DeVilbiss 515 Service manual

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CAUTION-Federal (U.S.A.) law restricts this device to sale by or on the order of a physician.

Service

Manual

DeVilbiss

4 & 5-Liter Series Oxygen Concentrators

DANGER – NO SMOKING

For Product Numbers: 515DS 515DZ 515KS 515KZ 515NS 515UK

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TABLE OF CONTENTS

GENERAL INFORMATION

Introduction.............................................................................................................................................................................................................................4

Important Safeguards.............................................................................................................................................................................................................5

Safety Precautions and General Warnings........................................................................................................................................................................5

UNPACKING AND SETUP

Initial Inspection......................................................................................................................................................................................................................6

Patient Setup............................................................................................................................................................................................................................6

Operating Instructions..........................................................................................................................................................................................................6

MAINTENANCE

Patient Alert System ..............................................................................................................................................................................................................8

Routine Patient Maintenance...............................................................................................................................................................................................8

Periodic Homecare Provider Preventative Maintenance ..............................................................................................................................................8

Between Patient Maintenance.............................................................................................................................................................................................9

Preventative Maintenance Summary ..................................................................................................................................................................................9

TROUBLESHOOTING

System Operation................................................................................................................................................................................................................10

Normal Operating Sequence............................................................................................................................................................................................

Simplified Troubleshooting.................................................................................................................................................................................................

Troubleshooting Chart A...................................................................................................................................................................................................12

Troubleshooting Chart B...................................................................................................................................................................................................

Troubleshooting Chart C...................................................................................................................................................................................................

Troubleshooting Chart D ..................................................................................................................................................................................................

Troubleshooting Chart E....................................................................................................................................................................................................

Troubleshooting Chart F....................................................................................................................................................................................................

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Proper Repair Procedures.................................................................................................................................................................................................15

Cabinet Removal..................................................................................................................................................................................................................

Accumulator Pressure Test................................................................................................................................................................................................

Capacitor ...............................................................................................................................................................................................................................

Compressor..........................................................................................................................................................................................................................

Cooling Fan ...........................................................................................................................................................................................................................

Final Check Valve..................................................................................................................................................................................................................

Flow Meter............................................................................................................................................................................................................................

Four-Way Valve .....................................................................................................................................................................................................................

Hour Meter...........................................................................................................................................................................................................................

Molecular Sieve Beds...........................................................................................................................................................................................................20

OSD (Oxygen Sensing Device).........................................................................................................................................................................................20

Power Cord...........................................................................................................................................................................................................................20

Power Switch........................................................................................................................................................................................................................20

Pressure Regulator..............................................................................................................................................................................................................2

Printed Circuit Board (PC board)...................................................................................................................................................................................21

Sieve Bed Check Valves ......................................................................................................................................................................................................21

FIGURES, DIAGRAMS, AND VIEWS

Figure Index...........................................................................................................................................................................................................................22

Exterior Views.................................................................................................................................................................................................................23-25

Interior Views..................................................................................................................................................................................................................26-37

Other Figures .................................................................................................................................................................................................................38-4

Wiring and Pneumatic Diagrams................................................................................................................................................................................42-44

WARRANTY INFORMATION........................................................................................................................................................................................45

ORDERING INFORMATION AND PARTS LIST

Ordering Information..........................................................................................................................................................................................................46

Parts Return and Ordering Policy....................................................................................................................................................................................46

Parts List ..........................................................................................................................................................................................................................47-48

SPECIFICATIONS.................................................................................................................................................................................................................49

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GENERAL INFORMATION

INTRODUCTION

This service manual was designed to provide Sunrise Medical Respiratory Products Division qualified service technicians and homecare providers with the proper maintenance, service, safety, and repair procedures for the DeVilbiss Oxygen Concentrator.

Read and understand all the information contained in this service manual before attempting to operate or perform any maintenance on the concentrator.

An oxygen concentrator is a device that delivers highly concentrated oxygen for therapeutic applications.

Room air is a mixture of 78% nitrogen, 2

1% oxygen, 1% argon

and other gases.The concentrator draws in room air, separates the nitrogen from the oxygen,and delivers concentrated oxygen to the patient through an oxygen port.

For more in-depth classroom type training, Sunrise Medical holds oxygen concentrator service schools. For service school information, contact the Service Department at

-800-333-4000 (8114-443-48811).

NOTE:

Sunrise Medical reserves the right to alter or change the design of the DeVilbiss Oxygen Concentrator series. Hence, slight differences in construction or components may exist between the unit in hand and what is described in this manual.

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GENERAL INFORMATION

IMPORTANT SAFEGUARDS

Read all instructions before operating the oxygen concentrator. Important information is highlighted by these terms:

WARNING: Safety information for hazards that might cause serious injury or death.

CAUTION: Information for preventing damage to the product.

NOTE:

Information to which you should pay special attention.

SAFETY PRECAUTIONS AND GENERAL WARNINGS

A. Federal (U.S.A.) law restricts this device to sale by or on the

order of a physician.

B. WARNING: Oxygen promotes rapid burning. Do

not smoke when using this unit or when near a person receiving oxygen therapy. Do not operate the oxygen concentrator within a minimum of five feet (

1.6m) from hot, sparking, or burning objects or naked

flames. Do not use in rooms heated by paraffin or portable gas heaters.

C. Do not place a humidifier with an oxygen patient unless pre-

scribed by a physician and then only a bubble-type humidifier should be used.

D. Do not connect the oxygen concentrator to an electrical out-

let controlled by a wall switch; the outlet should be independent of other appliances.

E. Do not use an electrical adapter or extension cord with the

oxygen concentrator.

F. Only operate the oxygen concentrator with all filters in place;

do not operate if the air filter is wet.

G. WARNING: Electric shock hazard. Do not remove cab-

inet.The cabinet should only be removed by a qualified Sunrise Medical homecare provider.

H. WARNING: Disconnect the power cord from the wall

outlet before attempting repairs on the unit. Extra care should be taken if it is necessary to operate the unit with the cabinet removed.

I. WARNING: Do not use oils, greases, or any petrole-

um-based solvents/cleaners on or near the unit. Use only materials that are compatible with oxygen.

J. WARNING:When replacing the capacitor, do not

touch the terminals or allow metal objects to come in contact with the terminals on the capacitor.The capacitor can retain a dangerous charge level for several days after the unit is turned off.The capacitor is located in the base of the unit next to the cooling fan.

K. Use only Sunrise Medical concentrator replacement parts and

accessories.

L. Do not use regenerated sieve material.

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UNPACKING AND SETUP

INITIAL INSPECTION

It is suggested that an initial inspection be performed upon receiving the oxygen concentrator.

1. After removing the DeVilbiss Oxygen Concentrator from the

carton, examine it for any external damage. If shipping damage has occurred, contact the Sunrise Medical Customer Service Department at

1-800-333-4000 (814-443-4881) for specific

instructions. Save the carton for possible later return;note the position of the unit and placement of the packing material.

2. Open the filter door (Figure 3) and record the number of hours on the hour meter. Check to make sure the air filter is in place.

3. Check to be sure the intake bacteria filter (Figure 4) is in place.

4. Plug the unit into an electrical outlet, turn the unit “On,” and check the audible and visible alarms.

5. Set the flow meter to maximum recommended liter flow and let the unit run for at least 20 minutes.

6. Use an oxygen analyzer to check the concentration.

NOTE: If the unit fails to operate properly (oxygen concentration not within specification) or if internal damage is found, contact the Sunrise Medical Customer Service Department at 1-800-333-4000 (814-443-4881).

PATIENT SETUP

1. Position the unit near an electrical outlet in the room where the patient spends most of his or her time.

NOTE: Do not connect to an electrical outlet controlled by a wall switch.The outlet should be independent of other appliances.

2. Position the unit at least 6 inches (

16 cm) from walls,

draperies, or any other objects that might prevent the proper flow of air in and out of the oxygen concentrator.

3. Locate the unit a minimum of 5 feet (

1.6 meters) from fire-

places, radiators, heaters, and hot-air registers.

WARNING: Oxygen promotes rapid burning. Do

not smoke when using this unit or when near a person receiving oxygen therapy. Do not operate the oxygen concentrator within a minimum of 5 feet (1.6 meters) from hot, sparking, or burning objects or naked flames. Do not use in rooms heated by paraffin or portable gas heaters.

WARNING—Electric Shock Hazard. Only qualified Sunrise Medical homecare providers may remove the cabinet.

4. Attach the appropriate oxygen accessories (oxygen tubing or humidifier) to the oxygen outlet port.

NOTE:A maximum of 50 feet (15 meters) of tubing plus 7 feet (2.

1 meters) of cannula plus a bubble humidifier is allowed

between the concentrator and the patient.

Oxygen Tubing Only Connection (Figure 1)

1. Thread the cannula fitting (part #CN100) onto the oxygen

outlet port.

2. Attach the 5/32” (4 mm) I.D. oxygen tubing (part #OST07, OST

15, OST25, or OST50).

Oxygen Tubing with Humidification Connection

If the physician has prescribed an oxygen humidifier as part of the patient’s therapy, follow these steps:

1. Fill the humidifier bottle (part #HUM16) with distilled water. Do not overfill. (If using a prefill, go to Step 3.)

2. Thread the wing nut located on the top of the humidifier bottle to the oxygen outlet port so that it is suspended. Make sure it is securely tightened.

3. Attach the 5/32" (4 mm) I.D. oxygen tubing (part # OST07, OST

15, OST25, or OST50), not to exceed 50 feet (15

meters), directly to the humidifier bottle outlet fitting. NOTE: For optimum performance, the DeVilbiss Oxygen

Concentrator has a preset nominal output pressure of 8.5 psi (58.6 kPa). Use only “bubble-type” humidifiers. Do not use “jet-type” humidifiers.

NOTE:Condensation from the humidifier may occur in longer lengths of tubing or if the tubing is laying on a cold floor.This can be reduced by using a removable humidifier stand (part #MC44DM-509).

To use the stand:

1. Attach a straight humidifier adapter fitting (part #444-506) to the bottle by turning the wing nut on the humidifier until it is tight on the fitting.

2. Secure the bottle in the strap.

3. Attach one end of the oxygen tubing to the oxygen outlet on the unit and the other end to the plastic adapter fitting on the humidifier. Locate the humidifier near the patient.

When ready for operation

1. Attach the nasal cannula (part #CAN00), catheter, or face mask to the oxygen tubing (per the manufacturer’s directions).

2. Follow the operating instructions given below.

OPERATING INSTRUCTIONS

1. Remove the power cord completely from the strap. Make sure the power switch is in the “Off” position.

115 Volt Units– Insert the plug into an electrical outlet.The DeVilbiss Oxygen Concentrator uses a two-prong polarized plug and is double-insulated to protect against electric shock. 230 Volt Units– The DeVilbiss Oxygen Concentrator is double-insulated to protect against electric shock. Insert the line cord into the IEC power connector located on the back of the unit. Insert the plug into an electrical outlet.

