350201F - O&m - I&mdocs 500-55 (-Ce)

TECHNICAL MANUAL
OPERATION AND MAINTENANCE
DEPLOYABLE OXYGEN CONCENTRATION SYSTEM

(DOCS 500)
PART AND (MODEL) NUMBERS:
796926-011 & -012 (IDOCS 500-55)

796926-013 & -014 (MDOCS 500-55)
799675-001 & -002 (IDOCS 500-55-CE)
799676-001 & -002 (MDOCS 500-55-CE)
Authorized Representative Manufacture

Emergo Europe Pacific Consolidated Industries, LLC
Prinsessegracht 20 12201 Magnolia Avenue
2514 AP The Hague Riverside, California 92503-4820
The Netherlands
350201 Revision F 23 July 2020

RECORD OF REVISIONS
REVISION DATE DESCRIPTION DCN

N/C 19 Jan 2016 Initial Release 4202
A 17 Nov 2016 Refer to DCN 4515 4515
B 27 April 2017 Refer to DCN 4603 4603
C 12 July 2017 Refer to DCN 4640 4640
D 30 Nov 2018 Refer to DCN 4852 4852
E 27 June 2019 Refer to DCN 5001 5001
Added: Section 3.3.4; To Section 2.5.7, Step 2 - Warning and
Note; To Section 3.2, Step 3 - if/then table; To Section
3.2.1 - Steps 7 and 8; To Section 3.3.3 - Step b.; Table 6-
F 23 July 2020 2; Figures 6-32 & 6-51; 5157
Revised: To Figure FO-2 - SV-100; To Figure FO-3 - SV-100 and
Sleep Switch; Table 6-1; Rewrite of Sections 6.8.23 and
6.8.24
Copyright  2020 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.
IDOCS & MDOCS
500-55 (-CE)
TABLE OF CONTENTS
PARAGRAPH PAGE
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
1 INTRODUCTION
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2.1 Application Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Model Designators in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Component Description and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8 Access Panels and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.9 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
2 PREPARATION FOR USE
2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Unpack the Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5 Commission the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.1 Interconnect Piping Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.2 Interconnect Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5.3 Electrical Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.3.1 Input Power Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5.4 Altitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.5 Flow Rate Adjustment {with optional MFC-1} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5.6 Discharge Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5.7 Product Discharge Port Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5.8 Calibration Gas Bottle Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.8.1 Calibrate Oxygen Analyzer / Sensor {IDOCS (-CE)}. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5.8.2 Calibrate Oxygen Analyzer {MDOCS (-CE)} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.9 Remote Control (Hard Wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
3 OPERATION
3.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.2 Product Output Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.3 Product Output Flow Adjustment {Optional MFC-1 Installed} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.4 Data Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.2.5 Sleep Mode (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3 Operation in Unusual and Harsh Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.1 Cold Climates (≤ 0°C (32°F)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.2 Hot Climates (> 38°C (100°F)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.3 Sandy or Dusty Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.3.4 Rainy or Humid Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
350201F i
IDOCS & MDOCS
500-55 (-CE)
PARAGRAPH PAGE
3.3.5 Salt Water Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.4 System Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3.5 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.6 Oxygen Analyzer / Sensor {IDOCS (-CE)} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.6.1 Manual Calibration {IDOCS (-CE)} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.6.2 Automatic Calibration {IDOCS (-CE)} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.7 Warnings and Shutdowns (Faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.7.1 Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3.8 System Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.8.1 LCD Main Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.9 Plant IP Address Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
4 SYSTEM OPERATION CONTROLS
4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.1.1 Sequential Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Discharge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.3 Discharge Pressure Alarm Trip Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.2.4 Discharge Pressure Alarm Clear Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.2.5 Discharge Pressure Alarm Delay Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.2.6 Product Purity Alarm Trip Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.2.7 Product Purity Alarm Clear Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.2.8 IP Configuration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.2.9 Direct I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.2.9.1 Direct IO Fault Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.2.9.2 Air Blower (BL-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.2.9.3 Booster Compressor (C-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.2.9.4 Air Blower Heat Exchanger (HX-100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.2.9.5 Purge Solenoid (SV-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.2.9.6 Sample Calibration Solenoid (SV-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.2.9.7 Off-Spec Solenoid (SV-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.2.9.8 Product Solenoid (SV-4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.2.9.9 Alarm Horn (H-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.2.9.10 Auxiliary Solenoid (SV-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.2.9.11 Digital Output (DO1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.2.9.12 Digital Output (DO2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.2.9.13 Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4.2.9.14 Running Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4.2.10 Save and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
5 REMOTE OPERATION AND DIAGNOSTICS
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Remote Operation Screen Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.3.1 Dashboard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.3.2 Normal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.3.3 Remote Data Logging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.3.4 Diagnostic Screen (Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
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5.3.5 Diagnostic Screen (Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.6 Diagnostic Screen (Cycle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.7 Diagnostic Screen (Key Indicators). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.8 Sensors Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.9 Event Log Page Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.3.10 E-Mail Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.3.11 Factory Setup Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.3.12 Clock Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.3.13 User Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.3.14 Maintenance Tracking Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
6 MAINTENANCE
6.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Maintenance Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Spare Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.7 Oxygen Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.8.1 Pre-Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.8.2 Distribution Box Cooling Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.8.3 Booster Heat Exchanger Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.8.4 Booster Motor Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.8.5 Electrical Cabinet Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.8.6 Air Blower Oil-Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.8.7 VSA Tank Lid Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.8.8 Air Supply Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.8.9 Booster Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.8.10 Product Particulate Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.8.11 Air Blower/Motor Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.8.12 Booster Scroll Compressor/Motor Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.8.13 Booster Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.8.14 Air Blower Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.8.15 Air Blower Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.8.16 Air Blower Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.8.17 Booster Scroll Compressor Lubrication and Tip Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.8.17.1 Scroll Compressor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.8.17.2 Tip Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.8.17.3 Tip Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6.8.17.4 Scroll Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.8.17.5 Scroll Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.8.18 Air Blower Heat Exchanger Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.8.19 Booster Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
6.8.20 Booster Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6.8.21 Oxygen Product Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6.8.22 Oxygen Product Analyzer/Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6.8.23 Booster Scroll Compressor/Motor Coupling Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
350201F iii
IDOCS & MDOCS
500-55 (-CE)
PARAGRAPH PAGE
6.8.24 Air Blower/Motor Coupling Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-74
6.8.25 Post Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-80
6.8.25.1 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-80
6.9 Calibration Gas Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-82
6.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-83
6.10.1 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-83
6.10.2 Fault Codes and General Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-84
6.10.3 Performance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-87
7 PREPARATION FOR SHIPMENT OR STORAGE
7.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2.1 Electrical Power Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.2.1.1 Interconnect Wiring Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.2.2 Interconnect Piping Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Appendix A Foundation Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-1
Appendix B P&ID & Electrical Drawings & Bills of Materials - - - - - - - - - - - - - - - - - - - - - - - - - B-1
Appendix C Spare Parts Lists - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C-1
iv 350201F
IDOCS & MDOCS
500-55 (-CE)
LIST OF ILLUSTRATIONS
FIGURE PAGE
1-1 MDOCS 500-55- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1-2 Blower Module (MDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1-3 VSA Module (MDOCS-CE shown)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
1-4 Distribution Box (MDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
1-5 Oxygen Sensor Box- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
1-6 Electrical Cabinet Back Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
1-7 Plant Access Panels and Doors (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
2-1 Interconnect Piping Connection (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
2-2 Blower Module Interconnect Cables (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2-3 Blower Module Interconnect Cables Hookup (electrical cabinet) - - - - - - - - - - - - - - - - - - - - 2-5
2-4 Motor Sensor Wires Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2-5 Blower Module Emergency-Stop Cable and Connector (MDOCS-CE shown) - - - - - - - - - - - - - - 2-7
2-6 Circuit Breaker (CB-1) Input Power Connections (electrical cabinet) - - - - - - - - - - - - - - - - - - 2-8
2-7 Normal Screen (LCD) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2-8 Setup Screen (pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2-9 Setup Screen (flow) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2-10 Out Press to Direct IO Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
2-11 Direct IO Fault Input Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
2-12 VSA FWD, VSA REV, SCR FWD & VSA Main Cooler Screens - - - - - - - - - - - - - - - - - - - - - 2-10
2-13 Blower Module Cooling Air Outlet Vent (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - 2-11
2-14 Normal Screen (Internet) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12
2-15 User Settings Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12
2-16 Product Discharge Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-14
2-17 Oxygen Calibration Kit (794873-001) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-16
2-18 Calibration Inlet Port (MDOCS shown)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-16
2-21 Setup (Flow) and Flow Rate Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-18
2-22 Out Press to Direct I/O Setup Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19
2-23 Direct IO Fault Input Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19
2-24 VSA FWD to O2 Sample Direct I/O Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19
2-25 Oxygen Analyzer (AE-2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
2-26 Off-Spec to Exit With Save Direct I/O Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
3-1 Operator Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3-2 Air Blower (BL-100) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3-3 Operator Controls (electrical cabinet) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-6 Setup (flow) and Flow Rate Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-7 Pressure Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-8 Pressure Alarm Trip Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-9 Pressure Alarm Clear Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-10 Pressure Alarm Delay Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3-11 PUR ALM Trip to Exit with Save Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
3-12 Setup (flow) Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
350201F v
IDOCS & MDOCS
500-55 (-CE)
FIGURE PAGE
3-13 Flow Rate Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
3-14 Settings Exit Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9
3-16 DOCS Remote Data Logging Page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-10
3-17 Charts Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-11
3-18 LOGDATA1 Spread Sheet (Partial) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-12
3-19 Operator Shutdown Controls (Electrical Cabinet) - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-14
3-20 Emergency-Stop Buttons (MDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-15
3-21 Calibration Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-16
3-22 Warning and Shutdown Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-17
3-23 Warning with Fault Code Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-17
3-24 Main Menu Sequential Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-19
3-25 Setup Screen (pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-20
3-26 Setup (flow) and Flow Rate Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-20
3-27 Output Pressure to TCPIP Configure Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-20
3-28 DHCP Setting Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-21
3-29 IP Address Edit Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-21
3-30 Mask Edit Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-22
3-31 Gateway Edit Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-23
3-32 IP Exit Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-23
3-33 Direct IO Entry Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-23
3-34 Settings Exit Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-24
4-1 Setup Entry (pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-2 Setup Entry (flow) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4-3 Flow Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4-4 Out Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4-5 Pressure Alarm Trip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4-6 Pressure Alarm Clear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4-7 Pressure Alarm Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4-8 Purity Alarm Trip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4-9 Purity Alarm Clear- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4-10 IP Configuration Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4-11 Direct I/O Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4-12 Direct IO Fault Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4-13 VSA Blower Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
4-14 VSA Blower Reverse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4-15 Scroll Forward - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4-16 VSA Main Cooler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-10
4-17 Purge Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-10
4-18 O2 Sample Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-11
4-19 Off-Spec Solenoid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-12
4-20 SV-4 Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-12
4-21 Auxiliary Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-13
4-22 Solenoid SV-6 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-13
4-23 Digital Output 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-14
4-24 Digital Output 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-14
4-25 Alarm Relay- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-15
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4-26 Running Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-15
4-27 Setup Exit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
4-28 Normal (LCD) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
5-1 Click to Enter Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5-2 Internet - Dashboard Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5-3 Safe Site Selection Menu and Windows - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
5-5 DOCS 500 Dashboard Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5-7 Remote Data Logging Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
5-8 Diagnostic Pressure Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
5-9 Diagnostic Temperature Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
5-10 Diagnostic Cycle Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
5-11 Diagnostic Key Indicators Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
5-12 Sensors Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
5-13 Event Log Page Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
5-14 E-Mail Setup Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
5-15 Factory Login Page Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-16 Factory Setup Menu Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
5-17 Clock Set Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18
5-19 Maintenance Tracking Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-20
6-2 Purge Receiver Tank Vent Valve (MDOCS-CE shown)- - - - - - - - - - - - - - - - - - - - - - - - - 6-7
6-3 Buffer and Purge Tanks Pressure Transducers (XT-3 & 4) (MDOCS shown) - - - - - - - - - - - - - - 6-8
6-4 Distribution Box Cooling Louvers and Fans (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - 6-9
6-5 Distribution Box Booster Motor Cooling Fan (FX300) {MDOCS shown} - - - - - - - - - - - - - - - - - 6-10
6-6 Electrical Cabinet Cooling Fans (FAN-1 & 2)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
6-7 Air Blower (BL-100) Lubricant Replacement (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - - 6-12
6-8 VSA Tank Lid Torque Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
6-9 Air Supply Filter (F-3) {IDOCS shown} - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-14
6-10 Distribution Box Filters (MDOCS shown)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
6-11 Booster Inlet and Product Particulate Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16
6-12 Air Blower/Motor Coupling (IDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
6-13 Coupling Hubs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
6-14 Booster Coupling Guard Remove/Install (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - 6-20
6-15 Booster Compressor/Motor Coupling (MDOCS shown)- - - - - - - - - - - - - - - - - - - - - - - - - 6-20
6-16 Coupling Elastomer Half Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-21
6-17 Booster Heat Exchanger (HX-200) (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - - - 6-22
6-18 Booster Heat Exchanger Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-23
6-19 Air Blower Motor (MTR-1) Lubrication (IDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - 6-24
6-20 Fan Cage Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-26
6-21 Air Blower Heat Exchanger (HX-100) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-27
6-22 Air Blower (BL-100) Shaft Seal Inspection (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - 6-29
6-23 Air Blower Piping Disconnection/Connection (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - 6-29
6-24 Blower Shaft Protector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31
6-25 T-Bar Puller Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-31
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6-26 Omega Blower Puller Usage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-31
6-27 Shaft Sleeve Installation Tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-32
6-28 Shaft Seal Guide Tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-33
6-29 Shaft Seal Greasing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-33
6-30 Shaft Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-33
6-31 Air Blower Coupling Hub Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-34
6-32 Blower Screw Torque Pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-35
6-33 Booster Compressor (C-1) Hose Disconnection (MDOCS shown) - - - - - - - - - - - - - - - - - - -6-36
6-34 Compressor Fan Duct Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-37
6-35 Fixed Scroll Hardware Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-37
6-36 Fixed Scroll LP Seal Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-37
6-37 Fixed Scroll Dust Seal Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-38
6-38 Fixed Scroll Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-38
6-39 Orbital Scroll Seals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-38
6-40 Tip Seal Kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-39
6-41 Orbital Scroll HP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-40
6-42 Orbital Scroll LP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-40
6-43 Orbital Scroll LP Seal Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-41
6-44 Fixed Scroll HP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-41
6-45 Fixed Scroll LP Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-41
6-46 Fixed Scroll Backup Tube Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-42
6-47 Fixed Scroll Dust Seal Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-42
6-48 Compressor Main Bearing Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-43
6-49 Compressor Pin Crank Bearing Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-43
6-50 Compressor Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-44
6-51 Torque Pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-44
6-52 Fan Duct installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-44
6-53 Booster Scroll Compressor (C-1) Hose Connections (MDOCS shown) - - - - - - - - - - - - - - - - -6-45
6-54 Fan Cage Removal/Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-46
6-55 Air Blower Heat Exchanger Motor (MTR-2) Removal/Installation - - - - - - - - - - - - - - - - - - - -6-47
6-56 Normal Screen (LCD) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-48
6-57 Setup Screen (pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-48
6-58 Setup (flow) and Flow Rate Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-48
6-59 Out Press to Direct IO Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-48
6-60 Direct IO Fault Input Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-49
6-61 VSA FWD, VSA REV, SCR FWD & VSA Main Cooler Screens - - - - - - - - - - - - - - - - - - - - -6-49
6-62 Air Blower Heat Exchanger Fan (FX-100) Air Direction {MDOCS-CE shown} - - - - - - - - - - - - - -6-50
6-63 Motor Starter/Contactor (MCP-1/M-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-50
6-64 Booster Coupling Guard Remove/Install (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - -6-52
6-65 Booster Motor (MTR-3) Removal/Installation (MDOCS shown) - - - - - - - - - - - - - - - - - - - - -6-52
6-66 Booster Motor Coupling Hub Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-53
6-67 Booster Compressor Coupling Guard and Hose Disconnections (MDOCS shown) - - - - - - - - - - -6-55
6-68 Booster Compressor (C-1) Removal (IDOCS shown)- - - - - - - - - - - - - - - - - - - - - - - - - -6-55
6-69 Scroll Compressor Disassembly/Assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-56
6-70 New Scroll Compressor Component Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-57
6-71 Compressor Coupling Hub Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-57
6-72 Scroll Compressor Nut Torque Pattern- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-58
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6-73 Oxygen Product Analyzer (AE-2) & Sensor (AE-1) {MDOCS shown} - - - - - - - - - - - - - - - - - - 6-59
6-74 O2 Sample Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-61
6-75 Oxygen Product Analyzer (AE-2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-61
6-76 Analyze/Sensor (AE-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-62
6-77 Motor / Booster Coupling Hub Spacing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-64
6-78 Easy-Laser Sensor Initial Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-64
6-79 Sensor Bracket on Shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-65
6-80 Enter Distances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-66
6-81 Sensors Rough Horizontal Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-67
6-82 Sensors Rough Vertical Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-68
6-83 Booster Motor Torque Pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-69
6-84 Soft Foot Alignment Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-70
6-85 Soft Foot Measure and Result Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-70
6-86 Easy Turn Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-71
6-87 Easy Turn Result Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-72
6-88 Air Blower / Motor Coupling Hub Distance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-75
6-89 Blower Motor Tighten / Torque Pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-75
6-91 Maintenance Tracking Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-81
6-92 DOCS 500 Dashboard Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-82
7-1 Purge Receiver Tank Vent Valve (IDOCS-CE shown) - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
7-2 Circuit Breaker (CB-1) Input Power Connections (electrical cabinet) - - - - - - - - - - - - - - - - - - 7-3
7-3 Blower Module Interconnect Cables Disconnection (electrical cabinet) - - - - - - - - - - - - - - - - - 7-3
7-4 Motor Sensor Wires Disconnection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
7-5 Blower Module Interconnect Motor Cables (IDOCS shown) - - - - - - - - - - - - - - - - - - - - - - 7-4
7-6 Blower Module Emergency-Stop Cable and Connector (MDOCS-CE shown) - - - - - - - - - - - - - - 7-5
7-7 Interconnect Piping Disconnection (MDOCS shown) - - - - - - - - - - - - - - - - - - - - - - - - - - 7-6
FO-1. Foundation Drawing (Sheet 1 0f 2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-3
FO-2. Process and Instrumentation Diagram (P&ID) (Sheet 1 of 2) - - - - - - - - - - - - - - - - - - - - - - B-7
FO-3. Electrical Schematic (Sheet 1 of 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B-11
FO-4. Alarm Schematic {MDOCS (-CE)} - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B-19
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LIST OF TABLES
TABLE PAGE
1-1 Model Designation Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 Blower Module Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3 VSA Module Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-4 Distribution Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-5 Oxygen Sensor Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-6 Electrical Cabinet Back Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-7 Plant Access Panels and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
3-1 Operator Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-2 IP Addressing Button Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
4-1 Operator Panel Button Assignments In Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-2 Direct IO Fault Input Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
6-1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-2 Alignment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-3 Life Expectancy Replacement Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-4 Tools Kit (797366-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-5 Specialty Tool Kit (797366-009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-6 Other Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-7 List of Consumables Kit (797366-002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-8 List of Other Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-9 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-10 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-84
6-11 General Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-85
6-12 Performance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-87
B-1 P&ID Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B-2 Electrical Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
C-1 Tool Kit (797366-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-2 Specialty Tool Spares Kit (797366-009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-3 Capital Spares Kit (797366-014) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C-4 On Hand Spares Kit (797366-015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C-5 1 Year Consumables Spares Kit (797366-016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C-8 Oxygen Analyzer Spares Kit {IDOCS (-CE)} (797366-019). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
C-9 Oxygen Sensor Spares Kit {MDOCS (-CE) & Models with AE-2} (797366-020) . . . . . . . . . . . . . . . . . . . . . C-6
C-10 Booster Compressor Seal Kit (797521-002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
C-11 Air Blower Shaft Seal Kit (799045-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
C-12 Air Blower Shaft Seal Tool Kit (798750-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
x 350201F
IDOCS & MDOCS
500-55 (-CE)
SAFETY SUMMARY
This safety summary has general safety warnings that must be understood and applied during operation and
maintenance of this equipment. Failure to obey these precautions can cause injury or death to people and damage to
the equipment. When first aid is necessary, refer to OSHA Standard 1910.151.
These are the safety and hazardous sentence structures used in the manual:
WARNING: Highlights an important operating or maintenance procedure, practice, condition, statement,

etc. which, if not completely obeyed, can cause injury to, or death of, people or long term health hazards.
CAUTION: Highlights an important operating or maintenance procedure, practice, condition, statement,

etc. which, if not completely obeyed, can cause damage to, or destruction of, equipment or loss of
mission effectiveness.
NOTE: Highlights an important operating or maintenance procedure, condition or statement.
Make sure you read the information in the warning, caution and notes carefully. Consult someone experienced in
handling oxygen equipment about unclear issues. Warnings must come before cautions, which in-turn must come
before notes. Warnings and cautions come before the step for which they are intended, and notes follow the step.
Additional safety guidelines related to components of the plant are specified in the correct sections.
SAFETY AND HAZARDOUS ICONS

These icons are shown on the plant or used in this manual to draw attention to the cautions and warnings found in the
manual.
GENERAL WARNING - This icon is used for all warnings/cautions not covered by these icons.
AUTO RUN - The equipment auto-runs and turns when power is applied.
CORROSIVE - The material used causes burns or irritation to the skin and is corrosive to other materials.
ELECTRICAL - There is the possibility of electrical shock or detriment to equipment from electrical
overload.
EXPLOSIVE RELEASE OF PRESSURIZED GAS - The line, tube, hose or container has pressurized
gas during operation and must be vented before
maintenance.
FIRE - The material is flammable or actions could cause a fire.
350201F xi
IDOCS & MDOCS
500-55 (-CE)
HEAVY - The object or component is heavy and requires more than one person to manage.
HOT - The material or component is hot to the touch or actions can overheat a component.
TURNING EQUIPMENT - The Plant has turning equipment and can capture or pinch hands and clothing.
TOXIC GASES / ASPHYXIATION - The exhaust gases are hazardous and can cause asphyxiation or
death
EYE PROTECTION - Eye protection must be worn during the completion of the task.
HAND PROTECTION - Gloves must be worn during the completion of the task.
LOCK-OUT/TAG-OUT - The electrical must be locked-out and tagged-out before continuing.
READ MANUAL - Read the manual instruction before continuing.
RESPIRATORY PROTECTION - Breathing protection must be worn during the completion of the task.
SOUND PROTECTION - Sound protection must be worn during the completion of this task.
TWO PERSON LIFT - Use two (2) people to lift the object.
NO SMOKING - No smoking within fifteen (15) meters (fifty (50) feet) of the equipment.
COMPRESSED OXYGEN - This Plant produces compressed oxygen.
xii 350201F
IDOCS & MDOCS
500-55 (-CE)
NOTE - This icon is used for all notes.
HAZARDOUS MATERIALS
ACETONE
Acetone is irritating to skin, eyes and respiratory tract. It is flammable. It is a solvent. Skin and eye protection must be
worn during use. Do not breath vapors. Refer to the MSDS for this product.
ISOPROPYL ALCOHOL
Isopropyl alcohol is weakly irritating to skin, eyes and respiratory tract. It is flammable. It is a solvent. Skin and eye
protection must be worn during use. Do not breath vapors. Refer to the MSDS for this product.
OMEGA SB SYNTHETIC OIL-LUBE

Omega SB synthetic oil lube is weakly irritating to skin, eyes and respiratory tract. It is flammable. Skin and eye
THREAD LOCKER, LOCTITE® 242
Loctite® 242 thread locker is weakly irritating to skin, eyes and respiratory tract. It is flammable. Skin and eye
Loctite® 271 thread locker is weakly irritating to skin, eyes and respiratory tract. It is flammable. Skin and eye
GREASE, ISOFLEX TOPAS NB 52

Isoflex Topas NB 52 grease is irritating to skin and eyes. It is flammable. Skin and eye protection must be worn during
use. Refer to the MSDS for this product.
350201F xiii
IDOCS & MDOCS
500-55 (-CE)
GREASE, MULTIPURPOSE, NLGI GRADE 2

Multipurpose NLGI grade 2 grease is weakly irritating to skin, eyes and respiratory tract. Skin and eye protection must
be worn during use. Do not breath vapors. Refer to the MSDS for this product.
OXYGEN LUBRICANT, KRYTOX®

Oxygen lubricant (Krytox®) is weakly irritating to the skin and eyes. It can cause a rash with repeated exposure. Skin
and eye protection must be worn during use. Refer to the MSDS for this product.
ELECTRICAL SAFETY AND LOCK-OUT/TAG-OUT PROCEDURES

Obey all lock-out/tag-out requirements and all electrical safety precautions and procedures. There is danger 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 people
 People working with or near dangerous voltage must be trained in modern methods of resuscitation
FINGER RINGS/JEWELRY
Remove rings, watches and other metallic objects that can cause shock or burn hazards. Unless specifically permitted
by shop safety procedures, remove finger rings before maintenance activity.
PERSONAL PROTECTIVE EQUIPMENT

Eye protection, hearing protection and Personal Protective Equipment (PPE) are chosen based on the task being
done and must be approved by a specialist before operating, maintenance, service and repair of the plant.
Use correct ear protection as continued high decibel noise can cause permanent hearing loss.
OXYGEN SYSTEMS
WARNING: Contaminants in enriched oxygen can cause explosive fires. If you are not familiar with
oxygen cleaning procedures contact the CGA or PCI before putting oxygen in your piping and distribution
system. The CGA web site is www.cganet.com.
The oxygen system must be cleaned and examined in accordance with Compressed Gas Association (CGA)
pamphlet G 4.1. Make sure no combustible materials stay in the connecting piping and fittings.
Oxygen is a powerful oxidizing agent that can accelerate a fire or explosion. Obey oxygen clean procedures when
fabricating and connecting oxygen piping.
xiv 350201F
IDOCS & MDOCS
500-55 (-CE)
OXYGEN LUBRICATION AND CLEANING COMPOUNDS

Do not lubricate oxygen components or connections with:
 Petroleum-based grease
 Oil
 Vaseline (petroleum jelly)
 Hydraulic fluid
 Other petroleum compounds.
Components include:
 Cylinder connections
 Valve adjustment stems
 Internal seal lubricants (used during assembly)
 Fittings, etc.
Only use inert oxygen-certified lubricants.
Do not clean oxygen components or parts in these petroleum-based cleaning solvents that have a residual film:
 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 enriched oxygen.
OXYGEN EQUIPMENT SAFE PRACTICES

Enriched oxygen can be hazardous; it accelerates combustion. A material that does not burn in air can burn in
enriched oxygen. Obey all guidelines and training for safe oxygen handling. These are general guidelines for
minimizing the chance of fire:
 Do not permit smoking within 15 m (50 ft) of oxygen equipment
 Store oxygen in clean dry locations away from direct sunlight
 Make sure cleaning, repair or transfilling of oxygen equipment is done by qualified trained people
 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 seal equipment from dust and dirt while not in use
 Make sure people using oxygen equipment are completely trained in its operation, oxygen safety and have
knowledge of the manufacturer’s instructions for use
HIGH OXYGEN CONCENTRATION

Oxygen concentrations greater-than 25% increase the hazard to people and equipment. Those materials that burn in
air burn more violently and explosively in oxygen.
People must be familiar with the hazards of oxygen and safe practices for oxygen systems to operate and service the
system.
Hydrocarbons can spontaneously combust in enriched oxygen. Elevated oxygen levels can linger after the source has
been shut off. Clothing can become saturated for long periods of time with enriched oxygen increasing the risk of
ignition from sparks, heat or flame.
350201F xv
IDOCS & MDOCS
500-55 (-CE)
People who work with enriched oxygen must not smoke until changing out of their work clothes.
All areas with enriched oxygen atmospheres must be continually monitored for fire loading. Fire loading is the storage
of combustible materials close to oxygen equipment. Flammable items must not be stored near enriched oxygen
sources. Some materials burn in enriched oxygen that do not burn in air.
To prevent unwanted combustion, make sure there is sufficient ventilation, prevent enriched oxygen component
contamination and prevent fire loading.
Closed areas with enriched oxygen can explode and burn violently with a spark or flame. Do not put a closed tent
around the plant without correct ventilation.
If there is insufficient ventilation, people can begin to suffer from these enriched oxygen induced problems:
 Nausea
 Vomiting
 Twitching or seizures
 Disorientation
 Chest pains
 Prolonged night vision adaptation
 Loss of consciousness
 Possible death.
LOW OXYGEN CONCENTRATION ASPHYXIATION

An oxygen concentration of less-than 19% can cause asphyxiation, including loss of life. Do not operate the plant in a
closed non-ventilated area.
This plant isolates oxygen from air and supplies it at low pressures. The waste gas (vented exhaust) produced is
nitrogen-rich. Nitrogen, while inert, does not sustain life. If permitted to collect, it causes hypoxia and asphyxiation in
people.
If the vented exhaust is permitted to collect in a closed, non-ventilated area, the air in the area could be oxygen
depleted sufficiently to cause asphyxiation, unconsciousness or death. If the plant is to be installed indoors, additional
ventilation must be supplied.
HIGH TEMPERATURES
Some areas of the plant can become very hot. These areas include:
 Heat exchangers and connecting piping
 Air blower/motor
 Scroll compressor/motor
 HP boosters/tubing
 Tubes and pipes
Use caution when servicing the equipment and permit the equipment to cool before doing maintenance.
TURNING EQUIPMENT
The plant must be operated with the doors closed and the panels installed. Turning parts can cause injury. Never do
adjustments while the plant is operating; unless otherwise specified by the service procedure. Keep body parts and
objects away from all moving parts and obey all safety precautions.
xvi 350201F
IDOCS & MDOCS
500-55 (-CE)
FOREWORD
PARTS AND SERVICE INFORMATION
Before contacting Pacific Consolidated Industries (PCI) for service and support, make sure you have this 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 this 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 these telephone
numbers:
Toll Free: (800) 309-8935
Voice: (951) 479-0860
Fax: (951) 479-0864
Or contact PCI on the Internet with the Support web page at: http://www.pcigases.com.
350201F xvii
IDOCS & MDOCS
500-55 (-CE)
Pacific Consolidated Industries 12201 Magnolia Avenue Riverside, CA 92503-4820

(951) 479-0860 Fax (951) 479-0861 www.pci-intl.com
Declaration of Conformity
Manufacturer: Pacific Consolidated Industries LLC, (PCI)

12201 Magnolia Avenue
Riverside, CA 92503-4820
Authorized Representative: Emergo Europe

Prinsessegracht 20
2514 AP The Hague
The Netherlands
Device Name/Type Deployable Oxygen Concentrator System (DOCS)
Product Identifier: DOCS 500
Classification per Annex IX: Class IIb, Rule 11
Conformity Assessment Procedure Annex II
Standards Applied: IEC 60601-1

IEC 60601-1-2
IEC 60601-1-8
ISO 13485
Notified Body: BSI Group

Say Building, John M. Keynesplein 9,
1066 EP Amsterdam
The Netherlands
Pacific Consolidated Industries LLC, (PCI) declares that the device(s) listed above fulfill the Essential
Requirements (Annex 1) of the Council Directive 93/42 EEC for Medical Devices. All supporting documentation
is retained by the manufacturer.
__________________________
Name/Title
Date declaration: 06/20/2019
Form 302333 Rev C
xviii 350201F
IDOCS & MDOCS
500-55 (-CE)
Pacific Consolidated Industries 12201 Magnolia Avenue Riverside, CA 92503-4820

(951) 479-0860 Fax (951) 479-0861 www.pci-intl.com
Declaration of Conformity
Manufacturer: PacificConsolidatedIndustriesLLC,(PCI)
12201MagnoliaAvenue
Riverside,CA92503Ͳ4820

AuthorizedRepresentative: Doceupoint Ltd.
The Old Methodist Chapel

Great Hucklow, Buxton, Derbyshire,
SK17 8RG, UK

InaccordancewiththefollowingDirective(s):

2006/42/ECMachineryDirective
97/23/ECPressureEquipment
2006/95/ECLowVoltage

Herebydeclarethat:
Equipment: DeployableOxygenConcentratorSystem(DOCS)
ModelNumber: DOCS500
Isinconformitywiththeapplicablerequirementsofthefollowingdocuments:

Ref.No. Title:

EN12100 SafetyofMachineryͲGeneralprinciplesfordesign–Riskassessmentandriskreduction

EN14120 SafetyofmachineryͲGuardsͲGeneralrequirementsforthedesignandconstructionoffixedand
movableguards

EN60204Ͳ1 Safetyofmachinery.Electricalequipmentofmachines.Generalrequirements

Iherebydeclarethattheequipmentabovehasbeendesignedtocomplywiththerelevantsectionsoftheabove
referencedspecificationsandisinaccordancewiththerequirementsoftheDirective(s)

Name/Title:_____________________________________

Placeanddateofdeclaration:

Thetechnicaldocumentationforthemachineryisavailablefrom:

PacificConsolidatedIndustriesLLC,(PCI)
12201MagnoliaAve
Riverside,CA92503
Form 302332 Rev B
350201F xix/(xx blank)

IDOCS & MDOCS
500-55 (-CE)
CHAPTER 1
INTRODUCTION
1.1 SCOPE
This manual has instructions for the operation and maintenance of the Deployable Oxygen Concentration
System (DOCS) here after referred to as the Plant or DOCS. These DOCS are manufactured by Pacific
Consolidated Industries, LLC (PCI):
 796926-011 & 012 (IDOCS 500-55) - - - - - - - - {IDOCS}
 796926-013 & 014 (MDOCS 500-55) - - - - - - - {MDOCS}
 799675-001 & -002 (IDOCS 500-55-CE) - - - - - - {IDOCS-CE}
 799676-001 & -002 (MDOCS 500-55-CE) - - - - - {MDOCS-CE}
1.2 PURPOSE
The Industrial DOCS (IDOCS) is an oxygen generator delivering European Pharmacopoeia Monograph
(EPM) Oxygen at 93% for supplemental oxygen use.
The Medical DOCS (MDOCS) is intended for use as a part of primary or secondary source of supply for a
Hospital Oxygen Supply System as a part of the hospital’s medical gas pipeline system. The Hospital
Oxygen Supply System shall comply with ISO 7396-1:2016. These steps describe the intended
incorporation of the MDOCS system in the Hospital Oxygen Supply System.
1. The Hospital Oxygen Supply System shall limit the output flow rate of the Plant to no more than the
maximum output specification.
2. The Hospital Oxygen Supply System shall have an alarm system in compliance with IEC 60601-1-8.
The alarm system shall have means of communicating all of the alarms generated by the Plant.
3. The Hospital Oxygen Supply System shall monitor the oxygen concentration and required impurities.
4. The Hospital Oxygen Supply System shall protect the Plant from pressures greater than the Plant
maximum outlet pressure rating.
5. The Hospital Oxygen Supply System shall start and stop the Plant.
1.2.1 APPLICATION SPECIFICATION
1. Intended Medical Indication:

The Deployable Oxygen Concentration System Family of devices generates and delivers USP and
European Pharmacopoeia grade 93 ± 3% oxygen.
These devices are to be used by trained personnel as key components in primary or backup Oxygen
Concentrator Supply Systems (OCSS) for hospitals, ambulatory patient use, in disaster relief, crisis
response or humanitarian relief situations, or by trained military medical personnel in mobile military
field hospitals.
DOCS Family devices can be used to fill high pressure oxygen cylinders.
2. Intended Patient Population:
As prescribed by authorized health care professionals
3. Intended Part of the Body or Type of Tissue Applied or Interacted with:
N/A - The DOCS does not interact with the body or tissue of a patient.
4. Intended User Profile:
Only factory trained professional technicians must set up, operate and do maintenance on the Plant.
350201F 1-1
IDOCS & MDOCS
500-55 (-CE)
5. Intended Conditions of Use:

Refer to Section 2.2.
6. Operating Principle:
Refer to Section 1.7 on page 1-13.
1.3 MODEL DESIGNATORS IN THIS MANUAL
This manual has procedures for the various models listed in Section 1.1. Most instructions cover all models,
when differences occur, the model or models affected are listed in the heading or leading paragraph in
accordance with Table 1-1. When models are listed, only those listed models are affected.
Table 1-1. Model Designation Matrix
DESIGNATION INCLUDES
IDOCS 796926-011 & -012 (IDOCS 500-55)

MDOCS 796926-013 & -014 (MDOCS 500-55)
IDOCS-CE 799675-001 & -002 (IDOCS 500-55-CE)
MDOCS-CE 799676-001 & -002 (MDOCS 500-55-CE)
796926-011 & -012 (IDOCS 500-55) &
IDOCS (-CE)
799675-001 & -002 (IDOCS 500-55-CE)
796926-013 & -014 (MDOCS 500-55) &
MDOCS (-CE)
799676-001 & -002 (MDOCS 500-55-CE)
1-2 350201F
IDOCS & MDOCS
500-55 (-CE)
1.4 LEADING PARTICULARS
The modular design has two (2) modules (Blower and VSA) mounted on separate skids (see Figure 1-1).
BLOWER MODULE
VSA MODULE
Figure 1-1. MDOCS 500-55
ENVIRONMENTAL CHARACTERISTICS
Operating Temperature -18 to 49°C (0 to 120°F)

Storage Temperature -18 to 60°C (0 to 140°F)
Sound Power Level (LWA): 84.1 dB(A)

Test Code: ISO 11201:2010 - Acoustics - Noise emitted by machinery and equip.
Serial Number 1000007937 (I)
Emission and Immunity Compliance Per EN60601-1-2:

 EN55011 Class A Group 1
 EN61000-4-2
 EN61000-4-3
 EN61000-4-5
 EN61000-4-6
 EN61000-4-8
350201F 1-3
IDOCS & MDOCS
500-55 (-CE)
INPUT POWER REQUIREMENTS
Site Requirements:
460 Vac ± 10%, 60 Hz ± 3%, 3-phase, 100 Amp
380 Vac ± 10%, 50 Hz ± 3%, 3-phase, 120 Amp
Plant Requirements:
460 Vac, 60 Hz, 3-phase, 80 FLA
796926-011 & -013
799675-001
799676-001
380 Vac, 50 Hz, 3-phase, 100 FLA
796926-012 & -014
799675-002
799676-002
PERFORMANCE CHARACTERISTICS
At standard ambient conditions (15°C, 1 Bar (59°F, 14.7 psia) & 50% RH)
Low Pressure Discharge 1.4 - 6.9 Bar (20 - 100 psig)

Low Pressure Flow 500 Lpm (18 scfm)
125 - 500 Lpm (4.4 - 18 scfm) {models with optional MFC-1}
Media EPM grade Gaseous Oxygen
Oxygen Purity 93 ± 3%
DISCHARGE AND CALIBRATION PORTS
Discharge 3/4 inch, Internal NPT Fitting

Calibration 1/4 inch, Tube, Swagelok Compression Fitting
BLOWER MODULE
Height 208 cm (82 inch)

Width 178 cm (70 inch)
Depth 112 cm (44 inch)
Exterior Volume 4.2 m3 (147 ft3)
Weight 1,216 kg (2,681 lb)
Lift Capabilities Forklift Slots
1-4 350201F
IDOCS & MDOCS
500-55 (-CE)
VSA MODULE
Height 188 cm (74 inch)

Width 180 cm (71 inch)
Depth 170 cm (67 inch)
3
Exterior Volume 5.8 m (203 ft3)
Weight 1,486 kg (3,277 lb)
Lift Capabilities Forklift Slots
1.5 COMPONENT DESCRIPTION AND LOCATION
8
1
3
10
4
11
5
12
6
13
Figure 1-2. Blower Module (MDOCS-CE shown)
350201F 1-5
IDOCS & MDOCS
500-55 (-CE)
Table 1-2. Blower Module Components
ITEM COMPONENT DESCRIPTION

Five (5) blade fan assembly coupled directly to the air blower heat exchanger fan
Air Blower Heat Exchanger Fan
1 motor (MTR-2). the fan assembly pushes the cooling air through the air blower
(FX-100)
heat exchanger (HX-100)
Air Blower Heat Exchanger Outlet
2 Resistive Temperature Detector Monitors the heat exchanger (HX-100) outlet air temperature
(RTD-2)
Air-to-gas fin-and-tube type heat exchanger. With 24 scmm (850 scfm) product
Air Blower Heat Exchanger gas and 113 scmm (4000 scfm) cooling air, 177°C (350°F) inlet gas temperature
3
(HX-100) produces 48°C (118°F) outlet gas temperature. Cools the air blower (BL-100)
discharge air
Blower Discharge Resistive
4 Monitors the blower (BL-100) discharge air temperature
Temperature Detector (RTD-1)
Low pressure two-lobe rotary blower coupled to the air blower motor (MTR-1)
supplies 24 scmm (856 scfm) output (max) at 0.28 Bar (4 psig) with 4180 RPM.
5 Air Blower (BL-100) The blower forces low pressure air into the VSA tank (C-300) during the pressure
cycle. During the vacuum cycle, pulls a vacuum on the VSA tank removing
contaminants
Air Blower/Motor (BL-100/MTR-1) Two (2) elastomer element coupling the air blower motor (MTR-1) to the air blower
6
Coupling (BL-100). Capable of 260 Nm (2300 in-lb) torque at 6600 RPM
Air silencer connected to the air blower (BL-100) down stream from the intake air
7 Air Blower In Silencer (S-100)
supply filter (F-3), attenuates 28 - 33 dBA
3 horse power electric motor coupled directly to the air blower heat exchanger fan
Air Blower Heat Exchanger Fan
8 (FX-100). Supplies rotation to the air blower heat exchanger fan pushing cooling
Motor (MTR-2)
air through the air blower heat exchanger (HX-100)
Air Blower Discharge Silencer Air silencer connected to the air blower (BL-100) up stream from the air blower
9
(S-200) heat exchanger (HX-100)
Removes control power from the system; does not remove input power (Vac)
10 Emergency-Stop Switch (SW-2)
{IDOCS-CE & MDOCS-CE}
50 horse power electric motor coupled to the air blower (BL-100). Supplies rotation
11 Air Blower Motor (MTR-1) (3600 RPM) to the air blower. The motor drives blower air into the VSA tank and
reverses direction to pull a vacuum on the VSA tank, then repeats
12 Coupling Guard Protects personnel from turning equipment {IDOCS-CE & MDOCS-CE}
High flow air filter with moisture resistant media. Air flow up-to 6.8 - 9.6 scmm
13 Air Intake Filter (F-3)
(240 - 340 scfm)
1-6 350201F
IDOCS & MDOCS
500-55 (-CE)
1 9
2 10
4
11
7 12
13
14
15
22
16
23
17
18
19 24
20 25
26
21
Figure 1-3. VSA Module (MDOCS-CE shown)
350201F 1-7
IDOCS & MDOCS
500-55 (-CE)
Table 1-3. VSA Module Components

