (W46040-205)
Contaminants and moisture can damage the sieve material in the

VSA bed. Make sure you maintain a clean environment while
connecting the interconnect plumbing.
1. Orient the VSA and blower modules next to each other as shown in the diagram in Appendix A.
2. Unlatch and remove the blower rear cover.
3. Remove the interconnect plumbing from the blower module and install and latch the blower rear cover.
4. On the hose assembly, remove the caps.
350124D 2-3
DOCS 200
M.E.2 200-55
5. On the blower discharge elbow, loosely connect the hose (with nipples installed) with the clamp and
gasket wet with Krytox grease (see Figure 2-3.).
BLOWER
DISCHARGE
ELBOW
CLAMP
HOSE
ASSY
CLAMP
ELBOW
CLAMP
PIPE
CLAMP
ELBOW
VSA INLET PIPE
CLAMP
Figure 2-3. Unit Interconnect Plumbing
6. On both elbows and the pipe, remove the caps.

7. On the bottom hose nipple, loosely connect the elbow with the clamp and gasket wet with Krytox
grease.
8. Loosely connect the pipe onto the elbow with a clamp and gasket wet with Krytox grease.
9. Loosely connect the pipe to the VSA inlet pipe with a clamp and gasket wet with Krytox grease.
10. Make sure the hose run is not binding and hangs free of constraint.
11. Tighten all the clamps.
2.4.4 INTERCONNECT WIRING HOOKUP
The unit on a single skid has the interconnect wiring connected. The separate skid mounted unit requires the
hookup of the interconnect wiring from the blower module to the electrical enclosure.
1. On the blower module, cut the cable ties and shipping restraints securing the two cables (wires)
(see Figure 2-4. on page 2-5).
2. Route the cables around to the left side of the electrical enclosure, unlatch and open the enclosure
3. On the left side bottom of the enclosure, route the large gauge cable (MTR-1 cable) through the 1 inch
conduit connector into the enclosure.
4. Inside the enclosure, remove two screws and the VFD front cover (see Figure 2-6. on page 2-6).
a. Retain the screws and cover for installation.
2-4 350124D
DOCS 200
M.E.2 200-55
MTR-1 CABLE TO VFD
MTR-2 CABLE TO M1
Figure 2-4. Blower Module Cables
1/2 INCH
1 INCH CONDUIT
CONDUIT CONNECTOR
CONNECTOR
Figure 2-5. Electrical Enclosure Interconnect Wiring Ports
5. Route the cable wires through the grommet in the bottom of the VFD enclosure.
6. Use the wire labels and connect the cable wires onto the terminals (T1 - T3).
7. Connect the ground wire onto the ground terminal.
8. Install the front cover on VFD-1 with the screws.
9. Tighten the 1 inch conduit connector on the cable.
10. Route the small wire cable (MTR-2 cable) through the 1/2 inch conduit connector in the bottom of the
electrical enclosure.
350124D 2-5
DOCS 200
M.E.2 200-55
GROUND
TERMINAL
TERMINALS
T1 - T3
VFD
1 INCH CONDUIT CONNECTOR
1/2 INCH CONDUIT CONNECTOR
TERMINALS T1 - T3
Figure 2-6. Electrical Enclosure (inside bottom) Interconnect Wiring
11. Inside the enclosure, route the cable up to the motor controller (M-1).
12. Use the wire labels and connect the cable wires onto terminals T1 - T 3.
13. Connect the ground wire to any ground or back panel grounded screw.
14. Tighten the 1/2 inch conduit connector on the cable.
15. Close and latch the electrical enclosure door.
2-6 350124D
DOCS 200
M.E.2 200-55
2.5 ELECTRICAL POWER HOOKUP
High voltage creates high current causing serious injury and

death. Remove the facility power (turn off) before connecting
power cables to the site source and the unit.
1. Remove power from the site electrical source (turn facility power OFF).
a. Lock-out/tag-out the site electrical power to the unit.
2. Route a three conductor + ground conductor cable from the site electrical source to the unit.
a. Refer to the NEC or local codes for conductor and cable sizes.
3. Unlatch and open the electrical enclosure door.
4. On top of the electrical enclosure, route the power cable through the conduit elbow (see Figure 2-7.).
ROUTE POWER
CABLE THROUGH
THIS CONDUIT
ELBOW
Figure 2-7. Unit Power Cable Routing
5. Inside the electrical enclosure, remove about 6 in. (15 cm) of cable insulation (leave strand insulation).
6. Strip the wire ends and connect the conductors into the top of circuit breaker (CB-1) and the ground
conductor into the ground lug (see Figure 2-8. on page 2-8).
7. Tighten the conduit elbow on the cable.
9. Route the power cable around the electrical enclosure, down and in-between the enclosure and the
buffer tank, and out the front.
10. On the site power source, remove the lock-out/tag-out.
350124D 2-7
DOCS 200
M.E.2 200-55
POWER WIRES
GROUND LUG
Figure 2-8. Input Power Circuit Breaker (CB-1) Power Cable Connections
2-8 350124D
DOCS 200
M.E.2 200-55
CHAPTER 3
OPERATION
3.1 CONTROLS AND INDICATORS
Figure 3-1. and Table 3-1. show and list the controls required to operate the unit.
2 10
3 11
4 12
5 13
START FAULT O2 PUR
PREV NEXT
STOP OVR CAL OVR
6 14
7 15
8 16
CONTROL LOW LOW PURITY
RUN FAULT
POWER PURITY PRESSURE OVERRIDE
17
DESIGNED AND MANUFACTURED BY

PACIFIC CONSOLIDATED INDUSTRIES
RIVERSIDE, CALIFORNIA, USA
18
Figure 3-1. Operator Panel
350124D 3-1
DOCS 200
M.E.2 200-55
Table 3-1. Operator Panel Components

1 LCD Display Display; two rows for data indication and entry
2 – Button; decreases LCD brightness
3 + Button; increase LCD brightness
4 FAULT OVR Button; overrides any fault condition not requiring shutdown
5 START/STOP Button; starts/stops product production
6 FAULT Indicator; red illumination during a fault condition
7 RUN Indicator; green illumination during product production
8 CONTROL POWER Indicator; green illumination when power is applied (CB-1 is ON)
Connector for connecting the unit to the internet. A laptop can access the unit’s
9 Ethernet Connector
internet address and be used to monitor the unit
10 O2 CAL Button; enables O2 calibration sequence for oxygen analyzer (AE-1)
11 PUR OVR Button; overrides the low purity product vent, sends product to discharge port
12 PREV Button; shows the previous screen (LCD)
13 NEXT Button; shows the next screen (LCD)
14 LOW PURITY Indicator; red illumination when product purity is less than 90%
Indicator; red illumination when product pressure is less than 2 psig below target
15 LOW PRESSURE
pressure
16 PURITY OVERRIDE Indicator; red illumination during purity override condition
17 Spare
18 EMERGENCY STOP Button; Emergency Stop push button
3.2 PRE-OPERATION
The current produced by a high voltage source can cause serious

injury or death. Make sure source power is OFF before working on
the unit.
1. Check indicators, push buttons and touch-screen for damage.

2. Check the EMERGENCY STOP push button for movement and operation.
a. Pull (or twist) the push button and reset the switch (disable).
3. On the blower module, unlatch and remove the rear access panel.
4. On the VSA module, unlatch the open the electrical enclosure door and the booster/filter enclosure
panel.
5. Check tubes and tube connectors for tightness and leaks.
6. Check hoses for visible signs of wear, secure attachment and leaks.
7. Check hose connectors for tightness and leaks.
3-2 350124D
DOCS 200
M.E.2 200-55
8. Check hardware for tightness.
NOTE
Check hardware for obvious looseness, missing, bent or broken

conditions. Look for chipped paint, bare metal or rust around bolt
heads. Tighten as necessary.
9. Check wiring harnesses and connectors for secure attachment and wear.
10. In the blower module, check lubricant level in both sight glasses on Blower (BL-100), fill as necessary
(see Figure 3-2.).
NOTE
The lubricant level must not be less than 1/8 inch below 1/2 of the
sight glass height. Fill with Lubricant Oil (582923-001).
FILL PORTS
CORRECT OIL LEVEL
Figure 3-2. Blower (BL-100)
11. On the blower module, install and latch the rear access panel.
Contaminants can cause become highly combustible when

combined with high purity oxygen. Make sure your oxygen
connection plumbing is oxygen clean.
12. On the bottom front of the distribution box frame, remove the cap from the discharge port and make
sure the port is clean (see Figure 3-3. on page 3-4).
a. Clean the port as necessary (refer to Section 5.6 on page 5-3).
350124D 3-3
DOCS 200
M.E.2 200-55
DISCHARGE PORT
CALIBRATION
CONNECTION PORT
(CC-1)
Figure 3-3. DOCS 200
13. Connect your external plumbing for use with the unit:
a. Remove the cap from your hose and make sure the connector is clean.
b. Connect your hose to the discharge port.
c. Install a bleed or relief valve and a flow control valve in the plumbing in-line with the oxygen hose.
3-4 350124D
DOCS 200
M.E.2 200-55
3.2.1 CALIBRATION GAS BOTTLE INSTALLATION (OPTIONAL)
The calibration gas bottle gives the operator a ready calibration source for calibrating the on-board oxygen
sensor. With the cal gas bottle installed (and charged), the unit can be set up to run calibration automatically
(adjustable interval) or on command (refer to Section 3.8 on page 3-13).
Cal Gas Bottle Requirements:
 Known purity (90 - 95%)
 Installed regulator set to 25 - 35 psig
 Oxygen clean hose.
1. Install the cal gas bottle:
a. On the front of the distribution box, remove the cap from the calibration connection port (CC-1) and
make sure the port is clean.
(1) Clean the port as necessary (refer to Section 5.6 on page 5-3).
b. Remove the cap from an oxygen clean hose and connect it onto the port (CC-1).
c. On the cal gas bottle, remove the cap from the bottle port and check it for contamination.
(1) Clean as necessary (refer to Section 5.6 on page 5-3).
d. On the oxygen clean hose, remove the cap and connect it onto the bottle port.
e. Slowly open the bottle valve.
2. On the unit, enter the cal gas bottle oxygen purity value:
NOTE
The unit has been factory set for a cal gas bottle purity of 93.5%.
a. Use a laptop or PC to access the unit.

(1) Refer to Section 3.4.2 on page 3-10.
b. On the laptop or PC, access the DASHBOARD page.
c. At the top of the page, select LCD DISPLAY.
d. On the bottom menu, select DIAG.
e. Select:
 SETUP
 AE1
 Reference Purity
f. Record the cal gas bottle purity (from label) and enter that value (90 - 95%).
g. Select:
 ENTER
 DONE
 BACK
 NORM
350124D 3-5
DOCS 200
M.E.2 200-55
3.3 OPERATION
The basic unit (M.E.2 200-55) discharges low pressure (10-100 psig) oxygen.
1. On the site power source, apply power to the unit.
2. On the operator panel, pull-out or twist the Emergency Stop button (see Figure 3-4.).
CIRCUIT BREAKER (CB-1)
E-STOP BUTTON
Figure 3-4. Unit (front view)
3. On the electrical enclosure, set circuit breaker (CB-1) to ON.

4. On the operator panel LCD, wait for the software initialization messages to finish.
After initialization is complete, the Normal screen shows (see Figure 3-5.).
PURITY 93.5
PRESSURE 55.0
Figure 3-5. Normal Screen
5. When the Normal screen shows, press the START/STOP button.
NOTE
As the system runs, the LOW PURITY and LOW PRESSURE

indicators are illuminated (red). Solenoid valve (SV-3) vents the
off-spec oxygen to atmosphere. When the purity is above 90%,
solenoid valve (SV-3) stops venting, LOW PURITY indicator
extinguishes and the PRESSURE indication on the LCD
increases.
3-6 350124D
DOCS 200
M.E.2 200-55
6. On the NORMAL screen, look at PRESSURE to monitor the pressure at the discharge port.
NOTE
The unit is shipped with a pressure output at 55 psig. To change

the output pressure (refer to Section 3.3.1).
3.3.1 OUTPUT PRESSURE ADJUSTMENT
Before or during operation, the output pressure can be adjusted 10 - 100 psig. Use these instructions and
set the output pressure for your requirement.
1. After unit initialization is complete, on the operator panel; press and hold the + and – buttons for
ten seconds.
The operator panel LCD display changes to the SETUP screen (see Figure 3-6.).
NOTE
During operation the system continues to run. The operator panel

buttons now have different functions. To cancel these new
functions (at any time), press and hold the + and – buttons for ten
seconds.
SETUP : NEXT
- : CANCEL
Figure 3-6. Setup Screen
2. Press the NEXT button and access the Pressure screen (see Figure 3-7.).
a. Or, press the – button to cancel and return to the Normal screen.
PRESSURE : 55.0
NEXT : IP CONFIG
Figure 3-7. Pressure Screen
3. Change the pressure setting (one press = one psig):

The pressure change is immediate, but it is not saved.
a. Press the + button to increase the pressure to 100 psig maximum.
b. Press the – button to decrease the pressure to 10 psig minimum.
350124D 3-7
DOCS 200
M.E.2 200-55
IF THEN
a. Press and hold the + and – buttons for ten seconds and show
You do not want to save the changes
the Normal screen.
a. Press the NEXT button.
The TCPIP CONFIG screen shows (see Figure 3-8.).
b. Press the NEXT button.
You want to save this pressure and The DIRECT IO screen shows (see Figure 3-9.).
return to the Normal screen c. Press the NEXT button.
The SETTINGS EXIT screen shows (see Figure 3-10.).
d. Press the + button.
The new setting is saved and the Normal screen shows.
TCPIP CONFIG
NEXT : SKIP + : ENTER
Figure 3-8. TCPIP CONFIG Screen
DIRECT IO STOPS DOCS

Figure 3-9. DIRECT IO Screen
+ : EXIT WITH SAVE

- : EXIT NO SAVE
Figure 3-10. SETTINGS EXIT Screen
3-8 350124D
DOCS 200
M.E.2 200-55
3.4 MONITOR THE SYSTEM
There are two ways to monitor the system during operation.