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UNPACKING AND SETUP

WARNING:The plug on the DeVilbiss 515DZ and 515DS concentrators has one blade wider than the other.To reduce the risk of electric shock, this plug is intended to fit in a wall outlet only one way. Do not attempt to defeat this safety feature.

WARNING: Improper use of the power cord and plugs can cause a burn, fire, or other electric shock hazards. Do not use the unit if the power cord is damaged.

WARNING: Oxygen promotes rapid burning.Do

not smoke when using this unit or when near a person receiving oxygen therapy. Do not operate the oxygen concentrator within a minimum of five feet (1.6m) from hot, sparking, or burning objects or naked flames. Do not use in rooms heated by paraffin or portable gas heaters.

3. Press the power switch to the “On” position.When the unit is turned on, the “Service Required” light will illuminate and an audible signal will sound (the patient alert system) momentarily. The “Power” light also illuminates.

Only DeVilbiss Oxygen Concentrators with OSD

NOTE:There are two 515 OSD concentrator models referred to throughout this Service Manual:

• Early - OSD models

(Concentrator serial number H

19999 and lower)

• Later - OSD models

(Concentrator serial number H20000 and higher)

The OSD is an optional device within DeVilbiss concentrators that monitors the oxygen produced by the unit.The OSD operates as follows:

• Normal Oxygen (green light) - oxygen purity normal

• Low Oxygen (yellow light) - oxygen purity low–requires servicing

NOTE:If the oxygen purity continues to fall, an audible signal will sound intermittently. If the oxygen purity continues to fall to a low enough level, the yellow “Low Oxygen” light will turn off and the red “Service Required” light will turn on.

NOTE:Refer to “Specifications” for specific alarm settings. When the unit with the OSD is turned “On,” all four indicator

lights (Power, Service Required, Low Oxygen, and Normal Oxygen) on the front panel will briefly illuminate. After a few seconds, only the “Power” and “Normal Oxygen” lights will remain on.

NOTE:After Power On, the OSD conducts a continuous diagnostic evaluation to check for a fault in the piezo electronics. If this condition is detected by the OSD electronics at any time duing concentrator operation, the green “Normal Oxygen” OSD light will turn off and the beeping audible and blinking red “Service Required” light alarms activate.

Otherwise for the first fifteen minutes of operation, the green “Normal Oxygen” light will remain illuminated during the oxygen stabilization process.After that time, the OSD will begin monitoring the oxygen purity every second.

4. Slowly turn the flow meter knob until the flow meter ball is centered on the line next to the appropriate flow rate.

NOTE:When the flow meter knob is turned clockwise, the flow decreases (and eventually will shut off the oxygen flow). When the knob is turned counter-clockwise, the flow increases.

NOTE: Use low output flow meter (part #515LF-607) for flow rates under

1 lpm.

NOTE:The unit may require up to 20 minutes for the oxygen concentration and flow rate to stabilize.The flow rate should be monitored and readjusted if necessary.

5. The flow meter has a locking device. If it is necessary to preset and lock in the prescribed flow rate, tighten the set screw located on the hex nut just below the control knob using a 1/16" Allen bit. No adjustment can be made without loosening the set screw.

6. The DeVilbiss oxygen concentrator is now ready for use.

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MAINTENANCE

PATIENT ALERT SYSTEM

The DeVilbiss Oxygen Concentrator patient alert system will detect unit component failure.This system is comprised of both visible and audible alarms which signal the patient if a malfunction should occur.

The visible alarm located on the front panel (Figure

1) reads

“Service Required.” The audible alarm system is internally powered; no batteries are required.When the indicator lights illuminate or the audible alarm sounds, other than during unit start-up, a problem has occurred.

Non-OSD and early-OSD models:

• Power Failure (Blinking red “Service Required” light and pulsing audible alarm)

• Low Pressure (Continuous red “Service Required” light and audible alarm)

• Below Normal Oxygen - OSD models only (Less than 85%, yellow “Low Oxygen” light. Less than 75%, yellow “Low Oxygen” light and audible alarm)

Later OSD models:

• Power Failure (Blinking red “Service Required” light and pulsing audible alarm)

• Low Flow (Below 0.5 lpm) (Continuous red “Service Required” light and audible alarm)

• Below Normal Oxygen (83.5% to 75%, yellow “Low Oxygen” light. 75% to 60%, yellow “Low Oxygen” light and beeping audi- ble alarm. Less than 60%, red “Service Required” light and beeping audible alarm.)

The visible and audible alarms will activate for approximately 15 minutes in a no power situation. If the unit is turned “On” and later the power is removed, no alarm will sound for the first

10 seconds.After that time, the alarm will produce an

audible pulse every few seconds while the visible alarm blinks. NOTE: If the concentrator has been unused for an extended

period, the unit must run several minutes before the power fail alarm will activate.

The printed circuit (PC) board (Figure 5) is responsible for controlling the system and alarms.

NOTE:A high pressure condition is indicated by the audible (a “popping” sound) release of pressure from a pressure relief valve located on the compressor head.

ROUTINE PATIENT MAINTENANCE

The oxygen patient should perform the following maintenance:

Oxygen Humidifier (reusable bottles only)

The patient should clean the humidifier bottle daily.The patient should follow the instructions supplied by the manufacturer. If no cleaning instructions were supplied, these steps should be followed:

• Wash the humidifier bottle in a solution of hot water and dishwashing detergent.

• Soak the humidifier in a solution of one part white vinegar to three parts hot water for 30-45 minutes.This solution acts as a germicidal agent.

• Rinse thoroughly with hot tap water and refill with distilled water for use. Do not overfill.

Cannula/Mask and Tubing

The patient should clean and replace the cannula or mask and tubing as instructed by the manufacturer.

Air Filter and Oxygen Outlet Connector

The air filter (Figure 3) and oxygen outlet connector should be cleaned at least once a week by the patient.To clean, these steps should be followed:

1. Remove the air filter located in the door on the back of the unit.

Remove the oxygen outlet connector (if used) from oxygen outlet port (Figure

1).

2. Wash in a solution of warm water and dishwashing detergent.

3. Rinse thoroughly with warm tap water and towel dry.The filter should be completely dry before reinstalling.

WARNING: Do not attempt to operate the unit without the air filter or while the filter is still damp.

NOTE:

The air filter should be monitored more closely in

environments with abnormal amounts of dust and lint.

CAUTION: Operation of the DeVilbiss Oxygen Concentrator in extreme environments or without the air filter will prematurely occlude the intake bacteria filter and cause a decrease in the unit performance.

Exterior Cabinet

The patient should clean the concentrator exterior cabinet by using a damp cloth or sponge with a mild household cleaner and wiping it dry.

WARNING: Do not apply liquids directly to the cabinet or utilize any petroleum-based solvents or cleaning agents.

PERIODIC HOMECARE PROVIDER PREVENTATIVE MAINTENANCE

Every DeVilbiss Oxygen Concentrator is tested at the factory. To assure continued trouble-free performance, the following preventative maintenance should be performed by the homecare provider during periodic oxygen patient visits.Failure to properly maintain the unit will void the warranty.

1. Check the oxygen concentration with an oxygen analyzer (part #O2ANA)—every 3 months on non-OSD units or every two years on OSD units.

a. Calibrate the oxygen analyzer prior to checking the oxy-

gen concentration.The analyzer should be properly calibrated using the manufacturer’s recommended procedure. NOTE: Changes in temperature, altitude, or humidity may affect the analyzer’s oxygen concentration reading.The analyzer should be calibrated in similar conditions to the location of the concentrator.

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MAINTENANCE

b. The concentrator must operate for a minimum of 20 min-

utes before checking the oxygen concentration.

c. Connect the analyzer to the unit’s oxygen outlet port

(Figure

1) and wait until the display stabilizes.

d. Record the reading.

2. Check the audible alarm and indicator lights every two years. When the power switch is turned “On,” listen for the audible alarm and check to see if the front panel indicator lights are operating.

3. Change intake filter as follows:

a. Extended life intake bacteria filter (part # MC44D-605) -

Inspect once a year. Change as necessary, not to exceed 8760 hours.

b. Round felt pre-filter (part # 444-503) - change once a

month. –OR– Rectangular felt pre-filter (part # MC44D-

722) - change every 3 monthes,AND

c. Intake bacteria filter (part # 444-504) - change every six

months.

d. Open the filter door and replace filters as required.

4. Change the final bacteria filter (part #PV5LD-65

1) every

two years.

a. Unplug the unit, remove the cabinet, and loosen the bib. b. Remove the hose from each end of the filter (Figure 8)

and discard the filter.

c. Install the new final bacteria filter with the “IN” fitting

toward the flow meter.

d. Tighten the bib and replace the cabinet.

5. Check the system performance every two years of operation by measuring the accumulator pressure swing.Use the accumulator pressure test described in the chapter “Component Testing, Repair and Replacement.”

6. Change the compressor HEPA filter—every five years or 25,000 hours of operation (whichever comes first).

a. Unplug the unit and remove the rear cabinet. b. Loosen the hose clamp and remove the hose from the

outlet fitting end of the HEPA filter (Figure 4).

c. Using a wrench, unscrew the HEPA filter from the com-

pressor head outlet fitting.

CAUTION: Use a second wrench to prevent twisting of the brass angle fitting screwed into the outlet port of the compressor.

d. Discard the HEPA filter.

NOTE: Teflon

tape or LOX-8®paste should be applied to the compressor fitting omitting the first thread, prior to installation of the HEPA filter.

e. Install the new HEPA filter by using a wrench to attach the

filter to the compressor head outlet fitting.

CAUTION: Use a second wrench to prevent twisting of the brass angle fitting screwed into the outlet port of the compressor. NOTE:

Make sure the filter end marked “IN” is toward

the compressor.

f. Attach the hose to the outlet fitting end of the filter and

secure with a hose clamp.

7. Leak test the HEPA filter fittings.Apply a leak test solution such as Epi-SEAL

LEAK-SEEK®to fittings and connections with the unit running. If an air leak is present, the solution will bubble.

The Preventative Maintenance Schedule stated above reflects a normal, clean operating environment.The homecare provider is responsible for determining the condition of the concentrator operating environment and determining a preventative maintenance interval frequency.

NOTE:This PM Schedule reflects:

• 5000 hour usage equal to one year

• a normal, clean operating environment.

The homecare provider is responsible for:

• determining the condition of the concentrator operating environment.

• determining a preventative maintenance interval frequency (not to exceed the schedule stated above which takes into consideration the specific operating environment).

BETWEEN PATIENT MAINTENANCE

1. Discard oxygen tubing, cannula & humidifier bottle.

2. Discard intake bacteria filter and felt pre-filter (if using these filters instead of the extended life intake bacteria filter).

3. Wash or replace the cabinet air filter.

4. Wash the concentrator cabinet.

5. Check oxygen concentration. If the unit falls within specification, the extended life intake bacteria filter does not need to be replaced between patients.

