Invacare 3-6 Service manual

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INV ACARE

OXYGEN CONCENTRATORS

INVACARE 3 & 5

Model 3LX Model 5LX

INV ACARE 5 & 6

Model 5LXO2 Model 5LXO2T Model 6LXO2 Model 6LXO2T Model 6LXO2H Model 6LXO2HT

with

SensO

with

SensO

with

SensO

SERVICE MANUAL

DEALER: KEEP THIS MANUAL. THE PROCEDURES IN THIS MANUAL MUST BE PERFORMED BY AN AUTHORIZED DEALER ONLY.

SPECIAL NOTES

S P

WARNING/CAUTION notices used in this manual apply to hazards or unsafe practices

which could result in personal injury or property damage.

THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITH-

OUT NOTICE.

L N

O T E S

NOTICE

WARNING

DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST

READING AND UNDERSTANDING THIS MANUAL. IF YOU

ARE UNABLE TO UNDERSTAND THE W ARNINGS AND

INSTRUCTIONS, CONTACT A HEAL THCARE

PROFESSIONAL (DOCTOR - THERAPIST) BEFORE

ATTEMPTING TO USE THIS EQUIPMENT - OTHERWISE

INJUR Y OR DAMAGE MAY RESULT.

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

SPECIAL NOTES .................................................2

SAFETY SUMMARY ............................................. 4

FEA TURES...... .....................................................7

SPECIFICA TIONS ................................................8

Recommended End-User Guidelines

for Optimum Performance .............................9

SHIPPING AND HANDLING INSTRUCTIONS ...... 10

INST ALLA TION / SEQUENCE OF OPERA TION... 11

SENS

O2 OXYGEN SENSOR TECHNOLOGY

CERAMIC ZIRCONIA SENSOR ..................... 12

Technical Description .................................. 12

Operating Sequence....................................12

Pneumatic Diagram ..................................... 13

TROUBLESHOOTING GUIDE ............................14

REP AIR/REPLACEMENT GUIDE ........................ 21

PROCEDURE 1 - REMOVING CABINET .............21

PROCEDURE 2 - PREVENTIVE

MAINTENANCE.................................................. 22

Cabinet Filters ............................................. 22

Inlet Filter .....................................................22

Bacteria Filter .............................................. 22

Exhaust Muffler Canister/

Exhaust Muffler ........................................... 23

Cleaning Finned Heat Exchanger ................ 23

Compressor T op End Rebuild - 3 Liter

Rebuilding Thomas Model 2638 or

2618..........................................................24

Compressor T op End Rebuild - 5 and 6 Liter

Rebuilding Thomas Model 2639 or

2619..........................................................29

Rebuilding Thomas Model 2650................33

Preventive Maintenance Record ..................37

PROCEDURE 7 - REPLACING COMPRESSOR

ASSEMBL Y OR CAP ACITOR....................... 43

Replacing Compressor Assembly............... 43

Replacing Capacitor ................................... 43

PROCEDURE 8 - REPLACING HEA T

EXCHANGER.............................................. 44

PROCEDURE 9 - REMOVING CONTROL

P ANEL ........................................................ 45

PROCEDURE 10 - REPLACING COOLING

FAN............................................................. 46

PROCEDURE 11 - REPLACING P.C.

BOARDS..................................................... 48

PROCEDURE 12 - REPLACING

TRANSFORMER ASSEMBL Y ...................... 50

PROCEDURE 13 - REPLACING ON/OFF

SWITCH ...................................................... 51

PROCEDURE 14 - REPLACING

FLOWMETER ............................................. 52

PROCEDURE 15 - REPLACING HOUR

METER ....................................................... 53

PROCEDURE 16 - REPLACING 4-WAY

V ALVE/MANIFOLD ASSEMBL Y/PILOT

VALVES...................................................... 54

Replacing 4-way Valve................................ 54

Replacing 4-way Valve Manifold

Assembly.................................................... 54

Replacing Pilot Valve Poppets and "O"

Rings .......................................................... 56

PROCEDURE 17 - SENSO2 ALARM

INDICA TORS AND SWITCH ......................... 58

PROCEDURE 18 - TIMING INV ACARE 5 AND

INV ACARE 6 CONCENTRATORS................ 59

T A B L E

C O N

T E N

T S

PROCEDURE 3 - REPLACING P.E. VALVE

(5LX/6LX/5LXO2/6LXO2) ............................. 38

PROCEDURE 4 - REPLACING SIEVE BEDS ....... 39

PROCEDURE 5 - REPLACING CHECK V AL VES ....40

PROCEDURE 6 - REPLACING/ADJUSTING

REGULA TOR ...............................................41

Replacing Regulator .................................... 41

Adjusting Regulator .................................... 42

PROCEDURE 19 - LEAK TEST ......................... 62

PROCEDURE 20 - ALARM AND SENSOR

TEST .......................................................... 63

PROCEDURE 21 - SIEVE BED PRESSURE

T AP-IN KIT INSTALLA TION AND BED

PRESSURE CHECK.................................... 67

WARRANTY ...................................................... 71

SAFETY SUMMARY

READ THE FOLLOWING INFORMATION BEFORE OPERATING THIS PRODUCT.

A F E

The use of oxygen therapy requires that special care be taken to reduce the risk of fire. Any

materials that will burn in air, and some that will not, are easily ignited and burn rapidly in high

concentrations of oxygen. For safety concerns, it is necessary that all sources of ignition be kept away from the product and preferably out of the room in which it is being used. NO SMOKING

signs should be prominently displayed.

A spontaneous and violent ignition may occur if oil, grease or greasy substances come in contact

with oxygen under pressure. These substances MUST be kept away from the oxygen concentra-

tor, tubing and connections, and all other oxygen equipment. DO NOT use any lubricants unless

recommended by Invacare.

For optimum performance, Invacare recommends that each concentrator be on and running for

a minimum of 30 minutes at a time. Shorter periods of operation may be harmful for maximum product life.

If it has a damaged cord or plug, if it is not working properly, if it has been dropped or damaged, or dropped into water, call Qualified Service Personnel for examination and repair.

W ARNING

Keep the cord away from HEATED or HOT surfaces. NEVER drop or insert any object into any opening. NEVER block the air openings of the product or place it on a soft surface, such as a bed or couch,

where the air opening may be blocked. Keep the openings free from lint, hair and the like. Fill humidifier with water to the level shown by the manufacturer. DO NOT overfill. Invacare recommends that Crush-Proof oxygen tubing (supplied by Invacare) be used with this

product and NOT exceed 50 ft. (15.2m) in length.

MAINTENANCE The Invacare Oxygen Concentrator was specifically designed to minimize routine preventative

maintenance at intervals of once per year. Only professionals of the healthcare field or persons fully conversant with this process such as authorized or factory trained personnel should perform preventative maintenance or performance adjustments on the oxygen concentrator.

RADIO FREQUENCY INTERFERENCE Most electronic equipment is influenced by Radio Frequency Interference (RFI). CAUTION should

be exercised with regard to the use of portable communications equipment in the area around such equipment.

SAFETY SUMMARY

SAFETY SUMMARY (Continued)

TO REDUCE THE RISK OF ELECTROCUTION.

WARNING

ALWAYS unplug this product IMMEDIATELY after using. Avoid using while bathing. If continuous usage is required by the physicians prescription:

The concentrator must be located in another room at least seven (7) feet from the bath. DO NOT come in contact with the concentrator while wet. DO NOT place or store product where it can drop into water or other liquid. DO NOT reach for product that has fallen into water. UNPLUG IMMEDIATELY.

TO REDUCE THE RISK OF BURNS, ELECTROCUTION, FIRE OR INJURY TO PERSONS.

WARNING This device is to be used only in accordance with the prescription of a physician and this Owners Manual. If at any time the patient or attendant conclude that the patient is receiving an insufficient amount of oxygen, the supplier and/or physician should be contacted immediately. No adjustments should be made to the flowrate unless prescribed by a physician.

S A

Y S

U M M A R Y

A product should NEVER be left unattended when plugged in. Close supervision is necessary when this product is used by, on or near children or bed

confined individuals. Use this product for only intended use as described in this manual.

DO NOT use unauthorized parts, accessories or adapters other than those authorized by Invacare.

SAFETY SUMMARY

GROUNDING INSTRUCTIONS

A F E T Y

A. This product should be grounded. In the event of an electrical short circuit, grounding

reduces the risk of electric shock by providing an escape wire for the electrical current. This product is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded.

SAFETY SUMMARY (Continued)

IMPROPER USE OF THE GROUNDING PLUG CAN RESULT IN A RISK OF ELECTRICAL SHOCK.

If repair or replacement of the cord or plug is necessary, do not connect the grounding wire to

either flat blade terminal. The wire with insulation having an outer surface that is green with or

without yellow stripes is the grounding wire. Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if doubt exists as to whether the

product is properly grounded.

B. This product is for use on a normal 120 V circuit and has a grounding plug that looks like

the plug illustrated in sketch A shown at the bottom of the page. A temporary adapter, which looks like the adaptor illustrated in sketches B and C, may be used to connect this plug to a 2-pole outlet as shown in sketch C if a properly grounded outlet is not available. The temporary adaptor should be used only until a properly grounded outlet (sketch D) can be installed by a qualified electrician. The green colored rigid ear, lug and the like extending from the adapter must be connected to a permanent ground such as properly grounded outlet box cover. Whenever the adapter is used, it must be held in place by the screw.