34 mBar (0.5 psig) crack pressure. Prevents product back flow from the buffer tank
1 Product Check Valve (CV-1)
(C-400) into the VSA tank (C-300) during the vacuum cycle
VSA Tank Pressure Transducer
2 Monitors the VSA tank (C-300) pressure
(XT-2)
Houses the booster compressor (C-1) and associated components, routing
3 Distribution Box
solenoids and product filters
1/4 inch, Tube, Swagelok Compression Fitting. Used as the input port for the
4 Calibration Port (CC-1)
calibration gas required to calibrate the Plant
5 Purge Receiver Tank (C-500) Product storage tank used as source of purge oxygen during the vacuum cycle.
Bidirectional normally closed 0.034 - 18 Bar (0.5 - 257 psig) 24 Vdc valve. Opens
Purge Receiver Fill/Drain Solenoid
6 at the end of the pressure cycle to fill the purge receiver tank (C-500), closes, then
Valve (SV-5)
opens during the vacuum cycle to purge the VSA tank (C-300) and closes
7 Purge Receiver Tank Vent Valve Ball Valve used to vent the purge receiver tank for storage or shipment
8 Purge Receiver Tank Vent Muffler Exhaust muffler reduces the sound caused by venting oxygen from tank
9 Electrical Cabinet Houses the electronics required to operate the Plant
Sounds when the product oxygen purity is below the purity setpoint
10 Product Purity Alarm Horn (H-1)
{MDOCS (-CE)}
11 VSA Tank (C-300) Contains the sieve material adsorbing the gases in air to release enriched oxygen
12 Interconnect Piping Connects the blower module discharge to the VSA tank inlet
Buffer Tank Pressure Safety Valve Pressure safety valve limiting the buffer tank (C-400) pressure to 1.1 Bar
13
(PSV-1) (16 psig)
150 Amp, 600 Vac circuit breaker, protects the Plant from the potential current in
14 Main Circuit Breaker (CB-1)
the sight power source
Operator interface to the Plant. It has the membrane push buttons and display
15 Operator Control Panel
required for the operation tasks
16 Ethernet Communication Port (J-3) External ports for communication to the variable frequency drive (VFD-2)
17 Ethernet Communication Port (J-1) External ports for communication to the controller PCB (A-1)
Red mushroom head push button, removes 120 Vac control power from the
18 Emergency-Stop Button (SW-1)
system. Does not remove 3-phase power from the cabinet.
19 Ethernet Communication Port (J-2) External ports for communication to the variable frequency drive (VFD-1)
Low Purity Alarm Silence Button
20 Push button disables the low purity alarm for thirty (30) minutes {MDOCS (-CE)}
(PB-1)
Product storage tank with inlet/outlet strainers. This tank has sieve material
21 Buffer Tank (C-400)
designed to capture more product per volume than can be stored in an empty tank
Houses the oxygen product analyzer/sensor (AE-1) {IDOCS (-CE)}
Oxygen Product Analyzer Box
22 Houses the oxygen product sensor (AE-1) (requires a separate analyzer (AE-2))
(see Figure 1-5 on page 1-10)
{MDOCS (-CE)}
Product Discharge Pressure Connected to discharge port, shows the product discharge pressure
23
Gauge (PI-3) {MDOCS (-CE)}
24 Product Discharge Port 3/4 inch, internal NPT Fitting
Purge Receiver Pressure
25 Monitors the pressure in the purge receiver tank (C-500)
Transducer (XT-4)
Buffer Tank Pressure Transducer
26 Monitors the pressure in the buffer tank (C-400)
(XT-3)
1-8 350201F
IDOCS & MDOCS
500-55 (-CE)
7 8 9 10 11 12 13
1
14
15
3 16
4
17
18
5
19
20
21
Figure 1-4. Distribution Box (MDOCS-CE shown)
Table 1-4. Distribution Box Components

Booster Heat Exchanger Fan 15.6 scmm (550 scfm), 33 Watt tubeaxial fan. Pushes cooling air through the
1
(FX-200) booster discharge heat exchanger (HX-200)
Booster Heat Exchanger 9400 BTUH @ 7.6 Lpm (2 gpm), tube-n-fin heat exchanger. Cools the booster
2
(HX-200) compressor (C-1) discharge
Converts the current from the oxygen sensor (AE-1) to a 4-20 mA signal
3 Oxygen Sensor Analyzer (AE-2)
{MDOCS (-CE)}
Booster Compressor Motor
4 5 horse power, 3600 RPM motor. Coupled to the booster compressor (C-1)
(MTR-3)
Booster Compressor Motor Fan 8.5 scmm (300 scfm), 50 Watt tubeaxial fan. Cools the booster compressor motor
5
(FX-300) (MTR-3)
Elastomeric polyurethane flexible coupling elements transfer motor power to
6 Booster Coupling (C-1 to MTR-3)
compressor
Booster Heat Exchanger Fan 15.6 scmm (550 scfm), 33 Watt tubeaxial fan. Pushes cooling air through the
7
(FX-201) booster discharge heat exchanger (HX-200)
Booster Compressor Discharge
8 Resistive Temperature Detector Monitors the booster compressor (C-1) discharge temperature
(RTD 3)
Booster Heat Exchanger Outlet
9 Resistive Temperature Detector Monitors the booster heat exchanger outlet temperature
(RTD-4)
0.01 micron particulate/coalescing filter. Filters the inlet oxygen to the booster
10 Booster Inlet Filter (F-4)
compressor (C-1)
Buffer Tank Outlet Check Valve 34 mBar (0.5 psig) crack pressure. Prevents booster compressor (C-2) back flow
11
(CV-3) into the buffer tank (C-400)
350201F 1-9
IDOCS & MDOCS
500-55 (-CE)
Table 1-4. Distribution Box Components (Continued)

Product Discharge Pressure 8.6 Bar (125 psig) relief valve. Limits the booster compressor (C-1) discharge
12
Safety Valve (PSV-2) pressure to 8.6 Bar (125 psig)
13 Product Particulate Filter (F-1) 0.01 micron particulate/coalescing filter. Filters the oxygen product discharge
Product Discharge Pressure
14 Monitors the booster compressor (C-1) discharge pressure
Transducer (XT-1)
Product Discharge Check Valve 34 mBar (0.5 psig) crack pressure. Prevents discharge back flow to the booster
15
(CV-4) compressor
16 Off-Spec Solenoid Valve (SV-3) Two-way solenoid valve. Routes below purity setpoint oxygen to atmosphere
Sample/Calibration Solenoid Three-way solenoid valve. Routes oxygen product to oxygen analyzer (AE-1) or
17
Valve (SV-2) connects calibration port (CC-1) to the oxygen analyzer (AE-1)
Oxygen Analyzer Pressure 0.9 Bar (13 psig) pressure regulator, sets the pressure to the oxygen analyzer
18
Regulator (PRV-1) (AE-1)
19 Product Solenoid Valve (SV-4) Two-way solenoid valve. Routes product to the discharge port
20 Mass Flow Controller (MFC-1) Controls the product discharge flow {Optional}
5 horse power, 3250 RPM scroll compressor. Compresses product oxygen
21 Booster Scroll Compressor (C-1)
1.4 - 6.9 Bar (20 - 100 psig)
IDOCS (-CE) MDOCS (-CE)
Figure 1-5. Oxygen Sensor Box
Table 1-5. Oxygen Sensor Box Components

1 Oxygen Analyzer/Sensor (AE-1) Analyzer/Sensor - Converts oxygen purity to a voltage for the PLC {IDOCS (-CE)}
Sensor - Converts oxygen purity to a current for the analyzer (AE-2)
2 Oxygen Sensor (AE-1)
{MDOCS (-CE)}
1-10 350201F
IDOCS & MDOCS
500-55 (-CE)
2, 3, 4, 5,
6, 7, 8 & 9
19
10
11, 12 & 13
20, 21 & 22
23
14
24
25
26
27
15, 16, 17
& 18
Figure 1-6. Electrical Cabinet Back Panel
Table 1-6. Electrical Cabinet Back Panel Components

1 Cooling Fans (FAN-1 & 2) 3.1 - 3.7 scmm (110 - 130 scfm) Tubeaxial fans. Cools the electrical cabinet
2 Power Supply (PS-1) 24 Vdc, 5 Amp power supply for controller PCB (A-1)
15 Amp, 24 Vdc relay. Connects 120 Vac to the motor contactor (M-1) and cabinet
3 Motor Start Relay (R-24)
fans (FAN-1 & 2)
Booster Heat Exchanger Cooling
4 1-6/10 Amp - protects the booster heat exchanger fans (FX-200 & FX-201)
Fans Fuse (FU-10)
5 Booster Motor Fan Fuse (FU-11) 3 Amp - protects the booster motor (MTR-3) cooling fan (FX-300)
350201F 1-11
IDOCS & MDOCS
500-55 (-CE)
Table 1-6. Electrical Cabinet Back Panel Components (Continued)

6 Vac Outlet Fuse (FU-12) 2 Amp - protects the optional Vac outlet
7 Spare Fuse Spare
8 Signal Conditioner (SC-1) Optional signal conditioner for remote communication
9 Signal Conditioner (SC-2) Optional signal conditioner for remote communication
Operator Interface to the system; has the components and software for Plant
10 Controller PCB (A-1)
operation
11 Terminal Board (TB-63) Connection terminals for wiring equipment interface to A-1
12 Terminal Board (TB-4) Connection terminals for wiring oxygen sensor interface to A-1
13 Terminal Board (TB-1) Connection terminals for wiring control power to components
Variable Frequency Drive
14 50 horse power drive for air blower motor (MTR-1)
(VFD-1)
15 Control Power Transformer (T-1) 750 VA, 2-phase to single 120 Vac transformer supplying 120 Vac control power
2-1/2 or 3-2/10 Amp - protects control power transformer (T-1) from 1-phase of
16 Control Transformer Fuse (FU-7)
power
2-1/2 or 3-2/10 Amp - protects the control power transformer (T-1) from 1-phase of
17 Control Transformer Fuse (FU-8)
power
18 Control Power Fuse (FU-9) 10 Amp - protects the components down stream of control power transformer (T-1)
Main Power Circuit Breaker
19 150 Amp, 3-phase circuit breaker. Protects the Plant from 3-phase line (site) power
(CB-1)
20 VFD-2 Line Fuse (FU-1) 15 Amp - protects variable frequency drive (VFD-2) from 1-phase of power
Variable Frequency Drive
23 3 horse power drive for booster compressor motor (MTR-3)
(VFD-2)
24 Motor Starter (MCP-1) 4 - 6.3 Amp motor starter - starts air blower heat exchanger fan motor (MTR-2)
25 Power Distribution Block (PDB-1) Terminal block for 3-phase power distribution
26 Motor Contactor (M-1) 9 Amp motor contactor - protects air blower heat exchanger fan motor (MTR-2)
27 Line Reactor (LR-1) 83 Amp, 3% line reactor - maintains steady line power during site power variations
1-12 350201F
IDOCS & MDOCS
500-55 (-CE)
1.6 THEORY OF OPERATION
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 in the air other than oxygen; 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 adsorb on the sieve while the oxygen passes through and is collected
downstream of the sieve bed in high concentrations. After a while, the sieve becomes saturated with the
contaminants.
The direction of flow through the sieve bed is then reversed, lowering the bed pressure. The sieve releases
the adsorbed gases. Some of the concentrated oxygen is introduced in the reverse flow stream to aid in the
purge. 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).
1.7 SYSTEM OPERATION
WARNING: An unmetered discharge from the Plant can cause low output performance and insufficient
oxygen production. The discharge of the IDOCS (-CE) & MDOCS (-CE) models is not metered or
controlled by the Plant. The oxygen flow must be metered or controlled by the down-stream equipment or
system.
Low flows (< 25% maximum capacity) can cause heat buildup in the booster compressor damaging the
internal components.
Refer to the Process and Instrumentation Diagram (P&ID) and Electrical Schematics in Appendix B.
On start-up, the air blower motor (MTR-1) drives the air blower (BL-100) in a one-time vacuum phase with
no purge to clean the system. Reversing the air blower motor (MTR-1) drives the air blower (BL-100)
drawing ambient air in through air supply filter (F-3) and air blower-in silencer (S-100) to the air blower
(BL-100). The air blower accelerates the air forcing it past the air blower discharge resistive temperature
detector (RTD-1) through the air blower discharge silencer (S-200), air blower heat exchanger (HX-100),
past air blower heat exchanger outlet resistive temperature detector (RTD-2) and to the VSA tank (C-300).
The oxygen is not adsorbed and passes through product check valve (CV-1) to the buffer tank (C-400).
When the pressure (monitored by XT-2) reaches the maximum setpoint; air blower motor stops, purge
receiver fill/drain solenoid valve (SV-5) opens routing product oxygen (at low pressure) to purge receiver
tank (C-500), the solenoid valve closes trapping the oxygen in the tank. This is the pressure phase.
The air blower motor reverses direction reversing the air blower. The pressure is lowered to a vacuum and
the adsorbed gases are released and flow out through the air blower heat exchanger, blower discharge
silencer, air blower, air blower-in silencer and air supply filter to atmosphere. At the maximum vacuum
setpoint (monitored by XT-2), purge receiver fill/drain solenoid valve opens routing the stored product
oxygen in the purge receiver tank to the VSA tank flushing it with product oxygen. The purge solenoid valve
then closes. This is the vacuum phase.
The pressure and vacuum phases are cycled until power is removed.
350201F 1-13
IDOCS & MDOCS
500-55 (-CE)
When the setpoint pressure is reached (monitored by XT-3), the booster compressor (C-1) runs drawing
product oxygen through buffer tank outlet check valve (CV-3) and booster inlet filter (F-4) to the booster. The
booster compresses the oxygen 1.4 - 6.9 Bar (20 - 100 psig) discharging it past booster discharge resistive
temperature detector (RTD-3) through booster heat exchanger (HX-200), past booster heat exchanger
resistive temperature detector (RTD-4),through booster check valve (CV-4) and product particulate filter
(F-1).
The compressed product oxygen is monitored by booster discharge pressure transducer (XT-1) to keep the
discharge pressure at the discharge pressure setpoint. Product oxygen flows through sample/calibration
solenoid valve (SV-2) {steady state is open to product oxygen}, is limited by oxygen analyzer pressure
regulator (PRV-1) and oxygen analyzer orifice (OR-1), and sampled by the oxygen sensor (AE-1).
When the product oxygen purity is lees-than the purity setpoint, the product oxygen flows through off-spec
solenoid valve (SV-3) {steady state is open} and off-spec orifice (OR-2) to atmosphere.
When the product oxygen purity is higher-than or equal-to the purity setpoint, off-spec solenoid valve closes.
Product solenoid valve (SV-4) opens routing the product oxygen to the discharge port.
MDOCS (-CE) - Product discharge port has a 0 - 21 Bar (0 - 300 psig) pressure gauge (PI-3).
{Optional} - These Plants do not have flow control. An optional in-line mass flow controller (MFC-1) can be
added. If it is not added, your inlet line must have a flow control device.
1-14 350201F
IDOCS & MDOCS
500-55 (-CE)
1.8 ACCESS PANELS AND DOORS
These panels and doors (used for maintenance access) must be installed and closed during operation
(see Figure 1-7 on page 1-16).
Table 1-7: Plant Access Panels and Doors
ITEM DESCRIPTION COMPONENTS ACCESSED
Blower Module Lid Air Blower Heat Exchanger (HX-100), Air Blower Heat Exchanger Fan Motor (MTR-2) &
1
Assembly Air Blower Heat Exchanger Fan (FX-100)
Blower Module Access Air Supply Filter (F-3), Air Blower In Silencer (S-100), Air Blower (BL-100), Air Blower
2
Panel Assembly Discharge Resistive Temperature Detector (RTD-1), Air Blower Discharge Silencer
Blower Module Air Access (S-200), Air Blower Heat Exchanger (HX-100), Air Blower Motor (MTR-1) & Air Blower/
3 Motor Coupling
Panel Assembly
Buffer Tank Outlet Check Valve (CV-3), Booster Compressor (C-1), Booster Compressor
Discharge Resistive Temperature Detector (RTD-3), Booster Compressor Motor (MTR-3),
Booster Compressor Motor Fan (FX-300), Booster Heat Exchanger (HX-200), Booster
Heat Exchanger Fan (FX-200), Booster Heat Exchanger Fan (FX-201), Booster Heat
Exchanger Resistive Temperature Detector (RTD-4), Booster Inlet Filter (F-4), Product
Distribution Box Access
4 Discharge Pressure Safety Valve (PSV-2), Product Particulate Filter (F-1), Product
Panel Assembly
Discharge Pressure Transducer (XT-1), Product Discharge Check Valve (CV-4), Sample/
Calibration Solenoid Valve (SV-2), Oxygen Analyzer Pressure Regulator (PRV-1),
Oxygen Analyzer Orifice (OR-1), Off-Spec Solenoid (SV-3), Off-Spec Orifice (OR-2),
Product Solenoid Valve (SV-4), Oxygen Analyzer (AE-2) {MDOCS (-CE)} & Mass Flow
Controller (MFC-1) {Optional}
Distribution Box Access
5 Same components accessed by the Distribution Box Access Panel Assembly
Window Panel Assembly
Oxygen Analyzer/Sensor (AE-1) {IDOCS (-CE)}
6 Oxygen Analyzer Box Door
Oxygen Sensor (AE-1) (requiring analyzer (AE-2)) {MDOCS (-CE)}
Cooling Fans (FAN-1 & 2), Signal Conditioner (SC-1), Alarm Time Delay Relay (TDR-1),
Alarm Solid State Relay (SSR-1), Controller PCB (A-1), Power Supply (PS-1), Motor Start
Relay (R-24), Booster Heat Exchanger Cooling Fans Fuse (FU-10), Booster Motor Fan
Fuse (FU-11), Signal Conditioner (SC-2), Variable Frequency Drive (VFD-1), Control
7 Electrical Cabinet Door Power Transformer (T-1), Control Transformer Fuse (FU-7), Control Transformer Fuse
(FU-8), Control Line Fuse (FU-9), Main Power Circuit Breaker (CB-1), VFD-2 Line Fuse
(FU-1), VFD-2 Line Fuse (FU-2), VFD-2 Line Fuse (FU-3), Variable Frequency Drive
(VFD-2), Motor Starter (MCP-1), Power Distribution Block (PDB-1), Motor Contactor (M-1)
& Line Reactor (LR-1)
8 Operator Panel Door Operator Panel
350201F 1-15
IDOCS & MDOCS
500-55 (-CE)
7
5
Figure 1-7. Plant Access Panels and Doors (MDOCS shown)
1-16 350201F
IDOCS & MDOCS
500-55 (-CE)
1.9 ACRONYMS AND ABBREVIATIONS
ACR/ABB DESCRIPTION
A - - - - - - - - - - - - - - - Amps
ACR/ABB - - - - - - - - - Acronyms / Abbreviations
ANSI/ASME - - - - - - - American National Standards Institute / American Society of Mechanical Engineers
AWG - - - - - - - - - - - - American Wire Gauge
DOCS - - - - - - - - - - - Deployable Oxygen Concentration System
FLA - - - - - - - - - - - - - Full Load Amperage
Gal - - - - - - - - - - - - - Gallon (3.8 Liters)
GND - - - - - - - - - - - - - Ground
HP - - - - - - - - - - - - - - High Pressure
hp - - - - - - - - - - - - - - horse power
Hz - - - - - - - - - - - - - - Hertz
ID - - - - - - - - - - - - - - Internal Diameter
LPM - - - - - - - - - - - - - Liters Per Minute
mH - - - - - - - - - - - - - milliHenrys
mt - - - - - - - - - - - - - - metric ton
N/A - - - - - - - - - - - - - Not Applicable
NC - - - - - - - - - - - - - - Normally Closed
NEC - - - - - - - - - - - - - National Electrical Code
NO - - - - - - - - - - - - - - Normally Open
NOM - - - - - - - - - - - - Nominal
NPT - - - - - - - - - - - - - National Pipe Thread
OEM - - - - - - - - - - - - Original Equipment Manufacture
Oz - - - - - - - - - - - - - - Ounce (28 grams) {30 milliliters}
P&ID - - - - - - - - - - - - Process and Instrumentation Diagram
psia - - - - - - - - - - - - - pounds per square inch absolute
PSIG - - - - - - - - - - - - Pounds per Square Inch Gauge
PTF - - - - - - - - - - - - - Pipe Thread Fine
PTFE - - - - - - - - - - - - PolyTetraFluoroEthylene (Teflon®)
Qt - - - - - - - - - - - - - - Quart (0.95 Liter)

RFI - - - - - - - - - - - - - Radio Frequency Interference
RH - - - - - - - - - - - - - - Relative Humidity
SCFM - - - - - - - - - - - Standard Cubic Feet per Minute
SCMM - - - - - - - - - - - Standard Cubic Meters per Minute
V - - - - - - - - - - - - - - - Volts
VA - - - - - - - - - - - - - - Volt-Amps
Vac - - - - - - - - - - - - - Volts alternating current
350201F 1-17
IDOCS & MDOCS
500-55 (-CE)
ACR/ABB DESCRIPTION
Vdc - - - - - - - - - - - - - Volts direct current

VSA - - - - - - - - - - - - - Vacuum Swing Adsorption
XT - - - - - - - - - - - - - - Pressure Transducer
1-18 350201F
IDOCS & MDOCS
500-55 (-CE)
CHAPTER 2
PREPARATION FOR USE
2.1 SCOPE
This chapter has the procedures to prepare the Plant for use. These procedures have instructions for:
 Site and location requirements and installation
 Commissioning
CAUTION: Only factory trained professional technicians must set up, operate and do maintenance on
the DOCS.
2.2 SITE REQUIREMENTS
WARNING: Nitrogen buildup can displace oxygen and cause asphyxiation or death. The Plant exhausts
nitrogen. The nitrogen can buildup in a closed area. Make sure the site has as a minimum ≥ 57 scmm
(2,012 scfm) air turn-over to eliminate the buildup of nitrogen.
Concentrated oxygen can cause explosive fires. The Plant vents off-spec oxygen. Make sure the site has
as a minimum ≥ 57 scmm (2,012 scfm) air turn-over to eliminate the buildup of oxygen.
Low air turn-over can deplete the intake air and cause low purity and pressure product gas. To prevent
alarm conditions, make sure the site has as a minimum ≥ 57 scmm (2,012 scfm) air turn-over.
CAUTION: If the site is higher-than 305 m (1000 ft) above sea level, contact PCI before installing the
Plant (refer to Foreword).
 The Site:
 Must have 460 Vac ± 10%, 60 Hz ± 3%, 3-phase @ 100 Amp electrical power for P/Ns:
 796926-011 (IDOCS) & -013 (MDOCS)
 799675-001 (IDOCS-CE)
 799676-001 (MDOCS-CE)
 Must have 380 Vac ± 10%, 50 Hz ± 3%, 3-phase @ 120 Amp electrical power for P/Ns:
 796926-012 (IDOCS) & -014 (MDOCS)
 799675-002 (IDOCS-CE)
 799676-002 (MDOCS-CE)
 Site power source must have 120 Amp protection.
NOTE: Use a volt meter and make sure the site power is within 10% of the voltage listed on the DOCS
nameplate. Contact PCI if the voltage is outside the 10% limit (refer to Foreword).
350201F 2-1
IDOCS & MDOCS
500-55 (-CE)
 Must be outside with ≥ 113 scmm (4,000 scfm) air turn-over

 If inside, extra ventilation is required to maintain standard ambient conditions and ≥ 11 scmm
(375 scfm) air turn-over
 Must not have smoking, open flames or other ignition sources within 15 m (50 ft) of the Plant
 Must be free of trash and debris causing a fire hazard, trip hazard or accumulate on cooling vents
and filter elements.
 Tarps, tents or containers must not reduce the air circulation around Plant or trap oxygen and
nitrogen being vented (off-spec oxygen is vented).
 Must be protected; with free access limited to authorized people only
 Must have sufficient space around the Plant for access to operation and maintenance tasks
 The Plant:
 Must be installed away from motor pools, fuel farms, diesel generators and other similar
hydrocarbon and exhaust emitting equipment or areas to prevent ingestion of fumes
 Must be operated on a relatively level surface, not on a slope or incline
 Must be operated in an area free of standing water and not in an area prone to flooding
 Must be protected from blowing dust, dirt, sand, rain, sleet and snow
 Must be shaded from direct sunlight
 Must be put in an area where equipment noise is not objectionable
2.3 EQUIPMENT LOCATION
Put the Plant within 5 m (16 ft) of the system requiring oxygen supply. The Plant must be outside in an area
closest to the expected highest demand requirement.
2.4 UNPACK THE PLANT
1. Remove the wooden shipping crate and other packing materials, as applicable.
2. Do a damage check on indicators, push buttons and the operator panel.
3. On the blower module, look for damage to the fiberglass air panels and access panels.
4. Release the latches and remove the blower module air access and access panels.
a. Make sure all installed components are attached to their mounting surfaces.
b. Make sure all pipes are tightly connected.
c. Examine the motor/blower coupling for cracks or misalignment.
5. Install and latch the bower module access panel and air access panel.
6. On the VSA module, release the latches and open the electrical cabinet access door.
a. Make sure wiring harnesses and connectors are connected.
7. Close and latch the cabinet access door.
8. On the distribution box; release the latches and remove the access window panel assembly.
a. Do a damage check on the window panel assembly latches.
b. Make sure the wiring and connections are connected.
c. Make sure all hoses and tubes are connected.
9. Install and latch the access window panel assembly.
10. Do a damage check on the product outlet and calibration ports.
2-2 350201F
IDOCS & MDOCS
500-55 (-CE)
11. Report all deficiencies to PCI (refer to Foreword).
2.5 COMMISSION THE PLANT
REQUIRED EQUIPMENT
Fork Truck (2 mt (2.2 ton))
1. Use the fork truck and slowly move the modules to the site.
2. Align the VSA and blower modules next to each other as shown in the foundation layout drawing
(see Figure FO-1).
2.5.1 INTERCONNECT PIPING CONNECTION
The Plant modules are mounted on two (2) separate skids requiring the installation of the interconnect
plumbing before operation.
REQUIRED CONSUMABLE
Oxygen Lubricant (Krytox®) (W46040-205)

CAGE - 75906
CAUTION: Contamination in the VSA tank can ruin the sieve material and degrade the output product.
Do not remove covers from the VSA tank inlet, interconnect and blower module outlet pipes until you are
connecting them. Use pre-cautions to prevent the entrance of contaminants.
The connecting pipe clamp has an RTD probe in it. Use care to prevent damage to the probe during
installation.
1. Find the interconnect piping attached to the inlet port on the VSA tank installed on the VSA module
2. Remove the packing and shipping material from the piping.
3. On the elbow, remove the cap.
4. On the blower module discharge pipe, remove the cap and connect the hose assembly elbow with a
pipe clamp and gasket wet with oxygen lubricant.
a. Move the blower module close to the VSA module.
b. Align the blower discharge pipe with the interconnect piping elbow.
c. Put the gasket wet with oxygen lubricant on the discharge pipe and interconnect elbow.
(1) Carefully move the blower module as needed to install gasket.
d. Install the pipe clamp.
350201F 2-3
IDOCS & MDOCS
500-55 (-CE)
PIPE CLAMP WITH GASKET & RTD

INTERCONNECT PIPING ELBOW BLOWER DISCHARGE PIPE
Figure 2-1. Interconnect Piping Connection (MDOCS shown)
2.5.2 INTERCONNECT WIRING CONNECTION
The Plant requires the hookup of the interconnect wiring from the blower module to the electrical cabinet.
WARNING: High voltage creates high current causing injury or death. This plant uses high voltage. Make
sure there is no electrical power connected to the Plant and the site power is off with lock-out/tag-out
applied.
1. On the blower module, cut the cable ties and shipping restraints attaching three (3) cables (wires)
2. Route the flexible conduits around to the bottom of the electrical cabinet.
3. Connect the cable with connector to the connector on the side of the cabinet.
4. Release the latches and open the electrical cabinet access door.
5. Connect the conduits bulkhead connectors to the bottom of the electrical cabinet:
a. On the conduit, remove the conduit elbow nut.
b. Insert the conduit conductors (wires) through the correct hole and install the conduit nut
c. Do Steps a. & b. again connecting the other conduit.
2-4 350201F
IDOCS & MDOCS
500-55 (-CE)
25 MM (1 INCH) CONDUIT (MTR-1)
13 MM (1/2 INCH) CONDUIT (MTR-2)
Figure 2-2. Blower Module Interconnect Cables (IDOCS shown)
T1 T3
T2
6 AWG 14 AWG
WIRES WIRES
Figure 2-3. Blower Module Interconnect Cables Hookup (electrical cabinet)
6. Connect the heat exchanger motor (MTR-2) conduit conductors (wires).

a. Inside the cabinet, route the 14 AWG conductors (wires) from the 13 mm (1/2 inch) conduit up to
motor controller (M-1).
b. Read the wire labels and connect the three 14 AWG conductors to the matching controller
terminals.
c. Connect the ground conductor to the ground terminal next to the motor controller.
350201F 2-5
IDOCS & MDOCS
500-55 (-CE)
7. Connect VFD-1 power conductors and motor sensor wires.

a. On VFD-1, remove the front cover (see Figure 2-3).
b. Route the 6 AWG conductors (wires) from the 25 mm (1 inch) conduit through the cable clamp up
to the terminal block on the VFD.
c. Read the wire labels and connect the conductors to the matching terminals on the output terminal
block.
d. Connect the ground conductor to the ground terminal on the right side of the VFD.
e. Tighten the cable clamp.
f. Connect the motor thermostat wires (two small wires with the motor conductors):
(1) On the upper terminal blocks below the VFD operator panel, read the wire labels and
connect the wires to terminals DI3 and COM (see Figure 2-4).
g. Install the VFD front cover.
MOTOR (MTR-1) SENSOR WIRES
Figure 2-4. Motor Sensor Wires Connection
8. Close and latch the electrical cabinet access door.
IF THEN
a. Below the electrical cabinet, find, uncoil and route the
emergency-stop cable (CBL-101) to the connector on the
IDOCS-CE or MDOCS-CE rear of the blower module next to the electrical cabinet
b. Connect the cable to connector (P-101).
IDOCS or MDOCS a. Continue
2-6 350201F
IDOCS & MDOCS
500-55 (-CE)
P-101 CBL-101
Figure 2-5. Blower Module Emergency-Stop Cable and Connector (MDOCS-CE shown)
2.5.3 ELECTRICAL POWER CONNECTION
WARNING: High voltage creates high current causing injury or death. The site power is high
voltage. Make sure the site power is OFF and lock-out/tag-out applied before connecting to or
disconnecting from the site power source.
1. Remove power from the site power source (turn facility power OFF).
a. Make sure the 3-phase electrical source is capable of:
 460 Vac, 60 Hz, 3-phase, 80 FLA
 796926-011 (IDOCS) & -013 (MDOCS)
 799675-001 (IDOCS-CE)
 799676-001 (MDOCS-CE)
 380 Vac, 50 Hz, 3-phase, 100 FLA
 796926-012 (IDOCS) & -014 (MDOCS)
 799675-002 (IDOCS-CE)
 799676-002 (MDOCS-CE)
350201F 2-7
IDOCS & MDOCS
500-55 (-CE)
b. The site electrical power source must have 120 Amp protection.
2. Lock-out/tag-out the site power source.
3. Route a three conductor + ground jacketed cable or individual conductors (three + ground) through
conduit from the site power source to the Plant.
a. Refer to the Euro-codes or local building codes for cable and conductor type and size.
5. On the bottom of the cabinet, route the conductors + ground (with conduit or cable) through the conduit
elbow.
a. If routing conduit, connect the conduit to the elbow.
6. Route the conductors + ground to the top of the cabinet and circuit breaker (CB-1).
7. Remove the conductor insulation:
IF THEN
a. Remove approximately 15 cm (6 inch) of cable jacket
insulation from the cable end.
Jacketed Cable
b. On each conductor, remove approximately 25 mm (1 inch) of
insulation from the conductor end.
a. On each conductor, remove approximately 25 mm (1 inch) of
Individual conductors
insulation from the conductor end.
8. Connect the conductors to the top of circuit breaker (CB-1) (see Figure 2-6).
9. Connect the ground conductor to the ground terminal strip.
11. Remove the lock-out/tag-out from the site power source.
L1 L2 L3 GND
Figure 2-6. Circuit Breaker (CB-1) Input Power Connections (electrical cabinet)
2-8 350201F
IDOCS & MDOCS
500-55 (-CE)
2.5.3.1 INPUT POWER PHASE
Use these instructions to do the input power phase sequence check. An incorrect input power phase
sequence forces the electrical motors to turn in the opposite direction. This condition causes backward fan
turning leading to incorrect cooling and system failure. These instructions list correction steps if required.
1. Set the site power source to ON.
2. On the electrical cabinet, set circuit breaker (CB-1) to ON.
3. Pull-out or twist the Emergency-Stop button (de-activate).
a. Pull-out or twist the Emergency-Stop button on the blower module {IDOCS-CE & MDOCS-CE}
4. On the operator panel, open the access door and stop until the Normal screen shows (see Figure 2-7).
Figure 2-7. Normal Screen (LCD)
5. Push and hold (at same time) the (+) and (–) buttons until the Setup Entry screen shows:
IF THEN
a. See Figure 2-8.
Model without optional MFC-1 b. Push the NEXT button eight (8) times to show the eight
screens in Figure 2-10 on page 2-10.
a. See Figure 2-9 (left screen).
Model with optional MFC-1 b. Push the NEXT button nine (9) times to show the right screen
in Figure 2-9 and the eight screens in Figure 2-10.
6. On the Direct IO Stops DOCS screen, push the (+) button to show the Direct IO Fault Input screen
7. Push the NEXT button four (4) times to show these screens (see Figure 2-12 on page 2-10).
8. On the VSA Main Cooler screen, push the (+) button.
The top line changes to VSA MAIN COOLER ON and the air blower heat exchanger fan (FX-100) turns.
Figure 2-8. Setup Screen (pressure)
Figure 2-9. Setup Screen (flow)
350201F 2-9
IDOCS & MDOCS
500-55 (-CE)
Figure 2-10. Out Press to Direct IO Screens
Figure 2-11. Direct IO Fault Input Screen
Figure 2-12. VSA FWD, VSA REV, SCR FWD & VSA Main Cooler Screens
9. Put a piece of paper or a dollar bill on the blower module cooling air outlet vent
IF THEN
The paper or dollar is blown away from
Go-to Step 20. on page 2-11.
the vent
The paper or dollar is pulled in the vent Continue
10. Push the (–) button and the top line shows VSA MAIN COOLER OFF.
11. Push and hold (at same time) the (+) and (–) buttons to show the Normal screen (see Figure 2-7)
12. Set circuit breaker (CB-1) to OFF.
13. On the site power source, set to OFF.
14. Lock-out/tag-out the site power source.
2-10 350201F
IDOCS & MDOCS
500-55 (-CE)
PUT PIECE OF
PAPER OR DOLLAR
BILL HERE
Figure 2-13. Blower Module Cooling Air Outlet Vent (IDOCS shown)
WARNING: High voltage creates high current causing injury or death. The inside of the
electrical cabinet has high voltage present. Make sure the site power source is locked-out and
tagged-out before opening the electrical cabinet access door.
15. On the Plant, release the latches and open the electrical cabinet access door.
16. On top of circuit breaker (CB-1), swap two (2) power input conductors (see Figure 2-6 on page 2-8).
 L1 - L2 or
 L2 - L3 or
 L1 - L3
18. On the site power source, remove the lock-out/tag-out.
19. Do Steps 1. - 9. again.
20. Push the (–) button and the top line shows VSA MAIN COOLER OFF.
21. Push and hold (at same time) the (+) and (–) buttons to show the Normal screen (see Figure 2-7).
2.5.4 ALTITUDE ADJUSTMENT
The altitude where the Plant is commissioned has an effect on the performance of the system. Altitudes
≤ 305 m (1000 ft) above sea level do not adversely effect the system. Altitudes > 305 m (1000 ft) above sea
level require a system adjustment to maintain the expected performance.
1. Do the instructions in Section 5.2 - Remote Operation and connect a laptop / PC to the Plant.
2. On the Normal screen, click SETTINGS (see Figure 2-14 on page 2-12) to show the User Settings
screen (see Figure 2-15 on page 2-12).
350201F 2-11
IDOCS & MDOCS
500-55 (-CE)
CLICK SETTINGS
Figure 2-14. Normal Screen (Internet)
3. On the bottom of the User Setting screen, click ALTITUDE.

4. Type the site altitude (in feet) and push Enter.
IF THEN
a. Set the flow rate, go-to Section 2.5.5 on page 2-13 and start
Model with optional MFC-1
with Step 3.
Model without optional MFC-1 a. Go-to Section 2.5.6 on page 2-13 and start with Step 3.
ALTITUDE
FLOWRATE
PRESSURE
Figure 2-15. User Settings Screen
2-12 350201F
IDOCS & MDOCS
500-55 (-CE)
2.5.5 FLOW RATE ADJUSTMENT {WITH OPTIONAL MFC-1}
The models with a mass flow controller (MFC-1) require adjustment for the required flow.
3. On the bottom of the User Setting screen, click FLOWRATE.
4. Type the required output flow (125 - 500 Lpm) and push Enter.
IF THEN
Need to set discharge pressure a. Go-to Section 2.5.6 and start with Step 3.
Discharge pressure is OK (3.8 Bar
a. Click DONE to show the Normal screen.
(55 psig))
5. Shutdown the Internet Explorer.

6. Disconnect the laptop / PC from the Plant.
7. On the Plant, set circuit breaker (CB-1) to OFF.
2.5.6 DISCHARGE PRESSURE ADJUSTMENT
The Plant discharge pressure is factory set to 3.8 Bar (55 psig). Use these instructions to set the discharge
pressure as required 1.4 - 6.9 Bar (20 - 100 psig).
3. On the bottom of the User Setting screen, click PRESSURE.
4. Type the required pressure (20 - 100 psig) and push Enter.
5. Click DONE to show the Normal screen (see Figure 2-14).
8. Set main circuit breaker (CB-1) to OFF.
350201F 2-13
IDOCS & MDOCS
500-55 (-CE)
2.5.7 PRODUCT DISCHARGE PORT CONNECTION
Use these instructions to connect your external piping (hose or tubing) to the product discharge port.
WARNING: Contaminants in enriched oxygen can cause explosive fires. This plant discharges enriched
oxygen. Make sure your connection piping, hose or tube is oxygen clean before connecting it to the Plant
product outlet port. Use pre-cautions to prevent the entrance of contaminants.
1. On the bottom front of the distribution box, remove the cap from the product outlet port and make sure
the port is clean (see Figure 2-16).
a. Clean the port as necessary (refer to Section 6.7).
PRODUCT OUTLET PORT

(3/4 INCH INTERNAL NPT) PRODUCT OUTLET PORT
(3/4 INCH INTERNAL NPT)
IDOCS (-CE) MDOCS (-CE)
Figure 2-16. Product Discharge Port
WARNING: Material not compatible with oxygen can cause material erosion, contaminated oxygen and a
source of combustion. All of these can cause leaks and explosive fires. Make sure all material used is
oxygen compatible.
2. Set up your product inlet plumbing for connection to the Plant product discharge port.
a. Remove the cap from your inlet line and make sure the connector is clean.
b. Connect your line to the 3/4 inch internal NPT product discharge port.
IF THEN
a. Connect a bleed or relief valve and a flowmeter/valve in-line
Model without optional MFC-1
with the product line.
a. Connect a bleed or relief valve in-line with the product line.
Model with optional MFC-1
Theses units have a flow controller in the circuit.
NOTE: Your piping must be sized for your equipment. The discharge port is 1/2 inch; the piping (or hose)
must be at least 1/2 inch. If the piping run is long, the piping diameter must increase to maintain the
pressure required. Consult someone and the local codes on the correct pipe size for the requirement.
2-14 350201F
IDOCS & MDOCS
500-55 (-CE)
2.5.8 CALIBRATION GAS BOTTLE INSTALLATION (OPTIONAL)
The calibration gas bottle gives the operator a ready calibration source for calibrating the on-board oxygen
sensor.
These procedures have instructions for using two (2) different concentrations of oxygen as the calibration
gas. The different oxygen sensors require different concentrations. Some concentrations are easier to find in
certain regions.
REQUIRED EQUIPMENT
Oxygen Calibration Kit (794873-001)

Calibration Gas Cylinder
90 - 95% Oxygen (5 - 10% Nitrogen with balance Oxygen)
or
99.50 - 99.99% Oxygen
CAGE - 75906
NOTE: IDOCS (-CE) models require 99.50 - 99.99% Oxygen for calibration gas.
MDOCS (-CE) models and models with AE-2 require 90 - 95% Oxygen for calibration gas.
WARNING: Contaminants in enriched oxygen can produce explosive fires. The plant product is enriched
oxygen. Make sure all ports and connectors are clean before connecting to this oxygen source. Clean as
necessary (refer to Section 6.7).
Incorrect calibration gas and not obeying this procedure can lead to diminished performance and lack of
correct product production. Make sure you use the correct calibration gas for your model DOCS and obey
these instructions.
1. Connect the oxygen calibration kit on the calibration gas cylinder (see Figure 2-17 on page 2-16).
a. Remove the cap from the gas cylinder.
b. Slowly crack the bottle valve and close again to clear the bottle port.
c. Remove the cap from the calibration kit bottle connector and make sure the connector is clean.
NOTE: The bottle connector is a CGA-540 connector for use with Cal Gas bottles. A connection adaptor
can be required for connection to European type bottles.
d. Connect the kit to the Cal Gas cylinder bottle port.

e. Remove the hose cal port connector cap and slowly crack the bottle valve and close to clear the kit.
2. On the right side of the distribution box, remove the cap from the calibration connection port (CC-1) and
make sure the port is clean (see Figure 2-18 on page 2-16).
3. Connect the hose cal port connector to the Cal port (CC-1).
4. On the Cal Gas cylinder, slowly open the bottle valve.
5. Set the kit regulator to 1.7 - 2.1 bar (25 - 30 psig).
6. On the site power source, set to ON.
350201F 2-15
IDOCS & MDOCS
500-55 (-CE)
CAL PORT CONNECTOR
RELIEF VALVE REGULATOR
GAUGE
BOTTLE CONNECTOR
Figure 2-17. Oxygen Calibration Kit (794873-001)
CC-1
Figure 2-18. Calibration Inlet Port (MDOCS shown)
7. On the Plant electrical cabinet, set circuit breaker (CB-1) to ON.