• Use the on-board LCD display (refer to Section 3.4.1)
• Connect the unit to the internet and use a PC or laptop to access the unit’s IP address
(refer to Section 3.4.2 on page 3-10)
3.4.1 LCD SCREENS
The various screens showing on the LCD are sequentially accessed by pressing the NEXT and PREV
buttons. Press NEXT to go through the list until it stops changing, then press PREV to go back through the
list until it stops changing. The figures in this section show the various screens in their sequential order.
1. To Navigate through the screens:
IF THEN
Normal screen is showing Use NEXT to see the next screen
Normal or Fault screens are not showing NEXT shows the next screen; PREV shows the previous screen
Fault screen is showing Use PREV to see the previous screen
NOTE
The O2 Cal screen changes as the calibration function continues.

The (START) O2 CAL screen shows the progress of the
calibration sequence, the (STATUS) screen shows the number of
calibration successes and failures.
NORMAL PURITY 93.5 O2 CAL O2 CAL PREP 75

PRESSURE 55.0 (START) PURITY 90.2
REMOTE REMRUN : INACTIVE O2 CAL CAL SUCCESS : 10

REMHOLD : INACTIVE (STATUS) CAL FAIL : 0
SENSORS XT-1 : 14.9 XT-2 : 14.9 TCP\IP IP : 192.168.001.100

XT-3 : 95.0
VFD VSA 44.0 NORMAL PHASE PHASE REVERSED!

SCR 30.0 NORMAL TURN OFF AND REVERSE
CYCLE CYCLE : PRESSURE 24 FAULT FAULT! PRESS FAULT

HOURS : 20 OVERRIDE TO CONTINUE
Figure 3-11. Operator Panel Screens
350124D 3-9
DOCS 200
M.E.2 200-55
3.4.2 REMOTE UNIT DIAGNOSTICS AND CONTROL
The remote diagnostics and control requires the use of a PC or laptop with MS Internet Explorer™ version 6
or higher. No additional software is required. Microsoft Office™ is recommended for data logging.
The unit is factory configured to be connected to a TCP/IP network supporting DHCP address assignments
the way a laptop does.
1. Connect a CAT5 network cable into the unit ethernet connector under the operator panel.
The DHCP network assigns an address to the unit.
2. There are two ways to access the unit:
IF THEN
a. On the unit operator panel, use the PREV and NEXT buttons
Using the assigned IP address and navigate to the TCP/IP screen.
b. Use the IP: address shown on the screen.
Using the DOCS URL address a. On the laptop or PC, enter http://DOCS200.
NOTE
If a DHCP network is not available, the unit can be configured to

run with a static IP address or a crossover cable. Contact PCI for
details (refer to Foreword).
3.4.2.1 DIAGNOSTIC MODES
There are three remote diagnostic modes:

 DASHBOARD
 LCD DISPLAY
 LOGGING
DASHBOARD
The page is green when the unit is operating to specifications. If it is yellow or red attention may be required.
LCD DISPLAY
This page is an in-depth version of the operator panel. This mode is used to configure and troubleshoot the
unit.
LOGGING
This page supports detailed parameter logging in a real time text file created on the laptop or PC desktop
using MS Excel ™ spreadsheets.
a. The URL or IP address must be set up as a trusted site.
b. The trusted site security is set to low.
c. https: verification must be un-selected (see Internet Explorer™ Tools - Internet Options, Security).
3-10 350124D
DOCS 200
M.E.2 200-55
3.4.2.2 DISCHARGE PRESSURE ADJUSTMENT (LAPTOP)
Use these instructions to change the unit discharge pressure 10 - 100 psig.
1. Connect the unit and a laptop or PC to the internet (refer to Section 3.4.2 on page 3-10).
2. Access the DASHBOARD page.
3. At the top of the page, select LCD DISPLAY.
4. On the bottom menu, select DIAG.
5. Select:
 SETUP
 SCROLL
 PRUN
6. Enter the desired discharge pressure (10 - 100 psig).
7. Select:
 ENTER
 DONE
 BACK
 NORM
3.5 OPERATION IN UNUSUAL AND HARSH ENVIRONMENTS
This is a listing of additional tasks required when operating the unit in unusual or harsh environments.
1. Cold Climates (≤ 32°F (0°C))
a. Periodically check the left and right grill panels for blockage.
b. Remove snow or ice buildup from the grills.
NOTE
If the blower compartment internal temperature drops below 60°F

(16°C), the grill panel can be partially blocked to maintain the
temperature above 60°F (16°C). Remove the blockage when the
temperature rises above 80°F (27°C).
2. Hot Climates (> 100°F (38°C)

a. Remove the unit from the direct sun.
b. Do not enclose the unit, provide ventilation to minimize the effect of nitrogen asphyxiation.
3. Sandy or Dusty Environments
This unit is not designed to operate in this type of environment.
a. Put the unit inside a well ventilated protected enclosure.
4. Rainy or Humid Climates
a. Keep the unit out of standing water.
b. On the blower module, put an open tent type hood over the top grill panel.
c. Periodically check the interior for standing water; remove if found.
350124D 3-11
DOCS 200
M.E.2 200-55
5. Salt Water Environments

a. Periodically wash the exterior of the unit with clean water.
b. Remove salt or mineral buildup.
3.6 SYSTEM SHUT-DOWN
1. On the operator panel, press the START/STOP button.

The unit stops running and the system pressure vents through the solenoid (SV-3).
NOTE
The vent (SV-3) does not release the pressure to the product
discharge port.
2. On the electrical enclosure access door, set circuit breaker (CB-1) to OFF.
3. Vent the low pressure oxygen hose.
a. If you disconnect the hose, install clean caps on the hose and port
3.7 EMERGENCY SHUT-DOWN
1. Press the Emergency Stop button (see Figure 3-12.).

The unit stops.
2. Clear the cause of the emergency stop.
3. Check personnel for injury and the unit for damage.
4. Pull-out or twist the Emergency Stop button.
CIRCUIT BREAKER (CB-1)
E-STOP BUTTON
Figure 3-12. E-Stop Button and Circuit Breaker (CB-1)
3-12 350124D
DOCS 200
M.E.2 200-55
3.8 OXYGEN SENSOR
Use these instructions and set up the calibration for the oxygen sensor. The sensor can be manually
calibrated or set to auto-calibrate after a specified period of time.
CAUTION
A charged calibration gas bottle must be connected to the unit

calibration port (CC-1) before the unit can be calibrated
(refer to Section 3.2.1 on page 3-5).
3.8.1 MANUAL CALIBRATION
1. Apply power to the unit.

2. On the operator panel, press the START/STOP button.
3. Run the unit for about 30 minutes to allow the system to stabilize (warm-up).
4. On the operator panel, press the O2 CAL button.
The unit does the calibration and shows Figures 3-13 - 3-17 as it completes the task:
O2 CAL PREP 75
PURITY 90.2
Figure 3-13. O2 Cal Prep Screen
O2 CAL SAMPLING 30
PURITY 90.3
Figure 3-14. O2 Cal Sampling Screen
O2 CAL CHECKING 10
PURITY 93.5
Figure 3-15. O2 Cal Checking Screen
O2 CAL OK
PURITY 93.5 +/- 1.5%
Figure 3-16. O2 Cal Screen
350124D 3-13
DOCS 200
M.E.2 200-55
CAL SUCCESS : 10
CAL FAIL : 0
Figure 3-17. Cal Status Screen
NOTE
The Cal Status screen shows the number of successful calibration

attempts and the number of failed attempts. If the calibration fails,
three attempts are made before you have to start again.
3.8.2 AUTOMATIC CALIBRATION
The unit does the calibration routine with no operator assistance or initialization. The period of time between
calibration routines is set up by the operator and can be changed or disabled with the use of a laptop or PC.
Auto Calibration Setup:
1. Connect the unit and a laptop or PC to the internet (refer to Section 3.4.2 on page 3-10).
2. Access the DASHBOARD page.
3. At the top of the page, select LCD DISPLAY.
4. On the bottom menu, select DIAG.
5. Select:
 SETUP
 AE1
 AUTO CAL
6. Enter the desired interval value in hours (integers only)
 24 = 1 day (recommended)
 0 = no calibration
7. Select:
 ENTER
 DONE
 BACK
 NORM
3.9 FAULTS
When the unit detects a fault, production stops and the FAULT screen shows (see Figure 3-11. on page 3-
9). Use these instructions when a FAULT screen shows.
1. On the operator panel, press the FAULT OVR button.
2. Use the PREV and NEXT buttons and navigate to the SENSOR and VSA screens to aid in
troubleshooting.
3. Use the instructions in Chapter 4 to test sub-assembly functions.
3-14 350124D
DOCS 200
M.E.2 200-55
3.10 UNIT IP ADDRESS CONFIGURATION
Use these instructions and change the unit’s IP address.

1. On the operator panel, press and hold (at same time) the + and – buttons for ten seconds.
The Setup Entry screen shows (see Figure 3-18.).
NOTE
The unit continues to run (if operating), but the operator panel
buttons now have different functions. Setting variations take
immediate effect on operation but will not be saved until you save
them before exiting this process. To exit this process, at any time
press and hold the + and – buttons for ten seconds (no save).
SETUP : NEXT
- : CANCEL
Figure 3-18. Setup Entry Screen
2. Press the NEXT button and show the Output Pressure screen (see Figure 3-19.).
a. Or, press the – button and return to the Normal screen.
PRESSURE : 55.0
NEXT : IP CONFIG
Figure 3-19. Output Pressure Screen
3. Press the NEXT button and show the IP Configure Enter screen (see Figure 3-20.).
TCPIP CONFIG
Figure 3-20. IP Configure Enter Screen
IF THEN
a. Press the NEXT button and show the Direct IO Entry screen
You are not changing the IP address (see Figure 3-26. on page 3-18).
b. Go-to Step 10. on page 3-18.
a. Press the + button and show the DHCP setting screen
You are changing the IP address (see Figure 3-21. on page 3-16).
b. Continue
350124D 3-15
DOCS 200
M.E.2 200-55
DHCP IS ENABLED DHCP TO BE DISABLED
SCREEN A SCREEN B
Figure 3-21. DHCP Setting Screens
4. If you want a new automatically generated IP address, show Screen A.

a. Press the + button to change the screen from B to A.
5. If you want to create your own custom address, show Screen B.
a. Press the – button to change the screen from A to B.
6. Press the NEXT button and show the Address Edit screen Figure 3-22.
The top line of each screen in Figure 3-22. shows which set of three numbers are active for editing. Use
the PREV and NEXT buttons to move to each set of three numbers. The IP Address in the bottom line
is the default IP address. The buttons on the operator panel have been assigned the functions listed in
Table 3-2. while in this portion of the process. Use these buttons to modify the active number if you are
assigning a new IP address.
Table 3-2. IP Addressing Button Assignments
BUTTON START/STOP FAULT OVR + – O2 CAL PUR OVR

FUNCTION Add 100 Add 10 Add 1 Sub 1 Sub 10 Sub 100
PREV
ADD: 192 . XXX . XXX . XXX
192 . 168 . 001 . 100
ADD: XXX . 168 . XXX . XXX

192 . 168 . 001 . 100
ADD: XXX . XXX . 001 . XXX

192 . 168 . 001 . 100
ADD: XXX . XXX . XXX . 100

192 . 168 . 001 . 100 NEXT
Figure 3-22. Address Edit Screens
IF THEN
a. Use the buttons listed in Table 3-2. and enter the custom
You are entering a custom address
address.
You are using the automatic IP address
a. Press NEXT until the last number is active.
function
3-16 350124D
DOCS 200
M.E.2 200-55
7. Press the NEXT button and show the Mask Edit screen.
The top line of each screen in Figure 3-23. shows which set of three numbers are active for editing. Use
the PREV and NEXT buttons to move to each set of three numbers. The MASK Address in the bottom
line is the default MASK address. The buttons on the operator panel have been assigned the functions
listed in Table 3-2. on page 3-16 while in this portion of the process. Use these buttons to modify the
active number if you are assigning a new MASK address.
PREV
MASK: 255 . XXX . XXX . XXX
255 . 255 . 255 . 001
MASK: XXX . 255 . XXX . XXX

255 . 255 . 255 . 001
MASK: XXX . XXX . 255 . XXX

255 . 255 . 255 . 001
MASK: XXX . XXX . XXX . 001

255 . 255 . 255 . 001 NEXT
Figure 3-23. Mask Edit Screens
IF THEN
a. Get the correct MASK address from your network
You are entering a custom MASK administrator.
address b. Use the buttons listed in Table 3-2. on page 3-16 and enter
the address.
You are using the default MASK address a. Press NEXT until the last number is active.
8. Press the NEXT button and show the Gateway Edit screen.
The top line of each screen in Figure 3-24. on page 3-18 shows which set of three numbers are active
for editing. Use the PREV and NEXT buttons to move to each set of three numbers. The Gateway
Address in the bottom line is the default Gateway address. The buttons on the operator panel have
been assigned the functions listed in Table 3-2. on page 3-16 while in this portion of the process. Use
these buttons to modify the active number if you are assigning a new Gateway address.
IF THEN
a. Get the correct Gateway address from your network
You are entering a custom Gateway administrator.
address b. Use the buttons listed in Table 3-2. on page 3-16 and enter
the address.
You are using the default Gateway
a. Press NEXT until the last number is active.
address
350124D 3-17
DOCS 200
M.E.2 200-55
PREV
GATE: 192 . XXX . XXX . XXX
192 . 168 . 001 . 001
GATE: XXX . 168 . XXX . XXX

192 . 168 . 001 . 001
GATE: XXX . XXX . 001 . XXX

192 . 168 . 001 . 001
GATE: XXX . XXX . XXX . 001

192 . 168 . 001 . 001 NEXT
Figure 3-24. Gateway Edit Screens
9. Press the NEXT button and show the IP Exit screen (see Figure 3-25.).
+ : CONTINUE & SAVE

NEXT : NO SAVE
Figure 3-25. IP Exit Screen
IF THEN
You do not want to save a new IP a. Press the NEXT button and show the Direct IO screen
address (see Figure 3-26.).
a. Press the + button and show the Direct IO Entry screen
You want to save the new IP address
(see Figure 3-26.).