PREVENTATIVE MAINTENANCE SUMMARY

Patient

Daily Clean the humidifier bottle (if used). Weekly Clean air filter on back of unit.

Clean exterior of cabinet.

Other Clean and replace cannula/mask and tubing as

instructed by manufacturer.

Homecare Provider

Change intake filter as necessary following requirements in step 3.

3 months Check oxygen concentration on non-OSD units.

Check the concentrator environment, and set a maintenance interval of less than 3 months if required.

2 years Check audible alarm and indicator lights.

Change final bacteria filter. Check system performance. Check oxygen concentration on OSD units.

5 years Change compressor HEPA filter

(change in 25,000 hours or earlier).

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TROUBLESHOOTING

SYSTEM OPERATION

The DeVilbiss Oxygen Concentrator uses a pressure swing adsorption system.The air is drawn into the unit through air filters and into a double-head compressor.

A pneumatic diagram of the system is shown in Figure

15.

The compressed air passes through a four-way valve (Figure 5), which is cycled at a pre-determined rate, and is directed into one of two sieve beds.The sieve beds contain molecular sieve material which is a synthetically-produced inorganic silicate. It is very porous and has the unique ability to selectively adsorb nitrogen from the air as it passes through the sieve bed.

As one bed is being pressurized, the other bed is quickly depressurized.This allows the nitrogen that was adsorbed during its pressurization cycle to be exhausted from the sieve material.

The nitrogen is released through exhaust ports located on the four-way valve assembly.The ports are connected to a single piece of black hose running from the valve to the exhaust muffler.

Also during each bed pressurization, a small amount of oxygen flows through an orifice (Figure 9) from the pressurized bed into the depressurizing bed.The orifice is clamped inside a long piece of blue tubing connecting the outlets of the two sieve beds.This helps purge the nitrogen from the depressurizing bed.

The beds will continue to be alternately pressurized and depressurized as the unit operates.

Oxygen leaving the sieve beds is directed through a check valve to the accumulator tank.A pressure regulator (Figure 9) on the tank controls the oxygen pressure as it leaves the accumulator and enters the flow meter.The flow meter allows the oxygen flow to be controlled and adjusted to the level prescribed by the patient’s physician. From the flow meter the oxygen passes through the final bacteria filter (Figure 8), a check valve, and finally the oxygen outlet port to the patient.

The DeVilbiss Oxygen Concentrator operates on a timed cycle.The cycling is controlled by the PC board.The PC board will send approximately 7.5 VDC (

12-15 VDC on non-OSD

and early-OSD models) to the four-way valve causing one of the two solenoids to energize.

The PC board also activates the electronic alarm system.A high pressure condition will be indicated with a “popping” type sound produced by release of pressure from a pressure relief valve on the compressor head.

NORMAL OPERATING SEQUENCE

When the concentrator is turned “On,” the following normal cycling sequence should be observed by attaching pressure gauges to the sieve bed test points.

1. The four-way valve is quickly cycled back and forth several times to relieve residual bed pressure preventing a static condition in the compressor.This rapid cycling only happens on start-up.

NOTE:The rapid cycling will be heard as several thumping noises at start-up.

2. An approximately 7.5 VDC (

12-15 VDC on non-OSD and

early-OSD models) signal from the PC board is supplied to the right solenoid for approximately 9-

10 seconds.The left

sieve bed pressurizes while the right sieve bed is being depressurized to approximately 2 PSI (

14 kPa).

3. The signal is then removed from the right solenoid.No voltage is applied to either solenoid for approximately

1 second. Both

sieve beds are being equalized in pressure during this phase.

4. An approximately 7.5 VDC (

12-15 VDC on non-OSD and

early-OSD models) signal from the PC board is applied to the left solenoid for approximately 9-

10 seconds.The right sieve

bed pressurizes while the left sieve bed is depressurized to approximately 2 PSI (

14 kPa).

5. The signal is then removed from the left solenoid.No voltage is applied to either solenoid for approximately

1 second. Both

sieve beds are being equalized in pressure during this phase.

6. The cycle then repeats with step 2. NOTE:High-end sieve bed pressure should not exceed 1/2

PSI (4 kPa) above high-end accumulator pressures. Refer to “Specifications” for normal pressures obtained during the cycle.

Page 11

TROUBLESHOOTING

SIMPLIFIED TROUBLESHOOTING

The key to simple troubleshooting is to recognize which type of problem exists and select the most effective approach to solving the problem.The different types of problems and the approaches for solutions are as follows:

Type I—The unit runs but a low pressure, low output flow or high pressure condition exists.

NOTE:

Low pressure and low flow are indicated by both a visible and audible alarm. High pressure is indicated by a “pop- ping” sound caused by the pressure relief valve.

NOTE:Non-OSD and early OSD models were equipped with the low pressure alarm. Later OSD models are equipped with the low flow alarm.

1. Connect test gauges.

2. Refer to the “Normal Operating Sequence” to make sure the unit is cycling properly.

3. If bed pressure is rising slowly, check for occluded filters and severe leaks. If filters are clean and there are no leaks, then the compressor is defective.

4. If the pressure relief valve is releasing pressure, observe whether the unit is cycling or not.

5. If the unit is not cycling, this indicates that the four-way valve is not shifting.

6. If the unit is cycling in conjunction with very high bed pressures, this indicates defective sieve beds.

Type II—The compressor will not start when the unit is turned on.

1. Verify that the cooling fan is running; if it is not, determine where you are losing power.

2. Check for compressor voltage at the compressor connector.

3. If voltage is present, then the capacitor or compressor is defective.

4. If voltage is not present, the wire harness is defective.

WARNING: Mechanical Hazard. Keep fingers,loose clothing, etc. away when working on compressor.

Type III—The concentrator runs and continues to cycle but has low oxygen concentrations.

1. Connect test gauges and check for higher or lower than normal bed pressures.

A.High pressures indicate defective sieve beds. B. Low pressures indicate occluded filters, leaks, or defec-

tive compressor.

2. Check for oxygen leaks at:

• sieve beds • flow meter

• accumulator tank • final bacteria filter

• pressure regulator • final check valve

• OSD • outlet port

NOTE: Check for leaks using a certified leak detection solution.Apply leak test solution to all fittings and hose connections with unit running. If an air leak is present, the solution will bubble.All leaks should be repaired before putting the unit back in service.

3. Test accumulator tank pressure. If pressure is lower than normal, then sieve bed check valves are defective.

NOTE:For normal system pressures refer to “Specifications”.

Page 12

TROUBLESHOOTING

TROUBLESHOOTING CHART A

Visible Alarm Audible Alarm Compressor Power Light

OFF OFF ON ON

Other Symptoms Possible Cause Possible Remedy

Pulsating air noise Intake filter not in place or defective Check filter and replace if necessary

Compressor intake hose disconnected Reconnect hose

Excessive noise Loose or defective motor mounts Replace motor mounts

Defective compressor Replace compressor Defective cooling fan Replace cooling fan

Fluctuating oxygen flow Occluded humidifier Clean or replace humidifier

Use of improper humidifier Use only a bubble-type humidifier Occluded filters Clean or replace filters Occluded or defective cannula and tubing Detach cannula from oxygen delivery tubing. If

proper flow is not attained, check tubing for kinks or other obstructions. Clean or straighten as required or replace tubing if necessary.

Use of excess oxygen tubing The unit is designed to deliver 5 lpm with a

cannula on 50 feet (

15 meters) of approximately

5/32” (4 mm) inside diameter tubing. Smaller diameter tubing or the addition of any other flow restriction may prevent obtaining the

desired flow rate. Defective flow meter Replace flow meter Leak in system Check for leaks in all hoses and fittings Defective compressor Replace compressor Defective compressor reed valve Replace compressor reed valve Defective check valve Replace check valve Pressure regulator not adjusted Adjust or replace pressure regulator properly or defective

Little or no oxygen flow Flow meter not adjusted properly Adjust flow meter

Hose disconnected to flow meter Reconnect hose Oxygen delivery tubing is kinked or blocked Straighten tubing or remove obstruction Occluded humidifier Clean or replace humidifier

Low oxygen concentration Leak in system Check for leaks in all hoses and fittings

Defective sieve bed check valve Replace check valve Defective compressor reed valve Replace compressor reed valve Defective compressor Replace compressor Four-way valve not fully shifted Clean or replace four-way valve Occluded filters Clean or replace filters Contaminated sieve beds Replace sieve beds

Audible alarm does not Unit has not been used for an extended Allow unit to run for 20 minutes and retry sound during power failure period of time. NOTE:If the concentrator

has been unused for an extended period, the unit must run several minutes before the power fail alarm will activate. Defective PC board Replace PC board Defective power switch Replace power switch Defective wire harness Replace wire harness

Audible alarm does not sound when Defective PC board Replace PC board unit is turned “On”

Pressure relief valve activated - Defective PC board Replace PC board “popping” sound Defective valve Replace valve

Service Required light does not Defective PC board Replace PC board illuminate when unit is turned “On.” Defective light Replace light

PC board connectors not properly latched Be sure tabs are pushed completely into place

Page 13

TROUBLESHOOTING CHART D

Visible Alarm Audible Alarm Compressor Power Light

ON ON OFF ON

Other Symptoms Possible Cause Possible Remedy

Fan operating Wiring harness disconnected/defective Reconnect/replace wiring harness

Loose compressor wire Tighten or attach wire Defective capacitor Replace capacitor Defective compressor Replace compressor

Unit warm to the touch and cannot Compressor overheated due to: be restarted for several minutes Occluded filters Clean or replace filters

Restricted input or output air passage Remove obstruction Low or high line voltage Check line voltage; use alternate circuit

independent of other appliances Defective cooling fan Replace cooling fan Defective compressor Replace compressor

TROUBLESHOOTING CHART E

Visible Alarm Audible Alarm Compressor Power Light

ON ON ON ON Other Symptoms Possible Cause Possible Remedy

Fluctuating or no flow *System pressure below 9 psi (62.1 kPa) due to:

Leak in system Check for leaks in all hoses and fittings Defective compressor Replace compressor

*Non-OSD and early OSD models only

TROUBLESHOOTING

TROUBLESHOOTING CHART B

Visible Alarm Audible Alarm Compressor Power Light

Blinking Pulsing OFF OFF

Other Symptoms Possible Cause Possible Remedy

Fan off Line cord not properly installed or defective Insert plug in receptacle or replace line cord

No power at receptacle Check building circuit breaker or fuse, or have

house wiring checked by qualified electrician

Circuit may be fully loaded with other

appliances and another receptacle

may be required Oxygen concentrator circuit breaker activated Press the circuit breaker reset button

If unit circuit breaker opens again, check

internal wiring Line cord quick-connect terminal inside Reconnect quick-connect terminal unit is disconnected Defective power switch Replace power switch Defective circuit breaker Replace circuit breaker

TROUBLESHOOTING CHART C

Visible Alarm Audible Alarm Compressor Power Light

Blinking Pulsing ON ON/OFF

Other Symptoms Possible Cause Possible Remedy

Fan and compressor operating. Blown fuse on PC board Replace fuse Pressure relief valve activated – Defective PC board Replace PC board “popping” sound

Page 14

TROUBLESHOOTING

TROUBLESHOOTING CHART F (OSD UNITS ONLY)

Compressor Power Light

ON ON

Other Symptoms Possible Cause Possible Remedy

No OSD lights are illuminated. Defective OSD or malfunctioning concentrator. Check concentration with an oxygen analyzer.