8. Use one of these procedures to calibrate the system to the installed gas bottle:
a. Look at the part number on the DOCS Nameplate.
b. Find the part number in the INCLUDES column of Table 1-1.
c. Look at the corresponding model in the DESIGNATION column.
d. Do one of these procedures:
 IDOCS (-CE): go-to Section 2.5.8.1 on page 2-17
 MDOCS (-CE) and models with AE-2: go-to Section 2.5.8.2 on page 2-18
2-16 350201F
IDOCS & MDOCS
500-55 (-CE)
2.5.8.1 CALIBRATE OXYGEN ANALYZER / SENSOR {IDOCS (-CE)}
These Plants have an analyzer/sensor requiring calibration to the calibration gas. These Plants can be set
up to run calibration automatically (adjustable interval) or on command (refer to Section 3.6).
1. Enter the Cal gas bottle oxygen purity value (factory default is 90.5%):
a. Do the instructions in Section 5.2 - Remote Operation and connect a laptop / PC to the Plant.
b. On the Normal screen, click SETTINGS (see Figure 2-14 on page 2-12) to show the User Settings
screen (see Figure 2-19).
c. On the bottom of the User Setting screen, click O2CAL %.
d. Enter the Cal gas value:
(1) Type 90.5.
(2) Push Enter.
O2CAL %
O2CAL HRS
e. Select Auto or Manual calibration:
IF THEN
a. Click O2CAL HRS.
b. Type the number of hours between calibrations (usually 24 or
Automatic calibration
48)
c. Push Enter.
a. Click O2CAL HRS.
Manual calibration
b. Type 0 and push Enter.
f. Click DONE to show the Normal screen (see Figure 2-14).

350201F 2-17
IDOCS & MDOCS
500-55 (-CE)
2.5.8.2 CALIBRATE OXYGEN ANALYZER {MDOCS (-CE)}
These Plants have a sensor (AE-1) with a separate analyzer (AE-2). The analyzer is calibrated to the sensor
using the calibration gas.
1. On the distribution box, release the latches and remove the window panel assembly.
2. On the site power source, remove the lock-out/tag-out and set to ON.
3. On the Plant, set main power circuit breaker (CB-1) to ON.
4. When the Normal screen shows on the operator panel, push and hold (at same time) the (+) & (–)
buttons until the Setup Entry screen shows.
IF THEN
a. See Figure 2-20.
Without optional MFC-1 b. Push the NEXT button eight (8) times to show the eight
screens shown in Figure 2-22 on page 2-19.
a. See left side of Figure 2-21.
b. Push the NEXT button nine (9) times to show the right screen
With optional MFC-1
in Figure 2-21 and the eight screens shown in
Figure 2-22.
Figure 2-21. Setup (Flow) and Flow Rate Screens
5. On the Direct IO Stops DOCS screen, push the (+) button to show the Direct IO Fault Input screen
6. Push the NEXT button six (6) times to show the O2 Sample screen (see Figure 2-24 on page 2-19).
7. On the O2 Sample screen, push the (+) button to open the sample solenoid (SV-2).
8. In the distribution box, push the MENU button on the analyzer (AE-2) (see Figure 2-25 on page 2-20).
The system menu shows on the LCD screen.
9. Use the Up/Down buttons to choose E:1 and push Enter.
10. When the indication stabilizes, use the Up/Down buttons to set the displayed value to match the
calibration gas bottle label purity value.
11. Push the Enter button.
2-18 350201F
IDOCS & MDOCS
500-55 (-CE)
Figure 2-22. Out Press to Direct I/O Setup Screens
Figure 2-24. VSA FWD to O2 Sample Direct I/O Screens
12. The analyzer shows a dashed line when calibration is completed.

13. Push the MENU button to close the system menu.
14. On the Plant operator panel with the O2 Sample screen showing, push the (–) button to close sample
solenoid valve (SV-2).
15. Push the NEXT button nine (9) times to show the Exit With Save screen
16. On the Exit With Save screen, push the (+) button.
The Normal screen shows.
350201F 2-19
IDOCS & MDOCS
500-55 (-CE)
LCD
SCREEN
MENU DOWN
ENTER UP
Figure 2-25. Oxygen Analyzer (AE-2)
Figure 2-26. Off-Spec to Exit With Save Direct I/O Screens
2-20 350201F
IDOCS & MDOCS
500-55 (-CE)
2.5.9 REMOTE CONTROL (HARD WIRE)
This procedure has instructions for the wiring of a remote control system (see Figure FO-3).
WARNING: The Plant automatically starts and stops during operation. Remote operation runs the Plant
from a remote location. Make sure there are no people servicing the Plant during remote operation.
1. Power Control:
a. Before connecting the site power to the Plant, connect a 120 Amp 3-phase circuit breaker in-line
with the Plant inlet power circuit breaker (CB-1).
b. Keep the Plant circuit breaker (CB-1) ON.
c. Control Plant power with the new circuit breaker.
2. Monitor Purity:
IF THEN
Signal conditioner (SC-1) installed a. Connect to current loop on SC-1 pins CI+ & CI-.
a. Connect (+) to terminal TB63.66 (0 - 10 Vdc).
Hard wire to TB-63
b. Connect (-) to terminal TB63.56 (ground).
NOTE: TB-63 is found in the electrical cabinet above VFD-1.
3. Monitor Pressure/Flow (output):
IF THEN
Without optional MFC-1 a. The output from the connection is Pressure.
With optional MFC-1 a. The output from the connection is Flow.
a. Connect to one of these:
IF THEN
Signal conditioner (SC-2) installed a. Connect to current loop on SC-2 pins CI+ & CI-.
a. Connect (+) to terminal TB63.64 (0 - 10 Vdc).
Hard wire to TB-63
b. Connect (-) to terminal TB63.56 (ground).
4. Start/Run:
a. Connect one lead of your 24 Vdc capable relay or switch to TB-63 - terminal TB63.55 (REMOTE
RUN).
b. Connect the other lead to TB-63 - terminal TB63.56 (GRND 1).
5. Monitor Alarm:
a. Connect to TB-63 - terminal TB63.67 (ALARM NC).
b. Connect to TB-63 - terminal TB63.68 (ALARM NO).
350201F 2-21
IDOCS & MDOCS
500-55 (-CE)
c. Connect to TB-63 - terminal TB63.63 (ALARM COM).
NOTE: On power-up, Alarm NO is connected to Common with no alarm condition present. When an
alarm occurs, Run NO is connected to Common (Alarm sounds).
2-22 350201F
IDOCS & MDOCS
500-55 (-CE)
CHAPTER 3
OPERATION
3.1 CONTROLS AND INDICATORS
2 9
3 10
4 11
5 START
STOP
FAULT
OVR
O2
CAL
PUR
OVR
PREV NEXT 12
6 13
7 14
8 15
CONTROL LOW LOW PURITY
RUN FAULT
POWER PRESSURE PURITY OVERRIDE
16
Figure 3-1. Operator Panel
Table 3-1. Operator Panel Components

1 LCD Display Display; two (2) 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)
9 O2 CAL Button; enables O2 calibration sequence for oxygen analyzer (AE-1) {IDOCS (-CE)}
10 PUR OVR Button; overrides the low purity product vent, sends product to discharge port
11 PREV Button; shows the previous screen (LCD)
12 NEXT Button; shows the next screen (LCD)
13 LOW PURITY Indicator; red illumination when product purity is less than 90%
14 LOW PRESSURE Indicator; yellow illumination when product pressure is < pressure alarm setpoint
15 PURITY OVERRIDE Indicator; yellow illumination during purity override condition
16 Spare
350201F 3-1
IDOCS & MDOCS
500-55 (-CE)
3.2 PRE-OPERATION
REQUIRED CONSUMABLE
Omega SB 220 Synthetic Oil-Lube (585953-001)

CAGE - 75906
WARNING: High voltage creates high current causing injury or death. The site power is high
voltage. Make sure the site power source is OFF and lock-out/tag-out is applied before opening
the electrical cabinet or doing maintenance.
CAUTION: The DOCS is specialized equipment requiring unique knowledge to operate and maintain.
Untrained operators and technicians can cause incorrect operation and poor product quality. Only factory
trained professional technicians must operate or do maintenance on the DOCS.
1. Do an operation check on the Emergency-Stop button.
IF THEN
a. On the electrical cabinet, pull-out or twist the push-button to
IDOCS or MDOCS
reset the switch (de-activate).
a. On the electrical cabinet, pull-out or twist the push-button to
IDOCS-CE or MDOCS-CE
b. On the blower module, pull-out or twist the push-button to
2. On the blower module, release the latches and remove the air access and access panels.
3. On the air blower (BL-100), look at the oil-lube level in the two sight glasses
IF THEN
a. Remove the fill port plug.
b. Add oil-lube until the level is 1/2 - 2/3 site glass height.
c. Remove the old thread seal tape from the fill port plug.
Level is < 1/2 site glass height
d. Apply 2 - 3 turns of new thread seal tape to the plug pipe
threads.
e. Install the fill port plug.
a. Put a catch container below the drain plug.
b. Remove the drain plug and drain until the level is 1/2 - 2/3
site glass height.
Level is > 2/3 site glass height c. Remove the old thread seal tape from the drain plug.
d. Apply 2 - 3 turns of new thread seal tape to the plug pipe
threads.
e. Install the drain plug.
Level is 1/2 - 2/3 site glass height a. Continue
3-2 350201F
IDOCS & MDOCS
500-55 (-CE)
FILL CAPS
CORRECT
OIL
LEVEL
ALTERNATE
Figure 3-2. Air Blower (BL-100)
4. Remove unwanted oil-lube with a clean lint-free towel.

5. Examine the air blower/motor coupling:
IF THEN
IDOCS-CE & MDOCS-CE a. Release the latch and open the coupling guard.
IDOCS & MDOCS a. Continue
a. Look for cracks in or discoloring of the elastomer halves.

(1) Replace if found (refer to Section 6.8.11).
IF THEN
IDOCS-CE & MDOCS-CE a. Close and latch the coupling guard.
IDOCS & MDOCS a. Continue
6. Make sure the air blower heat exchanger (HX-100) fins are not clogged or covered with debris.
a. Clean as necessary.
7. Install and latch the blower module air access and access panels.
350201F 3-3
IDOCS & MDOCS
500-55 (-CE)
3.2.1 OPERATION
1. On the site power source, set to ON.

2. Set circuit breaker (CB-1) to ON
3. On the electrical cabinet, release the latch and open the operator panel access door (see Figure 3-3).
4. Stop until the Normal screen shows on the operator panel (see Figure 3-4).
ALARM HORN (H-1)

{MDOCS (-CE)}
OPERATOR PANEL CIRCUIT BREAKER (CB-1)
A-1 (J-1) {ETHERNET} VFD-2 (J-3) {ETHERNET}
E-STOP (SW-1) ALARM DISABLE (PB-1)

{MDOCS (-CE)}
VFD-1 (J-2) {ETHERNET}
Figure 3-3. Operator Controls (electrical cabinet)
3-4 350201F
IDOCS & MDOCS
500-55 (-CE)
WARNING: Enriched oxygen can cause explosive fires. During operation when the low purity
LED is on (red), the Plant vents the off-spec oxygen to atmosphere. Make sure people in the
area are aware of possible fire and asphyxiation hazards.
5. On the operator panel, push the START/STOP button.
IF THEN
a. Push the alarm disable button (PB-1).
The alarm horn is disabled for 30 minutes each time the
MDOCS (-CE)
button is pushed. When LOW PURITY indicator is on, the
alarm sounds; unless it is disabled.
IDOCS (-CE) a. Continue
NOTE: As the system runs and pressure builds, the LOW PURITY and LOW PRESSURE indicators are
on (red and yellow). Solenoid valve (SV-3) vents the off-spec oxygen to atmosphere. When the purity is
higher-than 90%, solenoid valve (SV-3) stops venting and the LOW PURITY indicator goes out.
The output pressure is factory set at 3.8 bar (55 psig). To change the pressure
(refer to Section 3.2.2 on page 3-6).
WARNING: Calibrating a cold system or using the incorrect oxygen concentration calibration gas can
cause erroneous calibration and incorrect oxygen purity indication. Make sure the system is warm and the
correct Cal gas is used (refer to Section 2.5.8).
If your system is an MDOCS or MDOCS-CE, Do Not push the O2 CAL button. This button can cause
problems with older software versions.
6. When the system is warm (approximately 20 minutes after start), calibrate the oxygen sensor
{IDOCS (-CE)}.
IF THEN
There is a charged calibration gas bottle a. Push the O2 CAL button and calibrate the oxygen sensor
connected to the calibration port (CC-1) (refer to Section 3.6 on page 3-16).
Nothing is connected to the calibration
a. DO NOT push the O2 CAL button.
port (CC-1)
NOTE: The Plant is factory set to output 3.8 Bar (55 psig). To change the output pressure refer to
Section 3.2.2.
7. Do an initial air supply filter (F-3) check after 500 operating hours.
a. Go-to Section 6.8.8 - Air Supply Filter.
IF THEN
a. Adjust the air supply filter (F-3) replacement schedule to
Filter is dirty; must be replaced
500 hours of operation (refer to Table 6-1).
Filter is serviceable a. Continue
350201F 3-5
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8. Do an initial booster inlet (F-4) and product particulate (F-1) filters check after 500 operating hours.
a. Go-to Sections 6.8.9 & 6.8.10.
IF THEN
a. Adjust the booster inlet filter (F-4) and product particulate
Filter is dirty, must be replaced filter (F-1) replacement schedules to 500 hours of operation
(refer to Table 6-1).
Filter is serviceable a. Continue
NOTE: If the plant is operating in extreme environments, make sure you add the additional instructions
found in Section 3.3 - Operation in Unusual and Harsh Environments.
3.2.2 PRODUCT OUTPUT PRESSURE ADJUSTMENT

Before or during operation, the output pressure can be adjusted 1.4 - 6.9 bar (20 - 100 psig). Use these
instructions and set the output pressure for your requirement.
1. On the operator panel; push and hold (at same time) the (+) and (–) buttons until the Setup screen
shows.
IF THEN
a. See Figure 3-5.
Without optional MFC-1 b. Push the NEXT button to show the pressure screen
a. See Figure 3-6.
With optional MFC-1 b. Push the NEXT button twice (2) to show the Flow Rate
(Figure 3-6) and the Pressure screen (see Figure 3-7).
NOTE: During operation the system continues to run. The operator panel buttons now have different
functions as shown on the display. To cancel these new functions (at all times), push and hold (at same
time) the (+) and (–) buttons until the Normal screen shows (see Figure 3-4).
Figure 3-6. Setup (flow) and Flow Rate Screens
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Figure 3-7. Pressure Screen
2. Change the Output pressure (each push = 0.07 bar change).

a. Push (+) button to increase pressure up-to 6.9 bar (100 psig) maximum.
b. Push (–) button to decrease pressure down-to 1.4 bar (20 psig) minimum.
The pressure change is immediate but not saved.
IF THEN
a. Push and hold (at same time) the (+) and (–) buttons until the
You do not want to save the changes
Normal screen shows.
The Pressure Alarm Trip, Pressure Alarm Clear and Pressure
You want to save this pressure and Alarm Delay setpoints must be set.
return to the Normal screen a. Push the NEXT button to get to the Press Alm Trip screen
(see Figure 3-8).
Figure 3-8. Pressure Alarm Trip Screen
3. Set the trip setpoint when the alarm sounds (default is 3.1 Barg (45 psig)).
a. Push (+) or (–) buttons to adjust the setpoint to 1.4 Barg (20 psig) less-than the new pressure
setpoint.
4. Push the NEXT button to show the Press Alm Clr screen (see Figure 3-9).
Figure 3-9. Pressure Alarm Clear Screen
5. Set the clear setpoint when the alarm is disabled (silenced) (default is 3.5 Barg (50 psig)).
a. Push (+) or (–) buttons to adjust the setpoint to 0.35 Barg (5 psig) higher-than the new pressure
alarm trip setpoint.
6. Push the NEXT button to show the Press Alm Dly screen (see Figure 3-10).
Figure 3-10. Pressure Alarm Delay Screen
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IDOCS & MDOCS
500-55 (-CE)
7. Set the delay setpoint; the amount of time from the point the pressure drops less-than the trip setpoint
until the alarm sounds.
a. Push (+) or (–) buttons to adjust the amount of delay time in seconds.
NOTE: During the alarm delay time, the pressure must rise higher-than the clear setpoint and stay there
for the delay to time-out and not sound the alarm.
8. Push the NEXT button five (5) times to show the Settings Exit screen (see Figure 3-11).
Figure 3-11. PUR ALM Trip to Exit with Save Screens
9. On the Settings Exit screen, push the (+) button to save and show the Normal screen.
3.2.3 PRODUCT OUTPUT FLOW ADJUSTMENT {OPTIONAL MFC-1 INSTALLED}

If optional mass flow controller (MFC-1) is installed; before or during operation, the output flow can be
adjusted 125 - 500 Lpm. Use these instructions and set the output flow for your requirement.
1. On the operator panel; push and hold (at same time) the (+) and (–) buttons until the Setup screen
shows (see Figure 3-12).
NOTE: During operation the system continues to run. The operator panel buttons now have different
functions as shown on the display. To cancel these new functions, push and hold (at same time) the (+)
and (–) buttons until the Normal screen shows.
2. Push the NEXT button to show the Flow Rate screen (see Figure 3-13).
Figure 3-12. Setup (flow) Screen
Figure 3-13. Flow Rate Screen
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3. Set the outlet flow:

a. Increase the flow:
 Push (+) to increase 1 Lpm / press
 Push FLT OVR to increase 10 Lpm / press
 Push START / STOP to increase 100 Lpm / press
b. Decrease the flow:
 Push (–) to decrease 1 Lpm / press
 Push O2CAL to decrease 10 Lpm / press
 Push PUR OVR to decrease 100 Lpm / press
4. Push NEXT until the Settings Exit screen shows (see Figure 3-14).
Figure 3-14. Settings Exit Screen
5. Push (+), save to show the Normal screen (see Figure 3-15).
3.2.4 DATA LOGGING
Use remote operation to produce detailed parameter logging in a real time text file created on the laptop or
PC desktop using MS Excel ™ spreadsheets.
a. Make sure:
 The URL or IP address is set up as a trusted site.
 The trusted site security is set to Low.
 Require Server Verification (https:) for all Sites in this Zone check box is not checked.
2. On the DOCS REMOTE DATA LOGGING screen, type-in a new file name or use the Base File Name
shown and push Enter (see Figure 3-16 on page 3-10).
NOTE: When the log is started, a Current Log File name is created from the Base File Name or your new
file name.
3. Add Comments as needed to help find the file.
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Figure 3-16. DOCS Remote Data Logging Page
4. Type-in a Log Interval and push Enter.
NOTE: This is the interval between data updates. The number entered here is the time between data
gathering sets. Default is one (1) second.
5. While the Plant is running, start the log:
IF THEN
A text file is desired (.csv) {a file readable a. Click START TEXT LOG.
by the Windows™ Notepad or Excel™} Text files are stored on the Desktop.
An Excel™ file is desired (.xls) {a file a. Click START EXCEL LOG.
readable by Microsoft Excel™ only} Excel files are stored in My Documents.
NOTE: The data is logged at the entered Log Interval until STOP LOG is clicked.
If you exit the Logging page, the data stops logging.
6. Click STOP LOG to stop the data gathering.

7. To read the created Log file:
a. Find and select the File Name.
 Excel™ file - look in My Documents
 Text file - look on the Desktop
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DATA FROM
OXYGEN SENSOR
(AE-1)
BOOSTER
DISCHARGE
PRESSURE
TRANSDUCER
VSA TANK
PRESSURE
TRANSDUCER
BOOSTER INLET
PRESSURE
TRANSDUCER
BOOSTER
COMPRESSOR
VFD-2 DRIVE
OUTPUT
BLOWER VFD-1
DRIVE OUTPUT
Figure 3-17. Charts Log
b. Look at the File.
IF THEN
a. Click the LOGDAT1 tab to view a tabular list of the raw data
An Excel™ file is opened
b. Click the CHARTS tab to view the graphs of the components
listed on the top of the chart (see Figure 3-17).
A Text file is opened View a tabular list of the raw data.
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AVERAGE PURITY XT-4 SV-1 SV-2

CYCLE COUNT SV-3 SV-4
Figure 3-18. LOGDATA1 Spread Sheet (Partial)
3.2.5 SLEEP MODE (OPTION)

The IDOCS and MDOCS have optional components to put the system in a sleep mode. This mode isolates
the buffer tank to keep the pressure from bleeding off during non-operation. The system sets idle monitoring
the buffer and purge tanks pressures, and the oxygen purity. When one of these three parameters drops
below their setpoint, the system runs to bring the parameter above that setpoint; then back to sleep mode
(see Figure FO-3, Electrical Schematic (Sheet 4)). {IDOCS & MDOCS Option}
1. To start sleep mode, set the Sleep Switch to ON (closed).
2. To continue normal operation, set the Sleep Switch to OFF (open).
3.3 OPERATION IN UNUSUAL AND HARSH ENVIRONMENTS
This is a listing of additional tasks required when operating the Plant in unusual or harsh environments.
3.3.1 COLD CLIMATES (≤ 0°C (32°F))

a. At regular times, do a blockage check on the blower left and right vent panels.
b. Remove snow or ice buildup from the vents.
c. Change the blower oil-lube to Omega SB ISO 150 Synthetic (refer to Section 6.8.6).
NOTE: For extreme low temperatures ≤ -33°C (-28°F), contact PCI for assistance (refer to Foreword).
3.3.2 HOT CLIMATES (> 38°C (100°F))

a. Remove the Plant from the direct sun.
b. Do not contain the Plant, supply ventilation to minimize the effect of nitrogen asphyxiation.
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c. Change the blower oil-lube to Omega SB ISO 320 Synthetic (refer to Section 6.8.6).
NOTE: For extreme high temperatures ≥ 49°C (120°F), contact PCI for assistance (refer to Foreword).
3.3.3 SANDY OR DUSTY ENVIRONMENTS

This Plant is not designed to operate in this type of environment.
a. Put the Plant inside a well ventilated protected container.
b. Look at the air supply filter (F-3) every 500 hours of operation (refer to Section 6.8.8).
(1) Replace as necessary.
NOTE: If the Plant is exposed to blowing sand or dust, the intake and discharge cooling vents, and heat
exchangers fins (HX-100 & 200) must be cleaned. The air blower heat exchanger motor (MTR-2), air
blower (BL-100), air blower motor (MTR-1), booster compressor (C-1) and booster compressor motor
(MTR-3) must have the sand and dust removed from their cases.
3.3.4 RAINY OR HUMID CLIMATES

a. Keep the Plant out of standing water.
b. On the blower module, put an open tent type hood over the top access panel.
c. At regular times, look at the interior for standing water; remove if found.
3.3.5 SALT WATER ENVIRONMENTS

a. At regular times, wash the exterior of the Plant with clean water.
b. Remove salt or mineral buildup.
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3.4 SYSTEM SHUTDOWN
NOTE: The Plant stops running and the system pressure vents through off-spec solenoid (SV-3). The
product output port is not vented by SV-3.
2. On the electrical cabinet, set circuit breaker (CB-1) to OFF (see Figure 3-19).
CIRCUIT BREAKER (CB-1)

OPERATOR PANEL
E-STOP (SW-1)
Figure 3-19. Operator Shutdown Controls (Electrical Cabinet)
3. Vent your external inlet line.

a. If you disconnect your line, put an oxygen clean plug in the product outlet port and a clean cap on
your line.
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3.5 EMERGENCY SHUTDOWN
1. Push the Emergency Stop button.
IF THEN
IDOCS or MDOCS a. See Figure 3-19 on page 3-14.
IDOCS-CE or MDOCS-CE a. See Figure 3-20.
WARNING: The electrical cabinet still has power and some of the internal circuits still have power.
Control power is the only power lost when the E-Stop is pushed. To remove power from the Plant, set
circuit breaker CB-1 to OFF.
2. Do a injury check on people and a damage check on the Plant.

3. Clear the cause of the emergency stop.
4. Pull-out or twist the Emergency Stop button or buttons.
EMERGENCY-
STOP (PB-2)
{IDOCS-CE &
MDOCS-CE}
EMERGENCY-
STOP (PB-1)
Figure 3-20. Emergency-Stop Buttons (MDOCS-CE shown)
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3.6 OXYGEN ANALYZER / SENSOR {IDOCS (-CE)}
Use these instructions and calibrate the oxygen analyzer/sensor. The analyzer/sensor is factory set to be
manually calibrated or it can be set to an auto-calibration specified period of time {IDOCS (-CE)}.
CAUTION: Doing calibration without a calibrated gas source causes erroneous calibration and incorrect
product results. Make sure a charged calibration gas bottle is connected to the calibration port (CC-1).
Make sure the correct purity calibration gas is in the bottle before calibrating the Plant.
(refer to Section 2.5.8).
3.6.1 MANUAL CALIBRATION {IDOCS (-CE)}

1. Apply power to the Plant.
3. Run the Plant for approximately 20 minutes to permit the system to stabilize (warm-up).
4. On the operator panel, push the O2 CAL button.
NOTE: The Plant does the calibration and shows the sequential screens in Figure 3-21.
Figure 3-21. Calibration Screens
NOTE: The last 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.
3.6.2 AUTOMATIC CALIBRATION {IDOCS (-CE)}

The Plant can be set up to run automatic calibration routines (refer to Section 2.5.8.1).
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3.7 WARNINGS AND SHUTDOWNS (FAULTS)
When the Plant detects a fault, a warning can be shown or production stops and a shutdown screen shows.
This section shows the warning and shutdown screens and has instructions to do when one of those
screens show.
1. When one of the screens in Figure 3-22 shows:
IF THEN
a. You must shutdown the Plant
(refer to Section 3.4 on page 3-14).
One of top row screen shows (Warning) b. Follow the troubleshooting tables and basic troubleshooting
techniques to isolate and resolve the fault
(refer to Section 6.10).
a. The Plant automatically shuts down.
One of the other seven screens show b. Follow the troubleshooting tables and basic troubleshooting
(Shutdown) techniques to isolate and resolve the fault
(refer to Section 6.10).
Phase Relay
Installed Only
Figure 3-22. Warning and Shutdown Screens
2. When a screen with a fault code shows (see Figure 3-23), refer to Table 6-10.
Figure 3-23. Warning with Fault Code Screen
3. In the Plant log book, write the date, time and fault code.
CAUTION: Operating the Plant for oxygen production after pushing the FAULT OVR button can cause
damage to the system. The system has a fault or the button would not have to be pushed. DO NOT push
the START button until the source of the fault has been found and corrected.
4. On the operator panel, push the FAULT OVR button.

5. Use the PREV and NEXT buttons and navigate to the SENSOR and VSA screens to aid in
troubleshooting.
6. Use the instructions in Chapter 4 to do sub-assembly function tests.
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3.7.1 ALARM SYSTEM
The Plant has an alarm system for communicating hazards to the user. There are electrical contacts
available for the user to connect the DOCS to the Hospital Oxygen Supply System’s alarm system. The
DOCS is intended to be part of a ISO 7396-1:2016 system with an alarm system in compliance with IEC
60601-1-8. The Plant locally communicates these alarms:
 General fault (contact closure/visual - high priority).
 Refer to Table 6-11.
 Low oxygen concentration (contact closure/visual/auditory - high priority) {MDOCS (-CE)}.
 Relay closure on the oxygen sensor AE-1 when purity drops to 90.01%.
 The alarm clears (contact opens) when the purity rises to 90.46%.
 Loss of incoming power (contact closure - high priority).
 When power is applied to the Plant a normally closed contact is opened. When power is removed
from the Plant, this contact closes.
 Low pressure (contact closure/visual - medium priority).
 When the output pressure measured at XT-1 drops to less-than the pressure alarm setpoint a
contact closes. The alarm clears when the pressure reading at XT-1 is higher-than the pressure
alarm clear setpoint.
NOTE: High Priority alarm is loss of essential performance (red LED). This is associated with low purity,
general fault and incoming power loss.
Medium Priority alarm is degradation of performance (yellow LED). This is associated with low pressure.
There is one delay in the alarm system; the pressure alarm can have a user adjusted delay to permit
fluctuations in the system. The factory default is 60 seconds (refer to Section 4.2.5).
The other alarms are instantaneous, when a fault occurs, it is reported. If power is interrupted, the alarm
condition stays until it is cleared. The functionality of the alarm system is activated and tested at the factory
before shipment.
NOTE: Loss of incoming power is a contact closure to be monitored by an external system.
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3.8 SYSTEM MAIN MENU
There are two (2) ways to monitor and control the system during operation.
 Use the on-board LCD display main menu (refer to Section 3.8.1).
 Use a PC or laptop to access the Plant’s IP address remotely (refer to Section 5.2).
3.8.1 LCD MAIN MENU SCREENS
These screens are sequentially accessed by pushing the NEXT and PREV buttons. Push NEXT to go
through the list until it stops changing, then push PREV to go back through the list until it stops changing.
The screens shown in Figure 3-24 are indication only. The IP address setup screens are discussed in
Section 3.9 on page 3-20. The other Setup and Direct I/O screens are discussed in Chapter 4.
1. To Navigate through the main menu screens:
IF THEN
Purity/Pressure screen is showing Use NEXT to see the next screen
Normal or IP screens are not showing NEXT shows the next screen; PREV shows the previous screen
IP screen is showing Use PREV to see the previous screen
OR
PLANTS WITH OPTIONAL MFD-1 PLANTS WITHOUT OPTIONAL MFD-1
Figure 3-24. Main Menu Sequential Screens
350201F 3-19
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3.9 PLANT IP ADDRESS CONFIGURATION
Use these instructions and change the IP address.

1. On the operator panel, push and hold (at same time) the (+) and (–) buttons until the Setup Entry
screen shows.
IF THEN
a. See Figure 3-25.
Without optional MFC-1 b. Push the NEXT button seven (7) times to show the seven
screen in Figure 3-27.
a. See Figure 3-26.
With optional MFC-1 b. Push the NEXT button eight (8) times to show the flow rate
(Figure 3-26), and the seven screens in Figure 3-27.
NOTE: The Plant continues to run (if operating), but the operator panel buttons now have different
functions. Setting variations have immediate effect on operation but are not saved until you save them
before exiting this process through the IP Exit screen. To exit this process, push and hold the (+) and (–)
buttons until the Normal screen shows (no save).
Figure 3-27. Output Pressure to TCPIP Configure Screens
2. On the TCPIP Config screen, push the (+) button (see Figure 3-28 on page 3-21).
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SCREEN A SCREEN B
Figure 3-28. DHCP Setting Screens
IF THEN
a. Show screen A.
Automatically generate IP address
b. Push the (+) button to change screen B to A.
a. Show screen B.
Create custom IP address
b. Push the (–) button to change screen A to B.
3. Push the NEXT button to show the Address Edit screens (see Figure 3-29).
NOTE: The top line of each screen in Figure 3-29 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 section 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
NEXT
Figure 3-29. IP Address Edit Screens
IF THEN
a. Use the buttons listed in Table 3-2 and type the custom
Writing a custom address
address.
Automatic IP address a. Push NEXT until the last number is active.
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4. Push the NEXT button to show the Mask Edit screen (see Figure 3-30).
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 while in this section of the process. Use these buttons to modify the active
number if you are assigning a new MASK address.
PREV
NEXT
Figure 3-30. Mask Edit Screens
IF THEN
a. Get the correct MASK address from your network
Writing a custom MASK address administrator.
b. Use the buttons listed in Table 3-2 and type the address.
Using the default MASK address a. Push NEXT until the last number is active.
5. Push the NEXT button to show the Gateway Edit screen (see Figure 3-31 on page 3-23).
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 while in this section of the process. Use these buttons to modify the active
number if you are assigning a new Gateway address.
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PREV
NEXT
Figure 3-31. Gateway Edit Screens
IF THEN
a. Get the correct Gateway address from your network
Writing a custom Gateway address administrator.
b. Use the buttons listed in Table 3-2 and type the address.
Using the default Gateway address a. Push NEXT until the last number is active.
6. Push the NEXT button to show the IP Exit screen (see Figure 3-32).
Figure 3-32. IP Exit Screen
IF THEN
a. Push the NEXT button to show the Direct IO Entry screen
Not save a new IP address
(see Figure 3-33).
Push the (+) button to show the Direct IO Entry screen
Save the new IP address
(see Figure 3-33).
Figure 3-33. Direct IO Entry Screen
7. Push the NEXT button to show the Settings Exit screen (see Figure 3-34 on page 3-24).
NOTE: If you push (+) (ENTER), the Plant stops production and a manual type mode is accessed. This
mode is for testing and troubleshooting (refer to Chapter 4).
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IF THEN
Save the changes a. Push the (+) button to the Normal screen shows.
Not save the changes a. Push the (–) button to the Normal screen shows.
a. Shutdown and start the controller again:
1. Push the E-Stop button.
Changed the IP address
2. Stop ten seconds.
3. Turn or pull-out the E-Stop button.
Figure 3-34. Settings Exit Screen
NOTE: If the controller seems to have lost its IP address; after operation, shutdown and start the
controller again.
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CHAPTER 4
SYSTEM OPERATION CONTROLS
4.1 SCOPE
This chapter has procedures for using the Setup screens for production application and the Direct I/O
screens and functions to operate the sub-assemblies individually. The Setup and Direct I/O screens appear
sequentially by using the NEXT and PREV buttons to view forward and backward. The instructions listed
here are intended for use as a troubleshooting tool.
CAUTION: Only factory trained professional technicians must operate, do maintenance and troubleshoot
the DOCS.
4.1.1 SEQUENTIAL SETUP SCREENS
PLANTS WITHOUT OPTIONAL MFC-1 PLANTS WITH OPTIONAL MFC-1
Setup Entry (pressure) Setup Entry (flow)

Flow Rate
 Out Pressure
 Pressure Alarm Trip
 Pressure Alarm Clear
 Pressure Alarm Delay
 Purity Alarm Trip
 Purity Alarm Clear
 IP Configuration Setup
a. DHCP Setting Screens b. IP Address Edit Screens

c. Mask Edit Screens d. Gateway Edit Screens
e. IP Exit Screen
 Direct I/O Setup

a. Direct IO Fault Input b. VSA Blower Forward c. VSA Blower Reverse
d. Scroll Forward e. VSA Main Cooler f. Purge Solenoid
g. O2 Sample Solenoid h. Off-Spec Solenoid i. SV-4 Solenoid
j. Auxiliary Horn k. Solenoid SV-6 l. Digital Output 1
m. Digital Output 2 n. Alarm Relay o. Running Relay
 Setup Exit
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4.2 SETUP
When the setup screens and functions are started, the operator panel buttons have different functions to aid
the operator in modifying the listed parameters. The setup screens can be started with the Plant running; the
adjustments are instantaneous. If you do not save them, when you exit Setup and don’t save, the
modification defaults to the original setting.
1. On the operator panel, push and hold (at same time) the (+) and (–) buttons until the Setup Entry
screen shows.
IF THEN
a. See Figure 4-1.
b. Push the NEXT button to show the Out Press screen
Without optional MFC-1
c. Go-to Section 4.2.2 on page 4-3.
a. See Figure 4-2.
b. Push the NEXT button to show the Flow Rate screen
With optional MFC-1
c. Go to Section 4.2.1.
NOTE: To exit this process, push and hold the (+) and (–) buttons until Normal screen shows (no save).
Figure 4-1. Setup Entry (pressure)
Figure 4-2. Setup Entry (flow)
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4.2.1 FLOW RATE
IF THEN
a. Push the NEXT button to show Figure 4-4.
Do not change flow rate
b. Go-to Section 4.2.2.
a. Use the operator panel buttons (refer to Table 4-1) and set
the required flow.
Change flow rate
b. Push the NEXT button to show Figure 4-4.
c. Go-to Section 4.2.2.
Table 4-1. Operator Panel Button Assignments In Setup
BUTTON: START/STOP FAULT OVR (+) (–) O2 CAL PUR OVR
FUNCTION: Add 100 Add 10 Add 1 Sub 1 Sub 10 Sub 100
Figure 4-3. Flow Rate
4.2.2 DISCHARGE PRESSURE
IF THEN
a. Push the NEXT button to show Figure 4-5 on page 4-4.
Do not change discharge pressure
b. Go-to Section 4.2.3 on page 4-4.
a. Use the (+) and (–) buttons to adjust the discharge pressure
setpoint (psig).
Change discharge pressure
Figure 4-4. Out Pressure
NOTE: The discharge pressure adjustment range is 1.4 - 6.9 Bar (20 - 100 psig).
Each push (+) or (–) = 0.07 Barg (1 psig) change. The value shown in Figure 4-4 is psig.
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4.2.3 DISCHARGE PRESSURE ALARM TRIP SETPOINT
IF THEN
Do not change pressure alarm trip a. Push the NEXT button to show Figure 4-6.
setpoint b. Go-to Section 4.2.4.
alarm trip setpoint (psig).
Change pressure alarm trip setpoint
Figure 4-5. Pressure Alarm Trip
NOTE: The pressure alarm delay counter starts when the discharge pressure drops to less-than this
setpoint. Factory default is set to 1 Bar (15 psig) less-than the discharge pressure setpoint.
4.2.4 DISCHARGE PRESSURE ALARM CLEAR SETPOINT
IF THEN
Do not change pressure alarm clear a. Push the NEXT button to show Figure 4-7 on page 4-5.
setpoint b. Go-to Section 4.2.5 on page 4-5.
alarm clear setpoint (psig).
Change pressure alarm clear setpoint
Figure 4-6. Pressure Alarm Clear
NOTE: The discharge pressure must be higher-than and stay higher-than the pressure alarm clear
setpoint for the pressure alarm delay timer to clear. Factory default is set to 0.35 Bar (5 psig) less-than
the discharge pressure setpoint.
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4.2.5 DISCHARGE PRESSURE ALARM DELAY SETPOINT
IF THEN
Do not change discharge pressure alarm a. Push the NEXT button to show Figure 4-8.
delay setpoint b. Go-to Section 4.2.6.
Change discharge pressure alarm delay alarm delay setpoint (seconds).
setpoint b. Push the NEXT button to show Figure 4-8.
Figure 4-7. Pressure Alarm Delay
NOTE: The discharge pressure alarm delay permits short term pressure fluctuation without alarm. The
delay can be set to accommodate your system with its unique fluctuations. Factory default is set to
60 seconds.
Each push (+) or (–) = 1 second change. The value shown in Figure 4-7 is seconds.
4.2.6 PRODUCT PURITY ALARM TRIP SETPOINT
IF THEN
Do not change product purity alarm trip a. Push the NEXT button to show Figure 4-9 on page 4-6.
setpoint b. Go-to Section 4.2.7 on page 4-6.
a. Use the (+) and (–) buttons to adjust the product purity alarm
trip setpoint (%).
Change product purity alarm trip setpoint
Figure 4-8. Purity Alarm Trip
NOTE: The product purity alarm sounds when the product purity drops to less-than this percentage.
Factory default is set 3.5% less-than the product purity factory default 93%.
Each push (+) or (–) = 0.5% change. The value shown in Figure 4-8 is percent (%).
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4.2.7 PRODUCT PURITY ALARM CLEAR SETPOINT
IF THEN
Do not change product purity alarm clear a. Push the NEXT button to show Figure 4-10.
setpoint b. Go-to Section 4.2.8.
a. Use the (+) and (–) buttons to adjust the product purity alarm
Change product purity alarm clear clear setpoint (%).
setpoint b. Push the NEXT button to show Figure 4-10.
Figure 4-9. Purity Alarm Clear
NOTE: The product purity alarm is disabled when the product purity rises higher-than this percentage
and stays higher. Factory default is set 2.5% less-than the product purity factory default (93%).
Each push (+) or (–) = 0.5% change. The value shown in Figure 4-9 is percent (%).
4.2.8 IP CONFIGURATION SETUP
IF THEN
Do not change IP Configuration
Change IP Configuration a. Go-to Section 3.9 and start with Step 2.
Figure 4-10. IP Configuration Setup
NOTE: The instructions for changing the IP address, Mask and Gate are found in Section 3.9. When
those procedures are completed, the system must be re-started (re-booted) and you are exited out of the
setup screens.
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4.2.9 DIRECT I/O SETUP
The sub screens with this Setup are for operating a single component on/off. These screens are useful when
doing troubleshooting.
WARNING: Starting Direct I/O (press + Enter) stops the Plant operation. Make sure the down stream
draw is not depending on oxygen from this source.
IF THEN
Do not use direct I/O
a. Push the (+) button to show Figure 4-12.
Use Direct I/O
b. Go-to Section 4.2.9.1.
Figure 4-11. Direct I/O Setup
NOTE: When (+) is pushed, the Plant stops operation and starts a manual type of operation.
4.2.9.1 DIRECT IO FAULT INPUT
Figure 4-12. Direct IO Fault Input
NOTE: The fields in this screen are read-only and listed in Table 4-2 on page 4-8.
PHA: C shows A-1 connector TB63.52 is connected to TB63.51 or some other ground.
PHA: O shows A-1 connector TB63.52 is disconnected or held high by something.
1. Push the NEXT button to show VSA Fwd screen (see Figure 4-13 on page 4-8).
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Table 4-2. Direct IO Fault Input Fields
FIELD COMPONENT CONNECTOR SIGNAL PIN COMMON PIN
PHA Phase Reverse Relay J63 TB63.52 TB63.51