Figure 3-26. Direct IO Entry Screen
10. Press the NEXT button and show the Settings Exit screen (see Figure 3-27.).
NOTE
If you press ENTER, the unit stops production and a manual type
mode is accessed. This mode is for testing and troubleshooting
(refer to Chapter 4).
+ : EXIT WITH SAVE

- : EXIT NO SAVE
Figure 3-27. Settings Exit Screen
3-18 350124D
DOCS 200
M.E.2 200-55
IF THEN
You want to save the changes a. Press the + button and the Normal screen shows.
You do not want to save the changes a. Press the – button and the Normal screen shows.
You changed the IP address a. Go-to Step 11.
11. Re-start the controller:

a. Press the E-Stop button.
b. Wait ten seconds.
c. Rotate or pull-out the E-Stop button.
NOTE
If the controller seems to have lost its IP address; after operation,

re-start the controller. Do Step 11.
350124D 3-19/(3-20 blank)

DOCS 200
M.E.2 200-55
CHAPTER 4
MANUAL OPERATION
4.1 SCOPE
This chapter has procedures for using the operator panel setup functions to manually operate and monitor
the sub-assemblies individually.
The operator panel can be set up to:
 Change:
 Output Pressure Section 3.3.1 on page 3-7
 IP Address Section 3.10 on page 3-15
 Monitor:
 Phase Reversal Relay Input
 VSA VFD Fault Input
 Scroll (Booster) VFD Fault Input
 Pressure Switch 1 (reserved)
 Pressure Switch 2 (reserved)
 Accessory Input (reserved)
 Set:
 VSA Blower (BL-100) [vacuum/pressure]
 Booster (C-1) [on/off]
 Main Cooler (FX-100) [on/off]
 Purge Solenoid Valve (SV-1) [on/off]
 Sample/Calibration Solenoid Valve (SV-2) [on/off]
 Off-Spec Solenoid Valve (SV-3) [on/off]
 Solenoid (SV-4) [on/off] {spare}
 Horn [on/off] {if equipped}
 RIX (HP Compressor) Fan [on/off] {if equipped}
 RIX1 (HP Compressor) Motor 1 [on/off] {if equipped}
 RIX2 (HP Compressor) Motor 2 [on/off] {if equipped}
 Alarm Relay (RLY-3) [on/off]
 Running Relay (RLY-4) [on/off]
4.2 OPERATOR PANEL SETUP
The operator panel can be set up to use for a manual mode type of process to read I/O inputs and command
sub-assembly outputs. The process is a sequential operation using the LCD display and the operator panel
buttons to access and command. You have to skip past the output pressure and IP address screens and
functions as follows:
1. Set up the operator panel:
a. On the operator panel, press and hold (at same time) the + and – buttons for ten seconds.
The Setup Entry screen shows (see Figure 4-1. on page 4-2).
350124D 4-1
DOCS 200
M.E.2 200-55
SETUP : NEXT
- : CANCEL
Figure 4-1. Setup Entry Screen
NOTE
To exit this process at any time, press and hold the + and –
buttons for ten seconds (no save).
2. Press the NEXT button and show the Output Pressure screen (see Figure 4-2.).
a. Or, press the – button and return to the Normal screen.
PRESSURE : 55.0
NEXT : IP CONFIG
Figure 4-2. Output Pressure Screen
3. Press the NEXT button and show the IP Configure Enter screen (see Figure 4-3.).
TCPIP CONFIG
Figure 4-3. IP Configure Enter Screen
4. Press the NEXT button and show the Direct IO Entry screen (see Figure 4-4.).
4.3 MANUAL OPERATION
The procedures in this section use a manual mode type of operation. The connectors and pin call-outs in
these sections are on the controller board (operator panel board). The following process is a sequential step
through the screens (and functions) process; while on any screen, the NEXT button stops the current screen
function and shows the next screen, the PREV button stops the current function and shows the previous
screen.
From the Normal screen to get to the screen shown in Figure 4-4.:
 Do Section 4.2 on page 4-1

Figure 4-4. Direct IO Entry screen
4-2 350124D
DOCS 200
M.E.2 200-55
The unit stops operation when the + button is pressed with the
Direct IO Entry screen showing.
IF THEN
a. Press the NEXT button and show the Settings Exit screen
You do not want to use manual
commands
b. Go-to Section 4.3.15 on page 4-13.
a. Press the + button and show the Direct IO Input screen
You want to use manual commands (see Figure 4-5.).
b. Go-to Section 4.3.1.
4.3.1 MONITOR SUB-ASSEMBLY INPUTS
From the Normal screen to get to Figure 4-5.:

 With Figure 4-4. on page 4-2 showing, press the + button
PHA : C VSA : C SCR : C

PS1 : O PS2 : O ACC : O
Figure 4-5. Direct IO Fault Input Screen
The fields in this screen are read-only and listed in Table 4-1.
PHA : C shows connector J6 pin 7 is connected to J6 pin 8 or some other ground.
PHA : O shows connector J6 pin 7 is disconnected or held high by something.
Table 4-1. Direct IO Fault Input Fields
FIELD COMPONENT CONNECTOR SIGNAL PIN COMMON PIN
PHA Phase Reverse Relay J6 7 8

VSA VSA VFD-1 Fault Input J1 4 6,7,8 or 9
SCR Booster VFD-2 Fault Input J2 4 6,7,8 or 9
PS1 Pressure Switch 1 (reserved) J3 4 6,7,8 or 9
PS2 Pressure Switch 2 (reserved) J4 4 6,7,8 or 9
ACC Accessory Input (reserved) J11 5 1 & 2 Ground
1. Press the NEXT button and show VSA Blower Forward screen (see Figure 4-6. on page 4-4).
4.3.2 VSA BLOWER (BL-100)
From the Normal screen to get to Figure 4-6. on page 4-4:

 With Figure 4-5. showing, press the NEXT button
350124D 4-3
DOCS 200
M.E.2 200-55
IF THEN
a. Press the NEXT button and show the VSA Blower Reverse
You do not want to run the blower
screen (see Figure 4-7.).
forward (vacuum)
b. Go-to Step 2.
You want to run the blower forward
a. Go-to Step 1.
(vacuum)
VFD FWD OFF

+ : ON - : OFF
Figure 4-6. VSA Blower Forward Screen
1. Run the VSA blower (BL-100) forward (vacuum):

a. Press the + button and the top line on the screen shows VFD FWD ON.
The blower rotates in the vacuum direction at 10 Hz.
(1) Use a digital multimeter set to 200 Vdc range and measure about 23 Vdc between controller
board connector J1 pin 1 (+) and pins 6, 7, 8 & 9 (-).
b. Press the – button and the top line on the screen shows VFD FWD OFF.
The blower stops rotating.
c. Press the NEXT button and show the VSA Blower Reverse screen (see Figure 4-7.).
2. Run the VSA blower (BL-100) reverse (pressure):
IF THEN
a. Press the NEXT button and show the Scroll Forward screen
You do not want to run the blower in the
(booster) (see Figure 4-8. on page 4-5).
reverse direction (pressure)
You want to run the blower in the reverse
Continue
direction (pressure)
VFD REV OFF

+ : ON - : OFF
Figure 4-7. VSA Blower Reverse Screen
a. Press the + button and the top line on the screen shows VFD REV ON.
The blower rotates in the pressure direction at 10 Hz.
4-4 350124D
DOCS 200
M.E.2 200-55
b. Press the – button and the top line on the screen shows VFD REV OFF.
The blower stops rotating.
c. Press the NEXT button and show the Scroll Forward screen (see Figure 4-8.).
4.3.3 SCROLL (BOOSTER (C-1))

 When each of Figures 4-5 - 4-7 show, press the NEXT button
IF THEN
a. Press the NEXT button and show the Main Cooler screen
You do not want to run the booster (see Figure 4-9. on page 4-6).
You want to run the booster Continue
SCR FWD OFF

+ : ON - : OFF
Figure 4-8. Scroll Forward Screen
1. Press the + button and the top line on the screen shows SCR FWD ON.
The booster rotates at 10 Hz.
a. Use a digital multimeter set to 200 Vdc range and measure about 23 Vdc between controller board
connector J2 pin 1 (+) and pins 6, 7, 8 & 9 (-).
NOTE
The scroll fan should rotate counter-clockwise as viewed from the

scroll shaft end.
2. Press the – button and the top line on the screen shows SCR FWD OFF.
The booster stops rotating.
3. Press the NEXT button and show the Main Cooler screen (see Figure 4-9. on page 4-6).
4.3.4 MAIN COOLER (FX-100)

 When each of Figures 4-5 - 4-8 show, press the NEXT button.
350124D 4-5
DOCS 200
M.E.2 200-55
IF THEN
a. Press the Next button and show the Purge Solenoid screen
You do not want to run the main blower (see Figure 4-10.).
You want to run the main blower Continue
MAIN COOLER OFF

+ : ON - : OFF
Figure 4-9. Main Cooler Screen
1. Press the + button and the top line on the screen shows MAIN COOLER ON.
The cooler rotates.
connector J6 pin 10 (+) and pin 9 (-).
NOTE
The fan pushes air into the blower housing when rotating in the
correct direction.
2. Press the – button and the top line on the screen shows MAIN COOLER OFF.
The cooler stops rotating.
3. Press the NEXT button and show the Purge Solenoid screen (see Figure 4-10.).
4.3.5 PURGE SOLENOID (SV-1)

IF THEN
a. Press the NEXT button and show the O2 Sample Solenoid
You do not want to energize the purge
screen (see Figure 4-11. on page 4-7).
solenoid
You want to energize the purge solenoid Continue
PURGE OFF
+ : ON - : OFF
Figure 4-10. Purge Solenoid Screen
4-6 350124D
DOCS 200
M.E.2 200-55
1. Press the + button and the top line on the screen shows PURGE ON.
Solenoid valve (SV-1) energizes.
NOTE
When solenoid (SV-1) energizes there is an audible sound of

actuation.
2. Press the – button and the top line on the screen shows PURGE OFF.
Solenoid valve (SV-1) de-energizes.
3. Press the NEXT button and show the O2 Sample Solenoid screen (see Figure 4-11.).
4.3.6 O2 SAMPLE SOLENOID (SV-2)

IF THEN
a. Press the NEXT button and show the Off-Spec Solenoid
You do not want to energize the O2
screen (see Figure 4-12. on page 4-8).
sample solenoid
You want to energize the O2 sample
Continue
solenoid
O2 SAMP OFF
+ : ON - : OFF
Figure 4-11. O2 Sample Solenoid Screen
1. Press the + button and the top line on the screen shows O2 SAMP ON.
NOTE

actuation.
350124D 4-7
DOCS 200
M.E.2 200-55
2. Press the – button and the top line on the screen shows O2 SAMP OFF.
3. Press the NEXT button and show the Off-Spec Solenoid screen (see Figure 4-12.).
4.3.7 OFF-SPEC SOLENOID (SV-3)

IF THEN
a. Press the NEXT button and show the Solenoid (SV-4) screen
You do not want to energize the off- spec
solenoid
You want to energize the off-spec
Continue
solenoid
OFF SPEC OFF

+ : ON - : OFF
Figure 4-12. Off-Spec Solenoid Screen
1. Press the + button and the top line on the screen shows OFF SPEC ON.
NOTE

actuation.
2. Press the – button and the top line on the screen shows OFF SPEC OFF.
3. Press the NEXT button and show the Solenoid (SV-4) screen (see Figure 4-13. on page 4-9).
4-8 350124D
DOCS 200
M.E.2 200-55
4.3.8 SOLENOID (SV-4)
This output is reserved for expansion solenoid control as an option.

IF THEN
a. Press the NEXT button and show the Horn Sink screen
You do not want to energize solenoid
(SV-4)
You want to energize solenoid (SV-4) Continue
PRODUCT OFF
+ : ON - : OFF
Figure 4-13. Solenoid (SV-4) Screen
1. Press the + button and the top line on the screen shows SV4 ON.
2. Press the – button and the top line on the screen shows SV4 OFF.
3. Press the NEXT button and show the Horn Sink screen (see Figure 4-14. on page 4-10).
4.3.9 HORN SINK
This output is reserved for an optional horn for alarm recognition.

IF THEN
a. Press the NEXT button and show the RIX Fan screen (see
You do not want to energize the horn Figure 4-15. on page 4-10).
You want to energize the horn Continue
350124D 4-9
DOCS 200
M.E.2 200-55
HORN OFF
+ : ON - : OFF
Figure 4-14. Horn Sink Screen
1. Press the + button and the top line on the screen shows HORN ON.
The Horn sounds.
2. Press the – button and the top line on the screen shows HORN OFF.
The Horn silences.
3. Press the NEXT button and show the RIX Fan screen (see Figure 4-15.).
4.3.10 RIX (HP COMPRESSOR) FAN
This output is reserved for the cooling fans on optional high pressure compressors.
IF THEN
a. Press the NEXT button and show the RIX1 screen (see
You do not want to run the RIX fan Figure 4-16. on page 4-11).
You want to run the RIX fan Continue
RIX FAN OFF

+ : ON - : OFF
Figure 4-15. RIX Fan Screen
1. Press the + button and the top line on the screen shows RIX FAN ON.
The fans run.
connector J3 pin 5 (+) and pins 6, 7, 8 & 9 (-) and connector J4 pin 5 (+) and pins 6, 7, 8 & 9 (-).
2. Press the – button and the top line on the screen shows RIX FAN OFF.
The fans stop.
connector J3 pin 5 (+) and pins 6, 7, 8 & 9 (-) and connector J4 pin 5 (+) and pins 6, 7, 8 & 9 (-).
3. Press the NEXT button and show the RIX1 screen (see Figure 4-16. on page 4-11).
4-10 350124D
DOCS 200
M.E.2 200-55
4.3.11 RIX1 (HP COMPRESSOR 1)
This output is reserved for an optional high pressure compressor.

IF THEN
a. Press the NEXT button and show the RIX2 screen
You do not want to run the RIX1 high
pressure compressor
You want to run the RIX1 high pressure
Continue
compressor
RIX1 OFF
+ : ON - : OFF
Figure 4-16. RIX1 Screen
1. Press the + button and the top line on the screen shows RIX1 ON.
The high pressure compressor runs.
2. Press the – button and the top line on the screen shows RIX1 OFF.
The high pressure compressor stops.
3. Press the NEXT button and show the RIX2 screen (see Figure 4-17. on page 4-12).
4.3.12 RIX2 (HP COMPRESSOR 2)
This output is reserved for a second optional high pressure compressor.