If the concentration is within specification, replace

the OSD (early OSD models only). Replace the

PC board on later OSD models. If the concen-

tration is low,refer to low oxygen concentration

symptom in Troubleshooting Chart A.

No OSD lights are illuminated, Oxygen level is low* Check concentration with an oxygen analyzer. but red “Service Required” light is If the concentration is within specification, replace illuminated accompanied by a the PC board. If the concentration is low, beeping audible alarm. refer to low oxygen concentration (later OSD models only) symptom in Troubleshooting Chart A.

Both OSD lights are illuminated. Connector off between OSD and PC board. Reconnect connector. (early OSD models only) Defective OSD Replace OSD. Yellow Low Oxygen light Oxygen level is low* Check concentration with an oxygen analyzer.

is illuminated. If the concentration is within specification, replace

the OSD (early OSD models only). Replace the

PC board on later OSD models. If the concen-

tration is low,refer to low oxygen concentration

symptom in Troubleshooting Chart A.

Yellow Low Oxygen light Oxygen level is low* Check concentration with an oxygen analyzer. is illuminated and an intermittent If the concentration is within specification, replace audible alarm sounds every the OSD (early OSD models only). Replace the five seconds. PC board on later OSD models. If the concen-

tration is low,refer to low oxygen concentration

symptom in Troubleshooting Chart A.

*Refer to “Specifications” page for oxygen purity levels.

Page 15

PROPER REPAIR PROCEDURES

The DeVilbiss Oxygen Concentrator is designed for ease of service.To aid service personnel, a Service Kit (part #444-50

is available which contains the necessary gauges, tools, and testing instruments to properly service the oxygen concentrator. On parts that are sold separately, the part number is indicated in parenthesis.

The following parts are included in the Service Kit:

1 Slotted bit 1 #1 Phillips bit 1 #2 Phillips kit 1 7/16” Socket l/4” Drive 1 Crescent wrench 1 8” Duckbill pliers 1 T-10 Bit 1

5/32” Allen bit

1 5/64” Allen bit 1 9/64” Allen bit 1 7/64” Allen bit

2 0-30 PSI 0-30 in. Hg gauge (part #PVO2D-60

1 Tool box

2 Test Fittings (part #303DZ-637)

1 Torx screwdriver w/bits (part #MC44D-712) 1 AC/DC test light (part #PVO2D-603) 11/4” Ratchet wrench 1 3mm Hexbit 1 T- 15 Torx “L” wrench 110mm Socket l/4” Drive 11/4” Drive extension 1 Plastic storage case 1 Plastic error indicator tool (part #303DZ-635)

In addition to the Service Kit, an oxygen analyzer (part #O2ANA) is needed to periodically check oxygen concentration levels.A voltmeter will be needed for more accurate voltage testing.

NOTE: Be sure to read all of the steps involved before beginning any of the procedures in this manual.

NOTE:After repairing or replacing a component run the unit for 20 minutes, check the oxygen concentration and test for leaks.

Test for leaks using a certified leak detection solution such as Epi-SEAL

LEAK-SEEK®.Apply leak test solution to all fittings and hose connections with the unit running. If an air leak is present, the solution will bubble.All leaks should be repaired before putting the concentrator back in service.

WARNING:When servicing the DeVilbiss Oxygen Concentrator, be absolutely certain that the correct tools are used and that the parts are free of oil and grease or any material not compatible with oxygen. Teflon

tape is recommended and must be applied to the male threads omitting the first thread to eliminate the possibility of tape particles entering the oxygen system. LOX-8™ sealant may be used in place of Teflon tape.

WARNING: Electric shock hazard. Do not remove cabinet.The cabinet should only be removed by a qualified Sunrise Medical homecare provider.

WARNING: Disconnect the power cord from the wall outlet before attempting repairs on the unit. Extra care should be taken if it is necessary to operate the unit with the cabinet removed.

CABINET REMOVAL

To remove the front and back cabinets (Figures 2 and 3):

1. Ensure the unit is unplugged from the wall outlet.

2. Using a screwdriver, remove the six screws that hold the back cabinet to the internal structure and the bib.

NOTE:All six screws are the same size.

3. Remove the back cabinet by sliding it toward the rear until clear.

4. Remove the front cabinet by pushing the top shoulders toward the back of the unit, then outward away from behind the bib.Tilt the top of the front cabinet forward until it can be pulled out of the base of the unit.

The majority of all the servicing and repairs can be done without removing the front bib.However, to gain access to the components behind the bib, it may be loosened or removed.

To loosen the bib (Figure 4):

1. Remove the two screws (located directly above the hour meter) that hold the bib to the unit’s internal structure.This will allow access to the components behind the bib.

To remove the bib completely (Figure 8):

1. Remove the two screws as above.

2. Disconnect the ribbon connector from the PC board.

3. Disconnect the lines from the power switch and circuit breaker. Mark these wires accordingly.

4. Tilt the top of the bib forward to release it from the slot in the body of the concentrator.

5. Remove the hose connected to the bottom of the flow meter.

To reassemble bib:

1. Reconnect the wires and hose.

2. Insert the bib tab into the slot above the four-way valve, and push until it snaps into place.

3. Secure bib with two screws.

Teflon® is a registered trademark of DuPont. LOX-8™ is a trademark of Fluoramics, Inc. Epi-Seal® Leak-Seek® is a registered trademark of Bonded Products, Inc.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 16

ACCUMULATOR PRESSURE TEST

To check accumulator pressures:

1. Make sure the unit is “Off.”

2. Remove front and back cabinets.

3. Use the pressure-vacuum gauge (part #PVO2D-60

1) and pressure

test assembly (part #303DZ-637) included in the Service Kit.

4. On non-OSD and early-OSD models remove the

1/16" (1.6

mm) diameter tubing from the accumulator tank fitting and attach the

1/16" (1.6 mm) diameter tubing on the other end

of the pressure test assembly to the accumulator tank fitting just vacated above.This tubing goes from the accumulator to the pressure transducer on the PC board. On later OSD models remove the

1/16" (1.6 mm) diameter

tubing cap (part #370-0035-100) from the acumulator tank fitting and attach the pressure test assembly to the tank fitting just vacated. Use the tubing cap to plug one side of the pressure test assembly.

5. Install the gauge on the pressure test assembly.

6. Turn the unit “On” with the flow rate set to maximum recommended flow.

During each timed cycle, the average pressure in the oxygen accumulator will rise and fall.

NOTE: Normal pressures observed depend on altitude and flow rate. Increases in altitude and flow rate will slightly decrease accumulator pressures.Decreases in the two variables will slightly increase accumulator pressures. Acceptable accumulator pressure swing ranges at various altitudes at the maximum recommended flow are identified in the “Specifications.”

NOTE:A defective check valve may cause a rapid drop in accumulator pressure below the minimum value.

NOTE:A defective compressor will be indicated by slowly rising pressure. Pressure may only reach a certain level and then stop.

Low oxygen concentration levels and accumulator pressures higher than normal may indicate defective sieve beds. Severely contaminated beds may also cause the pressure relief valve on the compressor to open.

NOTE:A malfunctioning four-way will also cause high accumulator tank pressure and activation of the pressure relief valve. In this case it should be determined whether the problem is with the sieve beds, four-way,or both.

CAPACITOR

The capacitor enables the compressor to start and run by supplying voltage to the windings of the compressor motor.A defective capacitor will result in the compressor running slower or not starting.

WARNING: Electric Shock Hazard.When replacing the capacitor, do not touch the terminals or allow metal objects to come in contact with the terminals on the capacitor.The capacitor may hold a charge for several days after the unit is turned off.

If a defective capacitor is suspected, a new one must be installed.The capacitor is strapped into a well molded into the bottom of the unit (Figure

10) next to the cooling fan.

To replace the capacitor:

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets.

3. Remove the compressor.

4. Disconnect the two wires from the terminals on the capacitor.

5. Cut the nylon cable tie holding the capacitor in place and remove the capacitor.

6. Reconnect the wires to the new capacitor.

7. Install the new capacitor and secure with a new cable tie.

8. Replace the compressor.

9. Replace the front and back cabinets and secure with the six screws.

COMPRESSOR

The DeVilbiss Oxygen Concentrator uses a double-head, oilfree compressor.The compressor is secured to the compressor plate with four rubber motor mounts.

A compressor that is worn or defective may:

• cause pressure to rise slowly.

• cause excessive noise and/or vibration.

• cause lower oxygen concentrations.

A worn or defective compressor can be caused by a defective internal component such as:

• reed valve

• o-ring

• gasket

• Teflon

ring These components are included in the Compressor Service Kit (part #505DZ-643).

NOTE:A built-in thermal cutoff switch will shut the compressor off if it becomes overheated.This protects the compressor from damage caused by heat build-up. (Some models have an auxiliary thermostat mounted within the compressor compartment.)

NOTE:A pressure relief (PR) valve is located on the pressure head to prevent high pressure build up in the system should a component malfunction occur.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 17

To test the compressor operating voltage (Figure 4):

The compressor requires line voltage to operate. If the compressor does not start when the unit is turned on, the voltage input must be tested:

1. This voltage can be checked at the compressor connector

using a voltmeter or test light connected to the brown and blue wires.The voltmeter is the best way to test.

2. If no voltage is detected, disconnect power and check for loose or broken wires between the compressor connector and switch or wire harness.

3. If there is voltage at the compressor connector, then either the capacitor or the compressor itself is defective.

To test the compressor for proper output:

NOTE: If the compressor is not providing a high enough

output the patient alert system may be activated.

1. Remove the front and back cabinets.

2. Connect a pressure-vacuum gauge to the accumulator tank test point. See the section Accumulator Pressure Test in the chapter “Component Testing, Repair, and Replacement” for details on attaching the gauge.A defective compressor will be indicated by slowly rising pressure. Pressure may only reach a certain level and then stop.

If these conditions are observed then:

• The unit filter(s) may be occluded—check the air filter, intake filter, and the compressor filter for occlusions.

• There may be a severe leak in the system—check for air leaks using a leak detection solution.

• The compressor reed valves,Teflon ring, or the compressor itself may be defective. (refer to Figure

12).

If the filters are not occluded and no leaks are found, the compressor must then be removed and repaired or replaced.

