DeVilbiss 515 Service manual

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

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

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.

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.

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.

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.

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.

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).

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.

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”.

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

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

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.

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

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

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