IF THEN
a. Press the NEXT button and show the Alarm Relay screen
You do not want to run the RIX2 high
pressure compressor
You want to run the RIX2 high pressure
Continue
compressor
350124D 4-11
DOCS 200
M.E.2 200-55
RIX2 OFF
+ : ON - : OFF
Figure 4-17. RIX2 Screen
1. Press the + button and the top line on the screen shows RIX2 ON.
The second high pressure compressor runs.
2. Press the – button and the top line on the screen shows RIX2 OFF.
The second high pressure compressor stops.
3. Press the NEXT button and show the Alarm Relay screen (see Figure 4-18.).
4.3.13 ALARM RELAY (RLY-3)

IF THEN
a. Press the NEXT button and show the Running Relay screen
You do not want to energize the alarm
relay
You want to energize the alarm relay Continue
ALARM RELAY OFF

+ : ON - : OFF
Figure 4-18. Alarm Relay Screen
1. Press the + button and the top line on the screen shows ALARM RELAY ON.
The alarm relay energizes.
a. On the controller board, disconnect cable (797297-001) from connector J23.
b. Use a digital multimeter set to 200 Ohm range and measure about 0 Ohms between controller
board connector J23 pin 1 (+) and pin 2 (-).
2. Press the – button and the top line on the screen shows ALARM RELAY OFF.
The alarm relay de-energizes.
a. Use a digital multimeter set to 200 Ohm range and measure an open between controller board
b. On the controller board, connect cable (797297-001) into connector J23.
4-12 350124D
DOCS 200
M.E.2 200-55
3. Press the NEXT button and show the Running Relay screen (see Figure 4-19.).
4.3.14 RUNNING RELAY (RLY-4)

IF THEN
a. Press the NEXT button and show the Settings Exit screen
You do not want to energize the running
(see Figure 4-20.).
relay
You want to energize the running relay Continue
RUNNING RELAY OFF

+ : ON - : OFF
Figure 4-19. Running Relay Screen
1. Press the + button and the top line on the screen shows RUNNING RELAY ON.
The running relay energizes.
a. On the controller board, disconnect cable (797297-001) from connector J23.
b. Use a digital multimeter set to 200 Ohm range and measure about 0 Ohms between controller
board connector J23 pin 5 (+) and pin 4 (-).
2. Press the – button and the top line on the screen shows RUNNING RELAY OFF.
The running relay de-energizes.
a. Use a digital multimeter set to 200 Ohm range and measure an open between controller board
b. On the controller board, connect cable (797297-001) into connector J23.
3. Press the NEXT button and show the Settings Exit screen (see Figure 4-20.).
4.3.15 SAVE AND EXIT
There is nothing to save unless you changed the output pressure or the IP address while you were using
these procedures. When you were on a particular screen turning ON/OFF functions and pressed NEXT or
PREV to leave that function, the software automatically turned the function off.
+ : EXIT WITH SAVE

- : EXIT NO SAVE
Figure 4-20. Settings Exit Screen
350124D 4-13
DOCS 200
M.E.2 200-55
IF THEN
You made changes to the output
a. Press the + button, save the changes and show the Normal
pressure or the IP address and want to
save these changes
You used the manual operation and
a. Press the – button, save nothing and show the Normal
made no changes to the output pressure
or IP address you want to save
PURITY 93.5
PRESSURE 55.0
4-14 350124D
DOCS 200
M.E.2 200-55
CHAPTER 5
MAINTENANCE
5.1 MAINTENANCE SCHEDULE
Table 5-1. Maintenance Schedule
COMPONENT INTERVAL (HOURS) ACTION
Product Blower (BL-100) Lubricant 2000 Replace

Initial 500 Check Torque
VSA Bed Lid Screws
2000 Torque
Product Particulate Filter (F-1) 2000 Check / Replace
Air Supply Filter (F-3) 2000 Check / Replace
Inlet Filter (F-4) 2000 Check / Replace
Blower (BL-100) Coupling Screws † 2000 Check Torque
Booster (C-1) Coupling Screws 2000 Check Torque
Blower (BL-100) Coupling ‡ 1000 / 4000 Grease / Pack Bearings
Product Blower Motor (MTR-1) Bearings 4000 Grease
Booster Compressor (C-1) Tip Seals 8000* Replace
Booster Compressor (C-1) Bearings 10,000 Grease
* based upon typical operating conditions: 70°F @ 55 psig (21°C @ 3.8 bar)
† Coupling (585594-004) only (Blower Module (797067-001/-002) Post Revision F)
‡ Coupling (583832-008) only (Blower Module (797067-001/-002) Pre Revision F)
5.2 LIST OF CONSUMABLES
Table 5-2. List of Consumables Kit (797409-002)
DESCRIPTION PART NO. QTY USAGE
Filter Element 585104-001 4 Air Supply Filter (F-3)

Filter Element 792253-002 1 Inlet Filter (F-4)
Filter Element 583504 4 Product Particulate Filter (F-1)
Grease Cartridge 582172-006 1 Booster Compressor (C-1) Bearings
Grease, Multipurpose 581556-001 14.1 oz. Product Blower Motor (MTR-1) Coupling & Bearings
Lubricant Oil, Synthetic 582923-001 1 qt. Product Blower (BL-100)
Seal Kit 797521-001 1 Booster Compressor (C-1)
350124D 5-1
DOCS 200
M.E.2 200-55
Table 5-3. List of Other Consumables
Cover Gasket ‡ 583832-006 2 Product Blower Motor (MTR-1) Coupling Cover Gaskets
Cover Seal ‡ 583832-007 2 Product Blower Motor (MTR-1) Coupling Cover End Seals
Grid and Cover Assy ‡ 583832-003 1 Product Blower Motor (MTR-1) Coupling Cover and Grid
O2 Grease (Krytox) W46040-205 5 oz. tube O-rings and Pipe Gaskets
Thread Seal Tap W14420-050 2 rolls Pipe Threads
‡ Coupling (583832-008) only (Blower Module (797067-001/-002) Pre Revision F)
5.3 TOOLS
Table 5-4. Necessary Tools Kit (797409-001)
Brush 585674-001 1 General cleaning

Gloves, Powder Free 585675-001 box/100 Handling oxygen clean components
Grease Fitting S40300-101 5 Replacement fittings for damaged fittings
Grease Fitting, 90 degree G40300-016 5 Replacement fittings for damaged fittings
Grease Gun 584229-001 1 Multipurpose Grease (581556-001)
Hex Socket Set, Inch 581950-011 1 Standard hardware
Hex Socket Set, Metric 581950-012 1 Metric hardware
Leak Check Solution 581567-003 1 gal. Finding air and gas leaks
Towels, Lint Free 585673-001 box/500 General cleaning
Torque Wrench 582075-006 1 Coupling hardware
Table 5-5. Specialty Tools Kit (797409-009)
Grease Gun w/extension 582172-005 1 Grease Cartridge (582172-006)
5.4 SPARE COMPONENTS
The spares kits for the DOCS 200 are listed in Appendix C.
5-2 350124D
DOCS 200
M.E.2 200-55
5.5 TORQUE SPECIFICATIONS
Table 5-6. Torque Specifications
ASSEMBLY COMPONENT TORQUE
Blower (BL-100) Coupling (both) Coupling Hub Setscrews 24 ft-lb (32.5 N-m)
Blower (BL-100) Coupling (583832-008) Coupling Cover Bolts and Nuts 100 in-lbs (11.3 Nm)
Blower (BL-100) Coupling (585594-004) Coupling Screws 17 ft-lb (23 N-m)
Initial - 17 in-lb (1.9 N-m)
Fixed Scroll Screws and Nuts
Booster Compressor (C-1) Final - 175in-lb (19.8 N-m)
Hub Setscrews 7 ft-lbs (9.5 Nm)
VSA Bed (C-300) Bed Lid Bolts and Nuts 20 (+0/-2) ft-lb (27 (+0/-2.7) N-m)
5.6 OXYGEN CLEAN
These instructions are for oxygen cleaning components before installation.
REQUIRED EQUIPMENT
Suitable Solvent (Isopropyl Alcohol or Acetone ≥ 96%)

Nitrogen Gas (≥ 95%)
Tube and Fitting Caps (clean)
1. Put the component in a clean enclosed environment with good ventilation.
The solvents (Isopropyl Alcohol & Acetone) may irritate the eyes,
nose and skin. Make sure you wear Personal Protective
Equipment (PPE) and remain in a well ventilated area while
handling these solvents.
2. Rinse the component interior with copious amounts of suitable solvent.

3. Dry the tube or connector interior with nitrogen gas.
a. Make sure all wetted surfaces are dry and solvent vapors are removed.
4. Cap each component end or port with a clean cap.
5.7 MAINTENANCE TOOLS
The tools used to maintain oxygen clean parts/components must be cleaned before use and stored separate
from other use tools. Use these tools for oxygen equipment only and keep them in a clean container. Clean
them with the same reagents used for cleaning tubes and connectors.
350124D 5-3
DOCS 200
M.E.2 200-55
5.8 MAINTENANCE
Use these procedures and maintain your unit for optimum performance.
Before doing maintenance on components in this unit, check the

P&ID drawing and determine if the component is in the oxygen
flow. Oxygen flow components require an oxygen clean
environment during maintenance, oxygen clean tools and oxygen
clean replacement parts. Failure to obey can result in fire or
explosion during operation.
5.8.1 PRE-MAINTENANCE
1. Vent the system.
IF THEN
a. On the operator control panel, press the START/STOP push
The system is running
button.
The system is OFF a. On the electrical enclosure, set circuit breaker (CB-1) to ON.
The system is ON; not running a. Continue
2. On the NORMAL screen, make sure PRESSURE shows 0 (see Figure 5-1.).
a. Vent as necessary.
PURITY 93.5
PRESSURE 55.0
3. On the distribution box, remove the screws and the access panel.
a. Retain the panel and hardware for installation
4. Make sure pressure transducer (XT-1) shows 0 psig (see Figure 5-2. on page 5-5).
a. Vent as necessary.
IF THEN
You are not doing maintenance in the a. Install the distribution box access panel with the screws.
distribution box b. Continue
You are doing maintenance in the
Continue
distribution box
5. On the electrical enclosure, set circuit breaker (CB-1) to OFF.

6. On the site power source, remove power from the unit.
a. Lock-out/tag-out the site power source.
5-4 350124D
DOCS 200
M.E.2 200-55
XT-1
F-1
F-4
XT-3
Figure 5-2. Distribution Box
5.8.2 FILTER (F-1)
2. On the filter, twist and remove the bowl (see Figure 5-2.).
3. Remove and discard the element.
4. Install a new element (refer to Table 5-2. on page 5-1).
5. Install the filter bowl.
6. Install the access panel with the screws.
5.8.3 FILTER (F-4)
2. On the filter; push-up, twist and remove the bowl (see Figure 5-2.).
3. Remove and discard the element.
4. Install a new element (refer to Table 5-2. on page 5-1).
5. Install the filter bowl.
6. Install the access panel with the screws.
350124D 5-5
DOCS 200
M.E.2 200-55
5.8.4 FILTER (F-3)
2. On the filter (F-3), unlatch the filter clamp.
3. Loosen the hose clamp and remove the filter (see Figure 5-3.).
4. Keep the hose clamp and discard the filter.
5. Install a new filter (refer to Table 5-2. on page 5-1) through the filter clamp and secure it with the hose
clamp.
6. Latch the filter clamp.
7. Install and latch the rear access panel.
FILTER (F-3)
FILTER CLAMP
HOSE CLAMP
SILENCER (S-100)
Figure 5-3. Blower Module Filter (F-3)
5-6 350124D
DOCS 200
M.E.2 200-55
5.8.5 PRODUCT BLOWER (BL-100) LUBRICANT
Wait until the blower is cooled before changing lubricant oil. Hot
lubricant oil can cause serious burns.
1. On the compressor module, unlatch and remove the rear panel.

2. On top of the blower, remove the fill port plugs (see Figure 5-4.).
FILL PLUGS
SIGHT GLASSES
DRAIN PORTS
CORRECT LEVEL
Figure 5-4. Product Blower (BL-100)
3. Put a collection container under the drain port and remove the drain plug.
4. When the lubricant is completely drained, install the drain plug.
5. Repeat Steps 3. - 4. and drain the other side.
6. Fill the reservoir with fluid (refer to Table 5-2. on page 5-1) until the fluid level fills 1/2 (max.) of the sight
glass.
7. Repeat Step 6. and fill the other reservoir.
8. Check both drain plugs for leaks.
9. Install both fill port plugs.
350124D 5-7
DOCS 200
M.E.2 200-55
5.8.6 PRODUCT BLOWER MOTOR (MTR-1) BEARINGS
1. On the compressor module, unlatch and remove the rear access panel.
2. On each end of the motor, open the grease fitting cap, use a grease gun (refer to Table 5-4. on page 5-
2) and inject three or four pumps of grease (refer to Table 5-2. on page 5-1) into each fitting
(see Figure 5-5.).
3. Remove any excess grease and close the fitting caps.
GREASE FITTING
Figure 5-5. Product Blower Motor (MTR-1)
5.8.7 BLOWER (BL-100) COUPLING
IF THEN
a. The coupling must be greased every 1000 hours of
operation, this greasing is critical for the life of the coupling.
You have Blower Module 797067-001/-002 1. Go-to Section 5.8.7.1.
Pre Revision F b. Every 4000 hours of operation the coupling housing must be
removed and the grid-to-teeth surfaces packed with grease.
1. Go-to Section 5.8.7.2 on page 5-9.
a. The coupling screws must be torqued every 2000 hours of
You have Blower Module 797067-001/-002
operation.
Post Revision F
1. Go-to Section 5.8.7.3 on page 5-11
5.8.7.1 1000 HOUR COUPLING GREASE
This procedure has instructions for greasing the coupling installed on Blower Module 797067-001/-002 Pre
Revision F.
1. On the blower Module, unlatch and remove the rear access panel.
2. On the coupling, remove both lubrication plugs (see Figure 5-6. on page 5-9).
3. Use the grease gun (refer to Table 5-4. on page 5-2) and inject grease (refer to Table 5-2. on page 5-1)
into one plug hole until it is forced out the other hole.
5-8 350124D
DOCS 200
M.E.2 200-55
HUB
SETSCREWS
LUBRICATION PLUG
(ONE OPPOSITE)
Figure 5-6. Product Blower Motor Coupling
4. Wipe the excess grease from the coupling and install both lubrication plugs.
5. Use the torque wrench (refer to Table 5-4. on page 5-2) and check the torque on the hubs setscrews.
a. Torque each setscrew 24 ft-lb (32.5 N-m).
5.8.7.2 4000 HOUR COUPLING GREASE PACK
This procedure has instructions for grease packing the coupling installed on Blower Module 797067-001/
-002 Pre Revision F.
1. On the blower Module, unlatch and remove the rear access panel.
2. Use a clean dry cotton cloth and wipe clean the coupling and shafts.
3. Remove the four cap screws, nuts and carefully separate the housing halves
4. Check the gaskets on the housing halves:
a. If damaged, remove the gasket material.
(1) Clean the housing surface.
(2) Get a new gasket (refer to Table 5-3. on page 5-2).
5. Check the seals at each end of the coupling.
a. If damaged, they must be replaced (refer to Table 5-3.).
(1) On the coupling, remove the grease from the grid.
(2) Use a screwdriver, start with the cut end of the grid and carefully pry the grid from the teeth
on the two hubs.
(3) Alternate sides and pry each grid loop from the hub.
350124D 5-9
DOCS 200
M.E.2 200-55
GRID
SEAL
HUB
HOUSING
HOUSING END
MARK
Figure 5-7. Coupling
(4) Remove the grid from the hubs.