To remove the compressor:

1. Make sure the unit is unplugged from the wall outlet.

2. Disconnect the compressor wires by disconnecting the white electrical connector (Figure 4).

3. Remove the hose clamp and hose from the outlet fitting on the compressor filter (Figure 4).

4. Remove the two screws from the back of the compressor mounting plate(s) (Figure 4).

5. Remove the two

10 mm hex nuts that secure the mounting

plate to the front of the compressor housing (Figure 6).These nuts are located on each side of the four-way valve.

6. Lift compressor and mounting plate up and out of the compressor housing area.

7. Remove the tubing from the compressor intake port fitting.

CAUTION: If the unit has been running recently, the compressor may be hot.

To inspect and/or replace internal components (Figure 14):

1. Remove the eight screws that hold the compressor heads in

place.When removing the heads, be sure to keep each head and its components with the correct compressor side.

2. Check for proper placement of or damage to the gaskets on the bottom of the compressor heads. Replace if damaged.

3. Remove reed valve plates.A reed valve is located on each side of the valve plate.

4. The compressor reed valves should be flush with the valve plate. If the valve is broken or not flush with the valve plate, or foreign matter is detected inside the head, clean or replace the compressor reed valves.

To replace the compressor reed valves (Figure 14):

a. Remove the screw holding the compressor reed valves in

position on the valve plate and discard the used reed valves.

b. Position the new reed valves so that they are centered and

completely cover the holes in the valve plate.

c. Place the metal retainer on the reed valves and secure

with the reed valve screw.

5. Check for proper placement of or damage to the rubber oring on the bottom of the valve plate. Replace if damaged.

6. Remove piston sleeves by pulling upward and inspect Teflon ring on pistons. Replace if badly worn or damaged.

To replace Teflon ring (Figure 14):

a. Remove screw from top of piston. b. Remove the retainer plate. c. Discard defective Teflon ring. e. Place new Teflon ring into position. f. Replace retainer plate. g. Secure with screws.

7. Reposition sleeve on piston.

8. Place valve plates on the compressor so that heads of reed valve screws are aligned with the indentation in top of pistons.

9. Install the compressor heads so that the holes in the heads are aligned with the holes in the compressor housing.

10. Secure compressor heads with the screws.

To replace the compressor:

NOTE: For mounting plate and motor mount removal, refer

to sections below.Also refer to steps used in removing the compressor.

1. Inspect the motor mounts. Replace if damaged. Secure the mounting plate(s) to the bottom of the new compressor using the four compressor mounting hex nuts.

2. Reconnect tubing to the compressor intake fitting.

3. Position compressor on the base of the unit so that the studs on the mounting plates are aligned with notches on the front of the unit base.

4. Secure mounting plate with two screws on the back and install nuts on the front side of the plate.

5. Reconnect hose to the fitting at compressor filter outlet.

6. Reconnect the compressor electrical connector.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 18

To remove compressor from the mounting plate:

1. Turn compressor upside down so that it is resting on the heads.

2. Remove the four compressor mounting hex nuts and mounting plate.

NOTE:If the compressor must be replaced, the compressor filter must be removed from the defective compressor. Depending on the hours of operation, a new compressor filter should be installed on the compressor if it is replaced or rebuilt.

To remove motor mounts:

1. Unscrew studded motor mounts from compressor feet by hand.

COOLING FAN

The cooling fan provides a constant air flow to cool the compressor.The cooling fan is located in the bottom of the unit below the compressor (Figure

10).

A defective cooling fan may cause the compressor’s internal thermo-protective device to activate and shut the compressor off. Should this condition occur, the compressor will require several minutes for the thermo-protective device to reset.

If the cooling fan is defective, it must be replaced:

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets.

3. Remove the compressor.

4. Disconnect the cooling fan terminals.

5. Note the position of the fan before removing the four retaining screws that secure the fan to the base of the unit.

6. Remove the defective fan and secure the replacement fan in position with the four retaining screws.

NOTE:When installing the fan, be sure the air flow directional arrow on the side of the fan is directed away from the compressor.

7. Reconnect the electrical connector.

8. Reinstall the compressor.

FINAL CHECK VALVE

This check valve is located between the final bacteria filter and the oxygen outlet fitting.This check valve allows oxygen to flow only out of the unit.When the unit is turned off and oxygen flow stops, the check valve closes to prevent water from being drawn into the unit.

A defective final check valve may allow water to be drawn in from the humidifier bottle when the unit is turned off.This may occlude the final bacteria filter and/or the flow meter causing a restriction of flow and making it difficult to adjust the flow rate.

To replace the final check valve (Figure 8):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and loosen or remove the bib.

3. Remove the hose from the outlet side of the final bacteria filter.

4. Remove the two screws from the back of the oxygen outlet fitting assembly and remove the assembly.

5. Remove the hose from each end of the final check valve.

6. Attach the hoses to a new check valve. Make sure that the flat side of the check valve is directed toward the oxygen outlet fitting.

7. Replace the outlet fitting assembly and connect the hose to the filter.

8. Replace the bib and front and back cabinets.

FLOW METER

The pressure-compensated flow meter has an accuracy level of ±5% at full scale (exception: +0%,-5% at 5 lpm).The flow meter on the DeVilbiss Oxygen Concentrator is designed for use at 8.5 psi (58.6 kPa) at flow rates up to 5 lpm.

To check for leaks in the flow meter tubing:

1. Check for leaks using a certified leak detection solution such as Epi-SEAL

LEAK-SEEK®.

2. Apply leak test solution to all fittings and hose connections with the unit running.

3. If an air leak is present, the solution will bubble.All leaks should be repaired before putting the concentrator back in service.

WARNING: Electric Shock Hazard. Use caution when leak testing near electrical connections.

To replace the flow meter (Figure 8):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets.

3. From behind the bib remove the 2 hoses from the flow meter.

4. While squeezing tabs on flow meter brackets, push the flow meter through the bib.

5. Install new flow meter in bib and reconnect hoses.

FOUR-WAY VALVE

The timed four-way valve alternately distributes pressure supplied by the compressor to the two molecular sieve beds. While one bed is being pressurized the other bed is being exhausted through the four-way valve. Exhaust gases passing through the four-way are exhausted to a black hose connected to an exhaust muffler.

The dual solenoid four-way valve operates electrically to shift a spool inside the valve.The valve receives approximately 7.5 VDC (

12-15 VDC on non-OSD and early-OSD models) from

the PC board causing one of these solenoids to activate.When the left solenoid is activated, the right sieve bed will pressurize.After approx. 9-

10 seconds the approximately 7.5 VDC

(

12-15 VDC on non-OSD and early-OSD models) is removed

causing the left solenoid to deactivate. No voltage is applied to either solenoid for approximately

1 second.The right solenoid

is then activated causing the left bed to pressurize.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 19

If the four-way does not shift, the same bed will continue to

pressurize, and the pressure relief valve will relieve the pressure.

There are several reasons for the four-way to malfunction.The

cause of failure must be determined before corrective action can be taken.

Some reasons for four-way failure are:

Continuous or no voltage to four-way. Foreign matter inside valve preventing spool from shifting.

To test the four-way valve (Figure 6):

1. Remove the front cabinet.

2. Connect the pressure-vacuum gauges furnished in the service kit to the test points at the top of the sieve beds in order to observe unit cycling and bed pressures. Refer to the section on “Normal Operating Sequence.”

3. If it is determined that the four-way did not shift, continue testing with step 4.

4. Testing for proper four-way voltage is done at the four-way connector on the PC board. Place the test leads of a voltmeter in the two outside pins of the connector to check voltage to one of the solenoids. Place the voltmeter leads on the two inside pins to check voltage to the other solenoid. Approximately 7.5 VDC (

12-15 VDC on non-OSD and early-

OSD models) should be present for 9-

10 seconds alternately

on each solenoid (the green 4-way light on the PC board will be illuminated). Energizing the right solenoid will cause the left bed to pressurize, while energizing the left solenoid causes the right bed to pressurize.

5. If this reading is not obtained, check for loose or broken wires from the four-way valve to the PC board. If no loose or broken wires are found, replace the PC board.

6. If approximately 7.5 VDC (

12-15 VDC on non-OSD and early-

OSD models) is measured at the connecting leads to the valve, then the valve is either defective or foreign matter has gotten inside the valve causing it to malfunction. In either case the four-way valve must be removed to clean or replace it.

To remove the four-way valve:(Figures 6 & 7)

1. Unplug the unit from the wall outlet.

2. Remove the front cabinet and loosen the bib.

3. Disconnect the four-way connector from the PC board.

4. Loosen clamps and remove sieve bed hoses from bottom of four-way.

5. Remove the three screws that secure valve to the front of unit.

6. Loosen clamp and remove the compressor hose and exhaust hose(s) from four-way.Valve may now be cleaned or replaced.

To replace the four-way valve:

1. Reverse the above removal procedure.

2. If the tubing needs to be replaced make sure the new tubing is identical to the old tubing and is exactly the same length in order to ensure proper silencing.

To clean the four-way valve: (Figure 13)

1. Remove the valve as described above.

2. Using a flat screwdriver loosen the two slotted screws on both ends of the four-way.The solenoids may now be separated from the valve body.

3. Remove the spring retainer, spring, and spacer from each end of the valve body. Note the position of these parts.

4. Carefully remove the spool from the valve body. NOTE:The spool and sleeve are a matched set.Take care not

to mix different valve parts.

5. Using a non-metallic rod or dowel with a diameter no greater than the sleeve, slowly push the sleeve out either end of the valve body.

NOTE:Pushing too fast will cause o-rings to roll and jam.

6. Inspect the o-rings on sleeve. If they are badly worn or defective, they should be replaced using the valve rebuild kit (part# 5

15DZ-707).

7. The spool and sleeve can be cleaned using a spray-on evaporative electro-contact cleaner; for example, ENVI•RO•TECH™ 1677 or cleaned with a detergent powder; for example, ALCONOX

. If using these cleaners, follow manufacturer's instructions carefully. DO NOT USE ANY TYPE OF CLEANSER THAT IS ABRASIVE OR LEAVES A RESIDUE.

8. Rinse the spool and sleeve thoroughly and dry with a soft, clean, lint-free cloth.

9. Ensure that the air passages (ports) in the valve body are free of any foreign matter.A clean, lint-free cloth or a compressed air hose can be used to clean these.

10. Carefully push sleeve into valve body (turning it slightly) so you do not cut or nick the o-rings. Be sure sleeve is positioned properly in valve body.

11.Reassemble remaining parts of valve in reverse order.

12. Replace valve as described above.

HOUR METER

To replace the hour meter (Figure 9):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and loosen the bib.

3. Disconnect the hour meter connector from the PC board.

4. Remove the two screws securing the hour meter and remove the meter.

5. Install a new hour meter and secure with the two screws.

6. Connect the hour meter to the PC board.

ALCONOX® is a registered trademark of Alconox, Inc. ENVI•RO•TECH™ is a trademark of Tech Spray, Inc.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 20

MOLECULAR SIEVE BEDS

The two molecular sieve beds alternately remove the nitrogen

from the air passing through them and provide the patient with a constant supply of oxygen.