Grounding

Tab for Grounding Screw

DANGER

Adapter

Metal Screw Grounded

Outlet Box

Grounded Outlet

A B C D

Oxygen Outlet

Flowmeter

Elapsed Time

Meter

Power Indicator Light

FEATURES

Power Switch

Circuit Breaker

Cabinet Filter (2) ea.

FEATURES

F E A T U R E S

FEATURES - 3LX, 5LX

Oxygen Outlet

Flowmeter

Power Switch

Power Indicator

Light

Elapsed Time

Meter

SensO2 Status Indicator Lights (5LXO2,

5LXO2T , 6LXO2 and 6LXO2T ONL Y)

Circuit Breaker

Cabinet Filter (2) ea.

FEATURES - 5LXO2, 5LXO2T, 6LXO2, 6LXO2T

SPECIFICATIONS

S P E C

C A T

N S

SPECIFICATIONS

STANDARD SPECIFICATIONS Electrical Requirements: 120 VAC Rated Current Input: 4.0 A (ALL Models)

Sound Level: 52 dB Average (3LX)

53 dB Average (5LX, 5LXO2, 5LXO2T, 6LXO2, 6LXO2T)

Operating Altitude: Up to 6,000 ft. (1828 meters) above sea level without degradation of

performance. From 6,000 ft. (1828 meters) to 13,129 ft. (4000 meters) below 90% efficiency.

Ambient Temperature Range: 50 *Oxygen Output Concentration

Levels: ALL MODELS

Maximum Outlet Pressure: (5LX, 5LXO2, 5LXO2T, 6LXO2, 6LXO2T) (3LX)

Sens

O2 Alarm Thresholds:

95.6% to 87% at all flowrates.

* Stated performance maximum achieved after 30 min. of run time.

5 psi (34.5 kPa + 3.45 kPa.) (34.5 kPa + 3.45 kPa.)

+10% (132 VAC/108 VAC), 60 Hz

F - 95OF (10O - 35OC)

+ 0.5 psi. 5 psi + 0.5 psi.

Indicators

O2 Purity

Internal Switch

*Set at 73%

Internal Switch

Set at 85%

If no internal selector switch, 73%

operation ONLY.

Flow Range:

Power Consumption:

Pressure Relief Mechanism Operational at:

Over 85% (+ 2%)

73% (+ 3%) to 85% (+2%)

Below 73% (+ 3%)

1/2 - 5 L/min. (5LX, 5LXO2, 5LXO2T, 6LXO2, 6LXO2T) 1/2 - 3 L/min. 3LX) For flow rates less than 1/2 L/min., use the Invacare Pediatric Flowmeter

PF16. 460W (6LXO2, 6LXO2T) 350W/400W (3LX)

400W (5LX, 5LXO2, 5LXO2T)

35 psi + 3.5 psi (241 kPa + 24.1 kPa)

GREEN Indicator Light

YELLOW Indicator Light

RED Indicator Light -

Continuous Audible Alarm Sieve GARD Compressor Shutdown

* Factory Preset at 73%

GREEN Indicator Light

RED Indicator Light -

Continuous Audible Alarm Sieve GARD Compressor Shutdown

N/A

SPECIFICATIONS

SPECIFICATIONS, CONTINUED

Filters: Cabinet

Compressor Inlet Bacteria

Safety Systems: Current overload or line surge shutdown.

High temperature compressor shutdown. High pressure alarm w/compressor shutdown. Low pressure alarm w/compressor shutdown. Battery Free

Sens

O2 Oxygen System (5LXO2, 5LXO2T, 6LXO2, 6LXO2T ONLY).

Width: 18-inches (45.7 cm) Height: 23.75-inches (60.3 cm) Depth: 14-inches (35.6 cm)

Weight: 54 lbs. (24.5 kg) (All 5LX and 6LX Models) 53 lbs. (23.9 kg.) (3LX) Shipping Weight: 59 lbs. (27 kg) (All 5LX and 6LX Models) 58 lbs. (26.1 kg.) (3LX)

Operating Temperature

Exhaust: Less than Ambient + 35 Oxygen Output: Less than Ambient + 4O F (+2O C)

Power Loss Alarm.

F (+16O C)

S P E C

I C A T

O N

Cabinet: Impact Resistant flame-retardant plastic cabinet. Regulatory Listing: ETL certified complying with applicable portions of UL 1431

RECOMMENDED END-USER GUIDELINES FOR OPTIMUM PERFORMANCE:

Temperature: 50 Electrical: No extension cords. Placement: No closer than 3-inches from any wall. Tubing: Crush-Proof Tubing - 50 feet (15.2 m.) maximum (do NOT pinch). Room Characteristics: Smoke and soot-free

Relative Humidity: 20 to 60% Time of Operation: Up to 24 hours per day.

- 95OF (10O - 35OC)

No confined spaces (closet).

SHIPPING AND HANDLING

This Service Manual describes, in detail, the Invacare 3, 5 and 6 Oxygen Concentrators. It has been

carefully written to explain concentrator operation, service and preventative maintenance. Before

you install and operate the concentrator, please refer to OWNER'S MANUAL.

The Invacare concentrator should always be kept in the upright position to prevent cabinet damage while

being transported. The shipping container has been designed to assure maximum protection of the con-

centrator.

If the concentrator is to be reshipped by common carrier, it should be packed in a new carton. Additional

cartons are available from Invacare.

The air compressor suspension system has been engineered to withstand severe motion and orientation.

UNP ACKING (FIGURE 1)

1. Check for any obvious damage to the carton or its contents. If damage is evident, notify the carrier, or

Invacare.

SHIPPING AND HANDLING INSTRUCTIONS

2. Remove all loose packing from the carton.

3. Carefully remove all the components from the carton.

NOTE: After inspection, unless the Invacare Oxygen Concentrator is to be used immediately, retain carton and packing materials for use in storing until use of the concentrator is required.

INSPECTION

1. Examine exterior of the Invacare Oxygen Concentrator for nicks, dents, scratches or other damages. Inspect all components.

STORAGE

1. Store the repackaged Invacare Oxygen Concentrator in a dry area.

2. DO NOT place other objects on top of the repackaged concentrator.

Relief for Flowmeter to face Front of Unit.

Relief for Line Cord to face Back of Unit.

FIGURE 1 - UNPACKING

INST ALLATION/SEQUENCE OF OPERATION

INSTALLATION / SEQUENCE OF OPERATION

MODEL 3LX and MODELS 5LX,5LXO2, 5LXO2T, 6LXO2, 6LXO2T

INST ALLATION / VERIFICATION OF BATTERY FREE

When your new Invacare concentrator arrives, it should be checked for proper operating conditions.

1. If the unit has been in below-freezing temperatures, allow it to warm up to room temperature (approxi- mately 30 minutes) before operating.

2. The concentrator will need to be turned on for 4 to 5 seconds to charge the Battery Free Connect power cord to outlet and turn the concentrator on. Turn flow control knob counterclockwise and flow will begin immediately. Set flow rate of the Invacare 3 to 3 L/min., Invacare 5 to 5 L/min. and the Invacare 6 to 6 L/min. Turn unit off.

3. Unplug the power cord and press On/Off switch to the ON position. An intermittent audible alarm will sound. This confirms proper operation of the Battery Free OFF.

4. Connect cord to outlet and turn on concentrator. Unit will sound 3 BEEPS on startup.

POWER LOSS ALARM

Power Loss Alarm. Turn On/Off switch

Power Loss Alarm.

S T

L L

I O N

5. Check the oxygen concentration per specifications after 30-40 minutes running time.

SEQUENCE OF OPERA TION

Applying 120 VAC via the power switch energizes the compressor motor, hour meter, cooling fan and the printed circuit (P.C.) board.

Room air enters the compressor via the cabinet filter, compressor inlet filter, and sound muffler. The air is compressed by the wobble pistons in the compressor to a pressure of 20 PSI (137.72 kPa) BEFORE Serial No. "97K" or 21 PSI (144.79 kPa) AFTER Serial No. "97K".

As increased pressure creates increased temperature, a heat exchanger is utilized to lower the tempera-

ture by 20

F (6.7O C) before the air enters the 4-way valve. It is then channeled to a sieve bed containing the adsorption material. A restrictor downstream of the sieve bed causes pressure to build up inside the sieve bed which is necessary for the adsorption process. A small amount of relatively pure oxygen enters the top of the second bed with the balance entering a storage tank. The nitrogen removed is exhausted back from the bed through the four-way valve into room air. A muffler is located at the exhaust end of the valve to muffle the sound of the exhaust as it exits the concentrator.

The oxygen not being used to exhaust is channeled into the storage tank. The pressurized oxygen is regulated down to 5 PSI (34.4 kPa), enters an accurate flow-measuring device, flows through a bacterial filter, a check valve and out to the patient.

The electrical activation of the 4-way valve is accomplished every 8 to 21 seconds by the pressure sensor and P.C. board electronics when the pressure set point of 20

+ 3 PSI (137.72 + 51.32 kPa) BEFORE Serial No. "97K" or 21 + 3 PSI (144.79 + 51.32 kPa) AFTER Serial No. "97K" is reached. The time between cycles is dependent on altitude, flow rate and internal environmental factors.

E Q U

E N C

E O

F O

E R

I O N

On the 5LX/5LXO2/5LXO2T/6LXO2/6LXO2T, a P.E. or Pressure Equalization valve opens just prior to the shift of the 4-way valve. This allows highly concentrated oxygen to enter the just exhausted bed from the top. This additional pressure allows the bed to start its cycle at a higher pressure. The P.E. valve will close just after the shift of the 4-way valve.