VSA VSA VFD-1 Fault Input J40 4 8
SCR Booster VFD-2 Fault Input J41 4 8
PS1 Pressure Switch 1 (reserved) TB63 TB63.32 TB63.31
PS2 Pressure Switch 2 (reserved) J63 TB63.34 TB63.33
ACC Accessory Input (reserved) J64 TB64.52 TB64.51
All listed connectors are on controller board (A-1)
4.2.9.2 AIR BLOWER (BL-100)
The VSA blower is the air blower (BL-100).
IF THEN
Do not run the blower forward (vacuum)
b. Go-to Step 2.
Run the blower forward (vacuum) Continue
Figure 4-13. VSA Blower Forward
1. Run the air blower (BL-100) forward (vacuum):

a. Push the (+) button and the top line on the screen shows VFD FWD ON.
The blower turns in the vacuum direction at 10 Hz.
(1) Use a digital multimeter set to 200 Vdc range and measure approximately 23 Vdc between
controller board connector J40 pins 1 (+) and 8 (-).
b. Push the (–) button and the top line on the screen shows VFD FWD OFF.
The blower stops turning.
(1) Use the digital multimeter to measure approximately 0 Vdc between controller board connector
J40 pins 1 (+) and 8 (-).
c. Push the NEXT button to show Figure 4-14 on page 4-9.
2. Run the air blower (BL-100) in reverse (pressure):
IF THEN
Do not run the blower in the reverse a. Push the NEXT button to show Figure 4-15 on page 4-9.
direction (pressure) b. Go-to Section 4.2.9.3 on page 4-9.
Run the blower in the reverse direction
Continue
(pressure)
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Figure 4-14. VSA Blower Reverse
a. Push the (+) button and the top line on the screen shows VFD REV ON.
The blower turns in the pressure direction at 10 Hz.
(1) Use a digital multimeter set to 200 Vdc range and measure approximately 23 Vdc between
b. Push the (–) button and the top line on the screen shows VFD REV OFF.
The blower stops turning.
(1) Use the digital multimeter to measure approximately 0 Vdc between controller board connector
J40 pins 2 (+) and 8 (-).
c. Push the NEXT button to show Figure 4-15.
4.2.9.3 BOOSTER COMPRESSOR (C-1)
The Scroll is the booster compressor (C-1).
IF THEN
Do not run the booster compressor
b. Go-to Section 4.2.9.4 on page 4-10.
Run the booster compressor Continue
Figure 4-15. Scroll Forward
1. Push the (+) button and the top line on the screen shows SCR FWD ON.
The booster compressor motor (MTR-3) turns at 10 Hz.
a. Use a digital multimeter set to 200 Vdc range and measure approximately 23 Vdc between
NOTE: The booster compressor motor (MTR-3) must turn counterclockwise looking in the compressor
ventilation vent and viewing the orbital scroll rotation as referenced from the motor end.
2. Push the (–) button and the top line on the screen shows SCR FWD OFF.
The booster motor (MTR-3) stops turning.
a. Use the digital multimeter to measure approximately 0 Vdc between controller board connector J41
pins 1 (+) and 8 (-).
3. Push the NEXT button to show Figure 4-16 on page 4-10.
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4.2.9.4 AIR BLOWER HEAT EXCHANGER (HX-100)
The VSA Main Cooler is the air blower heat exchanger fan (FX-100). These instructions run the air blower
heat exchanger fan motor (MTR-2). When relay (R-24) is actuated, contact closure supplies power to the
motor controller (M-1) and the motor is powered. This tests the signal to relay (R-24).
IF THEN
Do not run the air blower heat exchanger a. Push the Next button to show Figure 4-17.
fan motor (MTR-2) b. Go-to Section 4.2.9.5.
Run the air blower heat exchanger fan
Continue
motor (MTR-2)
Figure 4-16. VSA Main Cooler
1. Push the (+) button and the top line on the screen shows VSA MAIN COOLER ON.
The air blower heat exchanger fan motor (MTR-2) turns.
a. Use a digital multimeter set to 200 Vdc range and measure approximately 23 Vdc on terminal
board (TB63) terminals TB63.20 (+) and TB63.21 (-).
NOTE: The air blower heat exchanger fan draws air in through the blower module top access panel and
pushes air out through the blower module right side vent when turning in the correct direction.
2. Push the (–) button and the top line on the screen shows VSA MAIN COOLER OFF.
The air blower heat exchanger fan motor (MTR-2) stops turning.
a. Use the digital multimeter to measure approximately 0 Vdc on terminal board (TB63) terminals
TB63.20 (+) and TB63.21 (-).
3. Push the NEXT button to show Figure 4-17.
4.2.9.5 PURGE SOLENOID (SV-1)
The controller board has this output.
IF THEN
Do not energize the purge solenoid
Energize the purge solenoid Continue
Figure 4-17. Purge Solenoid
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1. Push the (+) button and the top line on the screen shows PURGE ON.
Purge solenoid valve (SV-1) energizes.
controller board connector (J66) pins 2 (+) and 3 (-).
NOTE: When solenoid (SV-1) energizes there is an audible sound of actuation.
2. Push the (–) button and the top line on the screen shows PURGE OFF.
Purge solenoid valve (SV-1) de-energizes.
a. Use the digital multimeter to measure approximately 0 Vdc between controller board connector
(J66) pins 2 (+) and 3 (-).
4.2.9.6 SAMPLE CALIBRATION SOLENOID (SV-2)
The O2 sample solenoid valve is the sample/calibration solenoid valve. The controller board has this output.
IF THEN
Do not energize the O2 sample solenoid
Energize the O2 sample solenoid Continue
Figure 4-18. O2 Sample Solenoid
1. Push the (+) button and the top line on the screen shows O2 SAMPLE ON.
Sample/calibration solenoid valve (SV-2) energizes.
2. Push the (–) button and the top line on the screen shows O2 SAMPLE OFF.
Sample/calibration solenoid valve (SV-2) de-energizes.
(J66) pins 5 (+) and 6 (-).
3. Push the NEXT button to show Figure 4-19 on page 4-12.
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4.2.9.7 OFF-SPEC SOLENOID (SV-3)
The controller board has this output.
IF THEN
Do not energize the off- spec solenoid
Energize the off-spec solenoid Continue
Figure 4-19. Off-Spec Solenoid
1. Push the (+) button and the top line on the screen shows OFF SPEC ON.
Off-spec solenoid valve (SV-3) energizes.
2. Push the (–) button and the top line on the screen shows OFF SPEC OFF.
Off-spec solenoid valve (SV-3) de-energizes.
(J66) pins 8 (+) and 9 (-).
4.2.9.8 PRODUCT SOLENOID (SV-4)
This output is reserved for a product solenoid (SV-4). The controller board has this output.
IF THEN
Do not do the product solenoid output a. Push the NEXT button to show Figure 4-21 on page 4-13.
check b. Go-to Section 4.2.9.9 on page 4-13.
Do the product solenoid output check Continue
Figure 4-20. SV-4 Solenoid
1. Push the (+) button and the top line on the screen shows SV4 ON.
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2. Push the (–) button and the top line on the screen shows SV4 OFF.
(J66) pins 11 (+) and 12 (-).
4.2.9.9 ALARM HORN (H-1)
The alarm horn is currently a digital output for future use as an alarm.
IF THEN
Do not energize the alarm signal
Energize the alarm signal Continue
Figure 4-21. Auxiliary Horn
1. Push the (+) button and the top line on the screen shows HORN ON.
a. Use a digital multimeter set to 200 Vdc range and measure approximately 23 Vdc between terminal
2. Push the (–) button and the top line on the screen shows HORN OFF.
a. Use the digital multimeter to measure approximately 0 Vdc between terminal board (TB63)
terminals TB63.28 (+) and TB63.30 (-).
4.2.9.10 AUXILIARY SOLENOID (SV-6)
This output is reserved for an auxiliary solenoid valve (SV-6).
IF THEN
Do not energize solenoid (SV-6)
Energize solenoid (SV-6) Continue
Figure 4-22. Solenoid SV-6
1. Push the (+) button and the top line on the screen shows SV6 ON.
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2. Push the (–) button and the top line on the screen shows SV6 OFF.
4.2.9.11 DIGITAL OUTPUT (DO1)
This output is reserved for digital output #1.
IF THEN
Do not do a digital output 1 check
Do a digital output 1 check Continue
Figure 4-23. Digital Output 1
1. Push the (+) button and the top line on the screen shows DO1 ON.
2. Push the (–) button and the top line on the screen shows DO1 OFF.
terminals TB63.25 (+) and TB63-23 (-).
4.2.9.12 DIGITAL OUTPUT (DO2)
This output is reserved for digital output #1.
IF THEN
Do not do a digital output #2 check
Do the digital output #2 check Continue
Figure 4-24. Digital Output 2
1. Push the (+) button and the top line on the screen shows DO2 ON.
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2. Push the (–) button and the top line on the screen shows DO2 OFF.
4.2.9.13 ALARM RELAY
This output is for remote monitoring the alarm function relay of the alarm horn.
IF THEN
Do not do the alarm relay output check
Do the alarm relay output check Continue
Figure 4-25. Alarm Relay
1. Push the (+) button and the top line on the screen shows ALARM RELAY ON.
b. Use a digital multimeter set to 200 Ohm range and measure approximately 0 Ohms between
terminal board (TB63) terminals TB63.68 (+) and TB63.63 (-).
2. Push the (–) button and the top line on the screen shows ALARM RELAY OFF.
a. Use the digital multimeter to measure an open between terminal board (TB63) terminals
TB63.68 (+) and TB63.63 (-).
3. Push the NEXT button to show the Figure 4-26.
4.2.9.14 RUNNING RELAY
This output is for remote monitoring of the Plant running or not running.
IF THEN
Do not do the running relay output check
Do the running relay output check Continue
Figure 4-26. Running Relay
1. Push the (+) button and the top line on the screen shows RUNNING RELAY ON.
a. Use a digital multimeter set to 200 Ohm range and measure approximately 0 Ohms between
terminal board (TB63) terminals TB63.59 (+) and TB63.65 (-).
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2. Push the (–) button and the top line on the screen shows RUNNING RELAY OFF.
a. Use the digital multimeter to measure an open between terminal board (TB63) terminals
TB63.59 (+) and TB63.65 (-).
4.2.10 SAVE AND EXIT
Use this screen to save all your adjustments or exit without saving adjustments. When you were on a
particular direct I/O screen turning ON/OFF functions and pushed NEXT or PREV to leave that screen/
function, the software automatically turned the function off.
Figure 4-27. Setup Exit
IF THEN
Changes were made to the output
a. Push the (+) button, save the changes and show the Normal
pressure or the IP address and need to
save these changes
Used the manual operation and made no
a. Push the (–) button, save nothing and show the Normal
changes to the output pressure or IP
address to save
Figure 4-28. Normal (LCD)
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CHAPTER 5
REMOTE OPERATION AND DIAGNOSTICS
5.1 INTRODUCTION
Remote operation and diagnostics 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 DOCS is factory configured to be connected to a TCP/IP network supporting DHCP address
assignments similar to a laptop.
There are two (2) ways to connect to the DOCS:
1. Use a DHCP network:
a. Connect an Ethernet pass-through CAT5, CAT6 or CAT7 network cable from the DHCP network
into the Ethernet connector (A-1) below the operator panel.
b. Connect the laptop / PC to the DHCP network.
NOTE: The DHCP network assigns an address to the DOCS.
2. Connect laptop / PC directly to Plant:

a. Connect the laptop / PC into the Ethernet connector (A-1) below the operator panel.
NOTE: Older laptops can require a cross over cable because their Ethernet ports do not auto-sense the
connections. The controller automatically assigns your laptop /PC a TCP/IP address.
5.2 REMOTE OPERATION

1. On the electrical cabinet, set circuit breaker (CB-1) to ON.
2. Remove the cap from the Ethernet port (A-1).
3. Connect the laptop / PC to Ethernet port (A-1) (refer to Section 5.1).
4. Apply power to the laptop / PC and start Internet Explorer™ V6 or later.
5. Enter http:// followed by:
IF THEN
a. On the Plant operator panel, use the PREV and NEXT
buttons and navigate to the TCP\IP screen.
b. Use the IP: address shown on the screen
Using the assigned IP address
(192.168.001.010).
c. Do not use leading zeros (type: 192.168.1.10).
d. Push Enter.
a. DOCS500
Using the DOCS URL address
b. Push Enter.
NOTE: If you are having problems connecting to the DOCS, contact PCI for further instruction
(refer to Foreword).
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6. On the Click To Enter screen, click on CLICK TO ENTER (see Figure 5-1).
IF THEN
a. In the Username field, type: - - - - - - - admin
b. In the Password field, type: - - - - - - - magnolia
A Login pop-up window shows
c. Push Enter to show the Dashboard screen
(see Figure 5-2)
The Dashboard screen shows a. Continue
NOTE: On the initial CLICK TO ENTER after a Plant power up, the Login pop-up window shows. Every
CLICK TO ENTER after the initial, the Dashboard screen shows; unless you power down.
CLICK ON CLICK TO ENTER
Figure 5-1. Click to Enter Screen
TOOLS ICON
(NORMALLY WHITE)
Figure 5-2. Internet - Dashboard Screen
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7. Create a trusted web site using this Internet Explorer® tab or add this Internet Explorer® tab to the
trusted web site list:
IF THEN
A Trusted Web Site has previously been set a. Go-to Step 8.
A Trusted Web Site has not been set a. Continue
a. On the Internet Explorer® page, click the DOCS500 or DOCS IP Address tab, if necessary.
b. On the far right side of the menu bar, click the tools icon (see Figure 5-2).
c. On the drop-down menu, click Internet options (see Figure 5-3).
TOOLS DROP-DOWN MENU
INTERNET OPTIONS POP-UP SECURITY TAB
ADD IF NOT
IN
WEBSITES:
FIELD
MAKE SURE THIS BOX IS NOT

CHECKED
WHEN DONE
SITES POP-UP WINDOW
Figure 5-3. Safe Site Selection Menu and Windows
d. On the Internet Options pop-up window, click the Security tab.

e. In the Select a Zone to View or Change Security Settings field, highlight Trusted sites.
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f. Click the Sites button.

g. On the Trusted sites pop-up window:
IF THEN
a. Remove the check from the Require Server Verification
Websites zone (field) shows the
(https:) for all Sites in this Zone check box.
DOCS500 or DOCS IP address
b. Click Close.
a. Click the Add button.
Add this website to the zone shows the
a. Remove the check from the Require Server Verification
DOCS500 or DOCS IP address and the
(https:) for all Sites in this Zone check box.
Websites zone does not
b. Click Close.
h. On the Internet Options pop-up window in the Security level for this zone field, move the slider
down to show Low.
i. Click OK.
8. On the Dashboard screen:
IF THEN
a. Click DIAG PAGE to show the Normal screen
Running the Plant
a. Click LOGGING to show the DOCS Remote Data Logging
Data logging screen (see Figure 5-7 on page 5-8).
b. To log data, go-to Section 3.2.4.
NOTE: Before the LOGGING page loads, a prompt shows to run ActiveX. Run this program; logging can
not continue without this program being active. If you are not prompted to run ActiveX, the trusted site
security is not correctly set up. Contact PCI for more information (refer to Foreword).
The DASHBOARD selection shows the Dashboard screen.
9. On the Normal screen, choose the desired screen (function) from the bottom menu choices.
 START - - - - - Starts the Plant operating
 STOP - - - - - - Stops the Plant operation
 DIAG - - - - - - Shows the Diagnostic screen (pressures) (see Figure 5-8 on page 5-9)
 O2 CAL - - - - - Starts the manual oxygen sensor calibration process {IDOCS (-CE)}
 PUR OVR - - - - Toggles the override for the purity alarm and offspec venting of product oxygen
less-than the purity setpoint.
NOTE: The PUR OVR button is active on the IDOCS (-CE) units only. This function is not available on
the MDOCS (-CE) units.
 SENSORS - - - Shows the Sensors screen (see Figure 5-12 on page 5-13)
 SETTINGS - - - Shows the User Settings screen (see Figure 5-18 on page 5-19)
 MAINT - - - - - Shows the Maintenance Tracking screen (see Figure 5-19 on page 5-20)
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IP ADDRESS WAS USED
STATUS INDICATORS
CHOOSE FROM THIS

MENU
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5.3 REMOTE OPERATION SCREEN DEFINITIONS

These are the screens accessed through a laptop or PC connected to the DOCS indirectly through the
Internet or directly connected to the DOCS.
5.3.1 DASHBOARD SCREEN

This screen shows an overview of the Plant operation.
MAJOR FUNCTION SCREENS

MACHINE STATUS
OPERATION CONTROLS
OXYGEN PRODUCTION
Figure 5-5. DOCS 500 Dashboard Screen
MAJOR FUNCTION SCREENS (ON ALL SCREENS)

DASHBOARD- - - - - - Shows this screen (see Figure 5-5)
DIAG PAGE - - - - - - Shows the Normal screen (see Figure 5-6 on page 5-7)
LOGGING - - - - - - - Shows the Remote Data Logging screen (see Figure 5-7 on page 5-8)
MACHINE STATUS
MAINT - - - - - - - - - Green - within maintenance interval set on the Maintenance Tracking screen
Red - - - past maintenance interval set on the Maintenance Tracking screen
ALARMS - - - - - - - - Green - No alarm conditions exist
Red - - - An alarm setpoint has been breached
RUNNING - - - - - - - Green - Machine is producing oxygen
Black - - Machine is Static (power on / not producing oxygen)
PURITY OVR - - - - - - Yellow - purity override is active (ON)
Black - - purity override is inactive (OFF)
OPERATION CONTROLS
VSA ON/OFF - - - - - - Toggles the air blower ON (running = green) / OFF (running = black)
FAULT OVR - - - - - - Toggles fault override ON (overrides a fault warning) / OFF
PURITY OVR - - - - - - Toggles purity override ON (purity ovr = yellow) / OFF (purity ovr = black).
NOTE: The PUR OVR button is enabled on the IDOCS (-CE) units only. This function is not available on
the MDOCS (-CE) units.
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5.3.2 NORMAL SCREEN

This screen has machine control, operation indicators and access buttons to operator adjustable
parameters. NORM was clicked in the Function / Screen Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
FUNCTION / SCREEN MENU
Major Function Screens - Refer to Section 5.3.1 on page 5-6

Function / Screen Menu - Refer to Step 9. on page 5-4
MACHINE STATUS
CONT PWR - - - - - - Green- - continuous 24 Vdc from power supply (PS-1) supplied to controller (A-1)
Red - - - 24 Vdc is intermittent
FAULT - - - - - - - - - Black - - no fault conditions exist
Red - - - current fault condition
PURITY - - - - - - - - Black - - Plant not running
Green- - purity% is higher-than the current setpoint
Red - - - purity% is less-than the current setpoint
PRESS - - - - - - - - - Black - - Plant not running
Green- - discharge pressure is higher-than the current pressure setpoint
Red - - - discharge pressure is less-than the current pressure setpoint
VSA ON - - - - - - - - Black - - air blower is not operating (not turning)
Green- - air blower is operating (turning)
SCROLL - - - - - - - - Black - - booster compressor is not operating (not turning)
Green- - booster compressor is operating (turning)
TBA - - - - - - - - - - To Be Assigned
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PUR OVR- - - - - - - - Black - - purity override is not active (OFF)

Yellow - purity override is active (ON)
5.3.3 REMOTE DATA LOGGING SCREEN

This screen has the controls used to setup the log function and the log Start / Stop. LOGGING was clicked
in the Major Function Screens on DOCS Remote Diagnostics screens.
FILL-IN FIELDS
LOG START / STOP
INDICATORS
Figure 5-7. Remote Data Logging Screen
FILL-IN FIELDS
Type-in data fields - must write data specific for the log you are about to make
LOG START / STOP

START TEXT LOG - - - Starts a plain text log of the data
NOTE: If Active X has not been launched (started), a log file is not produced. Refer to
Section 5.2 on page 5-1 for instructions to open this program for logging.
START EXCEL LOG - - Starts a Microsoft™ Excel® log of the data

STOP LOG - - - - - - - Stops the data logging
NOTE: If you exit this screen during data logging, the data logging stops automatically.
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5.3.4 DIAGNOSTIC SCREEN (PRESSURE)

This is the first of four (4) diagnostic screens (pressure, temperature, cycle & key indicator). This screen has
all pressure indications displayed. From this screen the others can be accessed. DIAG was clicked in the
Function / Screen Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-8. Diagnostic Pressure Screen

Machine Status - Refer to Section 5.3.2 on page 5-7
FUNCTION / SCREEN SELECTION MENU

PRESS - - - - - - - Shows this screen (see Figure 5-8)
TEMP - - - - - - - Shows the Diagnostic Temperatures screen (see Figure 5-9 on page 5-10)
CYCLE - - - - - - - Shows the Diagnostic Cycle screen (see Figure 5-10 on page 5-11)
KEY IND - - - - - - Shows the Diagnostic Key Indicator screen (see Figure 5-11 on page 5-12)
SENSORS - - - - - Shows the Sensors screen (see Figure 5-12 on page 5-13)
ELOG - - - - - - - Shows the Event Log Page screen (see Figure 5-13 on page 5-14)
FLT OVR - - - - - - Toggles the fault override function; do not continuously operate with this function
active.
FACTORY - - - - - Shows the Factory Setup Menu screen; a password protected screen with access to
all the factory settings (see Figure 5-15 on page 5-16)
NORM - - - - - - - Shows the Normal screen (see Figure 5-6 on page 5-7)
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5.3.5 DIAGNOSTIC SCREEN (TEMPERATURE)

This screen has all the temperature indications displayed. On a diagnostic screen, TEMP was clicked in the
Function / Screen Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-9. Diagnostic Temperature Screen

Function / Screen Menu - Refer to Section 5.3.4 on page 5-9
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5.3.6 DIAGNOSTIC SCREEN (CYCLE)

This screen has most of cyclic type of operations displayed. CYCLE was clicked in the Function / Screen
Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-10. Diagnostic Cycle Screen

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5.3.7 DIAGNOSTIC SCREEN (KEY INDICATORS)

This screen has various important operation indications displayed. KEY IND was clicked in the Function /
Screen Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-11. Diagnostic Key Indicators Screen

5-12 350201F
IDOCS & MDOCS
500-55 (-CE)
5.3.8 SENSORS SCREEN

This screen has all the monitored sensors displayed. SENSORS was clicked in the Function / Screen Menu
on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-12. Sensors Screen


DONE - - - - - - - Closes this screen and shows the screen where SENSORS was clicked
350201F 5-13
IDOCS & MDOCS
500-55 (-CE)
5.3.9 EVENT LOG PAGE SCREEN

This screen offers the operator the ability view events (or processes) previously accomplished. The events
to be logged are setup at the factory. ELOG was clicked in the Function / Screen Menu on DOCS Remote
Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-13. Event Log Page Screen


CURRENT - - - - - Shows the current event indications
START - - - - - - - Shows the first event indications
PREV - - - - - - - - Shows the previous event indications
NEXT - - - - - - - - Shows the next event indications
END - - - - - - - - Shows the last event indications
CLEAR - - - - - - - Clears the displayed event indications
EMAIL - - - - - - - Shows the E-Mail Setup screen (see Figure 5-14 on page 5-15)
DONE - - - - - - - Closes this screen and shows the screen where ELOG was clicked
5-14 350201F
IDOCS & MDOCS
500-55 (-CE)
5.3.10 E-MAIL SETUP SCREEN

This screen is used to setup and send e-mails with logged events for analysis. EMAIL was clicked in the
Function / Screen Menu on the Events screen.
MACHINE STATUS
INDICATIONS
Figure 5-14. E-Mail Setup Screen


ENABLE - - - - - - Sends the E-mail to the recipient (TO)
TO - - - - - - - - - Type the recipient’s e-mail address and push ENTER
FROM - - - - - - - Type the sender’s e-mail address and push ENTER
SERVER - - - - - - Type the mail server address you are using and push ENTER
LOGIN - - - - - - - Type your login name and push ENTER
PASSWORD - - - - Type your related password and push ENTER
SUBJECT - - - - - Type the subject name and push ENTER
MESSAGE - - - - - Type the message and push ENTER
TEST - - - - - - - - Sends a test “ping” to the server
DFLT - - - - - - - - Sets the setup data to the factory default data
DONE - - - - - - - Closes the screen and shows the Event Log Page screen
(see Figure 5-13 on page 5-14)
350201F 5-15
IDOCS & MDOCS
500-55 (-CE)
5.3.11 FACTORY SETUP MENU SCREEN

This screen is password protected and does not show until the Login screen data is accepted. FACTORY
was clicked in the Function / Screen Menu on DOCS Remote Diagnostics screens.
MACHINE STATUS
INDICATIONS
Figure 5-15. Factory Login Page Screen


PASSWORD - - - - Type the password, push ENTER to show the Factory screen
NOTE: The screen you are trying to open has access to all the factory settings. Contact PCI for
assistance and the password (refer to Foreword).
CANCEL - - - - - - Closes the Login Page screen and shows the Diagnostic screen where FACTORY
was clicked.
5-16 350201F
IDOCS & MDOCS
500-55 (-CE)
WARNING: The settings on the Factory Setup Menu Screen effect the operation of the Plant. Incorrect
settings can cause erroneous oxygen purities and can damage the equipment. Make sure you contact
PCI before attempting to enter and change parameters accessed through this screen
MACHINE STATUS
INDICATIONS
Figure 5-16. Factory Setup Menu Screen

CAUTION: ADC, O2 CAL, SYSTEM, RTD, CYCLE, TCP/IP, BOOST, DIR IO, PID and EVENTS screens
have the factory settings critical to the operation of the Plant. An incorrect parameter can cause damage
to the equipment and produce less-than desirable or reported oxygen purity. For details about these
screens, contact PCI (refer to Foreword).
CLOCK - - - - - - - - - Shows the Clock Set screen (see Figure 5-17 on page 5-18)
EMAIL - - - - - - - - - Shows the E-Mail Setup screen (see Figure 5-14 on page 5-15)
LOGOUT - - - - - - - - Logs you out of the Factory Setup
DONE - - - - - - - - - Closes the screen and shows the Diagnostic screen where FACTORY was clicked
350201F 5-17
IDOCS & MDOCS
500-55 (-CE)
5.3.12 CLOCK SETUP SCREEN

This screen has the parameters required to set the system clock. CLOCK was clicked in the Function /
Screen Menu on the Factory Setup screen.
MACHINE STATUS
INDICATIONS
Figure 5-17. Clock Set Screen


MONTH- - - - - - - Type the current month (2 integers - 04 = April) and push ENTER
DAY - - - - - - - - Type the current day (2 integers - 09) and push ENTER
YEAR - - - - - - - - Type the current year (4 integers - 2015) and push ENTER
HOUR - - - - - - - Type the current hour (2 integers - 05 = 5 AM; 16 = 4 PM) and push ENTER
MINUTE - - - - - - Type the current minute (2 integers - 06) and push ENTER
SECONDS - - - - - Type the current seconds (2 integers - 07) and push ENTER
CLK SET - - - - - - Sets the clock to the Internet time (must be connected to the Internet)
HR MTR - - - - - - Sets the Machine Hours to 0
UTCOff - - - - - - - Type the time difference between Plant location and PCI factory (± 1 - 2 integers) and
push ENTER
SET NTP - - - - - - Type online (if Plant connected to Internet) or not online (if Plant not connected to
Internet) and push ENTER
DONE - - - - - - - Closes this screen and shows the Factory screen
5-18 350201F
IDOCS & MDOCS
500-55 (-CE)
5.3.13 USER SETTINGS SCREEN

This screen has the adjustable operation parameters an operator can set depending on location and load
requirements. SETTINGS was clicked in the Function / Screen Menu on the Normal screen.
MACHINE STATUS
INDICATIONS


ALTITUDE - - - - - Type the altitude (in feet) where the Plant is in operation and push ENTER
PRESSURE - - - - Type the desired discharge pressure (20 - 100 psig) and push ENTER
P-ALARM- - - - - - Type the low limit pressure value causing an alarm (psig) and push ENTER
P-CLEAR - - - - - - Type the pressure value (psig) where the low pressure alarm clears and push ENTER
FLOWRATE - - - - Type the desired discharge flow (Lpm) and push ENTER (Not Available)
O2CAL %- - - - - - Type the Cal Gas bottle purity value (label purity = 90 - 95% type value) or (label
purity = 99.05 - 99.99% type 90.5) and push ENTER {IDOCS (-CE)}
O2CAL HRS - - - - Type the time interval between automatic calibration processes (1 - 48 hrs)
(0 = manual calibration) and push ENTER {IDOCS (-CE)}
LOAD FOL - - - - - Type enabled (system self adjusts to keep the discharge pressure as the load varies);
disabled (no self adjustment) and push ENTER
IP ADDR - - - - - - Type a new IP address for the DOCS and push ENTER
DONE - - - - - - - Closes this screen and shows the Normal screen
350201F 5-19
IDOCS & MDOCS
500-55 (-CE)
5.3.14 MAINTENANCE TRACKING SCREEN

This screen the parameters to set up maintenance alerts for required maintenance on the Plant. MAINT was
clicked in the Function / Screen Menu on the Normal screen.
MACHINE STATUS
INDICATIONS
Figure 5-19. Maintenance Tracking Screen


OLDEST - - - - - - Shows the data from the oldest recorded maintenance log
PREV - - - - - - - - Shows the data from the previously recorded log
NEXT - - - - - - - - Shows the data from the next recorded log
NEWEST - - - - - - Shows the data from the newest recorded log
NEW - - - - - - - - Opens a new maintenance log
DESC- - - - - - - - Type the description of the maintenance done (write detailed data) and push ENTER
NEXT DUE - - - - - Type the amount of time before the next maintenance must be done (hours) and push
ENTER
NEXT WARN - - - - Type the amount of time before the next maintenance warning is displayed (hours)
and push ENTER
NEXT TYPE - - - - Type a short description of the maintenance required and push ENTER
CLR ALL - - - - - - Clears all data in the current log
SAVE - - - - - - - - Save the data in the current log (must do before leaving screen to record log)
DONE - - - - - - - Closes this screen and shows the Normal screen
5-20 350201F
IDOCS & MDOCS
500-55 (-CE)
CHAPTER 6
MAINTENANCE
6.1 MAINTENANCE SCHEDULE
Table 6-1. Maintenance Schedule
COMPONENT INTERVAL (HOURS) ACTION
Distribution Box Cooling Louvers 250 Clean

Examine/Clean/Replace Mats &
Booster Heat Exchanger Fans 250
Clean Fan Blades
Booster Motor Cooling Fan 250 Clean
Electrical Cabinet Cooling Fans 250 Clean
Initial 500
Air Blower Oil-Lube Replace Lubricant
2000
Initial 500
VSA Tank Lid Bolts Set Torque
2000
Initial 500
Air Supply Filter Examine / Replace Element
2000
Initial 500
Booster Inlet Filter Examine / Replace Element
2000
Initial 500
Product Particulate Filter Examine / Replace Element
2000
Set Screw Torque & Examine
Air Blower/Motor Coupling 2000
Coupling
Set Screw Torque & Examine
Booster Scroll Compressor/Motor Coupling 2000
Coupling
Booster Heat Exchanger 2000 Clean / Examine / Replace
Air Blower Motor Bearings 4000 Lubricate
Air Blower Heat Exchanger 6000 Clean / Examine / Replace
Air Blower Shaft Seal 8000 Examine / Replace
† - Based on typical operating conditions 15°C @ 3.8 Bar (59°F @ 55 psig)
Table 6-2. Alignment Procedures
COMPONENT ACTION
Booster Scroll Compressor/Motor Coupling Alignment Align Coupling

Air Blower/Motor Coupling Alignment Align Coupling
350201F 6-1
IDOCS & MDOCS
500-55 (-CE)
Table 6-3. Life Expectancy Replacement Schedule
COMPONENT INTERVAL (HOURS) ACTION
Lubricate Bearings &

Booster Scroll Compressor Lubrication and Tip Seals 4000 †
Replace Seals
Air Blower Heat Exchanger Motor 20,000 ‡ Replace
Booster Compressor Motor 20,000 ‡ Replace
Booster Scroll Compressor 20,000 ‡ Replace
Oxygen Product Sensor {MDOCS (-CE) & Models with AE-2} 43,800‡ Replace
Oxygen Product Analyzer/Sensor {IDOCS (-CE)} 43,800‡ Replace
† - Expected life (extreme operating conditions can shorten the life expectancy, contact PCI for direction based on your
operating conditions)
‡ - Minimum expected life
6.2 MAINTENANCE PERSONNEL
CAUTION: The DOCS is specialized equipment requiring unique knowledge to operate and maintain.
Untrained operators and technicians can cause incorrect operation and poor product quality. Only factory
trained professional technicians must operate or do maintenance on the DOCS.
6.3 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 (refer to Section 6.7 on page 6-5).
Unless otherwise stated, the part numbers listed in Tables 6-4 - 6-6 are PCI part numbers (CAGE 75906).
Table 6-4. Tools Kit (797366-001)
DESCRIPTION PART NUMBER QTY USAGE
Brush, Wire 585674-001 1 General cleaning

Gloves, Powder Free (100/box) 585675-001 1 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
Air blower motor (MTR-1) bearings (use multipurpose
Grease Gun, with 18 inch Hose 584229-001 1
grease (581556-001))
Leak Detection Solution (1 gal) 581567-003 1 Finding air and gas leaks
Socket Set, Hex ANSI/ASME 581950-011 1 ANSI/ASME hardware, 7-piece
Socket Set, Hex, Metric 581950-012 1 Metric hardware, 7-piece
Torque Wrench, 0.375 Drive 582075-006 1 6.8 - 108.5 Nm (5 - 80 ft-lb)
Towels, Lint Free (500/box) 585673-001 1 General cleaning
Drawing 797366 Rev W
6-2 350201F
IDOCS & MDOCS
500-55 (-CE)
Table 6-5. Specialty Tool Kit (797366-009)
Grease Gun, w/extension 582172-005 1 Grease cartridge (582172-006) booster compressor (C-1)
Table 6-6. Other Tools
Brush, soft bristle Z00269 1 Fan blades, screens and aesthetic cleaning
Laser Alignment Tool Kit (part of Kit 798750-001
585969-001 1 Air blower (BL-100) coupling hubs
(refer to Table C-12))
Shaft Seal Replacement Kit (refer to Table C-12) 798750-001 1 Air Blower (BL-100) shaft seal tools
6.4 CONSUMABLES
Unless otherwise stated, the part numbers listed in Tables 6-7 & 6-8 are PCI part numbers (CAGE 75906).
Table 6-7. List of Consumables Kit (797366-002)
DESCRIPTION PART NO. QTY USAGE
Element, Coalescer Filter 583503 4 Product Filter (F-1)

Element, Coalescer Filter 585151-002 1 Booster inlet filter (F-4)
Element, Particulate Filter 585150-001 4 Air supply filter (F-3)
Grease, Cartridge 582172-006 1 Booster compressor (C-1) bearings
Grease, Multipurpose (5 oz) 581556-001 1 Air blower motor (MTR-1)
Air blower (BL-100) lubricant
Oil-lube, Synthetic, SB-220 (1 Qt) 582923-001 3
{ambient temperatures 0 to 38°C (32 to 100°F)}
Seal Kit (refer to Table C-10) 797521-002 1 Booster (C-1)
Table 6-8. List of Other Consumables
Elastomer Coupling (includes screws) 585594-011 1 Air blower/motor coupling elastomer halves
Elastomer Coupling (includes screws) 585594-017 1 Booster compressor/motor coupling elastomer halves
Element, Coalescing Filter 583503 1 Product filter (F-1)
Emery Cloth (60-grit) {roll} Z0098 1 Air blower (BL-100) drive shaft
Filter Mat (5/pack) 585603-008 2 Distribution box booster heat exchanger fan louvers
Gasket 799791-002 1 Booster compressor (C-1) inlet port gasket
{ambient temperatures < 0°C (32°F)}
† is CAGE 94858
350201F 6-3
IDOCS & MDOCS
500-55 (-CE)
Table 6-8. List of Other Consumables (Cont)

{ambient temperatures > 38°C (100°F)}
Oxygen Lubricant (Krytox®) {0.5 oz} W46040-205 1 Pipe clamp O-ring gaskets
Shaft Seal Kit (refer to Table C-11) 799045-001 1 Air blower (BL-100) drive shaft
Temperature Indicating Crayon (107°C
86544 † 1 Air Blower (BL-100) drive shaft seal
(225°F))
Motor (MTR-3) mounting hardware and coupling
Thread Locker 242 (Blue) {10 ml} W46030-013 1
guard hardware
Thread Locker 271 (Red) {10 ml} W46030-018 1 Booster compressor (C-1) coupling hub/fan hardware
Thread Seal Tape, Teflon®,
W14420-050 2 Pipe threads
0.50 Wide (roll)
† is CAGE 94858
6.5 SPARE COMPONENTS
Refer to Appendix C for factory spare component parts kits.
6.6 TORQUE SPECIFICATIONS
Table 6-9. Torque Specifications
ASSEMBLY COMPONENT TORQUE
Blower Attaching Screws 73 Nm (54 ft-lb)

Blower Coupling Hub Setscrew 32.5 Nm (24 ft-lb)
Air Blower (BL-100) Coupling Elastomer Attaching Screws 40.7 Nm (30 ft-lb)
Motor Attaching Bolts / Nuts 130 Nm (96 ft-lb)
Motor Coupling Hub Setscrew 69.2 Nm (51 ft-lb)
Compressor Attaching Nuts 15 Nm (11 ft-lb)
Coupling Guard Attaching Screws 6.8 Nm (5 ft-lb)
Coupling Hubs Setscrew 17 Nm (13 ft-lb)
Elastomer Attaching Screws 23 Nm (17 ft-lb)
Booster Compressor (C-1)
6.8 (-0/+1.1) Nm
Inlet Port Hardware
(5 (-0/+0.8) ft-lb)
Motor Attaching Nuts 27 Nm (20 ft-lb)
Initial - 20.3 Nm (15 ft-lb)
Orbital-to-Fixed Hardware
Final - 29.8 Nm (22 Ft-lb)
91 (+0/-2.7) Nm
Tank Lid Bolts and Nuts
(67 (+0/-2) ft-lb)
VSA Tank (C-300)
27 (-2.7/+0) Nm
Tank Lid Eye-bolt Nuts
(20 (-2/+0) ft-lb)
6-4 350201F
IDOCS & MDOCS
500-55 (-CE)
6.7 OXYGEN CLEAN
ACETONE
ISOPROPYL ALCOHOL
Use these instructions to oxygen clean components before installation.
REQUIRED EQUIPMENT
Suitable Solvent (Isopropyl Alcohol or Acetone ≥ 96%)

Nitrogen Gas (Oil-free & ≥ 95%)
Tube and Fitting Caps (oxygen clean)
WARNING: Hand oils and other contaminants can cause explosive fires in enriched oxygen
environments. Make sure you wear gloves and use pre-cautions to prevent the entrance of
contaminants.
1. Put the component in a clean closed environment with good ventilation.
CAUTION: Isopropyl alcohol (hotter than 49°C (120°F)) partially dissolves Teflon® (PTFE) components
and tubes. Do not use this solvent at temperatures higher-than 49°C (120°F) to clean PTFE components
and tubes.
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 wet surfaces are dry and solvent vapors are removed.
4. Put a clean cap on or plug in each component end or port.
350201F 6-5
IDOCS & MDOCS
500-55 (-CE)
6.8 MAINTENANCE
Use these procedures to maintain the Plant for optimum performance.
WARNING: Before doing maintenance on the Plant, Look at the P&ID drawing to determine if
the component is in the oxygen flow. During maintenance, oxygen flow components require an
oxygen clean environment, oxygen clean tools, powder-free gloves on the hands and oxygen
clean replacement parts. Failure to obey can cause an explosive fire during operation.
1. Keep all removed parts unless stated otherwise.
6.8.1 PRE-MAINTENANCE
WARNING: Enriched oxygen supports explosive fires. The gas vented from the Plant is
enriched oxygen. Slowly open the vent device and be aware of possible asphyxiation.
1. Prepare the Plant.
IF THEN
a. On the operator control panel, push the START/STOP
The Plant is running
button.
The Plant is OFF a. On the electrical cabinet, set circuit breaker (CB-1) to ON.
The Plant is ON; not running a. Continue
2. On the NORMAL screen, make sure PRESSURE shows 0 (see Figure 6-1).
a. Vent as necessary.
NOTE: This pressure is monitored by the product discharge pressure transducer (XT-1). The pressure
between CV-4 and SV-4 is relieved by off-spec solenoid valve (SV-3). The pressure after SV-4 is relieved
by your in-line relief valve.
6-6 350201F
IDOCS & MDOCS
500-55 (-CE)
WARNING: Enriched oxygen can cause explosive fires. The vented gas is enriched oxygen.
Make sure the area is free of sparks and flame.
Venting the purge tank can create high decibel noise causing loss of hearing. Make sure you
wear sound protection when venting the purge tank.
3. On the Tee fitting below fill/purge drain solenoid valve (SV-5), slowly open the vent valve (V-1) and
drain the purge receiver tank (C-500) (see Figure 6-2).
a. When pressure transducer (XT-4) shows 0 bar (0 psig), close the valve
PURGE TANK
VENT VALVE
Figure 6-2. Purge Receiver Tank Vent Valve (MDOCS-CE shown)
4. On the buffer tank (C-400), look at buffer tank pressure transducer (XT-3).
IF THEN
a. Use the manual actuation handle on buffer tank out pressure
XT-3 shows pressure
safety valve PSV-1 and vent the pressure.
XT-3 shows 0 Bar (0 psig) Continue
5. On the electrical cabinet, set circuit breaker (CB-1) to OFF.
350201F 6-7
IDOCS & MDOCS
500-55 (-CE)
CB-1
PSV-1
PI-3
XT-3 XT-4
C-500
C-400
Figure 6-3. Buffer and Purge Tanks Pressure Transducers (XT-3 & 4) (MDOCS shown)
WARNING: High voltage creates high current causing injury or death. Make sure the Plant
power circuit breaker (CB-1) and the site power source are set to OFF, and lock-out/tag-out
applied to the site power source before doing maintenance or opening the electrical cabinet
access door.

a. Lock-out/tag-out the site power source.
6.8.2 DISTRIBUTION BOX COOLING LOUVERS
Use these instructions to clean the louvered covers on the front of the distribution box every 250 hours of
operation.
1. On the distribution box, release the latches and remove the distribution box access window panel
assembly.
2. On the inside of the access window panel assembly, use a clean dry lint-free towel (Table 6-4) or clean
soft bristle brush (Table 6-6) and clean the louvers on the front of the assembly.
3. On the outside of the access panel assembly, remove the front louvered covers (see Figure 6-4).
4. Use a clean dry lint-free towel or clean soft bristle brush and clean the louvered covers.
5. Install the front louvered covers.
6. Install and latch the distribution box access window panel assembly.
6-8 350201F
IDOCS & MDOCS
500-55 (-CE)
FRONT COOLING LOUVERS
REAR COOLING FANS
REAR COOLING FAN LOUVERS
Figure 6-4. Distribution Box Cooling Louvers and Fans (MDOCS shown)
6.8.3 BOOSTER HEAT EXCHANGER FANS
Use these instructions to clean/replace the fan louver mats and clean the booster heat exchanger fans
(FX-200 & 201) every 250 hours of operation.
1. On the rear of the distribution box, remove the louvered covers with the mats (see Figure 6-4).
a. Use a clean dry lint-free towel (Table 6-4) or clean soft bristle brush (Table 6-6) and clean the
louvered covers.
b. Examine the mats.
IF THEN
Mats are cleanable a. Clean and install them.
a. Discard the mats.
Mats are not cleanable
b. Install new mats (Table 6-8) in the covers.
2. Clean the fan blades (FX-200 & 201).