The efficiency of the molecular sieve material will be impaired

if it becomes contaminated by moisture. Contamination causes the molecular sieve material to lose its nitrogen adsorbing properties resulting in a decrease in oxygen concentration. The unit should run for a minimum of 20 minutes before turning "Off" to prevent problems associated with moisture contamination in the system.

To test the sieve beds:

1. Remove the 1/16" plugged piece of tubing from the top of

each sieve bed.

2. Connect the pressure-vacuum gauges to the sieve bed test points (Figure 9) in order to observe unit cycling and bed pressures. Refer to the section on “Normal Operating Sequence.”

3. If it is determined that the four-way did not shift, refer to the section on four-way testing. However, if the unit is cycling properly allow unit to run while observing the sieve bed pressures.

4. After 20 minutes of operation, check the oxygen concentration levels. Low oxygen concentration and high pressures indicate contaminated sieve beds.

NOTE:If the molecular sieve material is found to be no longer

effective, first locate the source of the malfunction or cause (such as leaks) for contamination and take corrective action.

To replace the molecular sieve beds (Figure 7):

1. Make sure any contamination problem has been corrected before replacing.

2. Make sure the unit is unplugged from the wall outlet.

3. Cut the plastic cable ties that secure the sieve beds to the internal structure of the unit.

4. Remove the tubing from the fittings at the top of each sieve bed.

5. Remove the hose clamps and black hose from the bottom of the sieve beds.

6. Install new sieve beds in reverse order using new plastic cable ties. Position the new beds so that the bed serial number label is at the top of the unit.

NOTE: Make sure that the sealing caps remain on the new

sieve beds until just prior to connecting hoses and tubing.

7. Leak test all connections with a certified leak detection solution.

OSD

(early OSD models)

The OSD is located beside the PC board.

To replace the OSD:

1. Ensure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and loosen the bib.

3. Disconnect the two terminal connectors for the OSD at the end of the wire harness by depressing the latches and pulling them straight out.

NOTE:To facilitate easier access to the OSD tubing, remove the 2 screws that hold the main PC board in place.

4. Remove the two screws from the bracket located on the side facing the inner structure.

5. Remove the two hose clamps and two hoses attached to the OSD.

6. Replace the two hoses and tighten the hose clamps to the new OSD.

7. Mount the OSD to the bracket using the two screws.

8. Reconnect the two terminal connectors.

9. Reinstall main PC board screws if they were removed.

NOTE:The OSD on later models is integrated into the printed circuit board. See “Printed Circuit Board” section for removal and replacement.

POWER CORD

To replace the power cord - 115 volt units only

(Figure 10):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the back cabinet.

3. Disconnect the power cord connector. NOTE: Loosening or removing the compressor mounting

plate may make it easier to service the power cord.

4. Note wire colors and socket locations before removing wires.

5. Using a pair of duckbill pliers, squeeze the power cord strain relief and pull it out of the base of the unit.

6. Insert a new power cord through the hole in the base of the unit and secure with strain relief.

7. Insert sockets into connector housing and then reconnect the power cord connector.

8. Replace back cabinet and secure with the six screws.

POWER SWITCH

To replace the power switch (Figure 8):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and loosen the bib.

3. Note the position of the wires and switch before removing the wires from the switch terminals.

4. While squeezing the locking tabs on the sides of the switch, push the switch out of the front of the bib.

5. Install the new switch in the correct orientation making sure that it locks into position.

6. Reconnect the wires to the switch terminals.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 21

PRESSURE REGULATOR

The pressure regulator stabilizes the flow of oxygen to the patient and establishes back pressure on the system. It is preset at 8.5 psi (58.6 kPa) and should not have to be adjusted in the field.

To test the pressure regulator:

1. Turn the unit “On.”

2. Set the flow meter at 2 lpm.

3. Use a pressure-vacuum gauge (part #PVO2D-60

1) and a fitting

suitable to fit on the oxygen outlet or on a short piece of tubing connected to the outlet.

4. If the pressure-vacuum gauge reads anything other than 8.5 ± .85 psi (58.6 ± 5.9 kPa) with gauge outlet blocked, adjustment to the pressure regulator may be required. If so, call Sunrise Service Department at

-800-333-4000 (8114-443-48811).

NOTE:

Make sure no leaks exist before adjusting the

pressure regulator. A malfunction in the pressure regulator will cause either a loss

or fluctuation in the oxygen flow which will be seen on the flow meter or a decrease in oxygen concentration.

To replace the pressure regulator (Figure 9):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets.

3. Remove the tubing clamp and tubing from the pressure regulator.

4. Unscrew the regulator from the accumulator tank.

5. Install a new regulator on the accumulator tank and attach the tubing and tubing clamp.

6. Replace the front and back cabinets.

PRINTED CIRCUIT BOARD

The printed circuit (PC) board is responsible for monitoring and controlling the DeVilbiss Oxygen Concentrator.

On non-OSD and early-OSD models, a pressure transducer on the PC board continuously senses the oxygen pressure in the accumulator tank.

The PC board has preset alarms for low pressure or low output flow and power failure. Should any of the alarm values be exceeded, the patient alert system will activate.

NOTE: Non OSD and early OSD models were equipped with the low pressure alarm. Later OSD models are equipped with the low flow alarm.

NOTE: If the concentrator has been unused for an extended period, the unit must run 20 minutes before the power fail alarm will be enabled.

To remove and replace the PC board

(without integral OSD) (Figure 7A):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and the bib.

3. Disconnect all wires, terminals, and connectors.

4. Remove the

1/16" (1.6 mm) tubing attached to the transducer.

5. Remove the two screws that secure the board to the unit and remove the PC board.

6. Install the new PC board and secure it using the two screws.

7. Reconnect all electrical wires, terminals, connectors and the tubing to the transducer

8. Replace the bib and front and back cabinets.

To remove and replace the PC board

(with integral OSD) (Figure 7B):

1. Make sure the unit is unplugged from the wall outlet.

2. Remove the front and back cabinets and the bib.

3. Disconnect all wires , terminals and connectors.

4. Remove the

1/8" (3.2mm) tubing attached to the sensor.

5. Remove the two screws that secure the board to the unit and remove the PC board.

6. Install the new PC board and secure it using the two screws.

7. Reconnect all electrical wires, terminals, connectors and the tubing to the sensor.

8. Replace the bib and front and back cabinets.

SIEVE BED CHECK VALVES

A check valve (Figure 9) located between the outlet of each sieve bed and the accumulator tank allows oxygen to pass through the sieve beds to the accumulator tank when the bed pressure is greater than the accumulator tank pressure.These valves also prevent reverse flow of oxygen from the accumulator to the sieve beds.

Run the accumulator pressure test described in the chapter Component Testing, Repair, and Replacement. It covers details of attaching the gauge and a table of acceptable pressure swing ranges at various altitudes.

A defective check valve will result in a decrease in oxygen concentration and lower accumulator pressures.

To replace a defective check valve, remove the tubing on either side of it and install a new valve making sure the outlet end is toward the accumulator tank.

COMPONENT TESTING, REPAIR, AND REPLACEMENT

Page 22

FIGURES, DIAGRAMS, AND VIEWS

Exterior Views

The following figures show the exterior of the DeVilbiss 4 & 5-Liter Series Concentrators. Figure

1 Front

Figure 2 Right side Figure 3 Rear

Interior Views

The following figures show the interior of the DeVilbiss 4 & 5-Liter Series Concentrators. Figure 4A Rear (early OSD models) Figure 4B Rear (later OSD models) Figure 5A Front (early OSD models) Figure 5B Front (later OSD models) Figure 6A Lower front close up (early valve version) Figure 6B Lower front close up (later valve version) Figure 7A Upper front close up (early OSD models) Figure 7B Upper front close up (later OSD models) Figure 8 Behind bib Figure 9A Top (early OSD models) Figure 9B Top (later OSD models) Figure

10 Lower rear close up

Other Figures

Figure 11 Compressor removed from base Figure

12 Compressor with head removed

Figure

13 Four-way valve

Figure

14 Compressor — exploded diagram

Figure

15 Pneumatic Diagram

Figure

16A Wiring Diagram (early OSD models)

Figure 16B Wiring Diagram (later OSD models)

NOTE:There are two 515 OSD concentrator models referred to throughout this Service Manual:

• Early - OSD models (Concentrator serial number H

19999 and lower)

• Later - OSD models (Concentrator serial number H20000 and higher)

Page 23

FIGURES, DIAGRAMS, AND VIEWS

Light Panel

Oxygen Outlet Port

Bib

Front Cover

Caster

Base

Power Light (green)

Flow Meter Knob

OSD Indicator Lights (OSD units only)

Service Required Light (Red)

Power Switch

Flow Meter

Circuit

Breaker

Figure 1. Exterior Front View

Page 24

FIGURES, DIAGRAMS, AND VIEWS

Front cover

Rear cover

Cabinet screw

Power

Cord Strap

Power Cord

Exhaust Grill

Caster

Figure 2. Exterior Side View

Page 25

FIGURES, DIAGRAMS, AND VIEWS

Air Filter

Communication Port

(OSD units only)

Figure 3. Exterior Rear View

Cabinet Screws

Filter Door

Cabinet Screws

Page 26

FIGURES, DIAGRAMS, AND VIEWS

Bib Screws

Figure 4A. Interior Rear View (early OSD models)

Cooling Fan

Mounting Plate Screw

Pressure Exhaust Hose (Silicone) 1/2" ID

Compressor

Strain Relief on

115 volt units.

IEC Power Connector on 230 volt units.

Compressor Electrical Connector

Accumulator Tank

Exhaust Muffler

(Hidden)

Intake

Filter

Communication Port

(OSD units only)

Oxygen Sensor Assembly

(OSD units only)

Compressor Filter

Motor Mount

Compresssor

Mounting Plate

Page 27

FIGURES, DIAGRAMS, AND VIEWS

Bib Screws

Figure 4B. Interior Rear View (later OSD models)

Cooling Fan

Mounting Plate Screw

Pressure Exhaust Hose (Silicone) 1/2" ID

Compressor

Strain Relief on

115 volt units.

IEC Power Connector on 230 volt units.