INST ALLATION / SEQUENCE OF OPERA TION

INSTALLATION / SEQUENCE OF OPERATION, CONTINUED

If main power is lost, the Battery FreeTM Power Loss Alarm will sound a short "beep", with a long pause,

intermittently. All units are equipped with a diagnostic alarm system that signals if the pneumatic pressure

or electrical systems malfunction. The Troubleshooting Guide explains the alarm system signals and

reasons in detail for your convenience.

T A

SENSO2 OXGYEN SENSOR TECHNOLOGY CERAMIC ZIRCONIA SENSOR

L L

Technical Description

The oxygen being produced by the concentrator flows out of the product tank and into the flowmeter.

In-line between these components is a tee fitting that directs a small flow of oxygen through a precision

orifice to the oxygen sensor mounted on a printed circuit board.

As the oxygen enters the sensor, it passes through a screen and contacts the sensing disk.

Electric current flowing through a metal film resistor heats the disk in excess of 300 contact the electrode of the disk and pick-up extra electrons to become oxygen ions. These oxygen ions are attracted to the electrode on the bottom of the zirconia disk. Because of the crystal structure of the zirconia, only oxygen ions can pass through. When the oxygen ions reach the bottom electrode, the extra electrons are released from the oxygen ions and oxygen molecules return to the air. The number of electrons is directly related to the oxygen concentration. The electrons travel to the PC board where they

are "counted" and the oxygen concentration "reading" is calculated.

A microprocessor on the P.C. board contains software that interprets the signal being received from the

sensor. It compares the signal to clinically acceptable limits that have been selected with the indicator

E N

switch mounted on the PC board. Signals outside of the clinically acceptable limits generate responses in

the form of lighted LEDs, audible indicators, and/or system shut-down.

Operating Sequence

Once the power switch has been turned ON, the SensO

begin producing clinically acceptable oxygen before activating. No LEDs will illuminate for at least 5

minutes.

E R

After 5 minutes, if the oxygen purity exceeds 85%

A T

If the oxygen level is not above 85%

wait for a maximum of 30 minutes from start-up to reach 85% + 2% before activating an alarm. Environ-

mental factors such as low voltage, high altitude, or age of the machine will affect the time required to

+ 2% after the first 5 minutes, LEDs will remain off. The system will

reach 85% + 2%.

circuit will wait 5 minutes for the concentrator to

+ 2% the GREEN LED will illuminate.

C. Oxygen molecules

If the oxygen level is not above 85%

+ 2% within the first 30 minutes, the oxygen concentration alarm sequence will activate, depending upon the position of the indicator switch. All units are preset at the factory at 73% + 3%.

When oxygen concentration is above 85%

+ 2%, the sensor measures oxygen purity every 10 minutes.

If a reading falls below 85% + 2% and the alarm indicator is in the 73% mode or no switch is present, the oxygen sensor measures purity continuously and a yellow LED will illuminate. If the oxygen purity falls below 73% + 3% the RED LED/Alarm/Shut-Down mode will activate. If the selector switch is present and it is set at 85%, the RED LED/Alarm/Shut-Down mode will activate if the oxygen purity falls below 85% + 2%.

PNEUMA TIC DIAGRAM

BACTERIA

FILTER

FLOWMETER

TEST POINT 1

(OXYGEN CONCENTRAT OR

OUTLET)

FLOW

RESTRICTOR

OPTIONAL

OXYGEN SENSOR

PNEUMATIC DIAGRAM

INVACARE 3 & 5 OXYGEN CONCENTRATORS

MODELS IRC3LX, IRC5LX, IRC5LXO2

RESTRICTOR

ASSEMBLY

IRC3LX &

IRC5LX

ONL Y

PRESSURE

REGULAT OR

(BETWEEN PRODUCT TANK AND

CHECK VALVES

PRODUCT TANK

P.C.BOARD

TEST POINT 2

CHECK VALVE)

RESTRICTOR

is EXTERNAL on

IRC3LX ONLY.

It is INTERNAL to

P.E. VALVE for

IRC5LX &

IRC5LXO2

CROSSOVER

ASSEMBLY

P N E U

A T

C D

R A

AIR INLET

COMPRESSOR

INLET FILTER

RESONA TO R

CABINET

(GROSS P ARTICLE)

FILTER

SOLENOID PILOT

VALVE

RELIEF

VALVE

SIEVE

BED

5LX/5LXO2/

5LXO2T/

6LXO2/

6LXO2T ONLY

P.E. VALVE

SIEVE

BED

4-WAY VAL VE

EXHAUST MUFFLER

AIR

COMPRESSOR

HEAT

EXCHANGER

LEGEND

and =

ELECTRICAL CONNECTIONS

TROUBLESHOOTING GUIDE

R O U B

E S H O O

N G

SYMPTOM: PROBABLE CAUSE: SOLUTION:

NORMAL OPERA TION: Internal Status Indicators:

RED: Off GREEN: Off

Unit plugged in, power switch on. 3 "beeps" on start up.

POWER LOSS: Internal Status Indicators: RED: Off GREEN: Off

Unit unplugged, power switch on, alarm off.

POWER LOSS: Internal Status Indicators: RED: Off GREEN: Off

Unit plugged in, power switch on, alarm off. "Battery Free drained.

TM"

circuit

TROUBLESHOOTING GUIDE

No problems. System O.K.

No problems.

1. No Power at outlet.

2. Power Cord. a. Frayed. b. Broken or damaged spade.

c. Spade connector from Power

Cord loose or disconnected (inside back of unit).

"Battery Free in cord and turn power switch ON to recharge.

1. Check electrical outlet with a tablelamp or voltmeter set on 150-200 VAC scale. If outlet isn't working, check protective device in home's electrical panel or consult an electrician. Also ensure that unit is properly plugged in. DO NOT use extension cords. Move to another outlet or circuit.

2a.Replace cord. 2b.Replace power cord connectors

on plug.

2c.Reattach connector.

" Circuit drained. Plug

3. On/Off switch. a. Disconnected wire.

b. Faulty switch.

3a.Check all electrical connections

to the On/Off switch for any disconnected wires.

3b.If the concentrator does not come

on at all and wiring is intact, color code and remove wires one at a time and clean the On/Off switch with contact cleaner while turning the switch on and off. Reinstall switch and turn power on. If switch still doesn't work, replace switch. Transfer wires from old switch to new switch one at a time to the matching contact.

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

SYMPTOM: PROBABLE CAUSE: SOLUTION:

POWER LOSS, Continued:

INTERNAL POWER LOSS SENSO2: Internal Status Indicators: RED: Off GREEN: Off

Alarm may or may not be on.

Control Panel Indicators: RED: Off YELLOW: Off GREEN: Off

Fan operates, power light on, compressor not operating.

TROUBLESHOOTING GUIDE

4. Circuit breaker. Tripped.

5. P.C. Board. a. Damaged. b. Loose or damaged connector.

1. Transformer Assembly. a. Faulty. b. Connector loose or discon-

nected.

c. Faulty wiring.

2. P.C. Board. Faulty.

4. Reset breaker.

NOTE: Breaker may trip to safeguard concentrator during a power surge. If breaker trips immediately, there is a probable short in the unit. Check for pinched or charred wires. If the breaker does not trip, run unit for approximately 2 hours. If breaker trips again, there is an internal problem. Contact INVACARE TECHNICAL SERVICE.

5a.Replace (PROCEDURE 1 1). 5b.Repair or replace connector.

1a.Replace (PROCEDURE 12). 1b.Reattach connector.

1c.Replace Transformer Assembly

(PROCEDURE 12).

2. Replace P.C. Board (PROCEDURE 11). For 5LX or 6LX -

Unit may require retiming after P.C. Board replacement (PRO-

CEDURE 18).

T R

U B L E S

H O O

N G

HIGH PRESSURE: Internal Status Indicators:

RED: On GREEN: Off

(

LX Control Board

RED: One (1) Flash GREEN : T wo (2) Flashes

(Integrated Sensor Board) (LX SMT Board)

Control Panel Indicators: RED: On YELLOW: Off GREEN: Off

Unit plugged in, power switch on, continuous alarm. Compressor shut down.

)

1. P.C. Board. a. Malfunction.

b. Disconnected Wire.

c. Shifting Valve at Pressures

greater than 25 p.s.i.

2. 4-way Valve a. Not Shifting.

1a.Set flow to max l/min. for concen-

trator. Check voltage across Pilot Valve 1 on 200 volt scale. If meter reads 0 volts when unit is turned on, replace P.C. Board (PROCEDURE 1 1).

1b.Check spade connectors on pilot

valves 1 and 2 and connectors on P.C. Board.

1c.Replace P.C. Board (PROCE-

DURE 11). For 5LX or 6LX Unit may require retiming after P.C. Board replacement (PRO-

CEDURE 18).

2a.If voltage rises to approximately

24 volts D.C. when unit shuts down, P.C. Board is functioning properly. Replace 4-way Valve (PROCEDURE 16).

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

R O U B

E S H O O

N G

SYMPTOM: PROBABLE CAUSE: SOLUTION:

HIGH PRESSURE, Continued

LOW PRESSURE: Internal Status Indicators: RED: On GREEN: On

LX Control Board

(

RED: One (1) Flash GREEN : One (1) Flash

(Integrated Sensor Board) (LX SMT Board)

Unit plugged in, power switch on, continuous audible alarm. Compressor shut down (Failure to cycle due to low pressure).

)

TROUBLESHOOTING GUIDE

b. Bad Coil.