3. Install the louvered covers.
350201F 6-9
IDOCS & MDOCS
500-55 (-CE)
6.8.4 BOOSTER MOTOR COOLING FAN
Use these instructions to clean the booster motor (MTR-3) cooling fan (FX-300) every 250 hours of
operation.
assembly.
2. In the distribution box, clean the booster motor cooling fan blades (FX-300) (see Figure 6-5).
a. Use a clean soft bristle brush (Table 6-6) or a clean dry lint-free towel (Table 6-4).
FX-300
Figure 6-5. Distribution Box Booster Motor Cooling Fan (FX300) {MDOCS shown}
b. Clean the fan guards on both sides.
WARNING: Using compressed air to clean can produce flying particles dangerous to unprotected eyes
and skin. Wear eye protection when using compressed air. Make sure all people are out of the area and
do not direct the air stream at people.
c. Wear eye protection.

d. Use dry oil-free shop air ≤ 2.1 Bar (30 psig) to clean the fan blades.
e. Blow all the debris out of the distribution box.
6-10 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.5 ELECTRICAL CABINET COOLING FANS
Use these instructions to clean the electrical cabinet cooling fans (FAN-1 & 2) every 250 hours of operation.
WARNING: High voltage creates high current causing injury or death. The interior of the
electrical cabinet has high voltage present. Make sure the site power source is OFF and lock-
out/tag-out applied before opening the electrical cabinet access door.
1. On the electrical cabinet, make sure circuit breaker (CB-1) is OFF.

3. Near the top of the cabinet, clean the cooling fans (FAN-1 & -2) (see Figure 6-6).
a. Remove the screws and the fan access panel.
b. Use a clean dry lint-free towel (Table 6-4) or a clean soft bristle brush (Table 6-6) to clean the fan
blades on the two fans.
c. Install the fan access panel with the screws.
FAN ACCESS PANEL

(FAN-1 & FAN-2)
Figure 6-6. Electrical Cabinet Cooling Fans (FAN-1 & 2)
350201F 6-11
IDOCS & MDOCS
500-55 (-CE)
6.8.6 AIR BLOWER OIL-LUBE
Use these instructions to replace the oil-lube in the air blower (BL-100). Do these instructions after the first
500 hours of operation and then every 2000 hours of operation.
WARNING: Hot oil-lube, air blower and piping can cause burns. These components are hot
after operation. Stop until the air blower has cooled to the touch before replacing lubricant oil.
The air blower motor automatically starts-runs-stops. Unexpected operation can cause injuries.
Make sure the power is OFF and the site power source is locked-out/tagged-out before
removing access panels.
1. On the blower module, release the latches and remove the rear air access and access panels.
2. On top of the air blower, remove the fill port plugs (see Figure 6-7).
3. Put a collection container below the drain port and remove the drain plug.
4. Remove the old thread seal tape from the plug pipe threads.
5. Apply 2 - 3 turns of new thread seal tape (Table 6-8) to the plug pipe threads.
6. When the lubricant is completely drained, install the drain plug.
CORRECT LEVEL
OR
FILL PORT
(ONE OPPOSITE)
DRAIN PORT
(ONE OPPOSITE)
BLOWER REAR VIEW
Figure 6-7. Air Blower (BL-100) Lubricant Replacement (IDOCS shown)
6-12 350201F
IDOCS & MDOCS
500-55 (-CE)
7. Do Steps 3. - 6. again to drain the other side.

8. Discard the old lubricant in accordance with the local codes on the disposal of waste oil.
9. Fill a reservoir with Omega SB ISO 220 synthetic oil-lube (Table 6-7) until the fluid level fills 1/2 to 2/3 of
the sight glass.
10. Do Step 9. again to fill the other reservoir.
11. Do a leak check on the two drain plugs.
12. Remove the old thread seal tape from the fill plugs pipe threads.
13. Apply 2 - 3 turns of new thread seal tape to the fill plugs pipe threads.
14. Install the two fill port plugs.
15. Use a clean dry lint-free towel (Table 6-4) and remove unwanted lubricant.
16. Install and latch the blower module access and air access panels.
6.8.7 VSA TANK LID BOLTS
Use these instructions to torque the nuts on the bolts attaching the VSA tank (C-300) lid. Do these
instructions after the first 500 hours of operation and then every 2000 hours of operation.
1. Use the torque wrench (Table 6-4) to torque the nuts on the bolts in the VSA tank lid
91 (+0/-2.7) Nm (67 (+0/-2) ft-lb).
a. Use the pattern shown in Figure 6-8 for the nut torque sequence.
b. The eye-bolts nuts (positions 3 & 4) must be torqued 27 (-2.7/+0) Nm (20 (-2/+0) ft-lb).
Figure 6-8. VSA Tank Lid Torque Sequence
350201F 6-13
IDOCS & MDOCS
500-55 (-CE)
6.8.8 AIR SUPPLY FILTER
Use these instructions to replace the air supply filter (F-3). Do these instructions after the first 500 hours of
operation and then every 2000 hours of operation. If the filter requires replacement after 500 hours of
operation, change the replacement schedule to every 500 hours of operation.
WARNING: The air blower motor automatically starts-runs-stops. Unexpected operation can cause
injuries. Make sure the power is OFF and the site power source is locked-out/tagged-out before removing
access panels.
2. On the filter (F-3), release the latch on the bracket clamp, loosen the hose clamp and remove the filter
(see Figure 6-9).
HOSE CLAMP
F-3
Figure 6-9. Air Supply Filter (F-3) {IDOCS shown}
3. Keep the hose clamp and discard the filter.

4. Install and latch a new filter (Table 6-7) in the filter clamp and attach it to the silencer with the hose
clamp.
5. Install and latch the access and air access panels.
6-14 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.9 BOOSTER INLET FILTER
Use these instructions to replace the booster inlet filter (F-4) element. Do these instructions after the first
500 hours of operation and then every 2000 hours of operation. Do these instructions after the first 500
hours of operation and then every 2000 hours of operation. If the filter requires replacement after 500 hours
of operation, change the replacement schedule to every 500 hours of operation.
assembly.
WARNING: Contaminants in enriched oxygen can cause explosive fires. This filter has
enriched oxygen passing through it. Make sure you wear clean powder-free latex gloves and
prevent the entrance of contaminants in the open filter housing.
2. Wear clean powder-free latex gloves (Table 6-4).

3. On the filter; push-up, twist and remove the bowl (see Figures 6-10 & 6-11).
F-1
F-4
Figure 6-10. Distribution Box Filters (MDOCS shown)
4. Use a clean lint-free towel (Table 6-4) to wipe-out the bowl interior.
5. Remove and discard the element.
6. Wear a new clean pair of powder-free gloves.
7. Put a new element (Table 6-7) in the filter head.
8. Install the filter bowl.
350201F 6-15
IDOCS & MDOCS
500-55 (-CE)
FILTER HEAD
FILTER ELEMENT
FILTER BOWL
Figure 6-11. Booster Inlet and Product Particulate Filters
6.8.10 PRODUCT PARTICULATE FILTER
Use these instructions to replace the product particulate filter (F-1) element. Do these instructions after the
first 500 hours of operation and then every 2000 hours of operation. If the filter requires replacement after
500 hours of operation, change the replacement schedule to every 500 hours of operation.
assembly.
WARNING: Contaminants in enriched oxygen can cause explosive fires. This filter has
enriched oxygen passing through it. Make sure you wear clean powder-free latex gloves and
prevent the entrance of contaminants in the open filter housing.
2. Wear clean powder-free latex gloves (Table 6-4).

3. On the filter, twist and remove the bowl (see Figures 6-10 & 6-11).
4. Use a clean lint-free towel (Table 6-4) to wipe-out the bowl interior.
5. Remove and discard the element.
6. Wear a new clean pair of powder-free gloves.
7. Put a new element (Table 6-7) in the filter head.
8. Install the filter bowl.
6-16 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.11 AIR BLOWER/MOTOR COUPLING
Use these instructions to set the air blower/motor (BL-100/MTR-1) coupling hubs setscrew and elastomer
attaching screws torque, and examine the coupling elastomer halves every 2000 hours of operation.
WARNING: Hot air blower, blower motor and piping can cause burns. These components are hot after
operation. Stop until these components have cooled to the touch before looking at the coupling.
The air blower motor automatically starts-runs-stops. Unexpected operation can cause injuries. Make
sure the power is OFF and the site power source is locked-out/tagged-out before removing access
panels.
IF THEN
a. On the blower/motor coupling guard, disengage the captive
screws and open the guard.
2. On the air blower/motor coupling, remove twelve (12) screws and the two coupling halves
3. Examine the elastomer element (coupling half):
a. Look for fatigue cracks over 13 mm (1/2 inch) long originating near the stress relief grooves
6 - 13 mm (1/4 - 1/2 inch) above the metal shoe.
b. Look for discoloration (a darker faded orange) showing possible material degradation.
c. If either condition Steps a. & b. shows, replace the elastomer coupling (585594-011).
d. Do Steps a. - c. again on the other elastomer coupling half.
4. Use the torque wrench (Table 6-4) and set the torque on each coupling hub setscrew
a. Torque the blower hub setscrew 32.5 Nm (24 ft-lb).
b. Torque the motor hub setscrew 69.2 Nm (51 ft-lb).
5. Install the two coupling halves on the coupling hub with twelve (12) screws wet with blue thread locker
(Table 6-8).
6. Torque each coupling screw 40 Nm (30 ft-lb).
a. Make sure all twelve (12) screws are torqued.
IF THEN
IDOCS-CE & MDOCS-CE a. Close the coupling guard and engage the captive screws.
350201F 6-17
IDOCS & MDOCS
500-55 (-CE)
LOOK HERE
INSIDE ELASTOMER ELEMENT
Figure 6-12. Air Blower/Motor Coupling (IDOCS-CE shown)
COUPLING HUBS SETSCREWS
Figure 6-13. Coupling Hubs
6-18 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.12 BOOSTER SCROLL COMPRESSOR/MOTOR COUPLING
Use these instructions to set the booster scroll compressor/motor (C-1/MTR-3) coupling hubs setscrew
torque and examine the elastomer coupling halves every 2000 hours of operation.
REQUIRED COMPONENT
(4) 5/16 Lock Washers {S57004-010}

CAGE - 75906
1. On the distribution box, release the latches and remove the access window panel assembly.
WARNING: The distribution box access panel assembly is heavy and cumbersome. Do not try
to remove alone. Use two (2) people when removing/installing the panel assembly
2. Use two (2) people, release the latches and remove the distribution box access panel assembly.
WARNING: The booster automatically starts-runs-stops. Unexpected operation can cause injuries. Make
sure the power is OFF and the site power source is locked-out/tagged-out before removing the booster
coupling guard.
3. On the booster coupling guard, remove the four (4) 5/16-18 screws, lock and flat washers, and coupling
guard (see Figure 6-14 on page 6-20).
a. Discard the lock washers.
4. On the coupling, remove eight (8) screws and the two elastomer halves.
5. Use the torque wrench (Table 6-4) to torque the hub setscrews 17.6 Nm (13 ft-lb).
6. Examine each coupling elastomer half (see Figure 6-16 on page 6-21).
a. Look for cracks extending across the width of the exposed coupling.
b. Look for discoloration on the coupling.
IF THEN
a. Discard the elastomer half.
Cracks or discoloration
b. Get a new elastomer half (585594-017).
No cracks or discoloration Continue
7. Install the elastomer halves with eight (8) screws wet with blue thread locker (Table 6-8).
a. Torque the screws 23 Nm (17 ft-lb).
350201F 6-19
IDOCS & MDOCS
500-55 (-CE)
COUPLING GUARD
HARDWARE
Figure 6-14. Booster Coupling Guard Remove/Install (MDOCS shown)
HUB SETSCREWS
Figure 6-15. Booster Compressor/Motor Coupling (MDOCS shown)
8. Install the coupling guard with four (4) 5/16-18 x 1 screws wet with blue thread locker, new lock washers
and flat washers.
9. Use two (2) people, install and latch the distribution box access panel assembly.
6-20 350201F
IDOCS & MDOCS
500-55 (-CE)
LOOK HERE
Figure 6-16. Coupling Elastomer Half Inspection
6.8.13 BOOSTER HEAT EXCHANGER
Use these instructions to clean/examine/replace the booster heat exchanger (HX-200) every 2000 hours of
operation.
REQUIRED COMPONENTS
(7) #6 Lock Washers {S57004-005}

(16) #10 Lock Washers {S57004-007}
(2) 1/2 inch Swagelok Compression Nuts {G48004-008}
CAGE - 75906
1. On the distribution box; release the latches and remove the distribution box access window panel
assembly.
3. On the rear of the distribution box, remove the fan louver covers.
4. Use a clean soft bristle brush (Table 6-6) to clean the heat exchanger fins
WARNING: Using compressed air to clean can produce flying particles dangerous to unprotected eyes
and skin. Wear eye protection when using compressed air. Make sure people are out of the area and do
not direct the air stream at people.
5. Use low pressure ≤ 2 Bar (30 psig) oil-free shop air to help clean the fins.
a. Blow out the fans area and the debris from the box.
6. Look at the booster heat exchanger.
a. Look for bent or damaged fins.
(1) Straighten bent and damaged fins.
350201F 6-21
IDOCS & MDOCS
500-55 (-CE)
TB-10
HX-200
DUCT
FITTINGS
Figure 6-17. Booster Heat Exchanger (HX-200) (MDOCS shown)
b. Look for signs of leaks.
IF THEN
No signs of leaks are found a. Go-to Step 8. on page 6-23.
a. The heat exchanger must be replaced (590633-001).
Signs of leaks are found
b. Continue
7. To replace the heat exchanger, do as follows:

a. Find the booster heat exchanger fans (FX-200 & -201) wires on terminal block (TB-10).
b. Identify the wires with a label and disconnect them.
WARNING: Contaminants in enriched oxygen can cause explosive fires. This heat exchanger
is used to cool enriched compressed oxygen. Make sure the caps and plugs are oxygen clean.
Use oxygen clean tools and wear powder-free latex gloves. Protect (cap or plug) all open ports
from the entrance of contaminants.
c. Disconnect the heat exchanger inlet and outlet ports from the system tubes.
(1) Put clean plugs in the inlet and outlet tubes.
d. Remove the seven (7) screws, lock and flat washers, and heat exchanger with duct and fans.
(1) Discard the lock washers.
e. On the side of the duct, remove the four (4) screws, flat washers and end cap
f. Remove the sixteen (16) screws, lock and flat washers, and both fans with wires.
(1) Discard the lock washers.
6-22 350201F
IDOCS & MDOCS
500-55 (-CE)
DUCT END CAP DUCT HEAT EXCHANGER 1 OF 2 FANS
Figure 6-18. Booster Heat Exchanger Assembly
g. Remove the eight (8) bolts, sixteen (16) flat washers, lock nuts and the heat exchanger from the
duct.
(1) Repair, recycle or discard the heat exchanger.
h. Install the new/repaired heat exchanger in the duct with eight (8) 10-32 x 3/8 bolts, eight (8) flat
washers and lock nuts.
i. Install the two (2) fans with wires on the heat exchanger with the sixteen (16) 10-32 x 3/8 screws,
new lock washers and flat washers.
j. Install the duct end cap on the duct with four (4) 6-32 x 3/8 screws and flat washers.
k. Install the heat exchanger with fans and duct in the distribution box with seven (7) 10-32 x 3/8
screws, new lock washers and flat washers.
l. Use two (2) new 1/2 inch Swagelok compression nuts and connect the heat exchanger to the
system tubing.
m. Route the fan wires to terminal block (TB-10), read the labeled wires and connect them to the
block.
8. Examine the filter mats in the fan louvers:
IF THEN
a. Clean the mats.
Mats are dirty and cleanable
b. Install the clean mats in the covers.
a. Discard the mats.
Mats are not cleanable b. Get a new mats (Table 6-8).
c. Install the clean mats in the covers.
Mats are clean and usable Continue
9. Install the fan louvers on the rear of the distribution box.

350201F 6-23
IDOCS & MDOCS
500-55 (-CE)
6.8.14 AIR BLOWER MOTOR BEARINGS
Use these instructions to lubricate the air blower motor (MTR-1) bearings every 4000 hours of operation.
GREASE, MULTIPURPOSE, NLGI GRADE 2
WARNING: Hot air blower motor and piping can cause burns. Stop until the air blower motor
has cooled before greasing the bearings.
The air blower motor automatically starts-runs-stops. Make sure the power is OFF and the site
power source is locked-out/tagged-out before removing access panels.
2. On each end of the motor, open the grease fitting cap, use a grease gun (Table 6-4) and inject eight to
ten (8 - 10) pumps of grease (Table 6-7) in each fitting (see Figure 6-19).
3. Use a clean dry lint-free towel (Table 6-4), remove unwanted grease and close the fitting caps.
a. Discard the greasy towel in accordance with local codes on the disposal of a hazardous material.
GREASE FITTING
Figure 6-19. Air Blower Motor (MTR-1) Lubrication (IDOCS-CE shown)
6-24 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.15 AIR BLOWER HEAT EXCHANGER
Use these instructions to clean/examine/replace the air blower heat exchanger (HX-100) every 6000 hours
of operation.

CAUTION: The top access panel is fiberglass, large and awkward to handle alone. Do not try to remove
this panel alone. Use two people to remove/install the top access panel.
2. Use two people to remove the top access panel:

a. Remove three (3) button head screws, flat washers and the blower module lid assembly.
3. Disconnect the motor wiring.
a. On the air blower heat exchanger fan motor (MTR-2), remove the four (4) screws and the wiring
box cover.
b. Identify the wires with a label and disconnect the motor wires from the cable wires.
c. Remove the conduit elbow nut and pull the conduit with elbow and cable (wires) out of the wiring
box.
d. Install the conduit elbow nut on the conduit elbow.
e. Install the wiring box cover with the four (4) screws.
f. Remove the screw and separate the conduit with clamp from the fan cage, if necessary.
WARNING: The fan cage with motor and fan assembly is heavy and cumbersome. Do not try to remove
without a lift. Use a lift to remove/install the one-piece fan cage.
4. Remove the fan cage (with motor and fan) (see Figure 6-20 on page 6-26).
a. On top of the heat exchanger, remove fourteen (14) screws, lock and flat washers, and the fan
cage (with motor (MTR-2) and fan (FX-100)).
b. Put the assembly on a clean work surface.
c. Use a clean dry lint-free towel (Table 6-4) and clean the fan blades.
WARNING: Using compressed air to clean can produce flying particles dangerous to
unprotected eyes and skin. Wear eye protection when using compressed air. Make sure people
are out of the area and do not direct the air stream at people.
5. On the heat exchanger, use low pressure ≤ 2 Barg (30 psig) oil-free shop air and a clean soft brush to
clean the fins.
350201F 6-25
IDOCS & MDOCS
500-55 (-CE)
MTR-2
FAN CAGE
FX-100
HX-100
HEAT EXCHANGER FAN COWL
Figure 6-20. Fan Cage Removal/Installation
6. Straighten bent or crushed fins.

7. Look for leaks.
a. Tighten a leaky fitting.
IF THEN
No leaks in heat exchanger a. Go-to Step 11. on page 6-27.
a. The heat exchanger must be replaced (590633-001).
Leaks in heat exchanger
b. Continue
8. Disconnect the heat exchanger plumbing.

a. On the bottom of the heat exchanger, disconnect and remove the inlet and outlet ports pipe clamps
and gaskets.
(1) Seal the greasy gaskets in a clean sealable bag.
9. Replace the air blower heat exchanger (see Figure 6-21 on page 6-27)
a. Remove seven (7) button head screws and the left acoustic panel.
b. Remove five (5) button head screws and the right acoustic panel.
c. Remove ten (10) lock nuts and heat exchanger fan cowl.
d. Remove ten (10) bolts, twenty (20) flat washers, lock nuts and the air blower heat exchanger
(HX-100).
(1) Repair, recycle or discard the heat exchanger.
e. Install a new/repaired air blower heat exchanger and heat exchanger fan cowl on top of the blower
module with ten (10) 3/8-16 x 1-1/4 bolts, twenty (20) flat washers and lock nuts.
(1) Put a flat washer below the bolt head and one below the nut.
f. Install the right acoustic panel with five (5) 1/4-20 x 5/8 button head screws.
g. Install the left acoustic panel with seven (7) 1/4-20 x 5/8 button head screws.
6-26 350201F
IDOCS & MDOCS
500-55 (-CE)
FAN COWL
RIGHT
PANEL
LEFT PANEL
HX-100
CLAMP
Figure 6-21. Air Blower Heat Exchanger (HX-100)
10. On the bottom of the heat exchanger, connect the inlet and outlet ports to the system piping elbows with
the pipe clamps and gaskets wet with oxygen lubricant (Table 6-8).
11. Install the fan cage (with motor (MTR-2 and fan (FX-100) on top of the heat exchanger with fourteen
(14) screws, lock and flat washers (see Figure 6-20).
12. Connect the motor wiring.
a. On the motor (MTR-2) remove the four (4) screws and the motor wire box cover.
b. On the motor wiring conduit, remove the conduit elbow nut, put the wires in the motor wire box and
install the conduit nut.
c. Read the wire labels and connect the system wires to motor wires.
d. Install the motor wire box cover with the four (4) screws.
e. Attach the conduit to the fan cage with a cable clamp.
13. Use two (2) people and install the blower module lid assembly with three (3) 1/4-20 x 5/8 button head
screws and flat washers.
350201F 6-27
IDOCS & MDOCS
500-55 (-CE)
6.8.16 AIR BLOWER SHAFT SEAL
Use these instructions to examine/replace the air blower (BL-100) drive shaft seal every 8000 hours of
operation.
GREASE, MULTIPURPOSE NLGI GRADE 2
REQUIRED COMPONENTS
(2) 3/8 Lock Washers {S57004-011}

(4) M12 Lock Washers {S57006-047}
CAGE - 75906
WARNING: Hot air blower and piping can cause burns. These components are hot after operation. Stop
until the air blower has cooled to the touch before looking at the shaft seal.
The air blower motor automatically starts-runs-stops. Unexpected operation can cause injuries. Make sure
the power is OFF and the site power source is locked-out/tagged-out before removing access panels.
IF THEN
a. On the coupling guard, disengage the captive screws and
open the guard.
2. On the blower, look at the seal around the drive shaft (see Figure 6-22 on page 6-29).
IF THEN
The area around the shaft is free of a. Close the coupling guard and engage the captive screws, if
weeping or leaked blower oil-lube. necessary.
b. Install and latch the access and air access panels.
c. Examine the air blower shaft seal again after 2000 hours.
The area around the shaft has blower oil-
a. The shaft seal (590561-001) and sleeve (585802-007) must
lube weeping or leaking from the shaft
be replaced, continue.
seal.
3. Remove the four (4) screws, lock and flat washers, and the coupling guard, if necessary.
4. On the drive shaft side of the blower, put a clean container below the drain port.
6-28 350201F
IDOCS & MDOCS
500-55 (-CE)
LOOK HERE FOR WEEPING

LUBRICANT
Figure 6-22. Air Blower (BL-100) Shaft Seal Inspection (IDOCS shown)
PIPE CLAMP
ELBOW
BLOWER COUPLING
PIPE CLAMP ELASTOMER HALVES
BLOWER
MOUNTING
BRACKET
PIPE CLAMP
Figure 6-23. Air Blower Piping Disconnection/Connection (IDOCS shown)
350201F 6-29
IDOCS & MDOCS
500-55 (-CE)
5. Remove the drain plug and drain the drive shaft side reservoir.
a. Loosen the fill port plug to aid the draining.
6. Remove the thread seal tape from the plug.
7. Apply 2 - 3 turns of new thread seal tape (Table 6-8) to the plug pipe threads.
8. Install the drain plug.
9. Discard the lubricant in accordance with local codes on the disposal of waste oil.
10. On the bottom of the air blower, disconnect the silencer (S-100) (see Figure 6-23 on page 6-29).
a. Remove the pipe clamp and gasket.
b. Seal the gasket in a clean sealable bag.
11. On top of the air blower, disconnect the discharge piping.
a. Remove the pipe clamps, gaskets and elbow assembly.
b. Seal the gaskets in the sealable bag.
12. Cover/seal the air blower discharge port with a clean dry plastic bag and shipping tape.
13. On the air blower coupling, remove the screws and the elastomer halves.
14. Below the air blower, remove four (4) M12 screws, lock and flat washers.
15. On the air blower mounting bracket, remove two (2) 3/8 screws, lock and flat washers attaching the
blower and bracket to the frame.
a. Do not remove the screws attaching the bracket to the blower.
b. Discard the lock washers.
WARNING: The air blower weighs approximately 89 kg (195 lb) and is in a small enclosed area. Do not
try to move alone. Use a small lift to move it.
16. Use a lift and carefully turn the blower to gain access to the blower shaft and seal.
17. Install one screw in the blower to keep it from moving.
18. On the blower shaft coupling hub, loosen the hub setscrew and remove the hub.
19. Put the Omega 4 shaft protector (Table 6-6) in the end of the blower shaft
NOTE: Table 6-6 lists the shaft seal replacement kit (798750-001). The tools referring to the table are in
that kit.
20. Use the vise grips to remove the shaft key.

21. Use a flat blade screwdriver and carefully remove the shaft seal.
a. Do not mar the shaft or the end cover sealing faces.
b. Discard the used seal.
6-30 350201F
IDOCS & MDOCS
500-55 (-CE)
Figure 6-24. Blower Shaft Protector
PUT THE RING ON THE

T-BAR PULLER AS
SHOWN
CENTER PULLER SCREW

BETWEEN ARMS
ARM SHOULDER
Figure 6-25. T-Bar Puller Preparation
OLD SLEEVE PULLER ARMS LATCHED IN

NOTCHES
LINE SHOWS BORDER OF

MISSING END COVER
RING SLID ONTO

SHOULDERS OF ARMS
Figure 6-26. Omega Blower Puller Usage
350201F 6-31
IDOCS & MDOCS
500-55 (-CE)
22. Find the Omega 4 puller ring and put it over the Omega blower T-bar puller arms
a. Move the arms to center the puller screw between them.
23. Put the Omega blower puller arms in the blower end cover over the shaft sleeve.
a. Evenly push the arms against the sleeve until the arm tabs latch in the notches in the sleeve.
b. Move the Omega 4 puller ring forward to the puller arms’ shoulders, attaching the latched arms on
the sleeve (see Figure 6-26 on page 6-31).
24. Turn the T-Bar puller screw and remove the sleeve.
a. Discard the used sleeve.
25. Use emery cloth to clean the shaft and the sealing surface of the end cover.
a. Wipe them down with a clean dry lint-free towel.
26. Make sure the shaft sleeve installation tool slides on and off the blower shaft (see Figure 6-27).
a. Use the emery cloth to clean the shaft until it does.
(1) Wipe the shaft down with a clean dry lint-free towel after each emery cloth use before trying
the sleeve installation tool.
27. Use the hot plate and heat the new shaft sleeve to a maximum temperature of 107°C (225°F).
a. Mark the sleeve with a temperature indicating crayon (107°C (225°F)) (Table 6-8).
b. When the mark melts, the sleeve is at temperature.
SLEEVE INSTALLATION NEW HOT SLEEVE

TOOL
Figure 6-27. Shaft Sleeve Installation Tool
WARNING: The hot shaft sleeve can cause burns. Do not touch the sleeve with bare hands. Wear heat
protective gloves (welders gloves).
28. Wear heat protective gloves and put the shaft sleeve over the blower shaft and in the end cover.
29. Use the shaft sleeve installation tool and seat the sleeve on the shaft.
30. Stop until the shaft sleeve is cool to the touch.
31. Put the Omega 4 seal guide tool on the blower shaft (see Figure 6-28 on page 6-33).
6-32 350201F
IDOCS & MDOCS
500-55 (-CE)
SEAL GUIDE TOOL NEW SHAFT SLEEVE END
Figure 6-28. Shaft Seal Guide Tool
FILL THIS GAP 2/3 FULL

WITH MULTIPURPOSE
GREASE
Figure 6-29. Shaft Seal Greasing
SEAL INSTALLATION
TOOL
Figure 6-30. Shaft Seal Installation
350201F 6-33
IDOCS & MDOCS
500-55 (-CE)
HUB
AIR BLOWER
5.8 MM (0.23 INCH) CLEARANCE
Figure 6-31. Air Blower Coupling Hub Alignment
32. Use the multi-purpose grease (Table 6-7) to fill the space in the inside diameter of the new shaft seal
2/3 full (see Figure 6-29 on page 6-33).
33. Apply a light coat of the grease on the seal guide tool and the shaft sleeve end.
34. Carefully move the new seal over the seal guide tool (see Figure 6-30 on page 6-33).
a. Make sure the seal lip does not deform.
35. Use the seal installation tool to seat the shaft seal in the end cover.
36. Remove the seal installation and guide tools.
37. Put the shaft key in the blower shaft.
38. Put the hub on the blower shaft (see Figure 6-31).
a. Align the hub until the end of the shaft is 5.8 mm (0.23 in) past the hub.
b. Torque the setscrew 32.8 Nm (24 ft-lb).
39. On the bottom of the blower, remove the screw.
40. Turn the blower body to align the blower coupling hub with the blower motor coupling hub.
41. Install four (4) M12 x 40 screws, new M12 lock washers and flat washers.
a. Torque the screws 73 Nm (54 ft-lb); use the pattern shown in Figure 6-32 on page 6-35.
42. On the blower mounting bracket, install the two (2) 3/8-16 x 3/4 screws and new 3/8 lock washers
attaching the blower bracket to the frame.
43. On the bottom of the blower, connect the silencer (S-100) (see Figure 6-23 on page 6-29).
a. Install the pipe clamp and gasket wet with oxygen lubricant (Table 6-8).
44. On top of the blower, connect the discharge piping.
a. Connect the elbow assembly with two pipe clamps and gaskets wet with oxygen lubricant.
45. Use the instructions in Section 6.8.24 starting with Step 2. on page 6-74 and align the coupling.
6-34 350201F
IDOCS & MDOCS
500-55 (-CE)
Figure 6-32. Blower Screw Torque Pattern
6.8.17 BOOSTER SCROLL COMPRESSOR LUBRICATION AND TIP SEALS
The booster scroll compressor (C-1) tip seals must be replaced and the scroll compressor bearings
lubricated every 4000 hours of operation.
6.8.17.1 SCROLL COMPRESSOR DISASSEMBLY
assembly.
to remove alone. Use two (2) people when removing/installing the panel assembly.
The booster compressor is hot after operation. It can cause burns when touched. Stop until the
booster compressor cools to the touch before doing maintenance.
Contaminants in enriched oxygen can cause explosive fires. The scroll compressor interior
must be kept oxygen clean. Make sure you use oxygen clean tools and wear clean powder-free
latex gloves. Put a tent around the Plant during this procedure or move the VSA module to a
clean environment before opening the scroll compressor.
2. On the booster scroll compressor, disconnect and put a clean plug in the inlet hose, and cap on elbow
3. Disconnect and put a clean plug in the discharge hose and cap on the elbow.
NOTE: Do not remove the inlet (elbow) and discharge (adapter-connector-elbow) fittings.
4. Remove three (3) screws, clip nut and the fan duct (see Figure 6-34 on page 6-37).
5. Put on clean powder-free latex gloves and use only oxygen clean tools.
350201F 6-35
IDOCS & MDOCS
500-55 (-CE)
INLET HOSE ASSY
DISCHARGE HOSE ASSY
Figure 6-33. Booster Compressor (C-1) Hose Disconnection (MDOCS shown)
WARNING: The booster compressor automatically starts-runs-stops. Unexpected operation can cause
injuries. Make sure the power is OFF and the site power source is locked-out/tagged-out before opening
the compressor.
6. Remove four (4) screws, two (2) nuts, washers and the fixed scroll (see Figure 6-35 on page 6-37).
6.8.17.2 TIP SEAL REMOVAL
1. On the fixed scroll, use a soft pointed tool, remove and discard the old Low Pressure (LP) seal
2. Remove and discard the High Pressure (HP) seal.
3. Remove and discard the dust seal (see Figure 6-37 on page 6-38).
4. Remove and discard the backup tube.
WARNING: Using compressed air to clean can produce flying particles dangerous to
unprotected eyes and skin. Wear eye protection when using compressed air. 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 oil-free compressed air (≤ 2 bar (30 psig)) or a clean dry lint-free towel (Table 6-4) to
clean the scroll channels (see Figure 6-38 on page 6-38).
6-36 350201F
IDOCS & MDOCS
500-55 (-CE)
SCREW
SCREW &
CLIP NUT FAN DUCT
SCREW
Figure 6-34. Compressor Fan Duct Removal
NUT & SCREW

WASHER
SCREW
SCREW
SCREW NUT &

WASHER
SHOWN WITH FITTINGS REMOVED
Figure 6-35. Fixed Scroll Hardware Removal
HP SEAL
LP SEAL
DUST SEAL
LP SEAL REMOVAL HP SEAL REMOVAL
Figure 6-36. Fixed Scroll LP Seal Removal
350201F 6-37
IDOCS & MDOCS
500-55 (-CE)
DUST SEAL REMOVAL BACKUP TUBE REMOVAL
Figure 6-37. Fixed Scroll Dust Seal Removal
Figure 6-38. Fixed Scroll Cleaning
LP SEAL
HP SEAL
Figure 6-39. Orbital Scroll Seals
6-38 350201F
IDOCS & MDOCS
500-55 (-CE)
6. On the orbital scroll, use a soft pointed tool, remove and discard the old LP seal
7. Remove and discard the HP seal.
8. Use low pressure oil-free compressed air (≤ 2 bar (30 psig)) or a clean dry lint-free towel (Table 6-4) to
clean the scroll channels.
6.8.17.3 TIP SEAL INSTALLATION
Refer to Table C-10 for the seal kit part numbers shown in Figure 6-40.
CAUTION: The tip seals are delicate and can easily tear. Use caution when inserting tip seals to prevent
tearing or distorting the seal.
Incorrect installation of the scroll seals can cause compressor failure. Make sure you obey these
instructions. If there is confusion, contact PCI for clarification (refer to Foreword).
LP SEAL (ORBITAL)
HP SEAL (ORBITAL)
DUST SEAL (FIXED)
BACKUP (FIXED)
HP SEAL (FIXED)
LP SEAL (FIXED)
Figure 6-40. Tip Seal Kit
NOTE: The high pressure (HP) seals are similar for the fixed and orbital scroll (different part numbers);
the difference is in the lip direction. The low pressure (LP) seals are the same seal (different part
numbers).
CAUTION: A seal (lip or dust) installed twisted or not seated in the channel, can tear apart and cause
metal-on-metal operation causing compressor failure. It is critical: all seals must be flush in the channels
after installation.
1. On the orbital scroll, install the HP seal (see Figure 6-41 on page 6-40).
a. With the seal’s grooved bottom down, align the seal with the scroll channel.
350201F 6-39
IDOCS & MDOCS
500-55 (-CE)
b. Put the end of the seal against the channel end.