Compressor Electrical Connector

Accumulator Tank

Exhaust Muffler

(Hidden)

Intake

Filter

Communication Port

(OSD units only)

Compressor Filter

Motor Mount

Compresssor

Mounting Plate

Page 28

FIGURES, DIAGRAMS, AND VIEWS

Figure 5A. Interior, Front View (early OSD models)

Left Sieve Bed

PC Board

Wires to Power Switch and Circuit Breaker on Bib

Four-Way Valve

Hose to Flow Meter

(shown disconnected

for removal of bib)

Intake Silencer

Wire Harness (main)

Right Sieve Bed

Page 29

FIGURES, DIAGRAMS, AND VIEWS

Figure 5B. Interior, Front View (later OSD models)

Left Sieve Bed

PC Board

Wires to Power Switch and Circuit Breaker on Bib

Four-Way Valve

Hose to Flow Meter (shown disconnected for removal of bib)

Intake Silencer

Wire Harness (main)

Right Sieve Bed

Page 30

FIGURES, DIAGRAMS, AND VIEWS

Sieve Bed Cable Tie

Figure 6A. Interior, Front Lower View (early valve version)

Compressor Mounting Plate Hex Nut

Slot for Bib Tab

Four-Way Valve

Hose Clamp for

1/2"

Rubber Hose

Hose to Right Sieve Bed

Hose to Left Sieve Bed

Four-Way

Retaining Screws

Four-Way Wires

1/2" ID Hose

(Braided)

Pressure Inlet

from

Compressor

1/2" ID

Exhaust Hose

(Nitrogen)

Page 31

FIGURES, DIAGRAMS, AND VIEWS

Sieve Bed Cable Tie

Figure 6B. Interior, Front Lower View (later valve version)

Compressor Mounting Plate Hex Nut

Slot for Bib Tab

Four-Way Valve

Hose Clamp for

1/2"

Rubber Hose

Hose to Right Sieve Bed

Hose to Left Sieve Bed

Four-Way

Retaining Screws

Four-Way Wires

1/2" ID Hose

(Braided)

Pressure Inlet

and Exhaust

Hoses Behind

Four-Way

Page 32

FIGURES, DIAGRAMS, AND VIEWS

Figure 7A. Interior, Front Upper View (early OSD models)

Sieve Bed Test Point

Oxygen Outlet Tubing

/8" ID

Hour Meter Electrical Connector

Pressure Transducer

Tubing to Accumulator Tank

Oxygen Outlet Tubing

1/8" ID

Sieve Bed Test Point

Accumulator Tank

Four-Way Electrical Connector

PC Board Fuse Right Sieve Bed

Tubing to Flow Meter (shown disconnected for removal of bib)Left Sieve Bed

Wires to Power Switch and Circuit Breaker

PC Board Screws (X2)PC Board

Page 33

FIGURES, DIAGRAMS, AND VIEWS

Figure 7B. Interior, Front Upper View (later OSD models)

Sieve Bed Test Point

Oxygen Outlet Tubing

/8" ID

Hour Meter Connector

OSD

Tubing to Accumulator Tank

Oxygen Outlet Tubing

1/8" ID

Sieve Bed Test Point

Accumulator Tank

Four-Way Electrical Connector

PC Board Fuse Right Sieve Bed

Tubing to Flow Meter (shown disconnected for removal of bib)Left Sieve Bed

Wires to Power Switch and Circuit Breaker

PC Board Screws (X2)PC Board

Page 34

FIGURES, DIAGRAMS, AND VIEWS

Flow Meter

Figure 8. Interior, Behind Bib View

Power Switch

Final Bacteria Filter

Circuit Breaker

Final Check Valve

Oxygen Outlet Port Screw

Handle

Bib Tab

Light Panel

Ribbon Connector

Brown Wire (or 2 Black Wires)

Red Wire

2 Black Wires (or Brown Wire)

RED WIRE

SWITCH DETAIL

BROWN WIRE

2 BLACK WIRES

EITHER RED WIRE CAN BE CONNECTED TO

EITHER LEFT HAND TERMINAL OF SWITCH

Page 35

FIGURES, DIAGRAMS, AND VIEWS

Figure 9A. Interior,Top View (early OSD models)

Sieve Bed Test Point

OSD Wire Harness (OSD units only) Fixed Orifice

Pressure Transducer

Hose 1/16" ID Sieve Bed Test Point

Pressure RegulatorHose Clamp

for

1/4" Tubing

Sieve Bed Check Valve

1/4" ID hose

Accumulator Tank Test Point Fitting

Hour meter

Sieve Bed Check Valve

Oxygen Sensor Assembly (OSD units only)

Page 36

FIGURES, DIAGRAMS, AND VIEWS

Figure 9B. Interior,Top View (later OSD models)

Sieve Bed Test Point

OSD Wire Harness (OSD units only)

Fixed Orifice

Tubing to Flow Meter Sieve Bed Test Point

Pressure RegulatorSieve Bed

Check Valve

1/4" x 1/8" Tubing Reducer

Accumulator Tank Test Point Fitting

Hour meter

Sieve Bed Check Valve

Page 37

FIGURES, DIAGRAMS, AND VIEWS

Pressure Exhaust Hose (Silicone) 1/2" ID

Figure 10. Interior, Rear Lower View

Hose Clamp for 1/2" Rubber Hose

Capacitor

Power Cord Strain Relief on

115 volt units.

IEC Power Connector on 230 volt units.

Cooling Fan

Compressor Intake Hose 1/2" ID Braided

Hose Clamp for

1/2"

Braided Tubing

Page 38

FIGURES, DIAGRAMS, AND VIEWS

Compressor

Figure 11. Compressor

Pressure Relief Valve

Exhaust Fitting

Intake Fitting

Motor Mount

Compressor

Mounting Plate

Compressor Filter

Electrical Connector

*Note– Model 515UK has one large compressor mounting plate.

Page 39

FIGURES, DIAGRAMS, AND VIEWS

Figure 12.Compressor With Head Removed

Retainer Valve Flapper Head Gasket Valve Plate Compressor RodScrew SleeveCup Retainer

Rod ScrewPiston CupValve FlapperScrewO-RingValve PlateCompressor FilterPressure Relief ValveCompressor Head

Page 40

FIGURES, DIAGRAMS, AND VIEWS

Figure 13. Four-Way Valve

End Cap Screws End Cap Left Solenoid Valve Body Right Solenoid End Cap End Cap Screws

Spring Retainer Spring Sleeve O-Ring Sleeve

Spool

Spacer

Spring

Spring Retainer

Spacer

End Cap Screws End Cap Left Solenoid Valve Body Right Solenoid End Cap End Cap Screws

Page 41

FIGURES, DIAGRAMS, AND VIEWS

Figure 14 Compressor (exploded view)

1 Connecting rod, eccentric

and bearing assembly 2 Piston cup 3 Cylinder sleeve 4 Screw - piston cup retainer 5 Piston cup retainer 6 Set screw - eccentric 7 O-ring - sleeve 8 Screw - head 9 O-ring

10 Head 11 Valve plate assembly 12 Valve keeper strip 13 Valve restraint 14 Valve flapper - intake & exhaust 15 Screw - valve flapper 16 Valve plate 17 Fan - white 18 Fan - black

Page 42

FIGURES, DIAGRAMS, AND VIEWS

Figure 15 Pneumatic Diagram

Page 43

FIGURES, DIAGRAMS, AND VIEWS

Figure 16A Wiring Diagram (early OSD models)

(2 BOARD SYSTEM)

Page 44

FIGURES, DIAGRAMS, AND VIEWS

Figure 16B Wiring Diagram (later OSD models)

COMPRESSOR

Page 45

WARRANTY INFORMATION

DeVilbiss 515DS/515DZ Oxygen Concentrators Limited Warranty

The DeVilbiss 515DS/515DZ Oxygen Concentrators, manufactured and sold by Sunrise Medical, are warranted as stated below.This warranty extends only to the Buyer purchasing the equipment directly from Sunrise Medical, or through its Providers, Distributors, or Agents, as New equipment.

This equipment is warranted by Sunrise Medical to be free from defects in workmanship and materials as stated below from date of shipment by Sunrise Medical to the original purchaser:

• Valving is warranted for the life of the unit.

• Compressor is warranted for five years.

• All other components are warranted for three years.

• Routine maintenance items, such as filters, are excluded from

warranty. Sunrise Medical’s obligation under this warranty is limited to

the option of repairing at its plant or an Authorized Service Center or supplying a replacement for component part(s).To make claim under this warranty, the original purchaser must notify Sunrise Medical or an Authorized Service Center.The claim will be evaluated and, if bona fide, further instructions will be issued. For component part(s) return(s), it shall be the responsibility of the provider to remove the defective component part(s), properly package in a Sunrise Medical approved shipping container, properly identify by a Return Authorization Number, and to make shipment prepaid.This warranty does not cover the cost of labor incurred, either by the homecare provider or Sunrise Medical, in removing or replacing the warranty component part(s). Service under this warranty must be performed by a qualified Sunrise Medical provider and/or an Authorized Sunrise Medical Service Center.

NOTE:This warranty does not obligate Sunrise Medical to replace an oxygen concentrator that is being repaired with a loaner unit during the time of repair.

NOTE: Replacement components do not carry a new warranty and shall only be warranted for the unexpired portion of the original Limited Warranty.

This warranty shall not apply, and Sunrise Medical shall be relieved of any obligation or liability if:

• This equipment is not operated and maintained in accordance with Sunrise Medical operating and service instructions.

• Routine maintenance, servicing, and repair are not performed by qualified Sunrise Medical service personnel.

• The equipment has been repaired or altered by the use of non-authorized parts or components (i.e., regenerated sieve material).

• The filters that were used on the unit were not authorized Sunrise Medical filters or quality filters approved by Sunrise Medical.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THE EXPRESS LIMITED WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED.THIS IS THE EXCLUSIVE REMEDY AND LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, OR THE LIMITATION OR EXCLUSION OF CONSEQUENTIAL OR INCIDENTAL DAMAGE, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

SUNRISE MEDICAL LABOR WARRANTY

Sunrise Medical backs up its reputation for unexcelled product quality and reliability by extending a free three-year labor warranty when the unit or components under warranty are returned to our Somerset, PA facility or an authorized Sunrise Medical warranty center. Repairs to units returned to other service centers are not covered by our free labor policy unless otherwise stipulated.

• Labor warranty is effective from date of shipment from Sunrise Medical to original purchaser (provider).

• Routine maintenance items, such as filters, are excluded.

OPTIONAL EXTENDED WARRANTY

The Optional Extended Warranty must be selected at time of purchase. Under the Optional Extended Warranty, the equipment is warranted by Sunrise Medical to be free from defects in workmanship and materials for a period of five years, except as stated below,from date of shipment by Sunrise Medical to the original purchaser.

• Valving warranted for the life of the unit.

• OSD warranted for the life of the unit (OSD models only).

• Routine maintenance items, such as filters, are excluded from

Warranty. Under the Optional Extended Warranty you will receive a free

five-year labor warranty when the unit or components under warranty are returned to our Somerset, PA facility or an authorized Sunrise Medical warranty center. Repairs to units returned to other service centers are not covered by our free labor policy unless otherwise stipulated.

A $50 charge for the Optional Extended Warranty will be added to your invoice at billing.

NOTE:International model warranties may vary.