3. Sieve Beds. Contaminated.

1. Inlet Filter Dirty or Plugged.

2. Compressor. a. Leaks at fittings or tubing. b. Leaking or defective relief

valve.

c. Insufficient voltage at outlet.

d. Worn Cup Seals or Gaskets.

3. Heat Exchanger a. Leak at tubing or body cham-

ber.

b. Inspect tubing and heat

exchanger.

2b.Replace 4-way Valve (PROCE-

DURE 16).

3. Replace Sieve Beds (PROCEDURE 4).

1. Replace Inlet Filter (PROCEDURE 2).

2a.Replace or repair. 2b.Repair leak or replace.

2c.DO NOT use extension cords.

Use another outlet.

2d.Rebuild Top End of Compressor

(PROCEDURE 2).

3a.Replace or retighten.

3b.Replace or retighten tubing. Re-

place Heat Exchanger (PROCE-

DURE 8).

4. Replace (PROCEDURE 6).4. Regulator cracked or leaking.

5. P.E. Valve leaking. 5. Replace P.E. valve. Check volt age at P.E. valve connector on 24 volt D.C. scale. The P.E. valve activates or energizes approximately 1 second prior to the activation of the 4-way Valve with approximately 24 volts. If voltage is in excess of 24 volts consistently, replace the P.C. Board. If the P.C. Board voltage acts normally, replace the P.E.valve (PROCEDURE 3).

NOTE: Check for leaks starting at the compressor output through all the pneumatic connections. Major leaks will cause system pressures to remain below adequate shift (exhaust) pressures and will cause compressor shut down.

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

SYMPTOM: PROBABLE CAUSE: SOLUTION:

LOW CONCENTRA TION: NOTE: Check for O2 purity using a calibrated Oxygen Analyzer at Test Point 1 (OXYGEN OUTLET) of the concentrator.

Internal Status Indicators: RED: On GREEN: Off

(

LX Control Board

RED: Two (2) Flash GREEN : One (1) Flash 73% Shutdown

)

(Integrated Sensor Board)

RED: Two (2) Flash GREEN : T wo (2) Flashes 85% Shutdown

(Integrated Sensor Board)

Control Panel Indicators: SensO2 ONL Y: RED: On YELLOW: Off GREEN: Off

For SensO2 units, the Red indicator will signal extremely low purity and will be accompanied by a continuous audible alarm and a system shutdown. Repairs are required.

Internal Status Indicators: RED: Off GREEN: Off

(

LX Control or Integrated Sensor

Board)

Control Panel Indicators: SensO2 ONL Y: RED: Off YELLOW: On GREEN: Off

A Yellow indicator signals low purity, but within specification for the user. Repairs are required.

TROUBLESHOOTING GUIDE

1. Cabinet Filters Dirty.

2. Inlet Filter Dirty.

3. Compressor.

a. Defective.

b. Faulty Capacitor.

c. Bad Motor Windings.

d. Worn Seals.

e. Bad Bearings.

f. Leak at fittings or tubing. g. Leaky or Defective Relief

Valve.

h. Insufficient voltage (outlet).

4. Heat Exchanger. a. Leak at tubing or body cham-

ber.

b. Inspect tubing and Heat

Exchanger.

5. Regulator Cracked or Leaking.

6. Exhaust Muffler dirty or plugged.

7. Fan a. Not Operating. Unit overheat-

ing.

b. Faulty Fan.

8. Sieve Beds defective

9. Tubing kinked or blocked.

10.P.C. Board a. Shifts at wrong pressures.

b. Pressure transducer tubing

leaks.

1. Clean or Replace (PROCEDURE

2).

2. Replace (PROCEDURE 2).

3a.Replace Compressor (PROCE-

DURE 7).

3b.Replace Capacitor (PROCE-

DURE 7).

3c.Replace Compressor (PROCE-

DURE 7).

3d.Rebuild Top End of Compres-

sor (PROCEDURE 2).

3e.Replace Compressor (PROCE-

DURE 7).

3f. Replace Fittings or Tubing. 3g.Replace Relief Valve.

3h.DO NOT use extension cords.

4a.Replace or Retighten.

4b.Replace or retighten tubing.

Replace Heat Exchanger (PRO-

CEDURE 8).

5. Replace (PROCEDURE 6).

6. Replace (PROCEDURE 2).

7a.Leads to fan Disconnected.

Reconnect (PROCEDURE 10).

7b.Replace (PROCEDURE 10).

8. Replace (PROCEDURE 4).

9. Repair or replace.

10a.Check pressure at product tank.

Pressure should rise to 20 p.s.i. at shift point. If not, replace P.C. Board (PROCEDURE 21).

10b.Inspect tubing at transducer and

at product tank. Replace tubing

ONLY if damage is evident. (PROCEDURE 9).

T R O U B

S H O O

I N G

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

R O U B

E S H O O

N G

TROUBLESHOOTING GUIDE

SYMPTOM: PROBABLE CAUSE: SOLUTION:

LOW CONCENTRA TION, Continued:

11.Flowmeter. a. Flowmeter opened beyond

maximum flow rate. b. Cracked or broken Fitting. c. Input tubing leaking or loose.

12.Timing.

13. P.E. Valve. a.Bad Coil.

b.Restrictor Blockage.

14. Inspect P.C. Board Restrictor tubing for kinks or tears.

11a.Return flow to maximum setting.

11b.Replace fitting. 11c.Repair or replace.

12. To accommodate for varying tolerances when replacing components, an adjustable timer is used to control the shifting of the Invacare 5 Pressure Equalization (P.E.) Valve (PROCE-

DURE 18).

13a.Replace P.E. Valve (PROCE-

DURE 3).

13b.Replace P.E. Valve (PROCE-

DURE 3).

14. Replace P.C. Board. Unit may need retiming after board replacement (PROCEDURE

11).

FLUCTUA TING FLOW :

UNIT EXCESSIVEL Y LOUD:

1. Regulator/Flowmeter. a. Incorrectly set regulator.

b. Flowmeter malfunction.

2. Bacteria Filter

a. Dirty or Plugged

1. Pneumatic Exhaust. a. Muffler cracked, damaged or

missing.

b. Muffler tubing disconnected or

damaged.

2. Intake Resonator. a. Damaged or missing. b. Tubing disconnected or dam-

aged.

3. Inlet Filter missing.

4. Compressor.

1a.Check pressure at oxygen outlet.

Adjust Regulator (PROCEDURE

6).

1b.If flow is still unstable, check for

leaks starting at the compressor outlet fitting through all pneumatic connections. If no leaks are found and flow is still fluctuating, replace the regulator (PROCEDURE 6). If pressure at test point is within spec (5 p.s.i. + 0.2 max. [34.4 kPa + 6.89]), replace flowmeter

(PROCEDURE 14).

2a. If low flow conditions persists, replace bacteria filter.

1a.Replace. (PROCEDURE 2).

1b.Reconnect or replace tubing.

2a.Install new resonator. 2b.Reconnect tubing or replace.

3. Replace inlet filter.

4. Replace Compressor. Internal

damage (PROCEDURE 7).

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

SYMPTOM: PROBABLE CAUSE: SOLUTION:

UNIT OVERHEA TS:

TROUBLESHOOTING GUIDE

1. Base Exhaust Vent Plugged or

restricted.

2. Cabinet Filters Dirty or blocked.

3. Fan.

a. Leads to fan disconnected. b. Defective Fan. c. Fan installed upside down.

4. Heat Exchanger.

a. Fins dirty or plugged.

b. Fins damaged.

5. Compressor. a. Defective.

b. Faulty capacitor.

c. Bad motor windings.

d. Worn seals.

e. Bad bearings.

1. Place unit at least 3-inches from any wall. DO NOT place unit on pile or shag carpeting that may restrict air flow.

2. Clean or replace (PROCEDURE

2).

3a.Reconnect leads. 3b.Replace fan (PROCEDURE 10). 3c.Install fan with air flow arrow

pointing down (PROCEDURE

10).

4a.Clean heat exchanger (PRO-

CEDURE 2).

4b.Replace heat exchanger (PRO-

CEDURE 8).

5a.Replace compressor (PROCE-

DURE 7).

5b.Replace capacitor (PROCE-

DURE 7).

5c.Replace compressor (PROCE-

DURE 7).

5d.Replace compressor (PROCE-

DURE 7).

5e.Replace compressor (PROCE-

DURE 7).

T R

U B L E S

H O O

N G

6. Line Voltage excessive (surge). 6. Have line voltage inspected by

certified electrician. A voltage regulator may be required and is obtainable from your local electric company.

OXYGEN PURITY: GOOD Internal Status Indicators:

RED: Off GREEN: Off

Control Panel Indicators: RED: Off YELLOW: Off GREEN: Off

Purity Switch setting at 73% or 85%: After 30 minutes of run time, unit operates normally, oxygen purity within normal range. Green or Yellow panel indicator should illuminate.

1. P.C. Board defective. 1. Replace P.C. Board (PROCE- DURE 11). Unit may need retiming after P.B. Board replacement (PROCEDURE 18).

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

TROUBLESHOOTING GUIDE

T R O U B

S H O O

I N G

UNIT NOT OPERA TING ALARM: OFF Internal Status Indicators: RED: Off GREEN: Off CONTROL P ANEL INDICA TORS: RED: Off YELLOW: Off GREEN: Off

Purity Switch setting at 73% or 85%.

UNIT NOT OPERA TING, Internal Status Indicators: RED: Off

GREEN: Off

Control Panel Indicators: RED: Off

YELLOW: Off

GREEN: Off

Power Switch ON. Continuous audible alarm.