2. Install the LP Seal (see Figure 6-42).
a. Put the LP seal against the HP seal.
b. Install approximately half of the seal then remove to make sure a locating notch is formed in the
seal.
c. Install the seal, cut and remove the unwanted end (see Figure 6-43 on page 6-41).
3. On the fixed scroll, install the HP seal (see Figure 6-44 on page 6-41).
a. With the seal’s grooved bottom down, align the seal with the scroll channel.
b. Put the end of the seal against the channel end.
4. Install the LP Seal (see Figure 6-45 on page 6-41).
a. Put the LP seal against the HP seal.
b. Install approximately half of the seal then remove to make sure a locating notch is formed in the
seal.
c. Install the seal, cut and remove the unwanted end.
PUT THESE
EDGES
AGAINST EACH
OTHER
Figure 6-41. Orbital Scroll HP Seal Installation
NOTCH
LP SEAL
SCROLL
Figure 6-42. Orbital Scroll LP Seal Installation
6-40 350201F
IDOCS & MDOCS
500-55 (-CE)
Figure 6-43. Orbital Scroll LP Seal Termination
PUT THESE
EDGES
AGAINST EACH
OTHER
Figure 6-44. Fixed Scroll HP Seal Installation
Figure 6-45. Fixed Scroll LP Seal Installation
350201F 6-41
IDOCS & MDOCS
500-55 (-CE)
START TUBE END

AGAINST CHANNEL
END
OVERLAP TUBE
TERMINATION ON
TUBE START END
Figure 6-46. Fixed Scroll Backup Tube Installation
START SEAL END

AGAINST CHANNEL
END
OVERLAP SEAL
TERMINATION ON
SEAL START END
Figure 6-47. Fixed Scroll Dust Seal Installation
5. Install the backup tube (see Figure 6-46)

a. Put the tube end against the channel end.
b. Overlap the start end and cut unwanted end.
6. Install the dust seal on-top-of the backup tube (same scroll channel) (see Figure 6-47).
a. Put the seal end against the channel end, overlap the start end and cut unwanted end.
6.8.17.4 SCROLL COMPRESSOR LUBRICATION
GREASE, ISOFLEX TOPAS NB 52

1. On top of the compressor housing, remove the plastic dust cap (see Figure 6-48 on page 6-43).
2. Look in the grease port, turn the booster shaft until the grease fitting is visible.
6-42 350201F
IDOCS & MDOCS
500-55 (-CE)
3. Use the grease gun (Table 6-5) with the cartridge of Isoflex Topas NB 52 grease (Table 6-7) and the
extension, and put four pumps of grease in the fitting.
4. Install the plastic dust cap.
5. Put four to six (4 - 6) pumps of grease in each pin bearing grease fitting (three) (see Figure 6-49).
6. Remove unwanted grease with a clean lint-free towel (Table 6-4).
GREASE GUN W/ EXTENSION
PLASTIC DUST CAP
GREASE FITTING
GAP IN COUNTER WEIGHT
Figure 6-48. Compressor Main Bearing Lubrication
ORBITAL SCROLL
PIN PIN BEARING

BEARING GREASE FITTING
GREASE
FITTINGS
Figure 6-49. Compressor Pin Crank Bearing Lubrication
6.8.17.5 SCROLL COMPRESSOR ASSEMBLY
1. Carefully install the fixed scroll on the orbital scroll with the four (4) screws, washers and two (2) nuts
NOTE: Make sure all seals stay in their channels while assembling the fixed scroll on the orbital scroll.
a. Use the pattern shown in Figure 6-51 on page 6-44 to torque the screws and nuts 20.3 Nm
(15 ft-lbs) {initial tightening}.
2. Turn the compressor shaft and make sure the scroll turns smoothly.
350201F 6-43
IDOCS & MDOCS
500-55 (-CE)
NUT & SCREW

WASHER
SCREW
SCREW
SCREW NUT &

WASHER
SHOWN WITH FITTINGS REMOVED
Figure 6-50. Compressor Assembly
Figure 6-51. Torque Pattern
SCREW
SCREW &
CLIP NUT FAN DUCT
SCREW
Figure 6-52. Fan Duct installation
3. Use the pattern shown in Figure 6-51 to torque the screws and nuts 29.8 Nm (22 ft-lbs) {final torque}.
4. Install the fan duct with the clip nut and three (3) screws (see Figure 6-52).
5. Remove the caps and plugs to connect the inlet and discharge tubes (see Figure 6-53 on page 6-45).
6-44 350201F
IDOCS & MDOCS
500-55 (-CE)
INLET HOSE ASSY
DISCHARGE HOSE ASSY
Figure 6-53. Booster Scroll Compressor (C-1) Hose Connections (MDOCS shown)
6.8.18 AIR BLOWER HEAT EXCHANGER MOTOR
The expected life of the heat exchanger motor (MTR-2) is 20,000 hours of operation. Use these instructions
to replace the motor after 20,000 operating hours or when it fails.
REQUIRED COMPONENT
Electrical Motor {583903-004}

CAGE - 75906
CAUTION: The top access panel is fiberglass, large and awkward to handle alone. Do not try to remove
alone. Use two people to remove/install the top access panel.
2. Use two people to remove the top access panel.

a. Remove three (3) button head screws, flat washers and the blower module lid assembly.
350201F 6-45
IDOCS & MDOCS
500-55 (-CE)
3. Disconnect the motor wiring.

a. On the air blower heat exchanger fan motor (MTR-2), remove the four (4) screws and the wiring
box cover.
b. Identify with a label and disconnect the motor wires from the cable wires.
c. Remove the conduit elbow nut and pull the conduit with elbow and cable (wires) out of the wiring
box.
d. Install the conduit elbow nut on the conduit elbow.
e. Install the wiring box cover with the four (4) screws.
f. Remove the screw and separate the conduit with clamp from the fan cage, if necessary.
WARNING: The fan cage with motor and fan assembly is heavy and cumbersome. Do not try to lift
alone. Use a lift to remove/install the one-piece fan cage.
4. Remove the fan cage (with motor and fan) (see Figure 6-54).
a. On top of the heat exchanger, remove fourteen (14) screws, lock and flat washers, and the fan
cage (with motor (MTR-2) and fan (FX-100)).
b. Put the assembly on a clean work surface.
MTR-2
FAN CAGE
FX-100
HX-100
HEAT EXCHANGER FAN COWL
Figure 6-54. Fan Cage Removal/Installation
5. On the air blower heat exchanger fan (FX-100), loosen the setscrews and remove the assembly from
the motor shaft (see Figure 6-55 on page 6-47).
6. Remove the four (4) bolts, lock and eight (8) flat washers, nuts and the motor.
7. On the motor, remove the shaft key.
8. Send the motor to the OEM for overhaul or credit, if due.
9. Put the key on the new motor drive shaft.
6-46 350201F
IDOCS & MDOCS
500-55 (-CE)
MTR-2
FAN CAGE
FX-100
Figure 6-55. Air Blower Heat Exchanger Motor (MTR-2) Removal/Installation
10. Install the new motor on the fan cage with four (4) bolts, lock and eight (8) flat washers, and nuts.
a. Put a flat washer below the bolt and one with the nut and lock washer.
11. Install the fan (FX-100) on the motor drive shaft.
a. Align the fan hub assembly face with the end of the drive shaft.
b. Tighten the hub setscrews.
12. Use the lift to put the fan cage (with motor and fan) on top of the air blower heat exchanger (HX-100).
13. Make sure the fan (FX-100) does not touch the heat exchanger.
IF THEN
a. Remove the fan cage (with fan and motor) and adjust the fan/
Fan blade touches the heat exchanger motor distance.
b. Do Steps 12. - 13. again.
Fan blades clear heat exchanger Continue
14. Attach the fan cage to the heat exchanger fan cowl with fourteen (14) screws, lock and flat washers.
15. Connect the motor wiring.
a. On the motor (MTR-2) remove the four (4) screws and the motor wire box cover.
b. On the motor wiring conduit, remove the conduit elbow nut, put the wires in the motor wire box and
install the conduit nut.
c. Read the wire labels and connect the motor wires to conduit wires.
d. Install the motor wire box cover with the four (4) screws.
e. Attach the conduit to the fan cage with a cable clamp.
16. Do a motor phase and fan direction check:
a. On the site power source, remove the lock-out/tag-out and set to ON.
350201F 6-47
IDOCS & MDOCS
500-55 (-CE)
b. On the Plant electrical cabinet, set circuit breaker (CB-1) to ON.

c. Pull-out or twist the Emergency-Stop button (de-activate).
d. On the operator panel, stop until the Normal screen to shows (see Figure 6-56).
e. Push and hold (at same time) the (+) and (–) buttons until the Setup Entry screen shows:
IF THEN
a. See Figure 6-57.
Without optional MFC-1 b. Push the NEXT button eight (8) times to show the next eight
setup screens shown in Figure 6-59.
a. See Figure 6-58.
b. Push the NEXT button eight (9) times to show the right
With optional MFC-1
screen in Figure 6-58 and the next eight setup screens
shown in Figure 6-59.
Figure 6-59. Out Press to Direct IO Screens
6-48 350201F
IDOCS & MDOCS
500-55 (-CE)
f. On the Direct IO Stops DOCS screen, push the (+) button to show the Direct IO Fault Input screen
(see Figure 6-60).
g. Push the NEXT button four times to show these screens (see Figure 6-61).
Figure 6-61. VSA FWD, VSA REV, SCR FWD & VSA Main Cooler Screens
h. On the VSA Main Cooler screen, push the (+) button and the top line changes to VSA MAIN
COOLER ON.
The air blower heat exchanger fan (FX-100) turns.
i. Put a piece of paper or a dollar bill on top of the air blower heat exchanger fan cage
IF THEN
a. Push the (–) button and the top line shows VSA MAIN
COOLER OFF.
b. Push and hold (at same time) the (+) and (–) buttons to show
The paper or dollar is pulled in the cage the Normal screen (see Figure 6-56 on page 6-48).
c. Set circuit breaker (CB-1) to OFF.
d. Lock-out/tag-out the site power source.
e. Go-to Step 17. on page 6-51.
a. Push the (–) button and the top line shows VSA MAIN
COOLER OFF.
b. Push and hold (at same time) the (+) and (–) buttons to show
The paper or dollar is blown away from the Normal screen (see Figure 6-56).
the cage
c. Set circuit breaker (CB-1) to OFF.
d. Lock-out/tag-out the site power source.
e. Continue
WARNING: High voltage creates high current causing injury or death. The electrical cabinet has high
voltage inside. Make sure the site power source is OFF, locked-out and tagged-out before opening the
electrical cabinet.
j. On the Plant, release the latches and open the electrical cabinet access door.
350201F 6-49
IDOCS & MDOCS
500-55 (-CE)
PUT PIECE OF PAPER OR

DOLLAR BILL HERE
Figure 6-62. Air Blower Heat Exchanger Fan (FX-100) Air Direction {MDOCS-CE shown}
SWAP TWO WIRES
Figure 6-63. Motor Starter/Contactor (MCP-1/M-1)
6-50 350201F
IDOCS & MDOCS
500-55 (-CE)
k. On the bottom of motor starter/contactor (MCP-1/M-1), swap two motor wires connected to
terminals 3T1, 3T2 or 3T3 (see Figure 6-63 on page 6-50).
 L1 - L2 or
 L2 - L3 or
 L1 - L3
l. Close and latch the electrical cabinet access door.
m. Do Steps a. - i. again.
17. Use two (2) people and install the blower module lid assembly with three (2) 1/4-20 x 5/8 button head
screws and flat washers.
6.8.19 BOOSTER COMPRESSOR MOTOR
The expected life of the booster compressor motor (MTR-3) is 20,000 hours of operation. Use these
instructions to replace the motor after 20,000 operating hours or when it fails.
REQUIRED COMPONENT
Electrical Motor {585525-012}

(4) 5/16 Lock Washers {S57004-010}
(4) 3/8 Lock Washers {S57004-011}
CAGE - 75906
assembly.
WARNING: Hot booster components can cause burns. The component is hot after operation.
Make sure the components are cool to the touch before doing maintenance.
The distribution box access panel assembly is heavy and cumbersome. Do not try to remove
alone. Use two (2) people when removing/installing the panel assembly
WARNING: The booster automatically starts-runs-stops. Unexpected operation can cause injury. Make
sure the power is OFF and the site power source is OFF, locked-out/tagged-out before removing the
booster compressor coupling guard.
3. On the booster coupling guard, remove the four screws, lock and flat washers, and coupling guard
4. Remove eight (8) screws and both coupling elastomer halves (see Figure 6-65 on page 6-52).
5. On the motor, remove the screws and the motor wiring box cover.
350201F 6-51
IDOCS & MDOCS
500-55 (-CE)
COUPLING GUARD
HARDWARE
Figure 6-64. Booster Coupling Guard Remove/Install (MDOCS shown)
HUB
MTR-3
COUPLING
HALVES
Figure 6-65. Booster Motor (MTR-3) Removal/Installation (MDOCS shown)
6. Identify with a label and disconnect the motor wires from the system wire cable.
7. Pull the wire cable out of the wiring box.
8. Remove the strain relief from the wiring box and install the wiring box cover with the screws.
6-52 350201F
IDOCS & MDOCS
500-55 (-CE)
WARNING: The motor weighs 46.3 kg (102 lb). Do not try to remove alone. Use a lift and carefully lift the
motor from the box.
9. Remove the four (4) locking nuts, four (4) attaching nuts, lock and flat washers, and motor from the
adjustment plate.
10. Leave the shims in their original positions.
a. Remove stuck shims from the motor and put back in original location.
11. On the coupling hub, loosen the setscrew and remove the hub.
12. Remove the motor shaft key.
13. Return the motor to the OEM for overhaul or credit, if due.
14. On the new motor, put the key in the drive shaft.
MTR-3
HUB
3.8 mm (0.15 inch)
Figure 6-66. Booster Motor Coupling Hub Alignment
15. Install the coupling hub on the motor drive shaft (see Figure 6-66).
a. Align the hub to extend 3.8 mm (0.15 inch) past the end of the drive shaft.
b. Tighten the setscrew just sufficient to keep the hub from moving.
16. Loosely install the motor on the motor adjusting base with new lock washers, flat washers and the four
(4) attaching 3/8-16 thin nuts (see Figure 6-65).
a. Do not install the thin locking nuts at this time.
17. Remove the screws and the motor wiring box cover.
18. Install the strain relief in the rear of the wiring box.
19. Insert the motor cable wires through the strain relief and in the wiring box.
20. Tighten the strain relief on the cable.
21. Read the wire labels and connect the motor wires to the motor cable wires.
350201F 6-53
IDOCS & MDOCS
500-55 (-CE)
22. Install the wiring box cover with the screws.

23. Use instructions in Section 6.8.23, start with Step 2. on page 6-63 and align the coupling.
6.8.20 BOOSTER SCROLL COMPRESSOR
The expected life of the booster scroll compressor (C-1) is 20,000 hours of operation. Use these instructions
to replace the compressor after 20,000 operating hours or when it fails.
REQUIRED COMPONENTS
Compressor {797300-002}
Compressor Inlet Gasket {799791-002}
(8) 5/16 Lock Washers {S57004-010}
(4) M6 Lock Washers {S57006-043}
CAGE - 75906
assembly.
WARNING: The distribution box access panel assembly is heavy and cumbersome, use two
(2) people when removing/installing the panel assembly.
Contaminants in enriched oxygen can cause explosive fires. The compressor and hoses route
enriched oxygen. Make sure the caps and plugs used are oxygen clean. Use only oxygen clean
tools and wear clean powder free latex gloves.
3. On the booster compressor, disconnect and put a plug in the inlet hose, and put a cap on the elbow
4. Disconnect and put a plug in the discharge hose, and put a cap on the elbow.
WARNING: The booster automatically starts-runs-stops. Unexpected operation can cause injuries. Make
sure the power is OFF and the site power source is locked-out/tagged-out before removing the booster
coupling guard.
5. On the booster coupling guard, remove the four screws, lock and flat washers, and coupling guard.
6. Remove eight (8) screws and the two coupling elastomer halves (see Figure 6-68 on page 6-55).
6-54 350201F
IDOCS & MDOCS
500-55 (-CE)
COUPLING GUARD
HARDWARE
INLET HOSE
DISCHARGE HOSE
Figure 6-67. Booster Compressor Coupling Guard and Hose Disconnections (MDOCS shown)
C-1
HARDWARE
COUPLING
HALVES
Figure 6-68. Booster Compressor (C-1) Removal (IDOCS shown)
7. Remove four (4) locking nuts, four (4) attaching nuts, lock and flat washers, and carefully lift the
compressor out of the box and put it on a clean work surface.
8. Put on clean powder-free latex gloves (Table 6-4).
9. On the compressor discharge port, remove the elbow/reducer/adaptor (do not disassemble these parts)
a. Put a cap on the discharge port.
350201F 6-55
IDOCS & MDOCS
500-55 (-CE)
FAN DUCT HUB ASSY/FAN GASKET INLET FITTINGS
SCROLL DISCHARGE FITTINGS
Figure 6-69. Scroll Compressor Disassembly/Assembly
b. Seal the removed components in an oxygen clean sealable bag.

10. On the compressor inlet port, remove four (4) screws, lock and flat washers, and the plate with elbow
installed.
a. Seal the plate (with elbow) in an oxygen clean bag.
b. Remove and discard the gasket.
c. Use a clean lint-free towel and clean the inlet port.
d. Cover the inlet port to prevent the entrance of contaminants.
e. Discard the lock washers
11. Remove five (5) screws and the fan shroud.
12. Loosen the hub setscrew and remove the hub assembly (hub & counterbalance) with fan attached.
13. On the new scroll compressor (see Figure 6-70 on page 6-57):
a. Remove five (5) screws and the fan shroud.
b. Remove the fan with pulley attached.
c. Use a soft bristle brush (Table 6-8) to clean the old compressor fan (with hub assembly attached).
d. Install the old compressor fan (with hub assembly attached) on the drive shaft
(1) Align the hub to extend 15.75 mm (0.63 inch) past the end of the drive shaft.
(2) Torque the hub assembly (counterbalance) setscrew 17.6 Nm (13 ft-lb) (see Figure 6-69).
e. Install the fan shroud with the five (5) screws.
14. On the old scroll compressor:
a. Put the new compressor fan (with pulley) on the drive shaft.
b. Install the fan shroud with the five (5) screws.
15. Return the old scroll compressor to PCI for replacement or credit, if due.
6-56 350201F
IDOCS & MDOCS
500-55 (-CE)
PULLEY
FAN
FAN DUCT
Figure 6-70. New Scroll Compressor Component Removal
ATTACHING SETSCREW IN COUNTERBALANCE
HUB
C-1
15.75 mm (0.63 inch)
Figure 6-71. Compressor Coupling Hub Alignment
16. On the adaptor/reducer/elbow assembly (discharge fittings), clean the thread seal tape from the adaptor
threads.
17. On the new scroll compressor discharge tube, remove the cap and apply 2 - 3 turns of thread seal tape
(Table 6-8) to the pipe threads.
350201F 6-57
IDOCS & MDOCS
500-55 (-CE)
18. Connect the adaptor/reducer/elbow assy to the compressor discharge tube (see Figure 6-69).
a. Align the elbow opening to the four o’clock position.
19. Remove the cover from the compressor inlet port and make sure the port is clean.
20. On the new inlet gasket (Table 6-8), apply a light coat of oxygen lubricant (Table 6-8).
21. Install the gasket and plate (with elbow) with four (4) M6 drilled screws wet with red thread locker
(Table 6-8), new M6 lock washers and flat washers.
a. Align the elbow opening to 3 o’clock.
b. Torque the screws in a criss-cross pattern 6.8 (-0/+1.1) Nm (5 (-0/+0.8) ft-lb).
22. Install the compressor on the mounting studs.
a. Align the compressor until the initial distance between the compressor hub and the motor hub is
approximately 21 mm (0.83 inch).
b. Install four (4) 5/16-18 nuts with new lock washers and flat washers attaching the compressor.
(1) Use the pattern in Figure 6-72 to torque the nuts 15 Nm (11 ft-lb).
c. Install the locking nuts wet with blue thread locker (Table 6-8) on top of the attaching nuts.
(1) Hold the attaching nut and tighten the locking nut.
23. Use instructions in Section 6.8.23, start with Step 2. on page 6-63 and align the coupling.
Figure 6-72. Scroll Compressor Nut Torque Pattern
6-58 350201F
IDOCS & MDOCS
500-55 (-CE)
6.8.21 OXYGEN PRODUCT SENSOR
Use these instructions to replace the oxygen product sensor (AE-1) and calibrate it to the analyzer (AE-2)
after five (5) years of operation {MDOCS (-CE) and models with AE-2}.
assembly.
to remove alone. Use two (2) people when removing/installing the panel assembly.
Contaminants in enriched oxygen can cause explosive fires. The sensor interior and hoses
route enriched oxygen. Make sure the caps and plugs used are oxygen clean. Use only oxygen
clean tools and wear clean powder free latex gloves.
2. Use two (2) people to release the latches and remove the distribution box access panel assembly.
3. In the distribution box, find the oxygen product analyzer (AE-2), identify with a label and disconnect
sensor wiring from the analyzer (see Figure 6-73 on page 6-59).
a. Remove all cable ties from the sensor cable.
4. On the side of the distribution box, release the latch and open the oxygen sensor box access door.
5. In the sensor box, loosen the cable relief and slowly pull the sensor cable through and out of the box.
6. On the sensor (AE-1), cut all ties, disconnect and put a plug in the two hoses.
7. Remove the pipe clamp screws and sensor (AE-1).
8. On the sensor, remove the two hose barbed elbows.
a. Clean the thread seal tape from the elbow pipe threads.
b. Put the elbows in a clean sealable bag.
AE-2
AE-1
HOSES
DISTRIBUTION BOX
OXYGEN SENSOR BOX
HOSE ELBOWS
Figure 6-73. Oxygen Product Analyzer (AE-2) & Sensor (AE-1) {MDOCS shown}
350201F 6-59
IDOCS & MDOCS
500-55 (-CE)
9. Measure the length of the old sensor cable from the sensor to the lead ends.
10. Discard the old sensor in accordance with the local codes on the disposal of e-waste.
11. On the new sensor (AE-1) cut the cable length to the length measured in Step 9.
12. Remove the elbows from the bag and apply 2 - 3 turns of new thread seal tape (Table 6-8) to the pipe
threads.
13. Remove the plugs from the sensor and install the hose barb elbows.
a. Align the elbows to 90 degrees from the plain of the sensor (openings at you).
14. Feed the sensor cable through the strain relief and mount the sensor in the pipe clamp and tighten the
clamp screws.
a. Tighten the cable strain relief.
15. Remove the plugs from the hoses and connect them to the hose barb elbows.
a. Attach the hoses on the elbow barbs with cable ties.
16. Close and latch the oxygen product sensor box access door.
17. In the distribution box, route the sensor cable to the analyzer on the DIN rail.
18. On the sensor cable, strip approximately 25 mm (1 inch) of cable insulation from the cable end.
19. Separate the five wires and strip approximately 6 mm (1/4 inch) of insulation from the end of each wire.
20. Connect the sensor wiring to the oxygen product analyzer (AE-2).
 Black wire to terminal 6
 White wire to terminal 7 or 13 (jumper wire from terminals 7 to 13)
 Red and Green wires to terminal 14
 Brown wire to terminal 16
a. Make sure the wire jumper is attached to terminals 7 & 13.
21. Use cable ties and attach the sensor cable to keep it from becoming damaged.
CAUTION: The calibration procedure requires a charged calibration bottle connected to the calibration
port (CC-1). Without the certified oxygen source the calibration gives erroneous results. Make sure a
charged certified oxygen gas bottle is connected to the calibration port and the bottle valve is open.
22. Calibrate the oxygen product sensor to the oxygen analyzer:

a. On the site power source, remove the lock-out/tag-out and set to ON.
b. On the Plant, set circuit breaker (CB-1) to ON.
23. On the operator panel, stop until the Normal screen to shows.
24. Push and hold (at same time) the (+) and (–) buttons until the Setup Entry screen shows.
IF THEN
a. Push the next button eight (8) times to show the Direct I/O
Without optional MFC-1
Stops DOCS screen.
a. Push the next button nine (9) times to show the Direct I/O
With optional MFC-1
Stops DOCS screen.
25. On the Direct IO Stops DOCS screen, push the (+) button to show the Direct IO Fault Input screen.
26. Push the NEXT button six (6) times to show the O2 Sample screen (see Figure 6-74 on page 6-61).
6-60 350201F
IDOCS & MDOCS
500-55 (-CE)
Figure 6-74. O2 Sample Screen
ENTER
Figure 6-75. Oxygen Product Analyzer (AE-2)
27. Push the (+) button and open solenoid (SV-2).

28. On the analyzer (AE-2), push the MENU button to open the system menu (see Figure 6-75).
29. Use the Up/Down arrow buttons to show option E:1 and push the Enter arrow.
30. Stop until the indication on the analyzer stabilizes.
31. Use the Up/Down arrow buttons to match the analyzer indication to the Cal Gas bottle label purity value
and push the Enter arrow.
32. When the dashed line shows in the display, push the MENU to close the system menu.
33. On the Plant operator panel, push the (–) button to close solenoid (SV-2).
34. Push the NEXT button nine (9) times to show the Exit With Save screen.
35. Push the (+) button
38. Use two (2) people to install and latch the distribution box access panel assembly.
CAUTION: Do Not push the O2 CAL button. It does nothing. On older versions of software, this button
can cause problems with calibrated indications leading to erroneous errors.
40. On start-up, Do Not push the O2 CAL button.
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6.8.22 OXYGEN PRODUCT ANALYZER/SENSOR
Use these instructions to replace the oxygen product analyzer/sensor (AE-1) after five (5) years of operation
{IDOCS (-CE)}.
REQUIRED COMPONENT
(2) #6 Lock Washers {S57004-005}

CAGE - 75906
1. On the side of the distribution box, release the latch and open the oxygen product analyzer/sensor box
access door.
2. In the sensor box, disconnect cable (CBL-11.1) from the oxygen analyzer/sensor (see Figure 6-76).
Figure 6-76. Analyze/Sensor (AE-1)
WARNING: Contaminants in oxygen can cause explosive fires. Make sure the plugs are oxygen clean
before using them. Use pre-cautions to prevent the entrance of contaminants.
3. On the analyzer/sensor, cut ties, disconnect and put a plug in the two hoses.
4. Remove two screws, lock and flat washers, and the analyzer/sensor.
5. Discard the old sensor in accordance with the local codes on the disposal of e-waste.
6. Install the new analyzer/sensor on the standoffs with two 6-32 x 1/4 screws, new lock washers and flat
washers.
7. Remove the plugs from the hoses and connect them to the hose fittings.
a. Attach the hoses to the fittings with cable ties.
8. Connect cable (CBL-11.1) to the analyzer/sensor board connector.
9. Close and latch the oxygen product analyzer/sensor box access door.
10. On start-up, make sure to calibrate the oxygen analyzer/sensor (refer to Section 3.6.1).
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6.8.23 BOOSTER SCROLL COMPRESSOR/MOTOR COUPLING ALIGNMENT
Use these instructions to align the motor (MTR-3) to the scroll compressor (C-1) for optimum coupling
performance and service life. The alignment must be done when the motor or the compressor are removed
(separated), or a hub is replaced (hub, motor or compressor). The compressor position is set with shims and
the motor is adjusted to align to the compressor.
REQUIRED COMPONENTS
Easy-Laser Alignment Tool {585969-001)

(4) 5/16 Lock Washers {S57004-010}
CAGE - 75906
1. Align (initial) the coupling hubs on the drive shafts.

a. Compressor (C-1):
(1) Remove five (5) screws and the fan shroud.
(2) Find and loosen the setscrew in the hub counterbalance.
(3) Align the hub to extend 15.75 mm (0.63 inch) past the end of the drive shaft
(4) Torque the hub counterbalance setscrew 17.6 Nm (13 ft-lb).
(5) Install the fan shroud with five (5) screws.
b. Motor (MTR-3):
(1) Loosen the hub setscrew.
(2) Align the hub to extend 3.8 mm (0.15 inch) past the end of the drive shaft
(3) Torque the hub setscrew 17.6 Nm (13 ft-lb).
2. Set the motor shaft to blower shaft distance (see Figure 6-77 on page 6-64).
a. Loosen the nuts attaching the motor sufficient to move it.
b. Move the motor until the distance between the motor drive shaft and the blower shaft is
approximately 53.3 mm (2.10 inch) and tighten the motor attaching nuts.
3. Set the motor hub to blower hub distance.
a. On the motor hub, loosen the setscrew and move the hub until the distance between the two hubs
is 41.2 mm (1.62 inch).
b. Torque the hub setscrew 17.6 Nm (13 ft-lb).
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41.2 MM (1.62 INCH) = HUB DISTANCE
SHAFT DISTANCE = 53.3 MM (2.10 INCH)
Figure 6-77. Motor / Booster Coupling Hub Spacing
CAUTION: The alignment of the booster motor shaft to the booster compressor shaft is critical to the life
of the coupling and booster motor drive bearing. Make sure you read the Easy-Laser user manual
carefully and together with these instructions set the vertical, horizontal and angular offsets.
4. Install the Easy-Laser sensors on the blower and blower motor shafts.
a. Put the sensors facing each other as shown in (see Figure 6-78).
(1) Move the sensors on the rods to permit adjustment up or down using the adjustment knobs.
(2) Make sure the M sensor is offset higher-than the S sensor.
BLOWER SHAFT MOTOR SHAFT
Figure 6-78. Easy-Laser Sensor Initial Alignment
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(3) Make sure the mounting brackets are tight and do not slip when the sensors are turned
around the clock during alignment.
(4) Make sure the shaft key is not directly below the bracket (see Figure 6-79).
KEY IS NOT DIRECTLY BELOW THE

MOUNTING BRACKET
Figure 6-79. Sensor Bracket on Shaft
5. On the display and the two sensors, push the power buttons (set to ON).
6. Stop until the system boots-up and initializes.
When the Bluetooth indicator comes on, the system is ready-to-go.
7. On the display unit, touch the Shaft Alignment icon and push an OK button .
NOTE: These instructions are written for the E420-Series Easy-Laser using a booster compressor speed
of 3600 RPM.
8. Touch the Horizontal icon and push an OK button .

9. On the Enter Distances screen, type-in the distances between various points on the assembly
a. Touch , measure the distance between the mounting rods on the S and M sensors; type the
value and push .
b. Touch , measure the distance between the mounting rods on the S sensor and the middle of the
coupling (center of area between hubs); type the value and push .
c. Touch . measure the distance between the mounting rods on the M sensor and the center of the
blower motor front foot; type-in the value and push .
d. Touch , measure the distance between the centers of the blower motor front foot and back foot;
type the value and push .
e. Touch the Diameter icon , type 58.93 mm (2.32 inch) and push .
The screen changes to the Easy Turn screen.
350201F 6-65
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WAS
TOUCHED AND
HIGHLIGHTED
Figure 6-80. Enter Distances
10. Do a rough alignment on the M and S sensors (see Figure 6-81 on page 6-67).
a. Turn the two sensors to the 9 o’clock position.
NOTE: The clocking positions are set looking at the booster from the booster motor. The twelve o’clock
position is straight up with 9 o’clock on your left and 3 o’clock on your right; 6 o’clock is straight down.
b. Use the adjustment knobs or move each sensor on the rods to move each laser line to the center of
each target.
c. Turn the sensors to the 3 o’clock position.
d. On the two sensors, make a mark 1/2 way between the laser line and the center of each target.
e. Use the adjustment knobs or move each sensor on the rod moving the laser lines to the marks
made in Step d.
f. Move the booster motor until each laser line hits the center of the target on each sensor.
(1) Loosen the attaching nuts sufficient to move the motor.
(2) Use the horizontal adjustment screw in the motor base to move the motor side-to-side until
the laser lines hit the center of the targets.
g. Turn the sensors to the 9 o’clock position.
IF THEN
Laser lines do not hit the center of both
a. Do Steps a. - g. again.
targets
Laser lines hit the center of both targets a. Continue
h. Turn the sensors to the 12 o’clock position (see Figure 6-82 on page 6-68).
i. Use the adjustment knobs or move each sensor on the rod moving each laser line to the center of
each target.
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Step 10.b. Step 10.d.
Step 10.e.
Step 10.f. Step 10.g.
Figure 6-81. Sensors Rough Horizontal Alignment
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Step 10.i. Step 10.l.
Step 10.k.
Step 10.m. Step 10.n.
Figure 6-82. Sensors Rough Vertical Alignment
j. Turn the sensors to the 6 o’clock position.

k. On the two sensors, make a mark 1/2 way between the laser line and the target center.
l. Use the adjustment knobs or move each sensor on the rod moving each laser line to the marks
made in Step k.
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m. Move the booster motor until each laser line hits the center of the target on each sensor.
(1) Lift the motor just sufficient to add or remove shims evenly below all four feet.
(2) Look at the laser lines:
IF THEN
Laser lines do not hit targets centers a. Do Step m. again.
Laser lines hit the targets centers a. Continue
n. Turn the sensors to the 12 o’clock position.
IF THEN
Laser lines do not hit the center of the
a. Do Steps h. - n. again.
two targets
a. Use the pattern shown in Figure 6-83 to torque the motor
Laser lines hit the center of the two
attaching nuts 27 Nm (20 ft-lb).
targets
1) Torque the bolts / nuts in increments of 10 Nm (7 ft-lb).
Figure 6-83. Booster Motor Torque Pattern
11. Touch the Soft Foot Function icon .

a. Adjust the lasers to the center of the targets (see Figure 6-84 on page 6-70).
b. Push to show the Soft Foot Measure screen (see Figure 6-85 on page 6-70).
c. Loosen and torque the first bolt / nut (highlighted with yellow) 27 Nm (20 ft-lb).
d. Push to register the first bolt value.

The next bolt to be loosened is highlighted with yellow.
e. Loosen and torque the next bolt / nut (highlighted with yellow) 27 Nm (20 ft-lb).
f. Push to register the next bolt value.

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Figure 6-84. Soft Foot Alignment Screen
MEASURE RESULT
Figure 6-85. Soft Foot Measure and Result Screens
g. Do Steps e. - f. until all four feet have registered values.

The screen changes to the Result screen.
h. Shim the foot with the largest movement.
(1) Loosen the attaching bolts / nuts sufficient to add / remove shims.
(2) Lift the motor sufficient to add / remove the shim.
(3) Torque the attaching bolts / nuts 27 Nm (20 ft-lb).
(a) Use the pattern shown in Figure 6-83 on page 6-69.
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i. Touch the Remeasure Soft Foot icon and do Steps a. - h. again.
IF THEN
Remeasure required another shim a. Do Step i. again.
Remeasure required no shims a. Continue
12. Measure Offset:
a. On the Soft Foot Result screen, touch the Leave Screen icon .
b. Touch the Switch to Easy Turn Method icon .
(1) If necessary, touch the Method Selection icon to show the Easy Turn Method icon.
c. Turn the two sensors to the 12 o’clock position.
d. Adjust each laser to the center of each target (see Figure 6-86).
e. Push to register the first value.

f. Turn the two sensors to the 9 o’clock position.
g. Push to register the second value.

h. Turn the two sensors to the 3 o’clock position.
i. Push to register the third value.

The screen changes to the Result screen (see Figure 6-87 on page 6-72).
j. Turn the two sensors to the 12 o’clock position.
Figure 6-86. Easy Turn Screen
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Figure 6-87. Easy Turn Result Screen
NOTE: In the top portion of the screen, the green value is within tolerance and the red value is out of
tolerance. The values at the bottom of the screen are the offsets on each foot pair. Note the units in the
top right of the screen.
13. Horizontal Offset Adjustment:

a. Turn the sensors to the 9 or 3 o’clock position.
b. Loosen the motor attaching nuts sufficient to move the motor side-to-side and add / remove shims.
c. Use the horizontal adjustment screw in the motor base to move the motor side-to-side until both
live values are as close to zero (0) as possible.
14. Vertical Offset Adjustment:
b. Add or remove shims as shown on the Result screen.
(1) Make sure to add or remove the same value shims below the two feet (front or rear).
(2) Do not stack more-than five (5) shims below a foot; replace the shim values as necessary.
c. Adjust the shim height until the two live values are as close to zero (0) as possible.
d. Use the pattern shown in Figure 6-83 on page 6-69 to torque the nuts 27 Nm (20 ft-lb).
(1) Torque the nuts in increments of 10 Nm (7 ft-lb).
15. Do an alignment check (measure again):
b. Touch the Remeasure icon .

c. Do Step 12. on page 6-71 starting with Step d.
d. Compare the results of the done again measurement:
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IF THEN
Horizontal is > 0.02 mm (1.0 mil) or
Angular offset is > 0.03 mm/100 mm a. Do Step 13. on page 6-72 and Step 15. again.
(0.3 mils/inch)
Horizontal is ≤ 0.02 mm (1.0 mil) or
Angular offset is ≤ 0.03 mm/100 mm a. Do a Vertical alignment check.
(0.3 mils/inch)
Vertical offset is > 0.02 mm (1.0 mil) or
Angular offset is > 0.03 mm/100 mm a. Do Step 14. on page 6-72 and Step 15. again.
(0.3 mils/inch)
Vertical offset is ≤ 0.02 mm (1.0 mil) and a. Install the motor locking nuts on the attaching huts.
Angular offset is ≤ 0.03 mm/100 mm 1) Hold the attaching nut and tighten the locking nut.
(0.3 mils/inch) b. Continue
16. Set the display unit and the two sensors to OFF.
17. Remove the two sensors from the motor and blower shafts.
18. Do a hub separation check:
a. Put a coupling elastomer half on the hubs.
b. Adjust the booster motor hub separation as necessary:
(1) Loosen the hub setscrew and adjust the distance.
(2) Torque the motor hub setscrew 17.6 Nm (13 ft-lb).
(3) Remove the elastomer half.
c. Turn the motor shaft until the shaft key is 180° from the booster compressor shaft key (vibration
reduction).
d. Install each elastomer half with four (4) screws wet with blue thread locker (Table 6-7).
(1) Torque each screw 23 Nm (17 ft-lb).
19. Install the coupling guard with four (4) 5/16-18 x 1 screws wet with blue thread locker, new lock washers
and flat washers.
a. Torque the screws 6.8 Nm (5 ft-lb).
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6.8.24 AIR BLOWER/MOTOR COUPLING ALIGNMENT
Use these instructions to align the motor (MTR-1) to the air blower (BL-100) for optimum coupling
performance and service life. The alignment must be done when the motor or the blower are removed
(separated), or a hub is replaced (hub, motor or blower). The air blower position is set with shims and the air
blower motor is adjusted to align to the air blower.
REQUIRED COMPONENTS
Easy-Laser Alignment Tool {585969-001)

(4) 1/4 Lock Washers {S57004-009}
(4) 5/8 Lock Washers (S57004-015}
(4) 5/8-11 Lock Nuts {S38060-024}
Six Foot Heavy Duty Pry Bar
CAGE - 75906
1. Align the coupling hubs on the drive shafts:

a. Air Blower (BL-100):
(1) Align the hub flush with the air blower shaft end.
(2) Torque the setscrew 32.8 Nm (24 ft-lb)
b. Air Blower Motor (MTR-1):
(1) Align the hub flush with the air blower motor shaft end.
(2) Tighten the setscrew just enough to hold the hub.
2. Set the initial distance between the air blower and motor drive shafts to approximately 3.3 mm
(0.13 inch) (see Figure 6-88 on page 6-75).
a. On the motor, loosen the four (4) attaching bolts / nuts.
b. On the four (4) horizontal adjustment bolts, loosen the locking nuts and the bolts.
c. Use a heavy pry bar to move the motor as required.
d. Use the pattern shown in Figure 6-89 on page 6-75 to tighten the attaching bolts / nuts.
3. Set the spacing between the coupling hubs raised mounting rails to approximately 62.2 mm (2.45 inch).
a. On the motor hub, loosen the setscrew.
b. Move the hub until the distance is 62.2 mm (2.45 inch).
c. Tighten the hub setscrew.
IF THEN
a. Remove the four (4) bolts, lock washers and nuts, and the
IDOCS-CE or MDOCS-CE coupling guard.
1) Discard the lock washers.
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SHAFT DISTANCE 3.3 MM (0.13 INCH)
HORIZONTAL
ADJUSTMENT
MOUNTING RAILS DISTANCE SCREWS
62.2 MM (2.45 INCH) (2 OF 4)
Figure 6-88. Air Blower / Motor Coupling Hub Distance
Figure 6-89. Blower Motor Tighten / Torque Pattern
CAUTION: The alignment of the blower motor shaft to the blower shaft is critical to the life of the coupling
and booster motor drive bearing. Make sure you read the Easy-Laser user manual carefully and together
with these instructions set the vertical, horizontal and angular offsets.
4. Install the Easy-Laser sensors on the blower and blower motor shafts.
a. Put the sensors facing each other as shown in (see Figure 6-78 on page 6-64).
(1) Move the sensors on the rods to permit adjustment up or down using the adjustment knobs.
(2) Make sure the M sensor is offset higher-than the S sensor.
(3) Make sure the mounting brackets are tight and do not slip when the sensors are turned
around the clock during alignment.
(4) Make sure the shaft key is not directly below the bracket (see Figure 6-79 on page 6-65).
350201F 6-75
IDOCS & MDOCS
500-55 (-CE)
5. On the display and the two sensors, push the power buttons (set to ON).
6. Stop until the system boots-up and initializes.
When the Bluetooth indicator comes on, the system is ready-to-go.
7. On the display unit, touch the Shaft Alignment icon and push an OK button .
NOTE: These instructions are written for the E420-Series Easy-Laser using a blower speed of
3600 RPM.
8. Touch the Horizontal icon and push an OK button .

9. On the Enter Distances screen, type-in the distances between various points on the assembly
a. Touch , measure the distance between the mounting rods on the S and M sensors; type the
value and push .
b. Touch , measure the distance between the mounting rods on the S sensor and the middle of the
coupling (center of area between hubs); type the value and push .
c. Touch . measure the distance between the mounting rods on the M sensor and the center of the
blower motor front foot; type-in the value and push .
d. Touch , measure the distance between the centers of the blower motor front foot and back foot;
type the value and push .
e. Touch the Diameter icon , type 113.79 mm (4.48 inch) and push .
The screen changes to the Easy Turn screen.
10. Do a rough alignment on the M and S sensors (see Figure 6-81 on page 6-67).
NOTE: The clocking positions are set looking at the blower from the blower motor. The twelve o’clock
position is straight up with 9 o’clock on your left and 3 o’clock on your right; 6 o’clock is straight down.
b. Use the adjustment knobs or move each sensor on the rods to move each laser line to the center of
each target.
c. Turn the sensors to the 3 o’clock position.
d. On the two sensors, make a mark 1/2 way between the laser line and the center of each target.
e. Use the adjustment knobs or move each sensor on the rod to move the laser lines to the marks
made in Step d.
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f. Move the booster motor until each laser line hits the center of the target on each sensor.
(1) Loosen the attaching bolts/nuts sufficient to move the motor.
(2) Adjust the horizontal adjustment screws until the laser lines hit the center of the targets.
g. Turn the sensors to the 9 o’clock position.
IF THEN
Laser lines do not hit the center of the
a. Do Steps a. - g. again.
two targets
Laser lines hit the center of both targets a. Continue
h. Turn the sensors to the 12 o’clock position (see Figure 6-82 on page 6-68).
i. Use the adjustment knobs or move each sensor on the rod moving each laser line to the center of
each target.
j. Turn the sensors to the 6 o’clock position.
k. On the two sensors, make a mark 1/2 way between the laser line and the target center.
l. Use the adjustment knobs or move each sensor on the rod moving each laser line to the marks
made in Step k.
m. Move the blower motor until each laser line hits the center of the target on each sensor.
(1) Lift the motor just sufficient to add or remove shims evenly below all four feet.
(2) Look at the laser lines:
IF THEN
Laser lines do not hit target centers a. Do Step m. again.
Laser lines hit the target centers a. Continue
n. Turn the sensors to the 12 o’clock position.
IF THEN
Laser lines do not hit the center of both
a. Do Steps h. - n. again.
targets
a. Use the pattern shown in Figure 6-89 on page 6-75 to torque
Laser lines hit the center of both targets the attaching bolts / nuts 130 Nm (96 ft-lb).
1) Torque the bolts / nuts in increments of 30 Nm (22 ft-lb).
11. Touch the Soft Foot Function icon .

a. Adjust the lasers to the center of the targets (see Figure 6-84 on page 6-70).
b. Push to show the Soft Foot Measure screen (see Figure 6-85 on page 6-70).
c. Loosen and torque the first bolt / nut (highlighted with yellow) 130 Nm (96 ft-lb).
d. Push to register the first bolt value.

e. Loosen and torque the next bolt / nut (highlighted with yellow) 130 Nm (96 ft-lb).
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f. Push to register the next bolt value.

g. Do Steps e. - f. until all four feet have registered values.
The screen changes to the Result screen.
h. Shim the foot with the largest movement.
(1) Loosen the attaching bolts / nuts sufficient to add / remove shims.
(2) Lift the motor sufficient to add / remove the shim.
(3) Torque the attaching bolts / nuts 130 Nm (96 ft-lb).
(a) Use the pattern shown in Figure 6-89 on page 6-75.
i. Touch the Remeasure Soft Foot icon and do Steps a. - h. again.
IF THEN
Remeasure required another shim a. Do Step i. again.
Remeasure required no shims a. Continue
12. Measure Offset:
a. On the Soft Foot Result screen, touch the Leave Screen icon .
b. Touch the Switch to Easy Turn Method icon .
(1) If necessary, touch the Method Selection icon to show the Easy Turn Method icon.
c. Turn the two sensors to the 12 o’clock position.
d. Adjust each laser to the center of each target (see Figure 6-86 on page 6-71).
e. Push to register the first value.

f. Turn the two sensors to the 9 o’clock position.
g. Push to register the second value.

h. Turn the two sensors to the 3 o’clock position.
i. Push to register the third value.