(a) If the grid is damaged, the coupling must be replaced.
1 Use these instructions, discard all old parts and install new.
(5) On the motor, remove the bolts, washers and nuts securing the motor.
(6) Carefully move the motor away from the blower until a hub can be removed.
(7) On each hub:
(a) Loosen the setscrew, slide the hub off the shaft, remove and discard the seal.
(b) Lightly coat the new seal with grease (refer to Table 5-3.).
(c) Install the new greased seal on the hub and slid the hub onto the shaft.
(d) Push the seal toward the back of the hub to the shaft.
(8) Carefully move the motor back toward the blower and loosely install the bolts, washers and
nuts.
(9) Use a feeler gauge and set the gap between the hubs (motor and blower) to 0.125 in
(3.175 mm) and tighten the setscrews in each hub.
(10) Do the angular alignment:
(a) Use a feeler gauge and check the gap between the hubs at 90° intervals around the
circumference of the hub.
(b) Use shims under the motor mounts and adjust the motor position as necessary to get
gap measurements around the circumference to vary less than or equal to 0.005 in
(0.127 mm).
(c) Make sure the overall gap between hubs is 0.125 in (3.175 mm).
(11) Do the parallel alignment:
(a) Use a straight edge and lay it across the teeth on both hubs at 90° intervals around the
circumference of the hubs.
(b) Use shims under the motor mounts and adjust the motor position as necessary until the
straight edge lays flat on the teeth of both hubs around the circumference.
(12) Repeat Steps (10) - (11) until the conditions of both alignments are completed.
(13) Tighten the motor hardware.
5-10 350124D
DOCS 200
M.E.2 200-55
(14) Pack the teeth on both hubs with grease (refer to Table 5-2. on page 5-1).
(15) Start at one end of the grid and fit it over the teeth of both hubs.
(16) Work the coils of the grid between the teeth and seat with a soft mallet.
(a) If the coils overlap, make sure the cut ends extend in the same direction.
6. Pack the grid with grease (refer to Table 5-2.).
a. Make sure the grease fills every gap and surface.
7. Lightly coat the housing gaskets with grease (refer to Table 5-2.).
8. Put a housing half around the under side of the coupling and put the seals in the housing groove.
9. Put the greased gaskets on the housing half.
10. Install the other housing half on the coupling.
a. Align the end marks in the housing halves.
b. Install the cap bolts and nuts.
c. Torque the bolts 100 in-lbs (11.3 Nm).
11. On the coupling, remove both lubrication plugs.
12. Use the grease gun (refer to Table 5-4. on page 5-2) and inject grease (refer to Table 5-2.) into one
plug hole until it is forced out the other hole.
13. Install both lubrication plugs.
14. Use the torque wrench (refer to Table 5-4.) and check the torque on the hubs setscrews.
15. Wipe excess grease from the coupling and area.
5.8.7.3 BLOWER (BL-100) COUPLING SCREWS
2. Use the torque wrench (refer to Table 5-4. on page 5-2) and check the torque on each coupling screw
IF THEN
a. Torque the screw 17 ft-lb (23 N-m).
The torque is not 17 ft-lb (23 N-m)
b. Check the torque on the next screw.
The torque is 17 ft-lb (23 N-m) a. Check the next screw.
a. Repeat Step 2. until all eight (8) screws have been checked.
3. Use the torque wrench and check the torque on the hubs setscrews.
4. Inspect the elastomer element:
a. Look for fatigue cracks over 1/2 inch long originating near the stress relief grooves about 1/4 - 1/2
inch above the metal shoe (see Figure 5-9. on page 5-12).
b. Look for discoloration (a darker faded orange) showing possible material degradation.
c. If either condition (Steps a. - b.) shows, replace the elastomer element (585594-004).
350124D 5-11
DOCS 200
M.E.2 200-55
CHECK SCREW TORQUE
CHECK SCREW TORQUE
Figure 5-8. Blower (BL-100) Coupling Screws
LOOK HERE
Figure 5-9. Coupling Element Inspection
5.8.7.4 BLOWER (BL-100) COUPLING ALIGNMENT
If the blower (BL-100) or the blower motor (MTR-1) have been moved or either replaced, use these
instructions to align the coupling before it is completely assembled.
1. Hub Installation (if necessary):
a. With the blower (BL-100) secured on its frame, install one hub on the blower shaft.
(1) Align the hub flush with the end of the shaft and secure.
b. Loosely install the hub on the motor shaft.
c. Move the motor until the motor hub is close to the blower hub (about 1/2 inch (13 mm) apart).
d. Install half of the coupling onto the two hubs with the four cap screws to get the correct spacing
5-12 350124D
DOCS 200
M.E.2 200-55
LOCKING ADJUSTMENT
SCREW
Figure 5-10. Coupling Hub Spacing
2. Remove the cap screws and the coupling half.

3. Use a laser alignment tool and align the coupling (see Figure 5-11.).
a. Use the locking adjustment screws in the motor base to adjust parallel offset and angular
displacement.
b. Use shims under the motor to adjust parallel offset and angular displacement.
c. Tighten the motor hardware and repeat Step 3. until no adjustment is required.
PARALLEL OFFSET
ANGULAR DISPLACEMENT
Figure 5-11. Blower Coupling Alignment
NOTE
The maximum allowable angular displacement is 4°. The

maximum allowable parallel offset is 1/16 inch.
350124D 5-13
DOCS 200
M.E.2 200-55
4. Install half of the coupling onto the hubs with four cap screws.
a. Adjust the hub separation as necessary.
(1) Use the torque wrench (refer to Table 5-4. on page 5-2) and torque the hubs setscrews
24 ft-lb (32.5 N-m).
5. Install the other half of the coupling on the hubs with four cap screws.
6. Torque each cap screw 17 ft-lb (23 N-m).
5.8.8 VSA BED LID BOLTS
The bolts securing the VSA Bed lid must be torqued every 2000 hours of operation. Their torque must be
checked after the initial 500 hours of operation.
1. Use the torque wrench (refer to Table 5-4. on page 5-2) and torque the nuts on the bolts in the VSA Bed
lid 20 (+0/-2) ft-lb (27 (+0/-2.7) N-m).
a. Use the pattern shown in Figure 5-12. on page 5-14 for the nut torque sequence.
2
7
6
3
8 1
Figure 5-12. VSA Bed Lid Torque Sequence
5-14 350124D
DOCS 200
M.E.2 200-55
5.8.9 BOOSTER COMPRESSOR (C-1) COUPLING SETSCREWS
Use these instructions to check and set the torque on the coupling hub setscrews.
a. Retain the screws and access panel for installation.
2. On the booster compressor assembly, remove the nuts, flat washers and the coupling guard
(see Figure 5-13.).
GUARD
SETSCREW
Figure 5-13. Booster Coupling Motor Hub
3. Use the torque wrench (refer to Table 5-4. on page 5-2) and make sure the torque on the motor hub
setscrew is 7 ft-lbs (9.5 Nm).
a. Set as necessary.
4. Remove the screws and move the fan cover to access the compressor hub setscrew
5. Use the torque wrench (refer to Table 5-4. on page 5-2) and make sure the torque on the compressor
hub setscrew is 7 ft-lbs (9.5 Nm).
a. Set as necessary.
6. Install the fan cover with the screws.
7. Install the coupling guard with the flat washers and nuts.
8. On the distribution box, install the access panel with the screws.
350124D 5-15
DOCS 200
M.E.2 200-55
FAN COVER HUB SETSCREW THROUGH HOLE IN SPACER
Figure 5-14. Booster Coupling Compressor Hub
5.8.10 BOOSTER COMPRESSOR (C-1) COUPLING ALIGNMENT
Use these instructions to align the motor to the compressor for optimum coupling performance and service
life. The alignment must be done when either the motor or the compressor are removed (separated), or a
hub is removed and installed due to replacement (hub, motor or compressor). The compressor position is
set and the motor is adjusted to align to the compressor.
1. Align the hubs on the shafts as follows:
a. Compressor:
(1) Remove the screws and the fan cover (see Figure 5-15. on page 5-17).
(2) Align the hub face as flush with the end of the shaft as possible (a small displacement from
flush is allowable).
(3) Torque the setscrew 7 ft-lbs (9.5 Nm).
(4) Install the fan cover with the screws.
b. Motor:
(1) Align the hub face flush with the end of the shaft and snug the setscrew
2. Put the coupling sleeve in the compressor hub and move the motor with hub to capture the sleeve in the
motor hub (see Figure 5-17. on page 5-18).
3. Set the spacing between the two hubs to 1.938 inch (49.2 mm).
a. Move the motor (move the hub on the motor shaft if necessary).
4. Torque the setscrew in the motor hub 7 ft-lbs (9.5 Nm).
5. Set the parallel offset:
a. Put a straight edge across the two hubs and measure the offset at 4 equal distant points around the
unrotated hub.
5-16 350124D
DOCS 200
M.E.2 200-55
SMALL SPACE AT SHAFT END TORQUE SETSCREW THROUGH HOLE IN SPACER
Figure 5-15. Booster Compressor Hub Alignment
HUB FLUSH WITH SHAFT END
Figure 5-16. Booster Motor Hub Alignment
b. Use shims under the motor to set the maximum offset to ≤ 0.015 inch (0.38 mm).
6. Set the angular displacement:
a. Use a micrometer, caliper or vernier and measure the distance from the outside of one hub to the
outside of the other hub at four equal distant points around the unrotated hub.
b. Use shims under the motor to set the maximum angular displacement to ≤ 0.056 inch (1.4 mm).
7. Repeat Steps 5. - 6. until no adjustment is required.
350124D 5-17
DOCS 200
M.E.2 200-55
FAN COVER COUPLING SLEEVE

REMOVED FOR
CLARITY
PARALLEL OFFSET
0.015 INCH MAX
XMAX ANGULAR
DISPLACEMENT
XMIN = 1.938 INCH
XMAX = 1.994 INCH
SPACING XMIN
1.938 INCH
Figure 5-17. Booster Coupling Alignment
8. Install the coupling guard with the flat washers and nuts.
5.8.11 BOOSTER COMPRESSOR (C-1) LUBRICATION AND TIP SEAL REPLACEMENT
The lubrication of the bearings in the booster is listed as every 10,000 hours of operation. The tip seals are
to be replaced every 8000 hours of operation. It would be cost effective to lube the bearings with every tip
seal replacement.
5.8.11.1 BOOSTER COMPRESSOR (C-1) REMOVAL
a. Retain the screws and access panel for installation.
2. Disconnect and cap the inlet tube from the booster (C-1) (see Figure 5-18. on page 5-19).
3. Disconnect and cap the discharge tube.
4. On the motor (MTR-3), remove the screws and the wiring box cover.
5. Label the motor and cable wires then disconnect them from the motor.
6. Carefully pull the cable out of the motor wiring box.
7. Loosely install the wiring box cover with the screws.
5-18 350124D
DOCS 200
M.E.2 200-55
INLET TUBE
MOUNTING
DISCHARGE
PLATE
TUBE
Figure 5-18. Booster Compressor (C-1) Tubing
8. On the booster mounting plate, remove the screws, lock and flat washers.
9. Use two people and carefully lift the booster compressor (C-1) out of the box.
10. Put the booster compressor (C-1) on a stable clean work surface in a clean room environment.
5.8.11.2 BOOSTER COMPRESSOR (C-1) DISASSEMBLY
Contamination in an oxygen rich environment can cause explosive

fires. The internal surfaces of the scroll compressor are oxygen
clean and must remain oxygen clean. Make sure you use oxygen
clean tools and work in an oxygen clean environment while
servicing the booster compressor.
1. Remove the discharge tube elbow and adaptor fitting (see Figure 5-19. on page 5-20).
a. Retain the adaptor and elbow for assembly.
2. Remove the screws and the fan duct (see Figure 5-20. on page 5-20).
3. Remove the screws, nuts, washers and the fixed scroll.
350124D 5-19
DOCS 200
M.E.2 200-55
ADAPTOR
ELBOW
Figure 5-19. Booster Compressor Fittings
NUT & SCREW

WASHER
SCREWS
FAN
DUCT SCREW NUT &
WASHER
Figure 5-20. Booster Compressor (compressor end)
5.8.11.3 TIP SEAL REMOVAL
1. On the fixed scroll, use a soft pointed tool (ball point pen), remove and discard the old Low Pressure
(LP) seal (see Figure 5-21. on page 5-21).
2. Remove and discard the High Pressure (HP) seal.
3. Remove and discard the dust seal (see Figure 5-22. on page 5-21).
4. Remove and discard the backup tube.
5-20 350124D
DOCS 200
M.E.2 200-55
HP SEAL
LP SEAL
DUST SEAL
HP Seal Removal
LP Seal Removal
Figure 5-21. Fixed Scroll LP Seal Removal
Dust Seal Removal Backup Tube Removal
Figure 5-22. Fixed Scroll Dust Seal Removal
Using compressed air to clean can produce flying particles

dangerous to unprotected eyes and skin. Wear eye protection
when using compressed air and do not direct the air stream at
people.
Oil in an oxygen environment can cause explosive reactions with

intense fire. Do Not use compressed air to clean the scroll fins
unless your compressed air source is oil-less.
5. Use low pressure compressed air or a clean dry cotton cloth and clean the scroll fins
350124D 5-21
DOCS 200
M.E.2 200-55
Figure 5-23. Fixed Scroll Cleaning
6. On the orbital scroll, use a soft pointed tool (ball point pen), remove and discard the old LP seal
(see Figure 5-24.).
LP SEAL
HP SEAL
Figure 5-24. Orbital Scroll Seals
7. Remove and discard the HP seal.