TROUBLESHOOTING GUIDE

SYMPTOM: PROBABLE CAUSE: SOLUTION:

1. Purity Switch. Defective.

2. Horn. Disconnected.

1. Transformer Assembly. a. Molex connector disconnected

from P.C. Board.

b. Faulty transformer assembly.

1. Replace P.C. Board. (PROCE- DURE 11). Unit may need retiming after board replacement.

(PROCEDURE 18).

2. Reattach horn connector to harness.

1a.Reattach connector.

1b.Replace transformer assembly

(PROCEDURE 12).

UNIT NOT OPERA TING, Internal Status Indicators: RED: Three (3) Flashes GREEN: One (1) Flash

(Integrated Circuit Board)

Control Panel Indicators: RED: Off

YELLOW: Flashing

GREEN: On

1. Internal repairs required.

1. Replace SensO2 circuit board

(PROCEDURE 11).

NOTE: REFER TO THE REPAIR/REPLACEMENT GUIDE IN THIS MANUAL FOR PROPER

REPLACEMENT OR ADJUSTMENT PROCEDURES

CABINET PROCEDURE 1

REPAIR / REPLACEMENT GUIDE

INV ACARE 3LX, INV ACARE - 5LX/5LXO2/5LXO2T AND INV ACARE - 6LXO2/6LXO2T

PROCEDURE 1 - REMOVING CABINET (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove the eight (8) mounting screws that secure cabinet assembly to the base assembly.

3. Lift the cabinet straight up.

NOTE: When required, vacuum inside of the cabinet and exposed foam insulation.

4. To re-install cabinet, reverse STEPS 2-3.

Cabinet Assembly

C A B

E T

Mounting Screws (8 each)

FIGURE 1 - REMOVING CABINET

Base Assembly

PROCEDURE 2 PREVENTIVE MAINTENANCE PROCEDURE 2 - PREVENTIVE MAINTENANCE

P R E

TO PREVENT ELECTRICAL SHOCK, ALWAYS

DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

NOTE: The Invacare Concentrators are specifi-

cally designed to minimize routine preventive

maintenance at intervals of once per year. In

places with high dust or soot levels, mainte-

nance may need to be performed more often.

The following must be performed at a minimum

of one (1) year in service to assure years of ad-

ditional reliability (Refer to TROUBLESHOOT-

ING GUIDE for plugged filter symptoms). Only

authorized or factory-trained personnel should perform preventive maintenance on the concentrator. Power should be disconnected before beginning preventive maintenance on the Invacare concentrator.

Cabinet Filters (FIGURE 1)

1. Clean or replace gross particle (cabinet) filters

on both side of the cabinet.

I L T E R S

CAUTION

Inlet Filter

Sound Box

FIGURE 2 - INLET FILTER

Bacteria Filter (FIGURE 3)

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

NOTE: The bacteria filter is accessible without removing the control panel but, if it becomes necessary to loosen the control panel to access the bacteria filter, refer to PROCEDURE 9 REMOVING CONTROL PANEL.

3. Remove FRONT of bacteria filter from the tygon

tubing extending to the top fitting of the flowmeter.

4. Remove REAR of bacteria filter from the tygon

tubing extending to back of in-line check valve.

5. Install NEW bacteria filter by reversing STEPS

3-4.

FIGURE 1 - CABINET FILTERS

Inlet Filter (FIGURE 2) NOTE: Perform this procedure as needed

depending upon the environment the concentrator is used in.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

3. Unscrew the inlet filter located on the top left of

the sound box (counterclockwise).

4. Discard existing inlet filter and replace with a

NEW inlet filter.

5. Reinstall cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

6. Reinstall cabinet (Refer to PROCEDURE 1 REMOVING CABINET).

In-line Check Valve

(SHOWN for identification.)

Tygon Tubing

(Remove Bacteria

Filter.)

Tygon Tubing

To Top Fitting of Flowmeter

(Remove Bacteria Filter.)

Bacteria Filter

FIGURE 3 - BACTERIA FIL TER

PREVENTIVE MAINTENANCE PROCEDURE 2 PROCEDURE 2 (continued) - PREVENTIVE MAINTENANCE

Exhaust Muffler Canister/Exhaust Muffler (FIGURE 4)

NOTE: The following should be performed at 20,000 hr. intervals although these procedures can be performed as needed depending upon the environment the concentrator is exposed to.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

3. Remove the ty-wraps that secure 4-way Valve manifold exhaust tubing to top fittings of muffler canister (canister).

4. Disconnect the exhaust hoses from fittings on top of canister.

5. Remove mounting screw(s) from rear of sound box and remove muffler canister.

6. Unscrew (counterclockwise) the exhaust muffler located on the muffler canister.

7. Inspect muffler canister for restriction of the internal filtration and do one of the following:

a). Replace muffler canister and muffler if

plugged or restricted.

b). Install NEW exhaust muffler if canister is in

good condition.

8. Install NEW /re-install existing muffler canister by reversing STEPS 3-5.

9. Reinstall cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

Cleaning Finned Heat Exchanger (FIGURE 5)

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

DO NOT damage fins of heat exchanger when removing, cleaning, or reinstalling.

3. Remove heat exchanger (Refer to PROCEDURE 8 - REPLACING HEA T EXCHANGER).

4. Remove excessive dirt build-up on heat exchanger fins using compressed air.

5. Reinstall heat exchanger (Refer to PROCE- DURE 8 - REPLACING HEA T EXCHANGER).

6. Reinstall cabinet (Refer to PROCEDURE 1 -

REMOVING CABINET).

CAUTION

FINS

Heat Exchanger Fins (Use

Compressed Air to Clean Dirt Buildup).

P R E V

I N T E N A N C E

T E

C H A N G

Exhaust Tubing

(From 4-way Valve Manifold.)

Exhaust Muffler Canister

Exhaust Muffler

FIGURE 4 - EXHAUST MUFFLER CANISTER/

EXHAUST MUFFLER

Ty-wraps

Mounting Screw(s)

Rear of Sound Box

FIGURE 5 - CLEANING FINNED HEA T EXCHANGER

PROCEDURE 2 PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

P R

TO PREVENT ELECTRICAL SHOCK, AL WA YS DIS-

CONNECT CONCENTRA TOR FROM ELECTRICAL

CAUTION

OUTLET BEFORE SERVICING.

NOTE: This kit is designed for rebuilding the Tho-

mas Model 2638 or 2618. These compressors use

this rebuild kit. The serial number is located on the

front of the compressor. If the serial number does

not begin in this way, this kit will not work.

The 3-Liter Thomas 2638 or 2618 Compressor

Rebuild Kit contains the following:

N C

1. Two (2) Connecting (Piston) Rod Assemblies.

2. Two (2) Connecting Rod Screws.

3. Two (2) Aluminum Piston Sleeves.

4. Four (4) Valves.

5. Two (2) Valve Restraints.

6. Two (2) Head Gaskets.

7. Two (2) Valve Plate Gasket.

8. Two (2) Connecting Rod Screw.

9. Twelve (12) Head Mounting Screws.

10. Four (4) Valve Screws.

11. Four (4) Connector (Crossover) Tube "O" Rings.

12. Hernon # 846 Lubricant.

13. Hernon # 423 Threadlocker.

5. Grasp both head assemblies and gently pull them apart.

6. Remove the crossover tubes from the head assembly.

NOTE: Replace all four (4) "O" rings.

7. Use a small flat screwdriver to get between the edge of the "O" rings and grooves in the crossover tubes or roll the "O" rings out of the grooves and remove from crossover tubes.

8. Slide NEW "O" rings into the grooves at each end of the crossover tubes.

9. Gently reinstall the crossover tubes into the end of one (1) compressor head.

10. Reinstall the remaining head onto the ends of the crossover tubes.

Mounting (Phillips Head) Screws

PREVENTIVE MAINTENANCE

(12)

Mark the Head

Assemblies

Tools Required:

One (1) 1/8 and 5/32-inch Allen Wrench attachment.

B U

Inch Pound Scale Torque Wrench.

One (1) Common (Flathead) Screwdriver. One (1) Small Common (Flathead) Screwdriver. One (1) Phillips Head Screwdriver.

Removing and Marking the Compressor Heads and Replacing Crossover Tube "O" Rings (FIGURE 6)

1. Unplug concentrator.

2. Carefully remove compressor from concentrator.

(Refer to PROCEDURE 7 - REPLACING COMPRESSOR ASSEMBL Y OR CAP ACITOR).

3. Use the Phillips screwdriver to remove the twelve (12) screws that secure the head assembly and valve plates to the compressor.

4. Mark the heads and valve plates to ensure proper reinstallation and set valve plates aside.

Separate the Head

Crossover Tubes

"O"

Ring

"O"

Ring

Assemblies

Groove

CROSSOVER TUBE

FIGURE 6 - REMOVING AND MARKING THE

COMPRESSOR HEADS AND REPLACING

CROSSOVER TUBE "O" RINGS

NOTE: After removing the head assembly, reinstall Valve Plate onto the side opposite the piston being rebuilt. This restricts movement of the other piston and prevents possible damage to the components.

PREVENTIVE MAINTENANCE PROCEDURE 2 PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Removing the Piston - 3 Liter Compressor (FIGURE 7)

1. Place the screw driver blade between the fan and the eccentric bearing and remove the fan blade from the side of the compressor being rebuilt by gradually prying it off.

2. Locate and align the eccentric set screw with the eccentric set screw access hole on the opposite side of the compressor body.