The screen changes to the Result screen (see Figure 6-87 on page 6-72).
NOTE: In the top portion of the screen, the green value is within tolerance and the red value is out of
tolerance. The values at the bottom of the screen are the offsets on each foot pair. Note the units in the
top right of the screen.
j. Turn the two sensors to the 12 o’clock position.

13. Horizontal Offset Adjustment:
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b. Loosen the motor attaching bolt / nuts sufficient to move the motor side-to-side and add / remove
shims.
c. Use the horizontal adjustment bolts to move the motor side-to-side until both live values are as
close to zero (0) as possible.
14. Vertical Offset Adjustment:
b. Add or remove shims as shown on the Result screen.
(1) Make sure to add or remove the same value shims below the two feet (front or rear).
(2) Do not stack more-than five (5) shims below a foot; replace the shim values as necessary.
c. Adjust the shim height until both live values are as close to zero (0) as possible.
15. One-at-a-time, replace the motor attaching lock washers and lock nuts.
a. Discard the old lock washers and nuts.
16. Do an alignment check (measure again):
a. Use the pattern shown in Figure 6-89 on page 6-75 to torque the bolts / nuts 130 Nm (96 ft-lb).
(1) Torque the bolts / nuts in increments of 30 Nm (22 ft-lb).
b. Turn the two sensors to the 12 o’clock position.
c. Touch the Remeasure icon .

d. Do Step 12. on page 6-78 starting with Step d.
e. Compare the results of the done again measurement:
IF THEN
Horizontal is > 0.02 mm (1.0 mil) or
a. Loosen the motor bolts / nuts.
Angular offset is > 0.03 mm/100 mm
b. Do Step 13. on page 6-78 again and Step 16. again.
(0.3 mils/inch)
Horizontal is ≤ 0.02 mm (1.0 mil) or
Angular offset is ≤ 0.03 mm/100 mm a. Do a Vertical alignment check.
(0.3 mils/inch)
Vertical offset is > 0.02 mm (1.0 mil) or a. Loosen the motor bolts / nuts.
Angular offset is > 0.03 mm/100 mm
b. Do Step 14. on page 6-79 again and Step 16. again.
(0.3 mils/inch)
Vertical offset is ≤ 0.02 mm (1.0 mil) and
a. Tighten the locking nuts on the horizontal adjustment screws.
Angular offset is ≤ 0.03 mm/100 mm
b. Continue
(0.3 mils/inch)
17. Set the display unit and the two sensors to OFF.
18. Remove the two sensors from the motor and blower shafts.
19. Put the display unit and the sensors in their case.
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20. Install the coupling elastomer halves.
IF THEN
a. On the motor hub, loosen the setscrew.
The distance between the hubs is not
b. Use the elastomer half and align the hub.
correct
c. Torque the hub setscrew 70 Nm (52 ft-lb).
The distance between the hubs is correct Continue
a. Install each elastomer half with six (6) screws wet with blue thread locker (Table 6-8).
(1) Torque the screws 41 Nm (30 ft-lb).
IF THEN
a. Install the coupling guard with four (4) 1/4-20 x 3/4 bolts, new
IDOCS-CE or MDOCS-CE lock washers and nuts.
b. Close the coupling guard and engage the captive screws.
21. Install and latch the blower access and air access panels.
6.8.25 POST MAINTENANCE
1. Remove tools, consumables, cleaning towels and equipment.

2. Close, install and latch open access panels or doors.
3. On the site power, remove the lock-out/tag-out.
4. Update the maintenance log (refer to Section 6.8.25.1).
6.8.25.1 MAINTENANCE LOG
Use this procedure to update the maintenance log and reset the maintenance warning.
1. Do the instructions in 5.2 Remote Operation and connect a laptop / PC to the Plant.
2. On the Normal screen, click MAINT (see Figure 6-90 on page 6-81) to show the Maintenance Tracking
3. On the Maintenance Tracking screen, click NEW.
4. Type a description of the work done in 40 characters or less.
5. Click ENTER.
The system automatically sets the next maintenance due date to be 2000 hours after the time of the
entry. The warning date is set to be 1800 hours after the time of the entry. This means the system
shows an alarm 200 hours before maintenance is due.
a. If you want other time values, click NEXT DUE and NEXT WARN to change the span of time when
the alarms should be raised.
b. When you are done, click SAVE.
6. Click DONE.
a. If the Normal screen is not showing, click DONE until it shows.
7. On the Normal screen, click DASHBOARD to show the DOCS 500 Dashboard screen
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SELECT MAINT
SELECT NEW
Figure 6-91. Maintenance Tracking Screen
8. On the DOCS Remote Dashboard screen, make sure the MAINT field is green.
10. Shutdown and disconnect the laptop / PC from the Plant.
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Figure 6-92. DOCS 500 Dashboard Screen
6.9 CALIBRATION GAS BOTTLE REPLACEMENT
Use these instructions to replace the calibration gas bottle.

1. Make sure the Plant is not doing an O2 calibration {IDOCS (-CE)}.
IF THEN
Installing cal gas bottle for the first time a. Go-to Section 2.5.8.
Replacing a cal gas bottle a. Continue
2. On the cal gas bottle, slowly close the bottle valve.

3. Slowly loosen the cal gas hose fitting venting hose pressure.
CAUTION: Contaminated caps and plugs can contaminate the component where they are used. The cal
gas connections must be oxygen clean to prevent purity indication errors. Make sure all caps and plugs
are oxygen clean before using them.
4. Disconnect and put a clean cap on the cal gas bottle.
IF THEN
a. Put a clean cap on the hose.
b. Disconnect the hose from the port (CC-1).
Not installing cal gas bottle
c. Put a clean plug in the hose and clean cap on the calibration
port (CC-1).
Installing a new bottle a. Go-to Section 2.5.8.
6-82 350201F
IDOCS & MDOCS
500-55 (-CE)
6.10 TROUBLESHOOTING
WARNING: Before parts are replaced, the site power source must be set to OFF and lock-out/
tag-out applied.
6.10.1 ALARMS
The DOCS has an alarm system for communicating hazards to the user. There are electrical contacts
available for the user to connect the DOCS to the Hospital Oxygen Supply System’s alarm system. The
DOCS is intended to be part of a ISO 7396:2016 system with an alarm system in compliance with IEC
60601-1-8. The DOCS locally communicates these alarms:
 General fault (contact closure/visual - high priority).
 Refer to Table 6-11 on page 6-85.
 Low oxygen concentration (contact closure/visual/auditory - high priority).
 Relay closure on the oxygen sensor AE-1 when purity drops to 90.01%.
 The alarm clears (contact opens) when the purity rises to 90.46%.
 Loss of incoming power (contact closure - high priority).
 When power is applied to the Plant a normally closed contact is opened. When power is removed
from the Plant, this contact closes.
 Low pressure (contact closure/visual - medium priority).
 When the output pressure measured at XT-1 drops 10 psig less-than the target setpoint, a
contact closes. The alarm clears when the pressure indication at XT-1 is 5 psig higher-than the
alarm setpoint.
NOTE: High Priority alarm is loss of essential performance (red LED). This is associated with low purity,
general fault and incoming power loss.
Medium Priority alarm is degradation of performance (yellow LED). This is associated with low pressure.
There is one delay in the alarm system; the pressure alarm can have a user adjusted delay to permit
fluctuations in the system. The factory default is 60 seconds (refer to Section 4.2.5).
The other alarms are instantaneous, when a fault occurs, it is reported. If power is interrupted, the alarm
condition stays until it is cleared. The functionality of the alarm system is activated and tested at the factory
before shipment.
NOTE: Loss of incoming power is a contact closure to be monitored by an external system.
350201F 6-83
IDOCS & MDOCS
500-55 (-CE)
6.10.2 FAULT CODES AND GENERAL FAULTS
Table 6-10 lists the fault codes and Table 6-11 on page 6-85 lists the general faults, probable causes and
possible solutions.
Table 6-10. Fault Codes
ERROR CODE PROBABLE CAUSE POSSIBLE SOLUTION
a. Set Facility (source) power to OFF.

b. Lock-out/tag-out Facility power.
c. On the Plant, release the latches and open the
electrical cabinet.
Incoming power is out of phase (initial startup) d. On top of circuit breaker (CB-1), swap two
wires.
e. Close and latch the electrical cabinet.
0001 f. Remove the lock-out/tag-out.
g. Set Facility (source) power to ON.
a. Set Facility (source) power to OFF.
b. Lock-out/tag-out Facility power.
Lose of one phase (after continued use) c. Look at the power connections.
d. Remove the lock-out/tag-out.
e. Set Facility (source) power to ON.
0002 Variable Frequency Drive (VFD-1) has faulted Refer to Schneider ATV71 Drive User Manual
0004 Variable Frequency Drive (VFD-2) has faulted Refer to Schneider ATV312 Drive User Manual
Motor controller (MCP-3) has tripped due to a. Clear the obstruction from the fan.
obstruction in the blower module heat exchanger b. Reset motor controller (MCP-3).
0008 fan (FX-100). c. Make sure controller is set to 2.0 Amp.
Motor (MTR-2) has failed Replace motor (MTR-2)
a. Look at the sensor screen to determine which
Pressure transducers (XT-1- 3) or RTDs (RTD 1 - device or devices are causing the fault code.
0010
4) have failed or lost signal b. Look a the device connection and cabling.
c. Replace device, if necessary.
a. Look at the sensor connection and cabling.
0020 Oxygen sensor (AE-1) has failed or lost the signal.
b. Replace the sensor as necessary.
a. Do an operation check on heat exchanger fan
Booster heat exchanger (HX-200) outlet (FX-200).
0100
temperature (RTD-4) is higher-than the setpoint b. Look for heat exchanger (HX-100) blockage.
c. Clean or replace as required.
a. Do an operation check on the electrical cabinet
Electrical cabinet fans (Top Fan & Bottom Fan)
0400 fan.
have failed
b. Clean or replace as necessary.
0800 Cycle parameters are out of tolerance a. Contact PCI for instruction (refer to Foreword)
a. Look for high ambient temperature.
1) Follow instructions in Section 3.3.2.
b. Make sure the air blower heat exchanger fan
VSA tank (C-300) inlet temperature (RTD-2) is
2000 (MTR-2 & FX-100) is operating.
higher-than the setpoint
c. Look for air blower heat exchanger (HX-100)
blockage.
d. Clean or replace as required.
Error Codes appear on the operator panel LCD
6-84 350201F
IDOCS & MDOCS
500-55 (-CE)
Table 6-10. Fault Codes (Cont)
ERROR CODE PROBABLE CAUSE POSSIBLE SOLUTION

b. Look for air supply filter (F-1) blockage.
The air blower (BL-100) discharge temperature
4000 c. Look at the oil-lube levels in the two air blower
(RTD-1) is higher-than the setpoint
(BL-100) reservoirs.
d. Make sure the air blower (BL-100) is operating.
e. Add oil-lube or replace as required.
The difference between the air blower heat
b. Make sure the heat exchanger fan (FX-200) is
8000 exchanger (HX-100) inlet (RTD-1) and outlet
operating.
(RTDD-2) temperatures is higher-than the setpoint
c. Look for heat exchanger (HX-100) blockage.
d. Clean or replace as required.
Error Codes appear on the operator panel LCD
Table 6-11. General Faults
FAULT PROBABLE CAUSE POSSIBLE SOLUTION
a. Make sure site power is OFF.

b. Apply lock-out/tag-out.
Site power source disconnected c. Connect the site power to the Plant.
d. Remove lock-out/tag-out.
e. Set site power to ON.
No electrical power Site power source is OFF Set site power to ON.
(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.
a. Do an operation check on circuit
Circuit breaker (CB-1) faulty breaker (CB-1).
b. Replace as necessary.
Connect interconnect wiring from

Interconnect wiring is not connected electrical cabinet to blower module
(refer to Section 2.5.2).
Variable frequency drive (VFD-1) is Refer to Schneider ATV71 Drive User
OFF or lost program Manual.
a. Do an operation check on VFD-1.
VFD-1 is faulty
Blower motor (MTR-1) does not turn b. Replace as necessary.
a. Do an operation check on motor
Motor (MTR-1) is faulty (MTR-1).
a. Do an operation check on blower
Blower (BL-100) is faulty (BL-100).
350201F 6-85
IDOCS & MDOCS
500-55 (-CE)
Table 6-11. General Faults (Cont)
FAULT PROBABLE CAUSE POSSIBLE SOLUTION
a. On the control panel, push START/

STOP.
b. Set circuit breaker (CB-1) to OFF.
c. Release the latches and open the
electrical cabinet..
Motor controller (MCP-1) is set to OFF d. Set motor controller (MCP-1) to ON.
or has tripped e. Set the current protection to 2.0 A.
f. Close and latch the electrical
cabinet.
g. Set circuit breaker (CB-1) to ON
h. On the control panel, push START/
STOP.
Heat exchanger (HX-100) fan does not
Motor Controller (MCP-1) faulty controller (MCP-1).
turn
Motor (MTR-2) faulty (MTR-2).
a. Do an operation check on the
electrical cabinet stirring fan.
Motor Start Relay (R-24) faulty b. If fan is not running, do an operation
check on motor start relay (R-24).
c. Replace as necessary.
a. Do an operation check on controller
Controller board (A-1) faulty (A-1).
a. Do an operation check on cooling

Electrical cabinet cooling fans (Fan-1 &
Fans (Fan-1 & Fan-2) faulty fans (Fan-1 & Fan-2).
Fan-2) do not turn
6-86 350201F
IDOCS & MDOCS
500-55 (-CE)
6.10.3 PERFORMANCE TROUBLESHOOTING
The Plant is rated for 500 Lpm @ 1.4 - 6.9 bar (17.7 scfm @ 20 - 100 psig) & 93 ± 3% Oxygen in standard
conditions (15°C, 1 bar (59°F, 14.7 psia) & 50% relative humidity).
The Plant is designed to operate in a range of site conditions outside the standard condition. These various
conditions cause an obvious degradation in the rated performance.
Table 6-12 lists performance faults, probable causes and possible solutions.
Table 6-12. Performance Troubleshooting
SYMPTOM PROBABLE CAUSE POSSIBLE SOLUTION
Ambient site conditions are higher-than Adjust the flow rate (customer device or
standard conditions system) or purity/off-spec setpoint
Reduce the flow rate (customer device
Overdraw on plant (flow rate too high)
or system) or purity/off-spec setpoint
Make sure there is correct ventilation
Plant site does not have sufficient fresh
and turnover of fresh air, and exhaust
air circulation, turnover and heat
hot air from the heat exchangers out of
removal
the plant space.
Do a leak check on plumbing
connections with oxygen safe leak
System leaks
detection solution and correct leaking
connection.
Do a leak check on the valve with
oxygen safe leak detection solution. If
Buffer tank pressure safety valve
exhaust port leak is found, remove and
(PSV-1) stuck or cracked open
Low performance flow or purity return the valve to PCI for repair or
replacement.
Off-spec shuts-off production flow if
purity drops less-than the setpoint. If
Off-Spec feature is enabled
required, disable this feature using the
control panel screens.
Remove and examine air supply filter
Plugged air intake filter (F-3)
(F-3); clean or replace.
a. Release the latches and remove the
blower module air access and
Air blower/motor (BL-100/MTR-1) access panels.
coupling failure b. Examine the coupling assy (refer to
Section 6.8.12 on page 6-19).
c. Replace as necessary.
Refer to Schneider ATV71 Drive User
Variable frequency drive (VFD-1) faulty
Manual
350201F 6-87
IDOCS & MDOCS
500-55 (-CE)
Table 6-12. Performance Troubleshooting (Cont)
Typically indicated by reduced purity.

a. Look at the purge time setting.
b. Make sure solenoid coil is energizing
during the purge cycle.
1. Use a small screwdriver and do a
Purge receiver drain/fill solenoid valve magnetic check on the coil.
(SV-5) does not open or opens 2. Make sure there is a 24 Vdc
intermittently signal.
c. Remove the valve and do a free
movement check on the valve stem.
d. Look at the wiring.
e. Replace the solenoid or valve as
necessary.
Low performance flow or purity {Cont.}
Typically indicated by reduced purity,
longer cycle durations or a decrease in
buffer tank pressure.
a. Remove the valve (CV-1) and do a
Product check valve (CV-1) stuck open damage check on the seat face.
or not seating correctly b. Look for obstruction in the flow path
or seat face.
c. Make sure the spring close actuation
is working.
d. Replace as necessary.
Excessive air blower (BL-100) rotor Measure the rotor clearance and contact
clearance Schneider or PCI
a. Look at the booster inlet filter (F-4).

Booster inlet filter (F-4) clogged
b. Replace as necessary
Booster compressor requires seal kit
Booster (C-1) weak discharge replacement
(refer to Section 6.8.17 on page 6-35).
Product discharge pressure safety valve Look at the setting on the valve
(PSV-2) open or needs adjustment (125 psig)
a. Look at the product filter (F-1).
Product filter (F-1) clogged
b. Replace as necessary
a. Make sure solenoid coil is energized
Low performance pressure after purity is reached.
1. Use a small screwdriver and do a
magnetic check on the coil.
2. Make sure there is a 24 Vdc
signal.
Off-spec solenoid (SV-3) open or not b. Remove the valve (SV-3) and do a
seating damage check on the seat face.
c. Look for obstruction in the flow path
or seat face.
d. Make sure the spring close actuation
is working.
e. Replace solenoid or valve as
necessary.
6-88 350201F
IDOCS & MDOCS
500-55 (-CE)
Table 6-12. Performance Troubleshooting (Cont)
Air blower shaft mis-alignment Align the air blower and motor shafts
Air blower/motor (BL-100/MTR-1) a. Remove the air blower (BL-100).
vibration, increased power consumption Air blower bearing failure b. Return the air blower to PCI for
or shafts not spinning freely repair.
Air blower/motor coupling damage Replace coupling
Abnormal air blower (BL-100) running Incorrect gear backlash, bearing Refer to the Kaeser service manual
noises clearance or rotors out of time Section 8.2.1 or contact PCI
Correct the blower lubrication level

Air blower lubrication level is too high
(refer to Section 6.8.6 on page 6-12)
Oil in the air supply filter (F-3) or system
plumbing before the VSA tank (C-300) a. Remove the air blower (BL-100).
Air blower sealing rings are worn b. Return the air blower to PCI for
repair.
350201F 6-89/(6-90 blank)

IDOCS & MDOCS
500-55 (-CE)
CHAPTER 7
PREPARATION FOR SHIPMENT OR STORAGE
7.1 SCOPE
This chapter has instructions to prepare the Plant for shipment or storage.
7.2 PREPARATION
1. Do the shutdown instructions in Section 3.4.
WARNING: Enriched oxygen can cause explosive fires. The vented gas is enriched oxygen.
Make sure the area is free of sparks and flame.
Venting the purge tank can create high decibel noise causing loss of hearing over time. Make
sure you wear sound protection when venting the purge tank.
2. On the bottom of the fill/purge drain solenoid valve (SV-5), slowly open the vent valve (V-1) and drain
the purge receiver tank (C-500) (see Figure 7-1).
a. Close the valve when venting stops.
PURGE TANK
VENT VALVE
Figure 7-1. Purge Receiver Tank Vent Valve (IDOCS-CE shown)
350201F 7-1
IDOCS & MDOCS
500-55 (-CE)
CAUTION: Contaminated caps and plugs can contaminate the component where they are used.
Contamination in enriched oxygen can cause explosive fires. Make sure all caps and plugs are oxygen
clean before using them (refer to Section 6.7).
3. Disconnect and put a clean cap on the product discharge hose or tube.
a. Put a clean plug in the Plant discharge port.
4. On the Plant, remove the cal gas bottle:
IF THEN
a. On the cal gas bottle, slowly close the bottle valve.
b. Disconnect the hose and put a clean cap on the bottle.
A cal gas bottle is connected to the c. Put a clean plug in the hose.
calibration port connector (CC-1) d. Disconnect the hose and put a clean cap on the calibration
port (CC-1).
e. Put a clean plug in the hose.
Calibration port connector (CC-1) is
Continue
capped
7.2.1 ELECTRICAL POWER DISCONNECTION
1. Set the site power source to OFF.

WARNING: High voltage creates high amperage causing injury or death. Make sure the power
to the Plant is OFF and lock-out/ tag-out applied before opening the electrical cabinet door.
2. Release the latches and open the electrical cabinet door.

3. On top of circuit breaker (CB-1), disconnect the three wires and the ground wire (ground lug)
4. On the bottom of the electrical cabinet, loosen strain relief and carefully pull the power cable out of the
cabinet.
a. Tighten the strain relief.
7.2.1.1 INTERCONNECT WIRING DISCONNECTION

1. Inside the electrical cabinet, make sure the wires (14 AWG) on motor controller (M-1) terminals T1 - T3
are identified with a label (see Figure 7-3 on page 7-3).
2. Disconnect the wires from terminals T1 - T3 and the cable ground wire from the ground terminal.
3. Cut the cable ties.
4. On the bottom of the electrical cabinet, remove the 13 mm (1/2 inch) conduit connector nut and carefully
pull the cable out of the cabinet.
a. Install the conduit connector nut.
5. On VFD-1, remove screws and the front cover (see Figure 7-4 on page 7-4).
6. Identify with a Label and disconnect the two wires from DI3 and COM.
7-2 350201F
IDOCS & MDOCS
500-55 (-CE)
L1 L2 L3 GND
Figure 7-2. Circuit Breaker (CB-1) Input Power Connections (electrical cabinet)
T1 T3
T2
6 AWG 14 AWG
WIRES WIRES
Figure 7-3. Blower Module Interconnect Cables Disconnection (electrical cabinet)
7. On the bottom of the VFD make sure the wires (6 AWG) on terminals T1 - T3 are identified with a label.
8. Disconnect the wires from terminals T1 - T3 and the cable ground wire from the ground terminal.
9. Install the VFD cover with the screws
350201F 7-3
IDOCS & MDOCS
500-55 (-CE)
MOTOR (MTR-1) SENSOR WIRES
Figure 7-4. Motor Sensor Wires Disconnection
25 MM (1 INCH) CONDUIT (MTR-1)
13 MM (1/2 INCH) CONDUIT (MTR-2)
Figure 7-5. Blower Module Interconnect Motor Cables (IDOCS shown)
10. On the lower left side of the electrical cabinet, remove the 25 mm (1 inch) conduit connector nut and
carefully pull the cable out of the cabinet.
a. Install the conduit connector nut.
11. Wind the cables/conduits together and attach them to the blower module discharge pipe
(see Figure 7-5).
12. Close and latch the electrical cabinet door.
IF THEN
a. On the back of the blower module next to the electrical
cabinet, disconnect cable (CBL-101) from connector
(P-101) (see Figure 7-6 on page 7-5).
b. Wind and attach the cable below the electrical cabinet.
7-4 350201F
IDOCS & MDOCS
500-55 (-CE)
P-101 CBL-101
Figure 7-6. Blower Module Emergency-Stop Cable and Connector (MDOCS-CE shown)
7.2.2 INTERCONNECT PIPING DISCONNECTION
CAUTION: Contaminants and moisture can damage the sieve material in the VSA bed. Make sure you
maintain a clean environment while disconnecting the interconnect plumbing. Use oxygen clean caps and
plugs.
1. On the blower module discharge pipe, remove the pipe clamp and gasket, and separate the
interconnect hose assembly elbow from the discharge pipe (see Figure 7-7 on page 7-6).
2. Move the blower module away from the VSA module to separate the piping.
a. Disconnect the blower discharge pipe clamp RTD.
b. Put a clean cap on the discharge pipe and hose assembly elbow.
350201F 7-5
IDOCS & MDOCS
500-55 (-CE)
PIPE CLAMP WITH GASKET & RTD

INTERCONNECT PIPING BLOWER DISCHARGE PIPE
Figure 7-7. Interconnect Piping Disconnection (MDOCS shown)
3. Seal the pipe clamp (with RTD) and gasket in a bag and attach it to the hose assembly.
4. Install shipping restraints on the hose assembly to keep it from moving during shipment.
a. Tie the hose assembly to the VSA chamber (C-300).
IF THEN
Shipping the Plant a. Transport the Plant in an closed container or truck.
a. The storage facility must be:
1) Covered and closed
Storing the Plant
2) Free of standing water
3) A clean cool dry place
7-6 350201F
IDOCS & MDOCS
500-55 (-CE)
APPENDIX A
Foundation
Drawing
350201F A-1/(A-2 blank)

IDOCS & MDOCS
500-55 (-CE)
3
4
154.1 cm (60.6 inch)
14 SITE REQUIREMENTS 177.5 cm (69.9 inch)

- THE AREA MUST NOT HAVE SMOKING, OPEN FLAMES OR OTHER IGNITION SOURCE WITHIN 15 M (50 FEET) 91.4 cm (36.0 inch)
BLOWER MODULE
OF THE UNIT. VENTILATION
SERVICE ACCESS
- THE AREA MUST BE FREE OF TRASH AND DEBRIS CAUSING A FIRE HAZARD, TRIP HAZARD CLEARANCE
CLEARANCE
OR ACCUMULATION 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 SPACE AROUND THE EQUIPMENT TO GIVE ACCESS 91.4 cm (36.0 inch)
FOR OPERATION AND MAINTENANCE TASK. BLOWER MODULE
- THE EQUIPMENT MUST BE INSTALLED AWAY FROM MOTOR POOLS, FUEL FARMS, DIESEL SERVICE ACCESS
GENERATORS AND OTHER SIMILAR HYDROCARBON AND EXHAUST EMITTING AREAS TO CLEARANCE
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 AREA
PRONE TO FLOODING. 203.2 cm
- THE UNIT MUST BE PROTECTED FROM BLOWING DUST, DIRT, SAND, RAIN, SLEET AND SNOW. (80.0 inch)
- THE UNIT MUST BE SHADED FROM DIRECT SUNLIGHT.
- THE UNIT SHOULD BE INSTALLED 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 @ 100/80 FLA. 111.8 cm (44.0 inch)
VENTILATION
13 EQUIPMENT LOCATION: CLEARANCE
TO MINIMIZE PRESSURE DROP IN DISTRIBUTION PIPING, THE DOCS SHOULD BE
INSTALLED AS CLOSE TO THE POINT OF USE AS POSSIBLE.
THE UNIT CAN BE INSTALLED OUTSIDE IN AN AREA CLOSEST TO THE EXPECTED HIGHEST
DEMAND REQUIREMENT.
12 ANCHORING: 484.1 cm (190.6 inch)

THE DOCS OPERATES WITHOUT PERMANENT ANCHORING. THERE ARE NO FUNCTIONAL
OVERALL FOOTPRINT
ANCHORING REQUIREMENTS; LOCAL CODE MAY REQUIRE THE DOCS TO BE ANCHORED.
INCLUDES MAINTENANCE
PCI DOES NOT SUPPLY AND IS NOT RESPONSIBLE FOR ANY DOCS ANCHORING. IT RECOMMENDS 301.2 cm
ACCESS 101.6 cm (40.0 inch)
CONTACTING A LOCAL CONTRACTOR FOR ANCHORING SOLUTIONS. (118.6 inch)
USER INTERFACE AND
ELECTRICAL ENCLOSURE
11 OXYGEN CALIBRATION CONNECTION (1/4 INCH TUBE COMPRESSION FITTING,
2.1 BARG (30 PSIG) INLET PRESSURE MAXIMUM). ACCESS CLEARANCE
10 FOR ACCEPTABLE SITE CONDITIONS, REFER TO O&M MANUAL CHAPTER 2. 180.3 cm
9 PERFORMANCE SPECIFICATIONS: 93 ± 3% O2 @ 500 LPM 20-100 PSIG (1.4-6.9 BAR)
(71.0 inch)
8 FORKLIFT LOCATIONS.
7 REMOVABLE PANEL LOCATIONS.

6 AIR TURNOVER REQUIREMENT:
- THE SITE IS CLIMATE CONTROLLED/AIR CONDITIONED TO STANDARD CONDITIONS:
11 SCMM (375 SCFM).
- THE SITE IS NOT CLIMATE CONTROLLED: 113 SCMM (4000 SCFM).
THE AIR TURNOVER REQUIREMENT IS THE RATE OF ACTUAL AIR REPLACEMENT AT
THE DOCS 500 SITE WITH THE FOLLOWING CONSIDERATIONS:
- DUCTING SHALL BE SIZED WITH CONSIDERATION TO FLOW LOSS DUE TO PRESSURE
DROP.
- SITE INTAKE AND EXHAUST FANS SHALL BE SIZED WITH CONSIDERATION TO FLOW 91.4 cm (36.0 inch)
LOSS DUE TO ELEVATION AND BACK PRESSURE. SCROLL COMPRESSOR
- SITE INTAKE AND EXHAUST FANS SHALL BE INSTALLED TO MAKE SURE BEST POSSIBLE
ACCESS
AIR FLOW AIDING BLOWER MODULE INTAKE AND EXHAUST.
5 AVERAGE POWER CONSUMPTION: LOW PRESSURE ONLY, 20.4 kW @ 3.8 BAR (55 PSIG)
4 POWER REQUIREMENTS: 380V/460V, 50/60 Hz, 3-PHASE, 100/80 FLA
3 DOCS 500 USER INTERFACE: CONTROLS: START, STOP, FAULT OVERRIDE
SCREEN BRIGHTNESS, O2 CALIBRATION, PURITY OVERRIDE, ETHERNET CONNECTION.
INDICATORS: CONTROL POWER, RUN, GENERAL FAULT, PURITY ALARM, PRESSURE 91.4 cm (36.0 inch)
ALARM, PURITY OVERRIDE STATUS, AND LCD DISPLAY. USER INTERFACE AND 169.9 cm (66.9 inch)
SAFETY CONTROLS: TWO EMERGENCY STOPS (O&M MANUAL CHAPTER 3) ELECTRICAL ENCLOSURE SCROLL COMPRESSOR
2 WEIGHTS: BLOWER MODULE (798877-001) 1,216 KG (2,681 LBS), ACCESS CLEARANCE ACCESS
VSA MODULE (798864-001 & 799375-001) 2,155 KG (4,750 LBS)
VSA MODULE + BLOWER MODULE 3,371 KG (7,431 LBS) 798886A 284.8 cm (112.1 inch)
1 INTERPRET DRAWING PER ASME Y14.100, Y14.24, Y14.34M OVERALL FOOTPRINT
AND Y14.35M INCLUDES MAINTENANCE
ACCESS
NOTES: UNLESS OTHERWISE SPECIFIED
FO-1. Foundation Drawing (Sheet 1 0f 2)
350201F A-3/(A-4 blank)

5
6
IDOCS & MDOCS
500-55 (-CE)
BLOWER
COOLING OPERATOR
3 PANEL
EXHAUST
VENT
EXHAUST
10.6 SCMM
(375 SCFM)
(INTAKE)
BLOWER
COOLING
INLET VENT 76.2 cm 180 cm (70.9 inch)
(30.0 inch)
8 22.3 cm (8.8 inch)
278.5 cm (109.6 inch)
11
PRODUCT OXYGEN
DISCHARGE
3/4 inch INTERNAL NPT
207 cm 7
(81.5 inch)
FO-1. Foundation Drawing (Sheet 2)
350201F A-5/(A-6 blank)

7
8
IDOCS & MDOCS
500-55 (-CE)
APPENDIX B
P&ID & Electrical
Drawings & Bills
of Materials
350201F B-1
IDOCS & MDOCS
500-55 (-CE)
Table B-1. P&ID Bill of Materials
TAG ID DESCRIPTION PART NUMBER QUANTITY
BLOWER - AIR, Omega 43 Rotary Two Lobe Blower, Maximum Output-

BL-100 584529-001 1
856 cfm at 4 psig & 4180 RPM, Ports - 4 FNPT, 38 mm Keyed Shaft
C-1 COMPRESSOR ASSY, Scroll, 5 Horsepower, Modified for Direct Drive 797300-002 1
VSA TANK ASSY (Tank), ASME, DOCS 500 (Steel Construction),
C-300 799074-003 1
30 inch Dia
C-400 BUFFER TANK ASSY, Vertical, 80 Gallon Capacity, DOCS 500 799288-001 1
C-500 PURGE TANK ASSY, Vertical, 80 Gallon Capacity, DOCS 500 799288-002 1
VALVE, Check, In-Line, 2 MNPT Inlet X 2 FNPT Outlet, 400 psi WOG,
CV-1 582189-010 1
0.50 psig Cracking Pressure, Cv = 81 gpm {Oxygen Cleaned}
VALVE, Check, In-Line, 1.00 FNPT Ends, 400 psi WOG, 0.50 psig
CV-3 582189-012 1
Cracking, Cv = 6.00 {Oxygen Cleaned}
VALVE, Check, Poppet, 3/4 MNPT, 1 psi Crack Pressure {Oxygen
CV-4 585886-001 1
Cleaned}
FILTER, Particulate, Parker H-Series, 3/4 FNPT Ports, 6C Filter Element
F-1 585527-004 1
0.01 Micron Rating
F-3 & 4 FILTER, Particulate, 4 inch Rubber Outlet Connection 240 - 340 scfm Flow 585150-001 1
FAN ASSY, 24 inch Diameter, 5 Position Hub, 5 Blades, 30 Deg Pitch,
FX-100 585875-002 1
0.875 inch Bore, 0.188 in Key Way
FAN, Tubeaxial, 115 Vac (50/60 Hz), 33 W, 1650 RPM, 550 cfm, 55 dBA,
FX200/201 583578-008 2
10.0 in Dia x 3.5 in Deep
FAN, Tubeaxial, 100 - 125 Vac, 50 W, 3300 RPM, 300 cfm, 61 dBA, 172 x
FX-300 583578-003 1
150 x 51 mm
HEAT EXCHANGER CORE ASSY, 30 X30 X 4 inch, 850 scfm Product
HX-100 590633-001 1
Gas, 4000 scfm Cooling Gas, Inlet Temp 350°F, Outlet Temp 118°F
HEAT EXCHANGER, 1/2 inch Tube Ports, Tube and Fin Design,
HX-200 582214-010 1
9400 BTU/hr @ 2 gpm Cooling Capacity
MOTOR, Elec, 50 hp, 3600 RPM, 3 Phase 208-240/460 Vac 60 Hz & 380
MTR-1 585156-001 1
Vac 50 Hz, 326TS NEMA Frame, 594 lbs, CE Marked
MOTOR, 3 hp, 1800 RPM, NEMA 56 Hz Frame, TEFC Construction, 208-
MTR-2 583903-004 1
230/460 Vac, 60 Hz, 6 Phase
MOTOR, Elec, 5 hp, 3600 RPM, 3 Phase 208-240/460 Vac 60 Hz, 184T
MTR-3 585525-012 1
NEMA Frame, 102 lbs, Thermostats 1 Per Phase
GAUGE, Pressure, 0 - 300 psi, Bottom Mount, (Std), 2.50 Dia, 1/4 NPT, 2
PI-3 584602-001 1
Scale (PSI/PKa) {Oxygen Cleaned}
REGULATOR, Pressure, Miniature, 1 - 10 psig, Ports 1/8 NPT {Oxygen
PRV-1 581680-018 1
Cleaned}
VALVE, Relief, 1.00 MNPT Inlet, 1-1/4 FNPT Outlet, Set at 16 psig {Oxygen
PSV-1 581419-010 1
Cleaned}
PSV-2 RELIEF VALVE, MP04 Inlet X FP04 Outlet, 6000 psi, SST 580984-003 1
PROBE-RTD, 1/4 NPT Pipe Plug, 3-Wire 100 Ohm Pt, -70 to 230°C, 72 Lg
RTD-1 & 2 582654-004 2
26 AWG
PROBE-RTD, 1/4 NPT Pipe Plug, 3-Wire 100 Ohm Pt, -70 to 230°C, Class
RTD-3 & 4 Alpha DIN 0.00385 Ohm/Ohm/Degree, 72 Lg 26 AWG, 0.24 Dia X 1.5 Lg 582654-005 2
SST Probe
B-2 350201F
IDOCS & MDOCS
500-55 (-CE)
Table B-1. P&ID Bill of Materials (Continued)
S-100 SILENCER, Exhaust, Modified, DOCS 500-55 CE 798623-001 1

SILENCER, Custom, 10 Diameter X 25.70 inch Length, 4 inch Pipe Groove
S-200 590502-001 1
Fittings
VALVE, Solenoid, 3 Way Univ, 1/4 NPT Ports, 24 Vdc DIN Coil-11.6 Watt ,
SV-2 583262 1
CV=0.56, 150 psi Air Max {Oxygen Cleaned}
VALVE, Solenoid, Brass Body, Normally Open 1/4 FNPT Ports, 0.21 CV,
SV-3 0 psig Min & 160 psig Max Operating Pressure, 24 Vdc 11.6 Watt Coil 583266-002 1
{Oxygen Cleaned}
VALVE, Solenoid, Normally Closed, 3/4 FNPT Ports, 6.5 CV, 5 psig Min &
SV-4 585885-001 1
125 psig Max Operating Pressure, 24 Vdc 11.6 Watt Coil {Oxygen Cleaned}
VALVE, Solenoid, 2/2-Way Co-Ax, 2 inch Orifice (50 mm), 2 FNPT Ports,
SV-5 Mounting Brackets, 0.5 - 257.0 psia Operating Pressure, 24 Vdc {Oxygen 586098-001 1
Cleaned}
SENSOR, Pressure, -1 to 16 Bar (-14.5 to 232 psi) Programmable,
XT-1 585024-002 1
1/4 MNPT, Programmable Current Output: 0 - 20 mA, or 20-0 mA
SENSOR, Pressure, Programmable, -1 to 2.5 Bar (-14.5 to 36 psi),
XT-2, 3 & 4 585024-001 1
1/4 MNPT, Programmable Current Output: 4 - 20 mA, or 20 - 0 mA
Table B-2. Electrical Bill of Materials
A-1 CONTROLLER PCB, Programmed 799423-002 1

OXYGEN ANALYZER/SENSOR, 5 Vdc {IDOCS (-CE)} 584259-002 1
AE-1 OXYGEN SENSOR, 0-96+/-0.01% O2, Zirconia, 20,000 Hours Life in
586162-003 1
Ambient O2, 24 Vdc, 4-20 mA {MDOCS (-CE) & Models with AE-2}
OXYGEN ANALYZER, Microx-211, DIN Rail Mount, 4-20 mA Output, 24
AE-2 586162-002 1
Vdc Power Supply, 3 Alarm Contacts, -20 to 50°C {MDOCS (-CE)}
CB-1 CIRCUIT BREAKER, 150 Amp, 100 KA, 600 Vac 584849-002 1
CBL-1, 3, 5
CABLE, 3-Conductor, 20 AWG 800651-010 4
&6
CBL-2 & 4 CABLE, 3-Conductor, 20 AWG 800651-011 2
CBL-10 CABLE, O2 Analyzer, 240 inch Long 590442-010 1
CBL-13 - 15 CABLE, Ethernet, Straight Through, 10 feet Long 583803-003 3
CBL-16 &
CABLE, DB9, Serial, 10 feet Long 585489-006 2
17
CBL-18 CABLE, VFD-2, 14 AWG, Shielded 585269-001 1
CON-1 - 3 CONNECTOR, Euro-Fast, 4 Conductor (Female) 585418-001 3
CON-4 - 7 CONNECTOR, Solenoid Valve 582586-001 4
FAN-1 & 2 FAN, Cooling 583578-018 2
FAN-3 FAN, Axial, 102 CFM, 115 Vac 583578-014 1
FAN-AUX FAN, Accessory, VFD-1 585812-010 1
All listed part numbers are CAGE 75906
350201F B-3
IDOCS & MDOCS
500-55 (-CE)
Table B-2. Electrical Bill of Materials (Continued)
FU-1 - 3 FUSE, 15 Amp 582091-033 3