8. Use low pressure compressed air or a clean dry cotton cloth and clean the scroll fins.
5.8.11.4 TIP SEAL INSTALLATION
Refer to Table 5-2. on page 5-1 for the seal kit shown in (see Figure 5-25. on page 5-23).
The tip seals are delicate and can easily tear. Use caution when
inserting tip seals to avoid tearing or distorting the seal.
1. On the orbital scroll, install the HP seal (see Figure 5-26. on page 5-23).
a. With the seal’s grooved bottom down, align the seal with the scroll groove.
5-22 350124D
DOCS 200
M.E.2 200-55
LP SEAL (ORBITAL)
HP SEAL (ORBITAL)
DUST SEAL (FIXED)
BACKUP (FIXED)
HP SEAL (FIXED)
LP SEAL (FIXED)
Figure 5-25. Booster Compressor (C-1) Seal Kit
PUT THESE
EDGES
AGAINST EACH
OTHER
Figure 5-26. Orbital Scroll HP Seal Installation
b. Put the end of the seal against the groove end.

2. Install the LP Seal (see Figure 5-27. on page 5-24).
a. Put the LP seal against the HP seal.
b. Install about half of the seal then remove and make sure a locating notch is formed in the seal.
c. Install the seal, cut and remove the excess (see Figure 5-28. on page 5-24).
3. On the fixed scroll, install the HP seal (see Figure 5-29. on page 5-24).
a. With the seal’s grooved bottom down, align the seal with the scroll groove.
b. Put the end of the seal against the groove end.
4. Install the LP Seal (see Figure 5-30. on page 5-25).
a. Put the LP seal against the HP seal.
b. Install about half of the seal then remove and make sure a locating notch is formed in the seal.
350124D 5-23
DOCS 200
M.E.2 200-55
NOTCH
LP SEAL
SCROLL
Figure 5-27. Orbital Scroll LP Seal Installation
Figure 5-28. Orbital Scroll LP Seal Termination
PUT THESE
EDGES
AGAINST EACH
OTHER
Figure 5-29. Fixed Scroll HP Seal Installation
5-24 350124D
DOCS 200
M.E.2 200-55
Figure 5-30. Fixed Scroll LP Seal Installation
c. Install the seal, cut and remove the excess.

5. Install the backup tube (see Figure 5-31.).
a. Put the tube end against the slot end.
b. Overlap the start end and cut excess.
START TUBE END

AGAINST SLOT END
OVERLAP TUBE
TERMINATION ON
TUBE START END
Figure 5-31. Fixed Scroll Backup Tube Installation
6. Install the dust seal on-top-of the backup tube (same scroll slot) (see Figure 5-32. on page 5-26).
a. Put the seal end against the slot end.
b. Overlap the start end and cut excess.
350124D 5-25
DOCS 200
M.E.2 200-55
START SEAL END

AGAINST SLOT END
OVERLAP SEAL
TERMINATIONAL ON
SEAL START END
Figure 5-32. Fixed Scroll Dust Seal Installation
5.8.11.5 BOOSTER COMPRESSOR LUBRICATION
1. On top of the compressor housing, remove the plastic dust cap (see Figure 5-33.).
GREASE GUN W/ EXTENSION
PLASTIC DUST CAP
GREASE FITTING
GAP IN COUNTER WEIGHT
FIXED SCROLL (SHOWN)
Figure 5-33. Booster Compressor Main Bearing Lubrication
2. Look into the grease port, rotate the booster shaft until the grease fitting is visible.
3. Use the grease gun (refer to Table 5-4. on page 5-2) with the cartridge of grease (refer to Table 5-2. on
page 5-1) and the extension and put four pumps of grease into the fitting.
4. Install the plastic dust cap.
5. Use the grease gun (refer to Table 5-4.) with the cartridge of grease (refer to Table 5-2.) and the
extension and put four pumps of grease into each pin bearing grease fitting (three)
6. Remove excess grease with a clean cotton cloth.
5-26 350124D
DOCS 200
M.E.2 200-55
ORBITAL SCROLL
PIN
BEARING PIN BEARING
GREASE GREASE FITTING
FITTINGS
Figure 5-34. Booster Pin Crank Bearing Lubrication
5.8.11.6 BOOSTER COMPRESSOR ASSEMBLY
1. Carefully install the fixed scroll onto the orbital scroll with the screws, washers and nuts
(see Figure 5-35.).
NOTE
Make sure all seals remain in their channels while assembling the
fixed scroll onto the orbital scroll.
a. Torque the screws and nuts 17 in-lbs (1.9 N-m) (initial tightening).
NUT & SCREW

WASHER
SCREWS
FAN
DUCT SCREW NUT &
WASHER
Figure 5-35. Booster Compressor (compressor end)
2. Rotate the compressor shaft and make sure the scroll rotates smoothly.
3. Torque the screws and nuts 175 in-lbs (19.8 N-m).
4. Install the fan duct with the screws.
5. On the discharge tube, clean the threads.
6. Wrap the discharge tube threads with thread seal tape (refer to Table 5-4. on page 5-2).
350124D 5-27
DOCS 200
M.E.2 200-55
7. On the discharge tube adaptor fitting, clean the threads and wrap them with thread seal tape.
8. Install the adaptor fitting onto the discharge tube (see Figure 5-36.).
ADAPTOR
ELBOW
Figure 5-36. Booster Compressor Fittings
9. Install the elbow onto the adaptor fitting.

a. Orient the elbow with the opening down.
5.8.11.7 BOOSTER COMPRESSOR (C-1) INSTALLATION
1. Use two people and carefully put the booster compressor assembly into the distribution box
(see Figure 5-37.).
INLET TUBE
MOUNTING
DISCHARGE
PLATE
TUBE
Figure 5-37. Booster Compressor (C-1) Installation
2. Secure the booster compressor assembly with the screws, lock and flat washers.
3. On motor (MTR-2), remove the screws and the motor wiring box cover.
5-28 350124D
DOCS 200
M.E.2 200-55
4. Route the power cable into the wire box and tighten the wire nut.
5. Use the wire labels and connect the motor wiring.
6. Install the wiring box cover with the screws.
7. Remove the plugs and connect the inlet and discharge tubes.
8. Install the distribution box access panel with the screws.
5.8.12 POST MAINTENANCE
1. Remove tools, consumables, cleaning cloths and equipment.

2. Close and latch any open door.
3. Install and latch any removed panel.
4. On the site power, remove the lock-out/tag-out.
5.9 CALIBRATION GAS BOTTLE REPLACEMENT
Use these instructions to remove and install the calibration gas bottle.
1. Make sure the unit is not doing an O2 calibration.
2. If you are installing the gas bottle for the first time, do Section 3.2.1 on page 3-5.
5.9.1 GAS BOTTLE REMOVAL
1. On the cal gas bottle, slowly close the bottle valve.

2. Slowly loosen the cal gas hose fitting venting any hose pressure.
Contaminated caps and plugs can contaminate the component

where they are used. Make sure all caps and plugs are oxygen
clean before using them.
3. Remove and cap the bottle with a clean cap.
IF THEN
a. Install a clean cap on the hose.
b. Disconnect and cap the hose from the port (CC-1).
Not installing cal gas bottle
c. On the unit, clean the port cap Section 5.6 on page 5-3.
d. Install the cap on the calibration port connection (CC-1).
Installing a new bottle Go-to Section 3.2.1 on page 3-5.
350124D 5-29
DOCS 200
M.E.2 200-55
5.10 TROUBLESHOOTING
Before any parts are replaced, the site power source must be set
to OFF and lock-out/tag-out applied.
5.10.1 ERROR CODES AND COMMON FAULTS
Table 5-7. lists the error codes and Table 5-8. on page 5-31 lists the common faults, probable causes and
possible solutions.
Table 5-7. Error Codes
ERROR CODE PROBABLE CAUSE POSSIBLE SOLUTION
a. Set Facility (source) power to OFF.

b. Lock-out/tag-out Facility power.
c. On the DOCS, unlatch and open the electrical
enclosure.
0001 Incoming power is out of phase d. On top of circuit breaker (CB-1), reverse any
two wires.
e. Close and latch the electrical enclosure.
f. Remove the lock-out/tag-out.
g. Set Facility (source) power to ON.
0002 Variable Frequency Drive (VFD-1) has faulted Refer to TECO MA7200 Drive User Manual
0004 Variable Frequency Drive (VFD-2) has faulted Refer to TECO MA7200 Drive User Manual
Motor controller (M-1) has tripped due to
a. Clear the obstruction from the fan.
obstruction in the blower module heat exchanger
0008 b. Reset motor controller (M-1).
(HX-1) fan.
Motor (MTR-3) has failed Replace motor (MTR-3)
a. Look at the sensor screen to determine which
transducer or transducers are causing the fault
Pressure Transducers (XT-1, XT-2 or XT-3) have code.
0010
failed or lost signal.
b. Check the transducer connection and cabling.
c. Replace transducer if necessary.
a. Check the sensor connection and cabling.
0020 Oxygen sensor (AE-1) has failed or lost the signal.
b. Replace the sensor as necessary.
Error Codes appear on the operator panel LCD
5-30 350124D
DOCS 200
M.E.2 200-55
Table 5-8. Common Faults
FAULT PROBABLE CAUSE POSSIBLE SOLUTION
a. Make sure site power is OFF.

Site source power disconnected b. Connect the site power to the unit.
c. Set site power to ON.
Site source power is OFF Set site power to ON
No electrical power
(operator panel blank) Circuit breaker (CB-1) is OFF Set circuit breaker (CB-1) to ON
E-Stop button is active (pushed-in) Twist or pull-out E-Stop button
Circuit breaker (CB-1) faulty Replace circuit breaker (CB-1)
RFI Filter (PF-1) faulty Replace RFI filter (PF-1)
a. On the unit control panel, touch or

press STOP.
b. Set circuit breaker (CB-1) to OFF.
c. Connect the blower motor (MTR-1)
Motor power cable is not connected
power per Section 2.4.4.
d. Set circuit breaker (CB-1) to ON
e. On the unit control panel, touch or
Blower motor (MTR-1) does not rotate press START.
Variable frequency drive (VFD-1) is Refer to the TECO MA7200 Drive User
OFF or lost program Manual
VFD-1 is faulty Replace VFD-1
Motor (MTR-1) is faulty Replace motor (MTR-1)
Blower (BL-100) is faulty Replace blower (BL-100)

press STOP.
b. Set circuit breaker (CB-1) to OFF.
Motor (MTR-3) power cable is not c. Connect the motor cable per
connected Section 2.4.4.
d. Set circuit breaker (CB-1) to ON
e. On the unit control panel, touch or
press START.
press STOP.
Heat exchanger (HX-100) fan does not b. Set circuit breaker (CB-1) to OFF.
rotate c. Unlatch and open the electrical
enclosure.
Motor controller (M-1) is set to OFF or d. Set motor controller (M-1) to ON.
has tripped e. Set the current protection to 3.0 A.
f. Close and latch the electrical
enclosure.
g. Set circuit breaker (CB-1) to ON
h. On the unit control panel, touch or
press START.
Motor Controller (M-1) faulty Replace motor controller (M-1)
Motor (MTR-3) faulty Replace motor (MTR-3)
350124D 5-31
DOCS 200
M.E.2 200-55
Table 5-8. Common Faults (Continued)
Cooling fans (distribution box, electrical Fuses (F-1A or F-1B) blown Replace blown fuses (F-1A or F-1B)
enclosure & HX-1) do not rotate Power transformer (T-1) faulty Replace transformer (T-1)
Fuse (F-2) blown Replace fuse (F-2)

Cooling fans (distribution box only)
Fan motor faulty Replace fan

Cooling fans (HX-1 only)
Cooling fans (electrical enclosure only)
5.10.2 PERFORMANCE TROUBLESHOOTING
The unit is rated for 200 Lpm @ 10 - 100 psig (7 scfm @ 0.69 - 6.9 bar) & 93 ± 3% Oxygen in standard
conditions (70°F, 14.7 psia (21°C, 1 bar) & 50% relative humidity).
The unit is designed to operate in a range of site conditions outside the standard condition. These various
conditions contribute to an obvious degradation to the rated performance.
Table 5-9. lists those conditions not contributed to ambient conditions.
Table 5-9. Performance Troubleshooting
Ambient site conditions are higher than Adjust the flow rate (customer device or
standard conditions system) or purity/off-spec setpoint
Reduce flow rate (customer device or
Overdraw on plant (flow rate too high)
system) or adjust purity/off-spec setting
Make sure correct ventilation and
Plant site does not have sufficient fresh
turnover of fresh air and exhaust hot air
air circulation, turnover and heat
from heat exchanger out of the plant
removal
space
Check all plumbing connections with
System leaks oxygen safe leak detector and correct
Low performance flow, purity or
any leaking connection
pressure
Check with oxygen safe leak detector. if
Relief valve (PSV-1) stuck or cracked exhaust port leak is found, remove
open valve and return to manufacture for
setting or replacement
Off-spec shuts off production flow if
purity drops below the setpoint. If
Off-spec feature is enabled
required, disable this feature on the
controller interface
Plugged inlet filter (F-1) (high differential Remove and inspect inlet filter (F-1),
pressure) clean or replace
5-32 350124D
DOCS 200
M.E.2 200-55
Table 5-9. Performance Troubleshooting (Continued)
Remove blower module panels and

inspect coupling assembly. Inspect
hubs for correct installation and
setscrew torque on shafts. Replace
Motor/blower (MTR-1/BL-100) coupling
complete elastomer element and
failure
screws if any indication of damage.
Check shaft alignment before
installation and apply correct torque
values.
Check recorded or indicated VFD faults
Variable Frequency Drive (VFD-1) fault and monitor parameters during
or failure operation. Refer to VFD manual and
correct as necessary
Typically indicated by reduced purity.
Check the purge time setting. Make
sure the solenoid coil is energizing
Low performance flow, purity or during the purge cycle; use a small
pressure (Cont) flathead screwdriver and check the coil
Purge solenoid valve (SV-1) does not for magnetism. Check for a 24 Vdc with
open or opens intermittently current signal on the coil during the
purge cycle. Remove the valve and
check the valve stem for free movement
during actuation. Check wiring, replace
solenoid or complete valve as
necessary.
Typically indicated by reduced purity,
longer cycle durations or a decrease in
Purge solenoid (SV-1) or check valve buffer tank pressure. Remove the valve
(CV-1) stuck open or not seating (SV or CV) and check the seat face for
correctly when closed damage, obstruction in the flow path or
seat face and the spring close actuation
is working
Excessive blower (BL-100) rotor Measure the rotor clearance and
clearance contact Kaeser
Blower shaft misalignment Align the blower and motor shafts