3. Use the 1/8-inch Allen wrench to loosen the set screw.

NOTE: DO NOT remove the eccentric set screw; loosen it ONLY.

NOTE: One (1) Piston Rebuild ONL Y SHOWN for Clarity

Head Assembly

Valve Plate

Eccentric Screw Access

Hole for this Piston

Aluminum

Sleeve

Connecting Rod Screw Access

FIGURE 7 - REMOVING THE PISTON - 3 LITER COMPRESSOR

4. Situate compressor so the piston being rebuilt is to your right and locate the connecting rod set screw access hole located on the lower portion of the compressor.

5. Use the 5/32-inch Allen wrench to remove the set screw located at the base of the connecting rod.

NOTE: It may be necessary to pry the spread point of the connecting rod to loosen it from the bearing of the eccentric.

6. Carefully slide the eccentric out of the compressor housing and set aside.

7. Remove the aluminum sleeve from the piston.

8. Tilt the piston slightly and with the other hand, slide the lower portion of the piston around the camshaft and out through the side of the compressor.

Mounting (Phillips Head)

Screws (12)

Head

Head Gasket Valve Plate

Valve Plate Gasket

Piston

Eccentric w/Bearing

Teflon Ring

Connecting Rod Screw

Connecting Rod

Hole for this Piston

Eccentric Set

Screw

Fan Blade

Access Holes are opposite side of Compressor Piston

Set Screw Access Holes.

P R E V

T E N A N C E

3 L

T R

O M

P R

E B U

I L D

NOTE: Eccentric Screw

PROCEDURE 2 PREVENTIVE MAINTENANCE PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Installing the New Piston (FIGURE 8)

R E V

DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a precision sealed

bearing.

1. Place a bead of Hernon # 846 on your finger and

T E N A N C E

apply around the inside of the bearing bore of the new connecting rod.

2. Install the new piston by inserting the piston head through the side of the compressor body.

3. Continue moving piston up into the upper compressor housing with the connecting rod situated around the eccentric nib (camshaft).

WARNING

CAUTION The eccentric set screw MUST face the flat spot on the eccentric nib (shaft). Failure to do so may cause

damage to the compressor.

4. Reinstall the eccentric ensuring that the bearing

on the eccentric sits inside the piston connecting rod.

C O

P R

E B U

Nib

(Camshaft)

Connecting

Rod

Piston Head

Piston Set Screw

Access Hole

(After Piston is upright,

Centered and Eccentric is

reinstalled into Compressor,

install Aluminum Sleeve onto

Connecting

(Slide Over

Piston).

Piston

Rod

Nib).

Compressor Housing Cut-away for Clarity

5. Align the front face of the connecting rod with the front face of the bearing leaving a clearance of .032 (1/16-inch).

6. Apply a small amount of Hernon #423 to threads of connecting rod screw.

7. Install connecting rod screw and torque to 15 in. lbs. DO NOT OVERTIGHTEN.

CAUTION DO NOT force aluminum sleeve onto piston. The T eflon ring may become damaged and make the piston unusable.

8. Turn the eccentric until piston is in the full up position.

9. Place the aluminum sleeve partially over the pis-

ton head at a 45

angle with the tooled edge up.

10. Hold the piston in place and gently rotate the sleeve onto the piston head and down until it rests on the locator ribs of the compressor housing and over the piston.

Aluminum

Eccentric Set

Piston Head

/Teflon Ring

Eccentric Bearing

Connector Rod

Connecting

Rod

Eccentric

Sleeve

Screw

Eccentric

Screw

Bearing Bore

Spread

CONNECTING ROD DETAIL

Connecting Rod Screw

Nib

.032

ECCENTRIC DET AIL

FIGURE 8 - INSTALLING NEW PISTON

PREVENTIVE MAINTENANCE

PROCEDURE 2

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Alignment of the Piston (FIGURE 8)

1. Hold sleeve down with one hand and slowly turn eccentric with the other.

2. As the piston travels up and down, the connecting rod will rock from front to back in normal operation.

3. If connecting rod rocks side to side, the rod is misaligned on the eccentric bearing.

4. If this is evident, loosen set screw and repeat STEPS 3-8 for INST ALLING THE PIST ON.

5. If connecting rod cannot be properly aligned, contact Invacare T echnical Service.

6. Twist the aluminum sleeve back up onto the piston until sleeve is approximately centered on the teflon ring of the piston.

7. With the aluminum sleeve firmly seated onto locator ribs, set the individual valve plate from that side of the compressor onto the aluminum sleeve and position it until the six (6) holes in the valve plate line up with the six (6) holes in the top of the compressor housing. This aligns the piston assembly.

8. Securely tighten the connecting rod screw against the flat spot on the nib (camshaft) (FIGURE 3).

CAUTION

Ensure that eccentric set screw is aligned with the flat spot on the cam shaft. Failure to do so may result in damage to compressor or possible injury .

9. Reinstall the fan blade securely over the nib in front of the eccentric (FIGURE 3).

10. Temporarily reinstall the valve plate for the piston just replaced to simplify installation of the other piston.

11. Begin at FIGURE 2 for installation of the new piston on the opposite side of the compressor.

Because of tooling of the valve keepers, ensure that the word "UP" on the valve keeper is facing you when installing the valve keepers.

1. Replace the top and bottom valves by doing one side of the valve plate at a time.

2. Use the small common (flathead) screwdriver to remove the valve screws securing the valve, valve keeper, and valve restraint to the valve plate.

3. Remove the valve keeper, and valve from the top of the valve plate.

4. Remove the bottom valve screw, valve keeper strip and valve from the bottom of the valve plate.

5. Remove the old gasket from the valve plate.

6. Reverse STEPS 1-5 to install the NEW valves and gasket onto the valve plate.

7. Remove the old gasket in the head assembly and install the new gasket in the compressor head and the valve plate gasket into the underside of the valve plate.

NOTE: DO NOT attempt to reinstall the head assembly at this time.

8. After the other piston and valves have been replaced, install the valve plates over the aluminum sleeves ensuring that the valve keeper strip fits into the cut-out in the top of the piston.

NOTE: Ensure that the gaskets are not pinched or out of position when reinstalling the valve plates and the head assembly. Doing this will prevent leaks and lowsystem pressures.

9. Reinstall the head assembly onto the valve plates noting the markings made when the head assembly and valve plates were removed.

10. Tighten the screws in a criss-cross manner and torque to 45 in. lbs.

11. Reinstall the compressor.

CAUTION

P R E V

I N T E N A N C E

L T R

O M

P R

E B U

I L D

Replacing the Top and Bottom Valves and Gaskets (FIGURE 9)

NOTE: Ensure that when installing the new valves, they are facing in the same direction that the old ones were in when removed from each plate and that they completely cover the compression opening in the valve plate. Ensure that no dirt or grease contacts them as this may inhibit their ability to open and close properly and severely reduce the compressor's ability to adequately compress air.

12. Run unit and check for leaks around compressor hoses and crossover tubes.

13. If crossover tube(s) leak, gently rotate the tube(s) approximately 1/4-turn. Once "O" ring(s) seat themselves, leaks should stop. If not, contact Invacare Technical Service at the number on back page of this instruction sheet.

PROCEDURE 2 PREVENTIVE MAINTENANCE PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

P R

14. Take pressure readings to ensure proper system pressures (Refer to PROCEDURE 21 - SIEVE BED PRES-

E V

SURE T AP-IN KIT INSTALLA TION AND BED PRESSURE CHECK in the IRC3LX/ IRC5LX/IRC5LXO2 SERVICE MANUAL).

E N A N C E

R C

Mounting

Valve Screw

(Phillips Head)

Screws (6 per

Head)

Head

Valve

Keeper

Valve

Gasket

Valve Restraint

Head

Compression

Opening under

Flapper

Valve Plate

Valve Plate Gasket

TOP SIDE

Valve Restraint

Valve

Keeper

FIGURE 9 - INST ALLING THE T OP AND BOTT OM FLAPPERS AND GASKETS

Valve Plate

Valve

Valve Screw

Gasket

BOTTOM SIDE

Compression

Opening under

Valve

Head Gasket

Head

L T

R E B U

PREVENTIVE MAINTENANCE PROCEDURE 2

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

Compressor Top End Rebuild - 5 Liter

NOTE: This kit is designed for rebuilding the Thomas Model 2639 or 2619. These compressors use this rebuild kit. The serial number is located on the front of the compressor. If the serial number does not begin in this way, this kit will not work.

The 5-Liter Thomas 2639 or 2619 Compressor Rebuild Kit contains the following:

1. Two (2) Teflon Piston Rings

2. Two (2) Aluminum Piston Sleeves

3. Four (4) Valves

4. Four (4) Valve Restraints

5. Two (2) Head Gaskets

6. Two (2) Valve Plate Gaskets

7. Eight (8) Head Mounting Screws

8. Four (4) Valve Screws

9. Four (4) Connector (Crossover) Tube "O" Rings

Tools Required:

One (1) Phillips Head TORX T-25 Driver. One (1) Phillips #2 Screwdriver Attachment for

Torque Wrench (for Retainer Screws).

One (1) 1/8-inch Allen Wrench attachment for

Torque Wrench (for Eccentric Set Screw).

One (1) 5/32-inch Allen Wrench attachment for

Torque Wrench (for Rod Clamping Screw).

One (1) Common (Flathead) Screwdriver attach-

ment (for Valve Screw).

Removing and Marking the Compressor Heads and Replacing Crossover Tube "O" Rings (FIGURE 10)

1. Unplug concentrator.

6. Remove the crossover tubes from the head assembly.

NOTE: Replace all four (4) "O" rings.