FU-7 & 8 FUSE, 3-1/2 Amp {380 Vac Site Power} 582399-020 2
FU-9 FUSE, 7 Amp 582399-012 1
FU-10 FUSE, 1-6/10 Amp 582841-010 1
FU-11 FUSE, 3 Amp 582841-011 1
FUSE, 1 Amp 582481-010 1
FU-12 & 13
BLOCK, Fuse, 1-Pole 580707-011 1
FX-200 &
FAN, Tubeaxial, 120 Vac, 33 Watt, 1650 RPM, 550 CFM 583578-008 2
201
FX-300 FAN, Tubeaxial, 120 Vac, 50 Watt, 3300 RPM, 300 CFM 583578-003 1
HTR-1 HEATER, Electric, 115 Vac, 400 Watt, 50/60 Hz 585822-001 1
HW-1 - 3,
5 - 8,
WIRE, 14 AWG, Black C13138-014BL 12
14 - 16,
18 - 20
HW-4, 9, 17
WIRE, 14 AWG, Green/Yellow C13132-014GRYL 4
& 21
HW-10 - 12 WIRE, 4 AWG, Black, 20 feet Long C13152-004BL 3
HW-13 WIRE, 4 AWG, Green/Yellow, 20 feet Long C13132-004GRYL 1
J-101 RECEPTACLE, Front Mount, 16 AWG Wires 584740-031 1
LR-1 LINE REACTOR, 83 Amp, 3% 585825-002 1
M-1 CONTACTOR, Motor, 9 Amp, 120 Vac Coil 581501-019 1
MCP-1 STARTER, Manual, 4 - 6.3 Amp 582459-008 1
MSP-1 OVERLAY, Membrane Switch 590466-008 1
MOTOR, Elec, 50 hp, 3600 RPM, 3 Phase 208-240/460 Vac 60 Hz &
MTR-1 585156-001 1
380 Vac 50 Hz
MTR-2 MOTOR, 3 hp, 1800 RPM, NEMA 56 Hz Frame, 208-230/460 Vac, 60 Hz 583903-004 1
MTR-3 MOTOR, Elec, 5 hp, 3500 RPM, 3 Phase 208-240/460 Vac 60 Hz 585525-002 1
P-101 PLUG, Front Mount, 16 AWG Wires 584740-032 1
PF-1 FILTER, RFI, Three Phase, 55 A, 690 Vac 585233-003 1
PO-1 THREE-RECEPTACLE OUTLET, DIN Rail Mounted, 125 Vac, 15 A 582838-001 1
PS-1 POWER SUPPLY, 120 Vac: 24 Vdc, 10 Amp 585823-002 1
RELAY, Start 585824-010 1
R-24
SOCKET, Relay 585824-011 1
SC-1 & 2 SIGNAL CONDITIONER, Isolator for Voltage/Current Signals 583986-002 2
BUTTON, Red Mushroom 581904-033 1
SW-2 BLOCK, Contact, 1 NC, 10 Amp 581903-002 1
NAMEPLATE, Emergency Stop, Yellow 581904-042 1
B-4 350201F
IDOCS & MDOCS
500-55 (-CE)
Table B-2. Electrical Bill of Materials (Continued)
TRANSFORMER, Single Phase, Control, 1000 VA, 208-600 V Primary,

T-1 582469-006 1
95/130 V Secondary
VFD-1 VARIABLE FREQUENCY DRIVE, 50 Horse Power 585812-018 1
VFD-2 VARIABLE FREQUENCY DRIVE, 5 Horse Power 585812-019 1
W-1 WIRELESS ROUTER KIT, Proxicast 4G, US 798793-00X 1
WA-5 WHIP ASSY 5 800651-009 1
WA-4 WHIP ASSY 4 800651-008 1
WA-3 WHIP ASSY 3 800651-007 1
WA-2 WHIP ASSY 2 800651-006 1
WA-1 WHIP ASSY 1 800651-005 1
350201F B-5/(B-6 blank)

IDOCS & MDOCS
500-55 (-CE)
PARTS LEGEND PARTS LEGEND

TAG NO. DESCRIPTION TAG NO. DESCRIPTION
BASIC BOOSTER PKG
AE-1 OXYGEN PRODUCT ANALYZER C-1 BOOSTER COMPRESSOR
BL-100 AIR BLOWER CV-4 DISCHARGE CHECK VALVE
C-300 VSA CHAMBER F-1 PRODUCT PARTICULATE FILTER
799545-A-1
C-400 BUFFER TANK FX-200/201 BOOSTER HEAT EXCHANGER FANS
C-500 PURGE RECEIVER TANK FX-300 COMPRESSOR MOTOR COOLING FAN
CC-1 CALIBRATION PORT HX-200 DISCHARGE HEAT EXCHANGER
CV-1 PRODUCT CHECK VALVE MTR-3 COMPRESSOR MOTOR
CV-3 BUFFER TANK OUTLET CHECK VALVE PSV-2 DISCHARGE SAFETY VALVE
EM-1 PURGE TANK VENT MUFFLER RTD-3 BOOSTER COMPRESSOR DISCHARGE TEMPERATURE
F-3 AIR INTAKE FILTER RTD-4 BOOSTER HEAT EXCHANGER OUTLET TEMPERATURE
F-4 BOOSTER INLET FILTER XT-1 BOOSTER DISCHARGE PRESSURE TRANSDUCER
FX-100 AIR INTAKE HEAT EXCHANGER FAN
HX-100 AIR INTAKE HEAT EXCHANGER
MFC-1 PRODUCT MASS FLOW CONTROLLER MEDICAL (MDOCS) ONLY
MTR-1 AIR BLOWER MOTOR PI-3 PRODUCT DISCHARGE GAUGE
MTR-2 AIR BLOWER HEAT EXCHANGER FAN MOTOR
OR-1 OXYGEN ANALYZER ORIFICE
OR-2 OFF-SPEC ORIFICE
PRV-1 OXYGEN ANALYZER PRESSURE REGULATOR 4 VSA CHAMBER (C-300) INLET TO BE CAPPED WITH
PSV-1 BUFFER TANK OUTLET PRESSURE SAFETY VALVE 581531-032 OR EQUIVALENT WHEN CHAMBER IS NOT
RTD-1 AIR BLOWER DISCHARGE TEMPERATURE FULLY ASSEMBLED OR IN USE
RTD-2 AIR INTAKE HEAT EXCHANGER OUTLET TEMPERATURE
S-100 AIR BLOWER INTAKE SILENCER 3. MODELS: IDOCS (-CE) & MDOCS (-CE) 500-55
S-200 AIR BLOWER DISCHARGE SILENCER
SV-2 SAMPLE / CALIBRATION SOLENOID VALVE
SV-3 OFF-SPEC SOLENOID VALVE 2 ALL COMPONENTS, TUBING AND FITTINGS DOWNSTREAM
SV-4 PRODUCT SOLENOID VALVE OF VSA CHAMBER (C-300) ARE CLEANED FOR
SV-5 PURGE RECEIVER FILL / DRAIN SOLENOID VALVE OXYGEN SERVICE
SV-100 SLEEP MODE SOLENOID VALVE {IDOCS & MDOCS OPTION}
V-1 PURGE TANK VENT VALVE 1. INTERPRET DRAWING PER ASME Y14.100, Y14.24,
XT-2 VSA OUT PRESSURE TRANSDUCER Y14.34M AND Y14.35M
XT-3 BUFFER TANK PRESSURE TRANSDUCER
XT-4 PURGE RECEIVER PRESSURE TRANSDUCER NOTES: UNLESS OTHERWISE SPECIFIED
FO-2. Process and Instrumentation Diagram (P&ID) (Sheet 1 of 2)
350201F B-7/(B-8 blank)

IDOCS & MDOCS
500-55 (-CE)
V-1 SV-5 CV-1

EM-1
BOOSTER PKG
2
PSV-2
125 PSIG
XT-2
RTD-4
C-500 XT-4 C-300 C-400 XT-3

FX-200 F-1
HX-200
0.01 MICRON
FX-201
RTD-3
4 XT-1
MTR
C-1
-3 CV-4 SV-2
PRV-1
FX-300
AE-1
RTD-2 OR-1
FX-100 CC-1
MTR F-4
HX-100 SV-3
-2 0.01 MICRON
OR-2
S-200 CV-3
RTD-1 IDOCS &

MDOCS OPTIONAL MDOCS (-CE)
SV-4
SV-100
MTR SLEEP MODE MFC-1 PI-3
BL-100
-1 VALVE
50 HP
S-100
799545A PSV-1
16 PSIG
F-3
NITROGEN AIR
EXHAUST SUPPLY
FO-2. Process and Instrumentation Diagram (P&ID) (Sheet 2)
350201F B-9/(B-10 blank)

IDOCS & MDOCS
500-55 (-CE)
CB-1 PDB-1
380-460VAC,3PH,50/60HZ
150 AMP LR-1
INCOMING POWER
1L1 2L1A 3L1
SOURCE
VFD-1
100 L1
DRIVE DRIVE
T1
129 A 129 B
SINK
ATV630
EXT.
FAULT RUN
D45N4 MTR-1
1L2 2L2A 3L2 2L1E 2L2E
101 L2 T2 50 hp
69.2 FLA. @ 380VAC 140
SWITCH 56.5 FLA. @ 460VAC FU-7 FU-8
3-1/2 AMP 3-1/2 AMP
1L3 2L3A 3L3
STOA
STOB
102 141
COM
AQ1
AQ2
R1A
R1B
R1C
R2A
R2C
R3A
R3C
L3 T3
24V
343 C T-1
1000 VA
103 142
ORG
GRN
RED
120V
REMOTE FU-9
TB1-1 TB1-5 E-STOP TB1-6 10 AMP TB1-2
1 E-STOP X1B X1A 2
104 SHIELD TO J40
143 SW-1 X1
CBL-16 PS-1
BOARD A1
MTR-1 1 2
105 209 D 144 +
24 VDC
-
COM
FDOCS & 2017
P24
24V
10V
DI1
DI2
DI3
DI4
DI5
DI6
AI1
AI2
AI3
OV
106 CONFIGURATIONS 145
BLUE 39 BLUE 38
342 E
GRAY
BRN
BLU
BLK
YEL
107 146
VIO
24 Vdc 24 Vdc RET
MODBUS TO A1
CBL-14 TO J-2
108 RJ45
ON DOOR 147 BLUE 39F
220 K BLUE 38F
FU-1 FU-12
15 AMP R24 1 AMP
2L1B 4L1 BLUE BLUE BLUE RED BLACK BLUE
SINK EXT.
109 VFD-2 148
SINK INT.
L1 T1
SOURCE
390A 42A POS A NEG A TB-3
FU-2 ATV320 TB-1
PTC
FU-13
DI6
15 AMP U30N4C MTR-3 38E TOP FANS
1 AMP
2L2B 4L2 BLUE BLUE BLUE RED BLACK BLUE
110 L2 T2 5 hp
7.0 FLA. @ 380VAC 149 390B 42B
TB-2 POS B NEG B TB-4
FU-3 SW2 DRIVE
SW1 FAULT 5.76 FLA. @ 460VAC
15 AMP
2L3B 4L3
111 L3 T3
325 F 150
R24 MCP-1
40 401 MTR-3
112 151 M-1
COM
COM
AQ1
START
R1A
R1B
R1C
R2A
R2C
A1 A2
10V
AI1
AI2
AI3
MTR-3
113 152
YEL
VIO
ORG
GRN
FU-10
FDOCS & 2017 1-6/10 AMP TB1-3 TB1-2
CONFIGURATIONS 45
114 SHIELD TO J41
153 SCROLL HEAT EXCHANGER
323 G CBL-17 BOARD A1
FU-11
3 AMP TB1-4 TB1-2
46
115 213 H 154
STO
SCROLL CABINET FAN
P24
+24
DI1
DI2
DI3
DI4
DI5
DI6
H1-H3 FOR 380V PRIMARY
GRAY
BLK
116 H1-H4 FOR 460V PRIMARY
MODBUS FU-1 FU-2

CBL-15 TO J-3
117 RJ45
ON DOOR WIRE COLOR CODES
H1 H2 H3 H4 H5 H6
WIRE COLOR CODES USAGE WIRE TYPE
118
GREEN W/YELLOW STRIPE GROUND THHN OR THWN
T-1
BLACK 480 VAC THHN OR THWN
119 MCP-1
M-1 RED 115 VAC (AC HIGH) THHN OR THWN
2L1C 3T1
X4 X3 X2 X1
WHITE 115 VAC (AC LOW/GROUND) THHN OR THWN
120
MTR-2 TB1-2 FU-9 ORANGE AC LOW VOLTAGE (<48 VAC) THHN OR THWN
2L2C 3T2
3 hp 120V
DARK (ROYAL) BLUE +24 VDC (OR +28 VDC) MIL-W-16878D, TYPE E
121 5.1 FLA. @ 380VAC TRANSFORMER TAP SETTING DETAIL
4.2 FLA. @ 460VAC BROWN +15 VDC MIL-W-16878D, TYPE E
2L3C 3T3
122 349 J NOTES: WHITE W/ BROWN STRIPE -15 VDC MIL-W-16878D, TYPE E
- TERMINAL POINT GRAY (SLATE) DC COMMON MIL-W-16878D, TYPE E
- EXTERNAL DEVICE
123 X - NO FACTORY CONNECTION
1 - PROTECTION BY OTHERS
THERMALLY PROTECTED MOTOR LOADS ONLY.
124 - X = SHEET NUMBER
800651A
XYY Z Y = SHEET LOCATION

Z = UNIQUE DESIGNATOR
125
9. REMOVED
4. WIRE COLORS ARE IN ACCORDANCE WITH THE WIRE
126 COLOR CODES PER IEC MACHINERY DIRECTIVE 13 PROXICAST OPTION - REROUTE CBL 13 TO WI-1,
ROUTE CBL-19 FROM WI-1 TO J12
8 DIP SWITCHES SET AS SHOWN ON SHEET 4.
3. SECURE ALL WIRING, CONDUIT AND CABLE ASSEMBLIES,
127 ROUTE TO PREVENT SNAGGING AND DAMAGE 7. REMOVE PAINT UNDER MOUNTING HOLES LOCATED ON RECOVERY TANK
12
2. WIRING IS IN ACCORDANCE WITH THE IEC 6. SIGNAL WIRES AND SHIELDED CABLES ARE
128 MACHINERY DIRECTIVE RUN SEPARATE FROM ALL OTHER WIRING 11 LOCATED ON DISTRIBUTION MODULE
1. INTERPRET DRAWING PER ASME Y14.00, Y14.24, Y14.34M 5. DC CONTROL WIRING IS SIZED CONDENSATION HEATER IS OPTIONAL
129 2L1E 2L2E AND Y14.35M FOR CIRCUIT RATING
10
131 A 131 B NOTES: UNLESS OTHERWISE SPECIFIED

130
FO-3. Electrical Schematic (Sheet 1 of 4)
350201F B-11/(B-12 blank)

IDOCS & MDOCS
500-55 (-CE)
200 OXYGEN SENSOR BOX

A-1 BUTTONS MSP-1 TO CBL-1 TB63.2 TB-63
XT1SUP
TB63.3
201 START [1..2]
J14
P14 [1..2] P-3 AE1 230 305 P TB63.1
XT1SINK
P66 J16 DISTRIBUTION BOX (584259-002) XT1SHLD
(586187-002) FLV OVR [1..2] P16 [1..2] TO CBL-2 TB63.5
(581838-003) XT2SUP
SHLD 1
202
TO CBL-100 P66.2
SV1SUP
+ [1..2]
J17
P17 [1..2] TB-4 TB-201 GROUND 231 308 Q TB63.6
XT2SINK
P66.3 J18 2 TB63.4
311 Z P66.1
SV1SINK - [1..2] P18 [1..2] SHLD 4 SHLD RD 16 RD ALARM 1
TO CBL-3 TB63.8
XT2SHLD
SV1SHLD BK WH WH 3
203 TO CBL-5 O2 CAL [1..2]
J19
P19 [1..2]
BK 3 15 GROUND_ 232 TB63.9
XT3SUP
P66.5
P66.6
SV2SUP J20
RD 2 WH SHLD 14 SHLD 4 312 R TB63.7
XT3SINK
PUR OVR [1..2] P20 [1..2] RD BK BK 9-18VDC IN
305 L P66.4
SV2SINK
J21
1 13
5
XT3SHLD
204 TO CBL-6 & CBL-7

SV2SHLD
J66 PREV [1..2] P21 [1..2] ALARM 3 233 TO CBL-22 TB63.11
XT4SUP
P66.8 BK 6 TB63.12
SV3SUP NEXT [1..2]
J22
P22 [1..2] SIG OUT (1MEG) 302 S TB63.10
XT4SINK
307 P66.9
SV3SINK 7
234
XT4SHLD
205 M P66.7 LEDS ALARM 2
309 P66.11
SV3SHLD
CONT PWR
RD 8
ALARM 4
48 TB63.19
CAB FAN+
SV4SUP BLUE
TO CBL-4 P66.12 9
206 P66.10
SV4SINK RUN NO ALARM 235 24 Vdc
COIL
R24
302 N SV4SHLD
FAULT
WH 10
+5VDC (IN/OUT)
49 TB63.20
CAB FAN-
BLUE
DOOR
207 LO PUR
PANEL 236 50 TB63.32
ACC SINK
CBL-10.1 CBL-11.2 CBL-11.1
LO PRESS
590442-010 C15529-245 C15528-203
M-1
208 ... 237 51 TB63.31
ACC SHIELD
PUR OVR
AIR BLOWER LCD DISTRIBUTION BOX
209 TO VFD-1 CBL-16 [1...9] OXYGEN SENSOR BOX 238 TB63.17
XT6SUP
AE-2 TB63.18
J40 (DB9) BLK LCD 2L X 2OC XT6SINK FDOCS & MDOCS (-CE)
104 D BRN
1
2 AE-1 (586162-004) TB63.16
XT6SHLD
210 RED
3 P1 (DB9) (586162-003) 17
TB-201 TB-4 239
ORG DEBUG [1...9] BR BR BR BR
4 16 18 10
YEL 14 GR GR 17 GR GR 9
5
211 GRN
6 O2SHLD
J22.1 RD 14 RD RD 16 RD RD 8 RD TB63.17 240
BLU J22.2 BK WH WH WH WH 7 WH TB63.18
7 O2PWR 13 15
VIO IDOCS (-CE) J22.3 SHLD SHLD SHLD TO CBL-7 TB63.14
8 NC 7 14 6 XT5SUP
212 GRAY
9 O2SIG
J22.4 6 BK BK
13 BK BK
5 BK TB63.16
241 316 T TB63.15
XT5SINK FDOCS
YW TB63.13
3 XT5SHLD
WH 2
BOOSTER
213 TO VFD-2 CBL-17 [1...9] GR 1 242 TO CBL-30 TB63.36
RTD-1A
J41 (DB9) BLK TB63.37
114 H BRN
1
361 U TB63.38
RTD-1B
2
214 RED
3 243 RTD-1C
ORG TO CBL-31 TB63.40
4 CBL-11.3 CBL-11.4 RTD-2A
YEL TB63.41
215 GRN
5 C15529-245 C15529-245
244 365 V TB63.42
RTD-2B
6 RTD-2C
BLU
7 TO CBL-32 TB63.44
VIO RTD-3A
8
216 GRAY
9 245 316 W
TB63.45
TB63.46
RTD-3B
RTD-3C
TO CBL-33 TB63.48
217 246 TB63.49
RTD-4A
318 X TB63.50
RTD-4B
RTD-4C
218 247
CBL-21 (SCSI) REMOTE
J63
J63
219 J65 P65 248
TO PS-1 59 BLUE TB63.53
39 J65.1 (586187-001) 24 Vdc SWITCHED
EHTERNET [1...8]
24 Vdc 58 BLUE TB63.51

220 146 K 38 J65.2
24 Vdc RET
GRND
OPTIONAL TB63.55
J65.3 REMOTE RUN
TB63.56
ESTOP1 SC-1 SC-2 GRND1
JA
221 J65.4
ESTOP2 B24V B24V
TB63.57
REMOTE HOLD
TB63.58
BOV BOV GRND2
J12 (RJ45)
CBL-13
TB63.59
222 CI+ CI+
TB63.60
RUNNING NO
CI- CI- GRND3
8 TB63.61
CV+ CV+ RUNNING NC
TB63.62
223 CV- CV- GRND4
TB63.63
AV+ AV+ ALARM COM
TB63.64
REM PRESS
224 AI+ AI+
TB63.65
ACOM ACOM RUNNING COM
J-12 TB63.66
REM PUR
TB63.67
225 56 BLUE TB63.68
ALARM NC
55 BLUE ALARM NO
57 BLUE
226
FO-3. Electrical Schematic (Sheet 2)
350201F B-13/(B-14 blank)

IDOCS & MDOCS
500-55 (-CE)
VSA MODULE BLOWER MODULE
300 PURGE TANK
SV-5
340
XT-4
301 P66.11
RD RD +
TB63.11
BN BN 1 +
TO J-66
BK CBL-4 BK -
12
TO TB-63
WH WH 2 SIG 341
P66.12 (C15528-203)
302 206 N P66.10 WH
WH
G 233 S
TB63.12
BU CBL-22
BU
3 - TO VFD-1 AI2 THERMOSTAT-1
TB63.10 BK
4
BK (586561-001) 342 105 E AI3 THERMOSTAT-2
303 T1 L1
343 TO VFD-1 T2 L2 MTR
SV-2
304 RD 101 C T3 L3 1
TO J-66 P66.5
CBL-5
RD
BK
+
BN
XT-1 344 GND CBL-20 GND
BK - TB63.2 BN 1 +
P66.6
305 203 L P66.4 WH
(C15528-203) WH
G
TO TB-63
WH WH 2 SIG 586553-001
230 P TB63.3
BU CBL-1
BU
3 - 345
TB63.1 BK
4
306 SV-3 BK (586561-001)
P66.8
RD RD +
346
TO J-66
CBL-6
307 P66.9
BK BK - VSA TANK
204 M P66.7 WH
(C15528-203) WH
G
XT-2 347
BN
308 SV-4
TO TB-63
TB63.5
BN 1 +
WH 2 SIG
RD RD TB63.6
WH
BU 348 3T1 HW-14 L1
TO J-66 P66.8
CBL-7 BK
+ 231 Q BU CBL-2 3 -
309 P66.9
BK - TB63.4 BK
4 TO M-1 3T2 HW-15 L2 MTR
204 M WH (C15528-203) WH
G BK (586561-001)
349 HW-16 2
P66.7 121 J 3T3 L3
310 IDOCS & MDOCS OPTION

GND HW-17 GND
SV-100 BUFFER TANK 350 586553-003
311 TO J-66 P66.2

RD RD +
XT-3
P66.3
BK CBL-100 BK - TO TB-63 TB63.8
BN BN 1 + 351
312 202 Z P66.1 WH
(C15528-203) WH
G TB63.9
WH WH 2 SIG
232 R BU CBL-3
BU
BK
3 -
352
TB63.7 4
FDOCS & 2017 CONFIGURATIONS BK (586561-001)
313
RTD-3 353
SH
SH
314 BN CBL-26 FDOCS ONLY INTAKE PANEL ASSY
(586561-001)
1 A 354
WH
2 B
315 TO TB-63 TB63.44
RD (1) TB-201
BU XT-5
TB63.45
BU (2) 3 C
BN BN 1 +
355 E-STOP 3 2
316 245 W TB63.46
GN (3)
RD
4
BK
4 TO TB-63
TB63.14
WH 2 SIG
TO J-101
WH
BU
5 RTD-4 241 T
TB63.15
BU
BU
3 - 356 SW-2 1
329 Y
GN CBL-7 BK
6 SH TB63.13 4 P-101
SH
317 OR BN CBL-27
BK (586561-001)
CON-3
TO TB-63 TB63.48
OR (1) 7
(586561-001)
1 A 357
YE (2) CBL-32 YE WH
8 2 B
318 246 X TB63.49
WH (3) (C15529-266) WH BU
TB63.50 6 3 C 358
BK
4
319
ELECTRICAL ENCLOSURE DISTRIBUTION BOX
320 359
TB-1 FDOCS & 2017 CONFIGURATIONS
321 1
360
1
1 RD (6)
SH
322 2
TB-10 FX 361 TO TB-63 1A TB63.36
WH (5) CBL-30 CBL-31
2 1B TB63.37 1 A
2
HW-18
102
200 242 U 1C TB63.38
BL (4) (C15529-266) (586561-001)
2 B RTD-1
TO VFD-2
323 2 102 AI2 THERMOSTAT-1
362 RD WH BL BK BU WH BN
2 HW-19
102 112 G AI3 THERMOSTAT-2 3 C
3 103 6 6 4
7 7
324 3 103 FX
201
T1 L1
363 5 5
TO VFD-2 T2 L2 MTR
102 8 585418-005
2 3 585418-004
325 2 HW-20
102 110 F T3 L3
364 1 4 4 1
4 104 GND CBL-18 GND
4 104 FX GN (1)
HW-21 586553-003 2 3 3 2 SH
326 300 365 TO TB-63 2A TB63.40
OR (2) CBL-30 CBL-31
5 2B TB63.41 GN OR YE BK BU WH BN 1 A
6 244 V 2C TB63.42
YE (3) (C15529-266) (586561-001)
2 B RTD-2
327 366 3 C
3 2
4
328 367
TO P-101 J-101
1
329 356 Y
368
350201F B-15/(B-16 blank)

IDOCS & MDOCS
500-55 (-CE)
CIRCUIT BREAKER
150 A, 380 V, 3 PHASE
CUSTOMER PROVIDED
FACILITY POWER
REFERENCE EXAMPLE
2 AWG 600 V
2 AWG 600 V
2 AWG 600 V
2 AWG 600 V
SLEEP
GROUND
SWITCH
L1
L2
L3
HLD IN SNK
TB 63.57
3 2 GRND2 DOCS 500
TB 63.58
{IDOCS
MDOCS} ALARM COM
TB 63.63
PRESS V J-12
TB 63.64
RUN COM
TB 63.65
GRND3
TB 63.60 SC-1 SC-2
RUN N.C.
TB 63.61 A.V+ A.V+
GRND4
TB 63.62 A.I+ A.I+
ALARM N.O. A.COM A.COM

TB 63.68
RUN N.O. 8
TB 63.59 B.24V B.24V
PUR V B.0V B.0V
TB 63.66
ALARM N.C.
TB 63.67
C.I+ C.I+
GRND1
TB 63.56 C.I- C.I-
RUN IN SNK C.V+ C.V+
TB 63.55
C.V- C.V-
CUSTOMER PROVIDED
EXTERNAL CONTROL SYSTEM
PLC D-1 RL-1 REFERENCE EXAMPLE
PLC DIGITAL INPUT PLC RELAY OUTPUT (RUN) (OPTIONAL)
COM
DI1
ALARM N.O. IS CLOSED
TO ALARM COM WHEN DI2
UNIT IS POWERED UP DI3
WITH NO ALARMS 8
DI4
OPTIONAL PRESSURE OPTIONAL PURITY
AI1+
AI2+
AI3+
AI4+
AI4+
AI1-
AI2-
AI3-
DI5 CURRENT LOOP CURRENT LOOP
OPTIONAL REMOTE RUN
24VDC CONTACT ENCLOSURE INTERFACE 4-20m A 4-20m A
DI6
22 AWG 300V MINIMUM 22 AWG 300 V MINIMUM 22 AWG 300 V MINIMUM
DI7 SHIELDING RECOMMENDED SHIELDING RECOMMENDED
SHIELDING RECOMMENDED
PLC AI-1
DI8
PLC 4-20m AINPUT
FIELD WIRING DIAGRAM

350201F B-17/(B-18 blank)

IDOCS & MDOCS
500-55 (-CE)
TDR1
25/21
A1
15
(582248-002)
28/24
26/22
H1
B1
(583172)
PB1
A2
18
16
(581904-044)
DISTRIBUTION AND SENSOR BOXES (581904-059)
TONE2
TONE1
POS2
POS1
NEG2
NEG1
AE2
(586162-004)
AE1 TB-201 TB4

(586162-003) 17
16 BR BR 18 BR BR 10 BR
15 GR GR 17 GR GR 9 GR SSR1
RD RD RD RD RD RD (581833-043) +24 Vdc TB63.28
14 16 8 TB63
BK 13 WH WH 15 WH WH 7 WH
SHLD SHLD SHLD 4 1
7 14 6 COIL- NO
6 BK BK 13 BK BK 5 BK 3 2 24 Vdc RET TB63.27
YW 3 COIL+ COM
WH 2
GR 1 TB63.11
TB63.10
CBL-11.3 CBL-11.4 TB63.12
797847-H
MDOCS (-CE)
FO-4. Alarm Schematic {MDOCS (-CE)}
350201F B-19/(B-20 blank)

IDOCS & MDOCS
500-55 (-CE)
APPENDIX C
Spare Parts Lists
350201F C-1
IDOCS & MDOCS
500-55 (-CE)
Table C-1. Tool Kit (797366-001)
DESCRIPTION PART NUMBER QUANTITY
BRUSH, Wire, 1.88 Long X 0.50 Wide, with Handle 585674-001 1

DETECTOR, Leak, O2 Compatible (1 gallon) 581567-003 1
FITTING, Grease, 0.12 PTF S40300-101 5
FITTING, Grease, 90 Degree, 1/8 External NPT G40300-016 5
GLOVES, Latex, No Powder (50 pr/Box) 585675-001 1
GREASE GUN, with 18 inch Flex Hose (multipurpose grease) 584229-001 1
SOCKETS, Hex Bit, 3/8 Drive, 7-Pieces, Metric 581950-012 1
SOCKETS, Hex Bit, 3/8 Drive, 7-Pieces, ANSI/ASME 581950-011 1
TOWEL, Lint Free, 12 X 13 (500/Box) 585673-001 1
WRENCH, Torque, 3/8 Drive, 5 - 75 ft-lb (6.8 - 102 Nm) 582075-006 1
797366 Revision W
All Part Numbers are CAGE 75906
Table C-2. Specialty Tool Spares Kit (797366-009)
GREASE GUN (grease cartridge) 582172-005 1

Table C-3. Capital Spares Kit (797366-014)
TAG ID DESCRIPTION PART NUMBER QTY
CONTROLLER PCB (IDOCS) 799469-001 1

A-1
CONTROLLER PCB (MDOCS) 799469-002 1
BLOWER, Air 584529-001 1
BL-100 COUPLING 585594-017 1
COUPLING ELEMENTS & SCREWS 585594-011 1
COMPRESSOR ASSY, Booster, 5 Horse Power, Modified 797300-002 † 1
C-1
GASKET, Booster Inlet Port 799791-002 † 1
CB-1 CIRCUIT BREAKER, 150 A 584849-002 1
VALVE, Check, In-Line, 1.00 inch FNPT Ends, 400 psi WOG, 0.50 psig
CV-3 582189-012 1
Cracking
CV-4 VALVE, Check, 1/3 PSI 585886-001 † 1
F-1 FILTER, Particulate 585527-004 † 1
F-4 FILTER, Particulate, Grade 6 585151-001 † 1
FU-1 - 3 FUSE, 15 Amp 582091-033 1
† - Oxygen Cleaned at Factory
C-2 350201F
IDOCS & MDOCS
500-55 (-CE)
Table C-3. Capital Spares Kit (797366-014) (Continued)
FUSE, 2-1/2 Amp (460 Vac) 582399-004 1

FU-7 & 8
FUSE, 3-2/10 Amp (380 Vac) 582399-015 1
FU-9 FUSE, 7 Amp 582399-008 1
FU-10 FUSE, 1-6/10 Amp 582481-010 1
FU-11 FUSE, 3 Amp 582481-011 1
HTR-1 HEATER, 400 Watt 585822-001 1
LR-1 REACTOR, Line, 83 Amp, 3% 585825-002 1
M-1 CONTACTOR, 9 Amp, 120 Vac 581501-019 1
MCP-1 STARTER, Manual, 4 - 6.3 Amp 582459-008 1
MOTOR, Electric, 50 Horse Power 585156-006 1
MTR-1 MOTOR, Electric, 50 Horse Power (Alternate) 585156-003 (1)
MOTOR, Electric, 50 Horse Power (Alternate) 585156-004 (1)
MTR-2 MOTOR, Electric, 3 Horse Power 583903-009 1
MOTOR, Electric, 5 Horse Power 585525-012 1
MTR-3 MOTOR, Electric, 5 Horse Power (Alternate) 585525-005 (1)
MOTOR, Electric, 5 Horse Power (Alternate) 585525-006 (1)
MTR-1 & 3 SHIM KIT, Size A, Slotted 585643-001 1
PS-1 POWER SUPPLY, 120 Vac / 24 Vdc, 10 Amp 585823-002 1
RELAY, Start 585824-010 1
R-24
SOCKET, Relay 585824-011 1
S-1 STRAINER, Tank Mounted 582178-002 † 1
S-2 STRAINER, Tank Mounted 582178-010 † 1
S-200 SILENCER, In-Line, 4.0 Internal NPT 590502-001 1
T-1 TRANSFORMER, Control, 380 Vac / 120 Vac, 1000 VA 582469-006 1
SV-2 VALVE, Solenoid, 150 PSI 583262 † 1
SV-3 VALVE, Solenoid, 125 PSI 583266-002 † 1
SV-4 VALVE, Solenoid, 125 PSI 585885-001 † 1
SV-5 VALVE, Solenoid, Coax 586098-001 1
VFD-1 Variable Frequency Drive, 50 Horse Power, 380 Vac 585812-018 1
VFD-2 Variable Frequency Drive, 5 Horse Power, 400 - 480 Vac 585812-019 1
– GASKET, Coupling, 4.0 inch Pipe, Style 77, Grade 0 583908-003 3
– GASKET, Coupling, 2.0 inch Pipe, Style 77, Grade 0 583908-001 † 3
– HOSE, High Temperature 4.0 Dia x 14 inch Long 585182-002 1
– LATCH, Compression 585533-001 1
350201F C-3
IDOCS & MDOCS
500-55 (-CE)
Table C-4. On Hand Spares Kit (797366-015)
CV-1 VALVE, Check, In-Line 582189-010 † 1

FAN-1 & 2 FAN, Tubeaxial 583578-016 1
FAN-3 FAN, Tubeaxial 583578-014 1
FAN-DIST FAN, Tubeaxial 583578-003 1
FX-200 & 201 FAN, Tubeaxial, 115 Vac, 33 Watt 583578-008 1
XT-1 SENSOR, Pressure 799073-002 † 1
XT-2 & 3 SENSOR, Pressure 799073-001 † 1
– ELBOW, Blower Out 797954-001 1
Table C-5. 1 Year Consumables Spares Kit (797366-016)
OIL-LUBE, Synthetic, Omega, SB-220, Blower Discharge Temp < 149°C (300°F) {1 quart} 582923-001 3
OIL-LUBE, Synthetic, Omega, SB-150, Blower Discharge Temp -34 to 121°C
582923-002 (3)
BL-100 (-30 to 250°F) {1 quart} [Cold Weather Alternate}]
OIL-LUBE, Synthetic, Omega, SB-320, Blower Discharge Temp > 149°C (300°F) {1 quart}
582923-003 (3)
[Hot Weather Alternate]
GREASE CARTRIDGE, Isoflex Topas NB 52 582172-006 1
C-1
SEAL KIT (refer to Table C-10. on page C-6) 797521-002 † 1
F-4 ELEMENT, Filter, Coalescer, Grade 6 585151-002 † 8
MTR-1 & GREASE, Multipurpose, NLGI Grade 2, -30 to 177°C (-22 to 350°F) {5 oz} 581556-001 1
2 GREASE, Multipurpose, NLGI Grade 2, -30 to 177°C (-22 to 350°F) {12 oz} [Alternate] 581556-004 (1)
– Filter Mat (5/pack) 585603-008 2
C-4 350201F
IDOCS & MDOCS
500-55 (-CE)
OIL-LUBE, Synthetic, Omega, SB-220. Blower Discharge Temp < 149°C (300°F)
582923-001 9
BL-100 (1 Quart)
SEAL KIT, Blower Shaft (refer to Table C-11. on page C-6) 799045-001 1
C-1
MTR-1 &
GREASE, Multipurpose, NLGI Grade 2, -30 to 177°C (-22 to 350°F) (5 oz) 581556-001 2
2
– Filter Mat (5/pack) 585603-008 6
OIL-LUBE, Synthetic, Omega, SB-220. Blower Discharge Temp < 149°C (300°F)
582923-001 15
BL-100 (1 Quart)
SEAL KIT, Blower Shaft (refer to Table C-11. on page C-6) 799045-001 2
C-1
MTR-1 &
GREASE, Multipurpose, NLGI Grade 2, -30 to 177°C (-22 to 350°F) (5 oz) 581556-001 2
2
– Filter Mat (5/pack) 585603-008 10
Table C-8. Oxygen Analyzer Spares Kit {IDOCS (-CE)} (797366-019)
AE-1 OXYGEN ANALYZER/SENSOR 584259-002 † 1

350201F C-5
IDOCS & MDOCS
500-55 (-CE)
Table C-9. Oxygen Sensor Spares Kit {MDOCS (-CE) & Models with AE-2} (797366-020)
AE-1 OXYGEN SENSOR 586162-003 † 1

Table C-10. Booster Compressor Seal Kit (797521-002)
SEAL, Small 797524-003 † 1

SEAL, Large 797523-003 † 1
TUBE, Seal 797525-001 † 1
SEAL, Small 797524-001 † 1
SEAL, Large 797523-001 † 1
SEAL, Dust 797522-001 † 1
Table C-11. Air Blower Shaft Seal Kit (799045-001)
SHAFT SLEEVE, Blower 585802-007 1

SEAL, Shaft, with Dust Seal, 38 mm Bore 590561-001 1
Table C-12. Air Blower Shaft Seal Tool Kit (798750-001)
ALIGNMENT TOOL KIT, E420 Shaft 585969-001 1

CASE, Pelican, 24.8 X 19.7 X 11.9 inch 582850-002 1
HAMMER, Dead Blow 585966-001 1
HEATER, Hot-Plate, 5 Wide X 3-5/8 High X 10 Deep inch 585963-001 1
PLIER, Locking-Vice Grip 585965-001 1
PULLER, Omega Blower, Series 2, 4 & 6 585967-001 1
PULLER, External Jaw Combo 585964-001 1
SHAFT SEAL TOOL ASSY, Blower Series 2 585968-001 1
SHAFT SEAL TOOL ASSY, Blower Series 4 585968-002 1
C-6 350201F

350201F - O&m - I&mdocs 500-55 (-Ce)

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TECHNICAL MANUAL

OPERATION AND MAINTENANCE

DEPLOYABLE OXYGEN CONCENTRATION SYSTEM

PART AND (MODEL) NUMBERS:

796926-011 & -012 (IDOCS 500-55)

Authorized Representative Manufacture

350201 Revision F 23 July 2020

REVISION DATE DESCRIPTION DCN

WARNING: Highlights an important operating or maintenance procedure, practice, condition, statement,

CAUTION: Highlights an important operating or maintenance procedure, practice, condition, statement,

NOTE: Highlights an important operating or maintenance procedure, condition or statement.

SAFETY AND HAZARDOUS ICONS

FIRE - The material is flammable or actions could cause a fire.

LOCK-OUT/TAG-OUT - The electrical must be locked-out and tagged-out before continuing.

READ MANUAL - Read the manual instruction before continuing.

COMPRESSED OXYGEN - This Plant produces compressed oxygen.

NOTE - This icon is used for all notes.

OMEGA SB SYNTHETIC OIL-LUBE

THREAD LOCKER, LOCTITE® 242

THREAD LOCKER, LOCTITE® 271

GREASE, ISOFLEX TOPAS NB 52

GREASE, MULTIPURPOSE, NLGI GRADE 2

OXYGEN LUBRICANT, KRYTOX®

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

PARTS AND SERVICE INFORMATION

CONTACT PCI FOR PARTS AND SERVICE

Pacific Consolidated Industries 12201 Magnolia Avenue Riverside, CA 92503-4820

Manufacturer: Pacific Consolidated Industries LLC, (PCI)

Authorized Representative: Emergo Europe

Device Name/Type Deployable Oxygen Concentrator System (DOCS)

Product Identifier: DOCS 500

Classification per Annex IX: Class IIb, Rule 11

Conformity Assessment Procedure Annex II

Standards Applied: IEC 60601-1

Notified Body: BSI Group

Date declaration: 06/20/2019

Form 302333 Rev C

Pacific Consolidated Industries 12201 Magnolia Avenue Riverside, CA 92503-4820

The Old Methodist Chapel

350201F xix/(xx blank)

1.2.1 APPLICATION SPECIFICATION

1. Intended Medical Indication:

5. Intended Conditions of Use:

1.3 MODEL DESIGNATORS IN THIS MANUAL

Table 1-1. Model Designation Matrix

IDOCS 796926-011 & -012 (IDOCS 500-55)

1.4 LEADING PARTICULARS

Figure 1-1. MDOCS 500-55

Operating Temperature -18 to 49°C (0 to 120°F)

Sound Power Level (LWA): 84.1 dB(A)

Emission and Immunity Compliance Per EN60601-1-2:

INPUT POWER REQUIREMENTS

Low Pressure Discharge 1.4 - 6.9 Bar (20 - 100 psig)

DISCHARGE AND CALIBRATION PORTS

Discharge 3/4 inch, Internal NPT Fitting

Height 208 cm (82 inch)

Height 188 cm (74 inch)

1.5 COMPONENT DESCRIPTION AND LOCATION