Blower/motor (BL-100/MTR-1) vibration,
increased power consumption or shafts Blower bearing failure Replace blower bearings
not spinning freely
Coupling damage Replace coupling
Abnormal blower (BL-100) running Incorrect gear backlash, bearing Refer to Kaeser Service Manual Section
noises clearance or rotors out of time 8.2.1
Oil in the air inlet filter (F-1) or system Blower oil level is too high Correct blower oil level
plumbing before the VSA bed (C-300) Blower sealing rings are worn Replace sealing rings
350124D 5-33/(5-34 blank)

DOCS 200
M.E.2 200-55
CHAPTER 6
SHIPMENT AND STORAGE PREPARATION
6.1 SCOPE
This chapter has instructions to prepare the unit for shipment and storage.
6.2 SHIPMENT PREPARATION
1. Do the shutdown instructions in Section 3.6 on page 3-12.

clean before using them Section 5.6 on page 5-3.
2. Disconnect and cap product discharge hose.

a. Disconnect and cap the hose.
b. Cap the unit discharge port.
3. On the unit, remove the cal gas bottle:
IF THEN
a. On the cal gas bottle, slowly close the bottle valve.
b. Disconnect and cap the bottle from the hose.
A cal gas bottle is connected to the c. Cap the hose.
calibration port connector (CC-1) d. Disconnect and cap the hose from the calibration port
connector (CC-1).
e. Install a clean cap on the connector.
Calibration port connector (CC-1) is
Continue
capped
6.2.1 ELECTRICAL POWER DISCONNECTION
1. Set the site power to OFF.

a. Lock-out/tag-out the site power.
High voltage with high amperage can cause serious injury and
death. Make sure the power to the unit is OFF.

3. On top of circuit breaker (CB-1), disconnect the three wires and the ground wire (ground lug)
4. On top of the electrical enclosure, loosen the conduit elbow nut and carefully pull the power cable out of
the elbow.
a. Tighten the conduit elbow nut.
350124D 6-1
DOCS 200
M.E.2 200-55
POWER WIRES
GROUND LUG
Figure 6-1. Input Power Circuit Breaker (CB-1)
6.2.2 INTERCONNECT WIRING DISCONNECTION
The unit on a single skid does not require interconnect wiring disconnection. The separate skid mounted unit
requires the disconnection of the blower module interconnect wiring from the electrical enclosure.
1. Inside the electrical enclosure, make sure the wires on motor controller (M-1) terminals T1 - T3 are
labeled (see Figure 6-2. on page 6-3).
2. Disconnect the wires from terminals T1 - T3 and the cable ground wire from the ground terminal.
3. On the wires cable, cut all cable ties down to the 1/2 inch conduit connector.
4. On the bottom of the electrical enclosure, loosen the 1/2 inch conduit connector nut and carefully pull
the cable out of the enclosure.
a. Tighten the conduit connector nut.
5. On the VFD, remove screws and the front cover.
a. Retain the cover and screws for installation.
6. Make sure the wires on terminals T1 - T3 are labeled.
8. Carefully pull the cable out of the VFD enclosure grommet.
9. Install the VFD cover with the screws
10. On the lower left side of the electrical enclosure, loosen the 1 inch conduit connector nut and carefully
pull the cable out of the enclosure.
a. Tighten the 1 inch conduit connector nut.
12. Coil both motor cables together and attach them to the blower discharge elbow
6-2 350124D
DOCS 200
M.E.2 200-55
GROUND
TERMINAL
TERMINALS
T1 - T3
VFD
1 INCH CONDUIT CONNECTOR
1/2 INCH CONDUIT CONNECTOR
TERMINALS T1 - T3
Figure 6-2. Electrical Enclosure (inside bottom)
MTR-1 CABLE TO VFD
MTR-2 CABLE TO M1
Figure 6-3. Blower Module Interconnect Cables
350124D 6-3
DOCS 200
M.E.2 200-55
6.2.3 INTERCONNECT PLUMBING DISCONNECTION
The unit mounted on a single skid does not require interconnect plumbing disconnection. The unit mounted
on two single skids requires the interconnect plumbing disconnection.
CAUTION

disconnecting the interconnect plumbing. Use clean caps and
plugs.
1. On the VSA bed (C-300) inlet pipe, remove the two clamps, elbow and gaskets
(see Figure 6-4.).
a. Put the gaskets in a sealable bag.
b. Cap both ends of the elbow
BLOWER
DISCHARGE
ELBOW
CLAMP
HOSE
ASSY
CLAMP
ELBOW
CLAMP
PIPE
CLAMP
ELBOW
VSA INLET PIPE
CLAMP
Figure 6-4. Unit Interconnect Plumbing
2. Cap the VSA bed inlet pipe.

3. Remove the clamp. pipe and gasket.
a. Put the gasket in the sealable bag.
b. Cap both ends of the pipe
4. Remove the clamp, elbow and gasket.
a. Put the gasket in a sealable bag.
6-4 350124D
DOCS 200
M.E.2 200-55

5. Remove the clamp, hose assembly and gasket.
b. Cap both ends of the hose assembly.
c. Cap the blower discharge elbow.
6. Unlatch and remove the blower module rear access panel.
7. Store the interconnect plumbing in the bottom of the module.
8. Install and latch the blower module rear access panel.
9. Transport the unit in an enclosed container or truck.
6.3 STORAGE PREPARATION
1. Do the shutdown instructions in Section 3.6 on page 3-12.

clean before using them Section 5.6 on page 5-3.
2. Disconnect and cap product discharge hose.

a. Disconnect and cap the hose.
b. Cap the discharge port.
3. On the unit, remove the cal gas bottle.
IF THEN
a. On the cal gas bottle, slowly close the bottle valve.
b. Disconnect and cap the bottle from the hose.
A cal gas bottle is connected to the c. Cap the hose.
calibration port connector (CC-1) d. Disconnect and cap the hose from the calibration port
connector (CC-1).
e. Install a clean cap on the connector.
Calibration port connector (CC-1) is
Continue
capped
6.3.1 ELECTRICAL POWER DISCONNECTION
1. Set the site power to OFF.

a. Lock-out/tag-out the site power.
High voltage with high amperage can cause serious injury and
death. Make sure the power to the unit is OFF.
350124D 6-5
DOCS 200
M.E.2 200-55
3. On top of circuit breaker (CB-1), disconnect the three power wires and the ground wire (ground lug)
4. On top of the electrical enclosure, loosen the conduit elbow nut and carefully pull the power cable out of
the elbow.
a. Tighten the conduit elbow nut.
6.3.2 INTERCONNECT WIRING DISCONNECTION
The unit on a single skid does not require interconnect wiring disconnection. The separate skid mounted unit
requires the disconnection of the blower module interconnect wiring from the electrical enclosure.
1. Inside the electrical enclosure, make sure the wires on motor controller (M-1) terminals T1 - T3 are
labeled (see Figure 6-2. on page 6-3).
3. On the wires cable, cut all cable ties down to the 1/2 inch conduit connector.
4. On the bottom of the electrical enclosure, loosen the 1/2 inch conduit connector nut and carefully pull
the cable out of the enclosure.
a. Tighten the conduit connector nut.
5. On the VFD, remove screws and the front cover.
a. Retain the cover and screws for installation.
6. Make sure the wires on terminals T1 - T3 are labeled.
8. Carefully pull the cable out of the VFD enclosure grommet.
9. Install the VFD cover with the screws
10. On the lower left side of the electrical enclosure, loosen the 1 inch conduit connector nut and carefully
pull the cable out of the enclosure.
a. Tighten the 1 inch conduit connector nut.
12. Coil both motor cables together and attach them to the blower discharge elbow
6.3.3 INTERCONNECT PLUMBING DISCONNECTION
The unit mounted on a single skid does not require interconnect plumbing disconnection. The unit mounted
on two single skids requires the interconnect plumbing disconnection.
CAUTION

disconnecting the interconnect plumbing. Use clean caps and
plugs.
1. On the VSA bed (C-300) inlet pipe, remove the two clamps, elbow and gaskets
a. Put the gaskets in a sealable bag.
6-6 350124D
DOCS 200
M.E.2 200-55
2. Cap the VSA bed inlet pipe.

3. Remove the clamp. pipe and gasket.
a. Put the gasket in the sealable bag.
b. Cap both ends of the pipe
4. Remove the clamp, elbow and gasket.
5. Remove the clamp, hose assembly and gasket.
b. Cap both ends of the hose assembly.
c. Cap the blower discharge elbow.
6. Unlatch and remove the blower module rear access panel.
7. Store the interconnect plumbing in the bottom of the module.
8. Do preventive maintenance (refer to Chapter 5 for procedures):
 Replace filters (F-1, F-3 & F-4)
 Replace the blower (BL-100) lubricant
 Grease the blower motor (MTR-1) bearings
9. Close and latch any open door.
10. Install and latch all access panels.
11. Single skid mounted unit with cover, only:
a. Install and latch the rear, sides, front and top panels.
6.3.4 STORAGE FACILITY
The storage facility must be:

 Covered and enclosed
 Free of standing water
 A clean cool dry place
350124D 6-7/(6-8 blank)

DOCS 200
M.E.2 200-55
APPENDIX A
Foundation
Drawing
350124D A-1/(A-2 blank)

DOCS 200
M.E.2 200-55
NOTES: UNLESS OTHERWISE SPECIFIED
15. BLOWER MODULE PROCESS AND COOLING EXHAUST

(130.40)
14. BLOWER MODULE PROCESS AND COOLING INTAKE MAXIMUM DISTANCE
13. OXYGEN CALIBRATION CONNECTION (1/4 INCH TUBE COMPRESSION FITTING, FOR POSSIBLE
30 PSIG INLET MAX), GASEOUS OXYGEN 90-94%. (66.56) CONFIGURATION
12. FOR ACCEPTABLE SITE CONDITIONS SEE SITE REQUIREMENTS. 2 (54.00)
11. PERFORMANCE SPECIFICATIONS: 93 +/- 3 % O2 @ 200 LPM 10-100 PSIG (5.25) BLOWER MODULE
(DONE AT STANDARD CONDITION OF 70°F, 14.7 PSIA) ENCLOSURE NOT SHOWN
ACCESS AREA TO EMPHASIZE FOOTPRINT
10. FORKLIFT LOCATIONS.
9. REMOVABLE PANEL LOCATIONS.
8. AIR TURNOVER REQUIREMENT: ( SEE SITE REQUIREMENTS)
- THE SITE IS CLIMATE CONTROLLED/AIR CONDITIONED TO STANDARD CONDITIONS: 150 SCFM
(4.25 SCMM)
- THE SITE IS NOT CLIMATE CONTROLLED: 2000 SCFM (56.63 SCMM)
THE AIR TURNOVER REQUIREMENT IS THE RATE OF ACTUAL AIR REPLACEMENT AT THE DOCS
200 SITE WITH THE FOLLOWING CONSIDERATIONS:
ADAPTIVE CONFIGURATIONS
- DUCTING SHALL BE SIZED WITH CONSIDERATION TO FLOW LOSS DUE TO PRESSURE DROP. (36.00)
(113.53) ANGLE OF LAYOUT NOT CRITICAL
- SITE INTAKE AND EXHAUST FANS SHALL BE SIZED WITH CONSIDERATION TO FLOW LOSS DUE
TO ELEVATION AND BACK PRESSURE. MAXIMUM DISTANCE
- SITE INTAKE AND EXHAUST FANS SHALL BE LOCATED AS TO INSURE BEST POSSIBLE AIR FLOW FOR POSSIBLE
TO AID BLOWER MODULE INTAKE AND EXHAUST. CONFIGURATION (R63.84)
7. AVERAGE POWER CONSUMPTION: 9.5 kW
6. DOCS 200 USER INTERFACE: INPUTS INCLUDE START, STOP, LCD DISPLAY, SCREEN
BRIGHTNESS, FAULT OVERRIDE, PURITY OVERRIDE, O2 CALIBRATION AND ETHERNET
CONNECTION. INDICATORS INCLUDE GENERAL FAULT, CONTROL POWER, LOW PURITY,
LOW PRESSURE, PURITY OVERRIDE.
5. TOTAL UNIT WEIGHT: 3,046 LBS (25.75)
4. FOUNDATION DETAIL COVERS DOCS 200 ASSEMBLY NUMBERS 796925-001/-002.
3. REMOVED
2. CROSS HATCH LOCATIONS SHOWN INDICATE ACCESS/MAINTENANCE CLEARANCE
AREAS.
1. POWER REQUIREMENTS:
380V/460V, 50/60Hz, 3-PHASE, 42/35 FLA. (68.00)
(56.64)
SITE REQUIREMENTS (49.69)
- THE AREA MUST NOT HAVE SMOKING, OPEN FLAMES OR OTHER IGNITION SOURCE WITHIN 50 FEET (40.00)
OF THE UNIT. (11.12)
- THE AREA MUST BE FREE OF TRASH AND DEBRIS THAT CAN CAUSE A FIRE HAZARD, A TRIP HAZARD
OR ACCUMULATE ON THE COOLING VENTS AND FILTERS.
- THE AREA, INCLUDING ANY TARPS, TENTS OR ENCLOSURES MUST NOT REDUCE THE AIR CIRCULATION
AROUND THE UNIT, OR TRAP OXYGEN OR NITROGEN BEING VENTED.
- THE AREA MUST BE PROTECTED WITH FREE ACCESS LIMITED TO AUTHORIZED PERSONNEL ONLY.
- THE AREA MUST HAVE SUFFICIENT SPACE AROUND THE EQUIPMENT TO PROVIDE ACCESS
FOR OPERATION AND MAINTENACE TASK (SEE FO-1. ON PAGE A-3 OF OWNERS MANUAL).
- THE EQUIPMENT MUST BE LOCATED AWAY FROM MOTOR POOLS, FUEL FARMS, DIESEL
GENERATORS AND OTHER SIMILAR HYDROCARBON AND EXHAUST EMITTING AREAS TO
(36.00)
PREVENT INGESTION OF FUMES. 2
USER INTERFACE
- THE UNIT MUST BE OPERATED ON A RELATIVELY LEVEL SURFACE, NOT ON A SLOPE OR INCLINE.
- THE UNIT MUST BE OPERATED IN AN AREA FREE OF STANDING WATER AND NOT IN AREA THAT
MIIGHT BE PRONE TO FLOODING. POWER INLET:
- THE UNIT MUST BE PROTECTED FROM BLOWING DUST, DIRT, SAND, RAIN, SLEET AND SNOW. 380V/460V, 50/60 Hz, 3-PHASE
- THE UNIT MUST BE SHADED FROM DIRECT SUNLIGHT. 1" 90DEG CONDUIT CONNECTOR
- THE UNIT SHOULD BE PLACED IN AN AREA WHERE EQUIPMENT NOISE IS NOT OBJECTIONABLE.
- THE SITE MUST HAVE AN ELECTRICAL SOURCE OF POWER 380/460 VAC, 3-PHASE,
(37.25) (8.68)
50/60 Hz @ 42/35 FLA.
- THE SITE MUST HAVE VENTILATION EQUIVALENT TO 2000 CFM OF FRESH AIR TURN OVER.
2 (68.00) 797202D
EQUIPMENT LOCATION ELECTRICAL ENCLOSURE
(36.00) 2
SCROLL COMPRESSOR
PUT THE DOCS NO MORE THAN 15 FT. (5 M) FROM THE SYSTEM REQUIRING OXYGEN SYPPLY. ACCESS AREA
THE UNIT CAN BE PLACED OUTSIDE IN AN AREA CLOSEST TO THE EXPECTED HIGHEST
DEMAND REQUIREMENT.
FO-1. Unit Foundation Drawing (Sheet 1 of 4)
350124D A-3/(A-4 blank)