7. Use a small flat screwdriver to get between the edge of the "O" rings and grooves in the crossover tubes and remove "O" rings from crossover tubes.

8. Slide NEW "O" rings into the grooves at each end of the crossover tubes.

9. Gently reinstall the crossover tubes into the end of one (1) compressor head.

10. Reinstall the remaining head onto the ends of the crossover tubes.

Head Mounting

(TORX) Screws

(8)

Separate the Head

"O"

Ring

FIGURE 10 - REMOVING AND MARKING THE

COMPRESSOR HEADS AND REPLACING

CROSSOVER TUBE "O" RINGS

Assemblies

Groove

CROSSOVER TUBE

Mark the Head

Assemblies

Crossover Tubes

"O"

Ring

P R E V

T E N A N C E

5 L

T R

O M

P R

E B U

I L D

2. Carefully remove compressor from concentra-

tor. (Refer to PROCEDURE 7 - REPLACING

COMPRESSOR ASSEMBL Y OR CAP ACITOR).

3. Use the TORX T-25 torque wrench to remove the

eight (8) screws that secure the head assembly and valve plates to the compressor.

4. Mark the heads and valve plates to ensure proper

reinstallation and set valve plates aside.

5. Grasp both head assemblies and gently pull them apart.

NOTE: After removing the head assembly, reinstall Flapper Plate onto the side opposite the piston being rebuilt. This restricts movement of the other piston and possible damage to the components.

WARNING DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a precision sealed bearing.

PROCEDURE 2 PREVENTIVE MAINTENANCE PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Removing the Piston Head and Teflon Ring

(FIGURE 11)

NOTE: An Allen wrench may be inserted into the connecting screw to keep to keep it from mov-

ing.

1. Remove the aluminum sleeve from the piston to

be rebuilt.

T E

Head Assembly

5 L

One (1) Piston Rebuild ONL Y SHOWN for Clarity

Aluminum Sleeve

Teflon Ring

Valve Plate

R C

Eccentric Screw Access Hole for this Piston

P R

FIGURE 11 - REMOVING THE PISTON HEAD AND TEFLON RING

B U

Piston Head

2. Remove the four (4) phillips screws on the top of the piston and remove the piston head and Teflon ring.

3. Discard the old teflon ring.

4. Remove any debris from top of piston.

5. Repeat STEPS 1-4 for other piston.

Mounting Screws

(4 per Head)

Head Head Gasket Valve Plate

Valve Plate

Gasket

Phillips Head

Screws

(4 per Piston

Head)

Piston

Connecting Rod Screw Access Hole for this Piston

Eccentric Screw Access

Holes are opposite side of

Compressor Piston Set

Screw Access Holes.

PREVENTIVE MAINTENANCE PROCEDURE 2

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Installing the New Teflon Rings and Piston Heads (FIGURE 12)

CAUTION

Piston head MUST be rotated 90

when reinstalling. This ensures proper wear on the piston head and will prolong it's life.

1. Place the aluminum sleeve onto its mounting position on the compressor housing.

2. Rest the new Teflon ring on the aluminum sleeve and center the ring with the piston head.

3. Install the piston head over the piston ring and into the aluminum sleeve.

Piston Head

Aluminum Sleeve

Valve Plate

4. Install and tighten the phillips head screws until snug to align the Teflon ring with the aluminum sleeve.

5. Once the Teflon ring is centered properly with the piston head and aluminum sleeve, torque the screws to 30 in. lbs.

DO NOT force aluminum sleeve onto piston. The Teflon ring may become damaged and render the piston unusable.

Phillips Head

Screws

(4 per Head) Teflon Ring

Piston

Mounting Position for

Aluminum Sleeve

CAUTION

One (1) Piston

Rebuild ONL Y

SHOWN for Clarity

P R E V

T E N A N C E

5 L

T R

O M

FIGURE 12 - INSTALLING THE NEW TEFLON RINGS AND PISTON HEADS

Installing Top and Bottom Flappers (FIGURE

13) NOTE: Ensure that new valves are facing in the

same direction that the old ones when installing and that they completely cover the compression opening in the valve plate. Make sure that no dirt or grease contacts the valves or valve plates as this may inhibit their ability to open and close properly and severely reduce the compressor's ability to adequately compress the air. Replace the top and bottom valves by doing one side of the valve plate at a time.

CAUTION Because of tooling of the valve keepers, ensure that the word "UP" on the valve keeper is facing you when installing the valve keepers.

1. Use the small common (flathead) screwdriver

to remove the valve screw securing the valve restraint, valve keeper, and valve to the top of the valve plate.

2. Remove the valve screw, valve keeper, and valve from the bottom side of the valve plate.

3. Reverse STEPS 1-2 to install the NEW top and bottom valves onto the valve plate.

4. Torque valve screws to 12 in. lbs.

5. Install the head gasket in the compressor head and the valve plate gasket into the underside of the valve plate.

6. After the other piston has been rebuilt, install the valve plates over the aluminum sleeves and reinstall the head assembly onto the valve plates noting the markings made when the head assembly and valve plates were removed.

R E B U

I L D

PROCEDURE 2 PREVENTIVE MAINTENANCE

NOTE: Ensure that the gaskets are not pinched or

out of position when reinstalling the valve plates

and the head assembly. Doing this will prevent

leaks and low system pressures.

7. Tighten the screws on the heads in a criss-cross

T E N A

manner until snug. DO NOT tighten completely.

8. Use a torque wrench with the TORX T-25 drive

and torque each head screw to 40 in. lbs. in a criss-cross manner.

9. Reinstall the compressor (Refer to PROCEDURE

7 - REPLACING COMPRESSOR ASSEMBLY OR CAP ACITOR).

N C E

Mounting Screws

Head

Head Gasket

(4 per Head)

Valve Screw

T R

Valve Plate

Gasket

Compression

Opening under Valve

10. Run unit and check for leaks around compres-

sor hoses (Refer to PROCEDURE 19 - LEAK TEST).

11. If crossover tube(s) leak, gently rotate the tube(s) approximately 1/4-turn. Once "O" ring(s) seat themselves, leaks should stop. If not, contact Invacare Technical Service at the number on back page of this Owner's Manual.

12. Take pressure readings to ensure proper system pressures (Refer to PROCEDURE 21 - SIEVE

BED PRESSURE T AP-IN KIT INSTALLATION AND BED PRESSURE CHECK in the IRC3LX / IRC5LX/IRC5LXO2 SERVICE MANUAL).

Valve Plate

Valve

Keeper

Valve Screw

Compression

Opening under

Flapper

Valve

Keeper

Valve

Restraint

Valve

Valve Plate

Gasket

Head Gasket

Head

TOP SIDE

BOTTOM SIDE

E B

FIGURE 13 - INST ALLING THE T OP AND BOTT OM FLAPPERS AND GASKETS

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Compressor Top End Rebuild - 5/6 Liter (For S/N after 98XXXXX)

CAUTION

TO PREVENT ELECTRICAL SHOCK, AL WA YS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

NOTE: This kit is designed for rebuilding the Thomas Model 2650 Series. This compressor uses this rebuild kit. The serial number is located on the front of the compressor. If the serial number does not begin in this way , this kit will not work.

REMOVING COMPRESSOR AND COMPRESSOR HEADS (REFER TO FIGURE 15).

Compressor

1. Unplug concentrator.

2. Carefully remove compressor from concentrator. (Re-

fer to PROCEDURE 7 - REPLACING COMPRESSOR ASSEMBL Y OR CAP ACITOR).

Compressor Heads

3. Clean loose dirt from the outside of the compressor.

4. Use the TORX T-25 torque wrench and loosen the eight (8) head screws.

5. Remove the compressor heads.

PROCEDURE 2PREVENTIVE MAINTENANCE

P R

E N A N C

The 5/6-Liter Thomas 2650 Series Compressor Rebuild Kit contains the following:

1. Two (2) Teflon Piston Cups

2. Two (2) Aluminum Piston Sleeves

3. Four (4) Flapper Valves - Intake and Exhaust

4. Four (4) Valve Keepers

5. Two (2) O-Ring - Sleeve

6. Two (2) Valve Plate Gaskets

7. Eight (8) Head Mounting Screws

8. Four (4) Valve Screws

9. Two (2) Valve Restraints

10. Two (2) Piston Cup Retainer Screws

T ools Required:

1. Torque wrench that has an inch-pound scale (for head screws, set screws, flapper valve screw, and pipe plugs)

2. Torx

T-25 drive for torque wrench (for head screws

or flat blade)

3. 5/32-inch Allen wrench attachment for torque wrench (for eccentric set screw)

4. Flat blade screwdriver attachment or 1/2-inch hex socket for torque wrench (for flapper valve screw)

5. Torx® T-27 screwdriver attachment for torque wrench (for retainer screws)

Valve Plate

6. Lift off the valve plate.

NOTE: Note the position of the tab on valve plate for reassembly (FIGURE 14).

Tab

NEW

OLD

Tab

FIGURE 14 - TAB POSITIONS

NOTE: To avoid confusion, ONL Y service one (1) end of the compressor at a time.

5/6

L T R

C O M

I L D

WARNING

DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a precision sealed bearing.

Fan

7. Remove the fan by releasing the pressure from the clip holding it to the shaft.

NOTE: Note position of fan/orientation for reassembly.