Page 46

ORDERING INFORMATION AND PARTS LIST

ORDERING INFORMATION

When ordering components, instruction guides, or service manuals the following must be provided:

• Unit Catalog Number

• Unit Serial Number

• Part Number

• Quantity Required DeVilbiss Concentrator Instruction Guide—part # SP-5

DeVilbiss 4 & 5 Liter Series Service Manual—part # LT-

1823

Orders may be placed by calling:

• Customer Service 800-333-4000

• Warranty parts - U.S.A. 800-333-4000

• Canada 905-660-2459

• International Department 8

14-443-4881

PARTS RETURN AND ORDERING POLICY

ALL DEFECTIVE COMPONENTS THAT ARE STILL UNDER WARRANTY MUST BE RETURNED TO THE FACTORY IN SOMERSET, PA WITHIN 30 DAYS AFTER SHIPMENT OF THE NEW COMPONENTS. IF THE COMPONENTS ARE NOT RECEIVED WITHIN THIS PERIOD, AN INVOICE WILL BE ISSUED TO YOUR ACCOUNT.

REBUILT EXCHANGE PARTS PRICING IS AVAILABLE ONLY WITH THE RETURN OF DEFECTIVE PARTS WITHIN 30

DAYS. COMPONENTS WILL THEN BE BILLED AT THE REBUILT COST;THERE WILL BE A CHARGE FOR SHIPPING. IF THE DEFECTIVE COMPONENT IS NOT RECEIVED WITHIN 30 DAYS,THEN A NEW COMPONENT INVOICE WILL BE ISSUED TO YOUR ACCOUNT. COMPONENTS THAT ARE OUT OF WARRANTY AND NOT ON A REBUILT/EXCHANGE PROGRAM DO NOT HAVE TO BE RETURNED TO THE FACTORY.

Before returning parts or units to the factory, call the Sunrise Medical Customer Service Department (800-333-4000) (8

14-443-4881) to obtain a return authorization number.

Include in the package a note indicating the return authorization number along with your company name, address, phone number, and account number.The return authorization number should also be written on the outside of the package.

To expedite your order for warranty or non-warranty parts, the following information should be given to the representative:

• Catalog number

• Serial number

• Hour meter reading for each concentrator

• Account number

• Company name and address

Page 47

ORDERING INFORMATION AND PARTS LIST

Accessories

Bubble Humidifier HUM16 Cannula CAN00 Cannula w/2.1m (7 ft) tubing CAN70 Fitting, Straight Hum.Adapter 444-506 Handle 303DZ-647 Humidifier Stand MC44DM-509 Low Output Flow Meter 515LF-607 Oxygen Analyzer O2ANA Oxygen Outlet Connector

Plastic CN

100

Metal CN200

Oxygen Tubing OST07, OST15, OST25, OST50 Rear Wheel Conversion Kit 505DZ-636

Components 515DS 515DZ 515KS 515KZ 515NS 515UK

Accumulator Tank 505DZ-610 Cable Tie - Sieve Bed 505DZ-617 Cabinet Parts

Base 515DZ-603 515KZ-604 Bib 303DS-603 303DZ-603 303DS-603 303DZ-603 303DS-603 Filter Door 515DZ-639 Front Cover 505DZ-601 515KZ-601 Oxygen Outlet Port 303DZ-606 Rear Cover 505DZ-602 505ID-602

Capacitor 515DZ-617 MC64D-617 MC44I-626 Carton with Shipping Inserts 505DZ-606

Shipping Inserts Only 505DZ-706

Caster, Non-locking 501DZ-603 Circuit Breaker 515DZ-615515KZ-615 Cooling Fan 515DZ-634 MC291-634 Compressor 515DZ-625 515KZ-625 515UK-625 Compressor Service Kit 505DZ-643 Compressor Mounting Plate 501DZ-631 505DD-631 Exhaust Muffler 515DZ-705 PVO2D-705 Filters

Cabinet Air Filter 505DZ-604 Compressor Filter 303DZ-639 Extended Life Intake Filter MC44D-605 Final Bacteria Filter PV5LD-651 Intake Bacteria Filter 444-504 Intake Rectangular Felt Filter MC44D-722 Intake Round Felt Filter 444-503

Fittings

Accumulator Tank 444-582 Compressor Exhaust 505DZ-648

Flow Meter 505DZ-607 Flow Meter Knob PVO2D-6

Parts List

Page 48

ORDERING INFORMATION AND PARTS LIST

Components (continued) 515DS 515DZ 515KS 515KZ 515NS 515UK

Hose & Tubing

1/16" ID Blue 444-526 1/8" ID Blue 444-554 1/4" ID Blue 444-525 1/2" ID Braided 444-549 1/2" ID Rubber 444-565 1/2" ID Silicone 505 DZ-634

Hose Clamps

For 1/4" Blue 444-524 For 1/2" Braided & Silicone 444-538 For 1/2" Rubber 444-566

Hour Meter PV5LD-617 Light Panel 303DS-615 505DZ-615 303DS-615 505DZ-615 303DS-615 Motor Mounts MC44D-626 505IZ-609 Nut, Compressor Mounting 303DZ-630 PC Board

(for non-OSD & early OSD models)

Main 515DS-622 515KS-622 515UK-622 Fuse for Board 099HI-626 515IZ-610 Oxygen Sensor Assembly 515DS-621 N/A 515DS-621 N/A 515DS-621

PC Board (for later OSD models) 515STD-622 N/A 515STK-622 N/A 515STK-622 515STU-622 Pressure Regulator MC29D-612 Power Switch 505DZ-508 Power Cord PV5LD-6185610U-627 N/A Power Cord Strap MC29D-657 Power Cord Strain Relief 505DZ-645 N/A Screws, Cabinet 303DZ-628 Sieve Bed 515DZ-619 Thermostat N/A 505KZ-624 Valves

Final & Sieve Bed Check Valve PVO2D-607 Four-Way Valve 515DS-702 Starting Serial Numbers listed below – All previous serial numbers use 515DZ-702

H13146DS H12602DZ H10532KS H10034KZ H10001NS H10642UK

Pressure Relief Valve 515DZ-614 Valve Rebuild Kit 515DZ-707

Valve Isolation Mount 515DZ-703 Wire Harness

Communication Harness 515DS-608 N/A 515DS-608 N/A 515DS-608 Main Wire Harness 515DZ-623 515UK-623 OSD Wire Harness 303DS-601 N/A 303DS-601 N/A 303DS-601

Tools

AC/DC Test Light PVO2D-603 Pressure Test Assembly 303DZ-637 Pressure Vacuum Gauge PVO2D-601 Service Kit 444-501 Screwdriver with Bits MC44D-712 Test Point Plugs PV5LD-706

Parts List

Page 49

SPECIFICATIONS

DEVILBISS 4-LITER DEVILBISS 5-LITER SERIES

Catalog Number 5115UK 5115DZ, 5115DS 5115KZ, 5115KS, 5115NS

Delivery Rate (Lower delivery rates 1 to 4 LPM 1 to 5 LPM

available for low flow applications)

Maximum Recommended Flow 4 LPM 5 LPM

Outlet Pressure 8.5 psig (58.6 kPa) Electrical Rating 230V, 50 Hz,

1.4 Amp 115V, 60 Hz, 4.2 Amp 220-230V~, 50 Hz, 1.7 Amp 230V~, 60 Hz, 1.9 Amp

Operating Voltage Range

195 - 253V~, 50 Hz 97 - 127V~, 60Hz 187 - 255V~, 50Hz

218 - 253V~, 60 Hz

Oxygen Percentage 1 - 4 LPM=93% ±3% 1 - 5 LPM=93% ±3%

Operating Altitude

(tested at 2

1°C only) Across the voltage range: Across the voltage range: Across the voltage range:

0 - 1500 M (0 - 4921 ft) No degradation in performance No degradation in performance No degradation in performance

Tested at nominal voltage only: Tested at 230V/50Hz only:

1500- 3000 M (4921 - 9842 ft) Not recommended / Not tested No degradation in performance ~4% oxygen performance drop at 5LPM

3000 - 4000 M (9842 - 13,123 ft) Not recommended / Not tested Not recommended / Not tested Not recommended / Not tested

Operating Environment Range* No degradation in performance across

~4% oxygen performance drop at 5 LPM

10°C to 35°C, the operating voltage range

and 35°C condition. No degradation in

humidity range of 30% to 75% (tested at sea level) per

formance across the operating voltage

range at other liter flows (tested at 670 M).

Power Consumption 295 Watts Average 400 Watts Average 230V/50Hz–365 Watts Average

230V/60Hz–435 Watts Average

Weight 53 lbs. (24.5 Kg) 52 lbs. (23.5 Kg) 53 lbs. (24.5 Kg)

Sound Level

(ISO 8359:1996 from front) 50.5 dbA overall average 52.5 dbA overall average** 50.5 dbA (50Hz) overall avg.

Dimensions 27.75"H x 16"W x 14"D (70.5 x 40.6 x 35.6 cm)

Pressure Relief Valve 44 psig ±3 psig (303 kPa ±21 kPa)

Operating System Time Cycle /

Pressure Swing

For units equipped with an OSD, Units with serial numbers less than H20000: 85% ±2%

the visible “low oxygen” indicator (The audible alarm will alert at approximately 75%.)

will activate at the following levels Units with serial numbers of 20000 and greater: 83.5% ± 1.5%

(The audible alarm will alert at approximately 75%.

Less than 60%, the red “Service Required” light will activate)

Storage and Transport Conditions -40°C to 70°C, humidity range of 10% to 100%, including condensation (tested at ~933 hPa)

Equipment Class and Type Class II Equipment Double Insulated Type B applied Part

Approval Body and TUV CSA TUV

Safety Standard IEC 60

1-1 +A1 + A2 CAN/CSA-C22.2 IEC 601-1 +A1 + A2

EN 6060

1 + A1 + A2 No. 601.1-M90 EN 60601 + A1 + A2

ISO 8359:

1996 ISO 8359: 1996

(515KZ excluded)

EMC Compliance To: IEC 601-1-2

Typical Accumulator Pressure

at Maximum Recommended Flow 50Hz

@ Sea Level

18 - 23 psig (125 - 160 kPa) 22 - 28 psig (150 - 200 kPa) 21-27 psig (145-190 kPa)

@ 750 M (2460 Ft)

16 - 21 psig (110 - 145 kPa) 20 - 26 psig (140 - 180 kPa) 20-26 psig (140-180 kPa)

1500 M (4921 Ft) 14 - 19 psig (95 - 130 kPa) 17 - 23 psig (120 - 160 kPa) 18-24 psig (125-165 kPa)

60 Hz

27-33 psig (

190-230 kPa)

24-30 psig (

165-210 kPa)

21-27 psig (110-190 kPa)

Note: Specifications subject to change without notice. *Note:The OSD performance at 10°C to 35°C, 95% R.H.

through the voltage range has been verified on a 5

15DS

at 670m.

**Note:This corresponds with a sound level of 50 dbA overall

average as measured according to the guidelines of the now defunct ANSI Z79.13-1981 standard.

Page 50

NOTES

Page 51

Page 52

Sunrise Medical Home Healthcare Group

7477 East Dry Creek Parkway

Longmont, Colorado 80503

(800) 333-4000

In Canada (800) 263-3390

303-218-4600

LT-1823 Rev.B