DOCS 200
M.E.2 200-55
A
9
(66.44) 6 USER INTERFACE

(55.38)
POWER INLET
(31.00)
SUGGESTED LAYOUT PROCESS OUTLET

MAIN VIEWS SHOWN WITHOUT ACCESSORIES
ALTERNATE LAYOUTS SHOWN AS BROKEN LINES (3/8" MALE AN 37DEG FLARE TUBE FITTING)
A
CALIBRATION
PORT
(1/4" COMPRESSION FITTING)
9
IN
TA
KE
KE
TA
IN
14
14
FO-1. Unit Foundation Drawing (Sheet 2)
350124D A-5/(A-6 blank)

DOCS 200
M.E.2 200-55
(72.00)
(72.00) MOUNTING SKID
MOUNTING SKID, FORKLIFT CAPABLE
(2.00) FORKLIFT CAPABLE
(8.75)
INTAKE INTAKE
14 14
(69.43)
MOUNTING SKID
FORKLIFT CAPABLE
(72.00)
MOUNTING SKID,
EXHAUST
FORKLIFT CAPABLE
15
(3.00)
(2.00)
10 10
(23.00) (26.00)
(3.50)
ACCESSORY DETAIL ACCESSORY DETAIL

TOP VIEW FRONT VIEW
SKID, FORKLIFT CAPABLE SKID, FORKLIFT CAPABLE
350124D A-7/(A-8 blank)

DOCS 200
M.E.2 200-55
350124D A-9/(A-10 blank)

DOCS 200
M.E.2 200-55
APPENDIX B
P&ID and
Electrical
Drawings
350124D B-1/(B-2 blank)

DOCS 200
M.E.2 200-55
FO-2. Process and Instrumentation Drawing (P&ID)
350124D B-3/(B-4 blank)

DOCS 200
M.E.2 200-55
FO-3. Electrical Schematic (Sheet 1 of 3)
350124D B-5/(B-6 blank)

DOCS 200
M.E.2 200-55
FUSE REPLACEMENT CHART

COOPER BUSSMAN PART NUMBER
FUSE ID PCI PART NUMBER LITTLEFUSE PART NUMBER MFG PART NUMBER DESCRIPTION
FERRAZ SHAWMUT PART NUMBER
FO-3. Electrical Schematic (Sheet 2)
350124D B-7/(B-8 blank)

DOCS 200
M.E.2 200-55
FO-3. Electrical Schematic (Sheet 3)
350124D B-9/(B-10 blank)

DOCS 200
M.E.2 200-55
FO-4. VFD Wiring
350124D B-11/(B-12 blank)

DOCS 200
M.E.2 200-55
APPENDIX C
Spares Kits
350124D C-1
DOCS 200
M.E.2 200-55
Table C-1. Necessary Tools SpareV Kit (797409-001)
DESCRIPTION PART NUMBER QUANTITY
BRUSH, WIRE, 1.88 LG X 0.50 W, W/HANDLE 585674-001 1

FITTING, GREASE, 1/8 MNPT S40300-101 5
FITTING, GREASE, 90 DEGREE, 1/8 MNPT G40300-016 5
GLOVES, NO POWDER (50 PR/BOX) 585675-001 1
GREASE GUN, W/18 INCH LG HOSE 582398-001 1
LEAK DETECTOR, O2 COMPATIBLE (1 GAL) 581567-003 1
SOCKETS, 3/8 DRIVE (MM) 581950-012 1
SOCKETS, 3/8 DRIVE (INCH) 581950-011 1
TORQUE WRENCH, 3/8 DRIVE 582075-006 1
TOWEL, LINT FREE (500/BOX) 585673-001 1
Drawing Number 797409 Rev J
Table C-2. Consumables SpareV Kit (797409-002)
FILTER (F-3) 585104-001 4

FILTER ELEMENT (F-4) 792253-002 1
FILTER ELEMENT, PARTICULATE (F-1) 583504 4
GREASE, CARTRIDGE (C-1) {GREASE GUN 582172-
582172-006 1
005}
GREASE, MULTIPURPOSE (MTR-1 & C-1) {14.1 oz} 581556-001 1
OIL-LUBE, SYNTHETIC (BL-100) {1 qt) 582923-001 1
SEAL KIT (C-1) 797521-001 1
Table C-3. Capital Spares Kit (797409-003)
BLOWER, AIR (BL-100) 584940-001 1

CHECK VALVE (CV-1) 582486-001 1
CHECK VALVE (CV-3) 585153-003 1
CHECK VALVE, 1/3 PSI (CV-4) 581525-020 1
CIRCUIT BOARD ASSY, MINI CONTROLLER (A-1) 798105-004 1
CIRCUIT BREAKER, 480 V, 50 A (CB-1) 580705-008 1
CONTROL UNIT, 24 VDC 583297-002 1
FAN, TUBEAXIAL (FAN-1, FAN-2, -TOP & -BOT) 582214-003 3
FAN, TUBEAXIAL (FAN-DIST) 583578-003 1
FAN & MOTOR (MTR-2) 590336-003 1
FERRITE CORE, 25 - 300 MHZ 585270-001 1
C-2 350124D
DOCS 200
M.E.2 200-55
Table C-3. Capital Spares Kit (797409-003) (Continued)
FILTER, PARTICULATE (F-1) 583502 1

FILTER, RFI, 3 PHASE (PF-1) 585233-001 1
FILTER ASSY, LIQUID SEPARATOR (F-4) 792252-001 1
FUSE, MIDGET, 2 A (FUSE-1) 582399-002 1
FUSE, MIDGET, 1-1/2 A (FUSE-2) 582091-003 1
FUSE, MIDGET, 10 A (FUSE-5, -6 & -7) 585553-002 1
GASKET, COUPLING, 3.0 INCH PIPE, STYLE 77
581531-020 3
GRADE L
GASKET, BOOST COMPRESSOR (C-1) 793263-001 1
HOSE, HIGH TEMPERATURE, 3.0 ID x 22.0 LG 585182-001 1
LATCH, COMPRESSION 585533-001 1
MOTOR, 25 HP (MTR-1) 585105-001 1
MOTOR ASSY (MTR-2) & FAN 590336-003 1
MOTOR, 3 HP (MTR-3) 585525-001 1
OXYGEN ANALYZER (AE-1) 584259-002 1
POWER SUPPLY, 3 PHASE, 24 VDC, 5 A (PS-1) 585234-001 1
PRESSURE SENSOR (XT-1) 797759-001 1
PRESSURE SENSOR (XT-2 & XT-3) 797759-002 1
RELAY, REVERSE PHASE, 50/60 HZ (K-1) 583987-001 1
RESISTOR, DYNAMIC BRAKING, 1200 WATT (R-1) 585232-003 1
BOOSTER COMPRESSOR ASSY, 3 HP (C-1) 797272-001 1
SHIM KIT, SIZE A, SLOTTED 585643-001 1
SILENCER, IN-LINE (S-200) 590509-001 1
SOLENOID VALVE, 125 PSI (SV-1) 583265 1
SOLENOID VALVE, 150 PSI (SV-2 & SV-3) 583262 1
Starter, Electric Motor, 3 PHASE, 120 V, 12 A (M-1 &
582653-001 1
M-2)
STRAINER, TANK MOUNTED (S-1 & S-2) 582178-002 1
VARIABLE FREQUENCY DRIVE, 30 HP (VFD-1) 585114-001 1
VARIABLE FREQUENCY DRIVE, 3 HP (VFD-2) 585115-001 1
350124D C-3
DOCS 200
M.E.2 200-55
Table C-4. On Hand Spares Kit (797409-004)
CHECK VALVE (CV-1) 582486-001 1

FAN, TUBEAXIAL (FAN-1, -2, -TOP & -BOT) 582214-003 3
FAN, TUBEAXIAL (FAN-DIST) 583578-003 1
FUSE, MIDGET, 1-1/2 A (FUSE-2) 582091-003 1
PRESSURE SENSOR (XT-1) 797759-001 1
PRESSURE SENSOR (XT-2 & XT-3) 797759-002 1
SOLENOID VALVE, 125 PSI (SV-1) 583265 1
Table C-5. Specialty Tools Spares Kit (797409-009)
GREASE GUN, W/EXTENSION (USE CARTRIDGE

582172-005 1
582172-006)
Table C-6. 3 YR Consumables Spares Kit (797409-010)
FILTER (F-3) 585104-001 12

582172-006 3
005}
SEAL KIT (C-1) 797521-001 3
SEAL KIT, BLOWER SHAFT (BL-100) 585802-020 1
C-4 350124D
DOCS 200
M.E.2 200-55
Table C-7. 5 YR Consumables Spares Kit (797409-011)
FILTER (F-3) 585104-001 20

582172-006 5
005}
SEAL KIT (C-1) 797521-001 5
SEAL KIT, BLOWER SHAFT (BL-100) 585802-020 2
350124D C-5/(C-6 blank)

Manual Docs-200

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Docs-200

Uploaded by

Copyright:

Available Formats

TECHNICAL MANUAL

OPERATION AND MAINTENANCE

DEPLOYABLE OXYGEN CONCENTRATION SYSTEM

MODEL NUMBER: M.E.2 200-55

Pacific Consolidated Industries, LLC

350124 Rev. D 17May 2012

REVISION DATE DESCRIPTION DCN

350124D vii/(viii blank)

PARTS AND SERVICE INFORMATION

CONTACT PCI FOR PARTS AND SERVICE

350124D ix/(x blank)

Highlights an essential operating or maintenance procedure,

Highlights an essential operating or maintenance procedure,

Highlights an essential operating or maintenance procedure,

ELECTRICAL SAFETY AND LOCK-OUT/TAG-OUT PROCEDURES

PERSONAL PROTECTIVE EQUIPMENT

OXYGEN LUBRICATION AND CLEANING COMPOUNDS

OXYGEN EQUIPMENT SAFE PRACTICES

HIGH OXYGEN CONCENTRATION

LOW OXYGEN CONCENTRATION ASPHYXIATION

350124D xiii/(xiv blank)

1.3 LEADING PARTICULARS

Blower and VSA Modules on single skid:

1.4 LOCATION AND DESCRIPTION OF COMPONENTS (DOCS)

Figure 1-1. Blower Module Major Components

Table 1-1. Blower Module Major Components

ITEM COMPONENT DESCRIPTION

Table 1-1. Blower Module Major Components (Continued)

ITEM COMPONENT DESCRIPTION

Table 1-2. VSA Module Major Components

ITEM COMPONENT DESCRIPTION

Figure 1-2. VSA Module Major Components

Figure 1-3. Distribution Box Major Components

Table 1-3. Distribution Box Major Components

ITEM COMPONENT DESCRIPTION

1.5 THEORY OF OPERATION (DOCS)

The air separation capability is based on the principle of adsorption.

1.6 SYSTEM OPERATION (DOCS)

1.7 ACRONYMS AND ABBREVIATIONS

FLA . . . . . . . . . . . Full Load Amperage

2.2 SITE REQUIREMENTS

2.3 EQUIPMENT LOCATION

2.4 EQUIPMENT INSTALLATION

1. Remove the wooden shipping crate, or other packing materials, as applicable.

2.4.1 ACCESS PANELS AND DOOR (DOCS)

Figure 2-1. Access Panels

Table 2-1. Access Panels

ITEM DESCRIPTION COMPONENTS ACCESSED

Primary Heat Exchanger Fan Motor (MTR-2), Primary Heat

2.4.2 INSTALLATION CONFIGURATION

The Blower Module can be rotated in a half circle around the

Figure 2-2. Typical Module Configuration

2.4.3 INTERCONNECT PLUMBING CONNECTION

O2 Lubricant {Krytox grease} (W46040-205)

Contaminants and moisture can damage the sieve material in the

Figure 2-3. Unit Interconnect Plumbing

6. On both elbows and the pipe, remove the caps.

2.4.4 INTERCONNECT WIRING HOOKUP

MTR-1 CABLE TO VFD

Figure 2-4. Blower Module Cables

Figure 2-5. Electrical Enclosure Interconnect Wiring Ports

1 INCH CONDUIT CONNECTOR

1/2 INCH CONDUIT CONNECTOR