PROCEDURE 2 PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

P R E

I N T E N

A N C E

PREVENTIVE MAINTENANCE

5/6

T R

C O

P R

E B U

L D

Item Description 1 2 Valve - Pressure Relief 3 Teflon Piston Cup 4 Piston Sleeve 5 Screw - Piston Cup Retainer 6 Piston Cup Retainer 7 Set Screw - Eccentric 8 Screw - Head Mounting 9 O-Ring - Head Gasket 10 Piston Head

Connecting Rod, Eccentric & Bearing Assembly

11 Valve Plate Assembly 12 Valve Keeper 13 Valve Restraint 14 Valve Flapper - Intake & Exhaust 15 Screw - Valve Flapper 16 Valve Plate 17 O-Ring Sleeve 18 Fan - Gray 19 Fan - Black

FIGURE 15 - COMPRESSOR EXPLODED VIEW

PROCEDURE 2PREVENTIVE MAINTENANCE

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

Connecting Rod/Eccentric Assembly

8. Rotate shaft to align the eccentric's set screw with the access hole in the bottom of the compressor housing.

9. Insert the 5/32-inch allen wrench into the access hole in the bottom of the compressor housing.

10. Loosen the setscrew 1/4 turn.

11. Rotate connecting rod to top dead center (180 and slide the connecting rod/eccentric assembly off the shaft.

12. Secure the rod assembly in a fixture.

13. Remove the sleeve from the connecting rod and discard.

Piston Cup

14. Remove the screw (discard) from the cup retainer (retain for reassembly).

15. Remove the piston cup (discard) and wipe debris from the top of the connecting rod with a clean damp cloth.

O-ring, Intake Valve and Valve Keeper

16. Remove the O-ring, intake valve and valve keeper from the bottom of the valve plate. Discard all.

17. Clean the bottom of the valve plate with a clean, soft cloth.

Exhaust Flapper Valve, Valve Restraint and Valve Keeper

18. Remove the exhaust flapper valve, valve restraint and valve keeper from the top of the valve plate. Discard all.

19. Clean the top of the plate with a clean, soft cloth.

Gasket

20. Remove the OLD gasket from the top of the valve plate and discard.

21. Clean the valve plate with a clean, soft cloth.

Exhaust Flapper Valve, Valve Restraint and Valve Keeper

2. Install the NEW exhaust flapper valve, valve restraint and valve keeper to the top of the valve plate (FIGURE 16).

NOTE: T orque flapper screws to 18 inch-lbs.

)

FIGURE 16 - INSTALL THE NEW EXHAUST FLAPPER

VALVE, VALVE RESTRAINT AND VALVE KEEPER

O-ring, Intake Valve and Valve Keeper

3. Install the NEW valve keeper on top of the NEW intake flapper so that the word "UP" is visible (FIGURE 17).

FIGURE 17 - INSTALL O-RING, INTAKE VALVE AND

4. Install the NEW O-ring, seating it firmly into the grove with your finger or blunt object.

VALVE KEEPER

E V

T E

A N C

5/6

OLDNEW

O M

I L D

REBUILDING COMPRESSOR (REFER TO FIGURE 15).

NOTE: Before reassembly , wipe any residue from all components with a clean soft cloth.

Gasket

1. Install NEW gasket; seating the gasket firmly in the groove at the top of the valve plate with your finger or blunt object.

CAUTION

Make sure that the O-ring is NOT twisted when seated in the groove of the top of the valve plate.

NOTE: T orque flapper screws to 18 inch-lbs.

Piston Cup

5. Place cylinder sleeve over rod top with smooth edge facing up.

6. Place piston cup on rod top making sure it is CENTERED.

7. Place retainer on top of piston cup and seat retainer in rod top pocket, making sure the retainer and cup lineup properly along with screw holes.

8. Insert new screw into rod top and torque to 65 inch-lbs.

PROCEDURE 2

PROCEDURE 2 - PREVENTIVE MAINTENANCE (continued)

P R

Connecting Rod/Eccentric Assembly

9. With gloved-hand or clean cloth, pre-form piston cup if

I N T E N

A N C E

5/6

L T

R C

O M P

R E B U

necessary.

10. Gently slide cylinder sleeve up and over cup to fully form it.

WARNING

DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a precision sealed bearing.

CAUTION

DO NOT crimp the piston cup when you replace the sleeve. If the cup is crimped, it MUST be replaced.

11. With bearing side (FIGURE 18) of connecting rod/eccentric assembly facing the center (motor) of the compressor, slide the assembly onto the shaft bringing it flush to the motor bearing.

NOTE: Make sure the eccentric setscrew is positioned over the flat of the shaft.

12. Tighten setscrew to 100 inch-lbs.

13. Hold the sleeve down by the housing with one (1) hand and slowly rotate the eccentric with the other hand to ensure all the components are lined-up properly.

Cylinder Sleeve

Retainer

Piston Cup

Rod Top

Fan

14. Reinstall the fan onto the shaft in original orien-

Valve Plate

15. With the sleeve located and firmly seated on the

NOTE: Make sure the top edge of the sleeve locates in the O-ring groove in the bottom of the valve plate.

Make sure that the O-ring is NOT twisted when seated in the groove of the bottom of the valve plate.

Compressor Heads

16. Place the heads on top of the valve plates.

17. Tighten the head screws in a criss-cross pattern

Compressor

To avoid personal injury or property damage, rotate the fan by hand prior to connecting the unit to a power source. Check for suction at the air inlet by placing your finger over the port as you rotate the fan. Y ou should feel a slight suction with each rotation of the fan. If you don't feel a suction but you feel or hear a thump as you turn the fan, DO NOT connect the unit to a power source. Review the assembly procedure for possible error.

18. Reinstall compressor (Refer to PROCEDURE 7 -

19. Run unit and check for leaks around compres-

PREVENTIVE MAINTENANCE

tation.

housing, replace the valve plate in the same manner as it was (FIGURE 18).

CAUTION

to 40 inch-lbs.

WARNING

REPLACING COMPRESSOR ASSEMBLY OR CAP ACITOR).

sor hoses and compressor tubes (Refer to PROCEDURE 19 - LEAK TEST).

NOTE: As the piston travels up and down it will also rock from side-to-side. This is a feature of the WOB-L Piston.

FIGURE 18 - CONNECTING ROD/ECCENTRIC

ASSEMBLY

20. Take pressure readings to ensure proper system pres-

sures (Refer to PROCEDURE 21 - SIEVE BED

PRESSURE T AP-IN KIT INSTALLA TION AND BED PRESSURE CHECK in the IRC3LX/IRC5LX/ IRC5LXO2 SERVICE MANUAL).

PREVENTIVE MAINTENANCE

PROCEDURE 2

P R E V

T E N A N C E

MODEL NO. IRC SERIAL NO.

INVACARE OXYGEN CONCENTRATOR

PREVENTIVE MAINTENANCE RECORD

O2)

SENS

Record Date of Service

Record Elapsed

Hours On Hour Meter

Clean Cabinet Filter(s)

ON EACH INSPECTION

Check Prescribed L/min. Flow Rate

Check Oxygen Concentration

EVERY 90 DAYS

(UNITS WITHOUT

Clean/Replace Cabinet Filter(s)

ANNUALLY or DURING PREVENTIVE MAINTENANCE SCHEDULE

Replace Bacteria Filter

O2 MODELS)

SENS

Check/Replace Compressor Inlet Filter

Check Power Loss Alarm

Check Oxygen Concentration

(

Clean Heat Exchanger

Replace Exhaust Muffler

Rebuild Top End of Compressor

AS REQUIRED

EXCEPT 3LX,5LX,5LXO2,

Replace In-line Filter -

(ALL MODELS

5LXO2T, 6LXO2, 6LXO2T)

EVERY 20,000 HOURS

PROCEDURE 3 P. E. VALVE PROCEDURE 3 - REPLACING P.E. VAL VE - 5LX/5LXO2/5LXO2T/6LXO2/6LXO2T ONL Y (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

P E

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove spade connectors from P.E. Valve assembly.

L V

4. Remove ty-wraps from P.E. Valve tubing.

5. Remove P.E. valve assembly from tubing.

CAUTION If P.E. Valve is not to be installed immediately, plug the P.E. Valve tubing to prevent sieve bed contamination.

6. Install new P.E. valve assembly immediately, by reversing STEPS 3-5. NOTE:After replacing P.E. valve, retiming may be necessary. Refer to PROCEDURE 18 - TIMING

OF THE INV ACARE 5 CONCENTRATOR.

7. Run unit and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

8. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

P. E. Valve Tubing

Ty-Wrap

P. E. Valve Tubing

P. E. Valve Assembly

Spade Connectors

Ty-Wrap

Sieve Beds

(SHOWN for Reference)

FIGURE 1 - REPLACING P.E. VALVE (5LX/5LXO2/5LXO2T/6LXO2/6LXO2T ONLY)

SIEVE BEDS PROCEDURE 4 PROCEDURE 4 - REPLACING SIEVE BEDS (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

NOTE: Always replace Sieve Beds in pairs to ensure that both beds are in optimum condition.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove ty-wraps and disconnect P.E Valve and sieve bed tubing from top of sieve beds.

4. Remove P.E. Valve assembly (Refer to PROCEDURE 3 - REPLACING P.E. VALVE (5LX/5LXO2/ 5LXO2T/6LXO2/6LXO2T ONL Y).

5. Loosen adjustable clamps on sieve beds and slide clamps down below the adjustable clamp hangers.

6. Lift sieve beds up and rest sieve beds on top rear of base.

7. Remove plastic clamps and reinforced tubing from bottom of both sieve beds and remove sieve beds.

CAUTION DO NOT remove plastic caps from NEW sieve bed fittings until ready to install NEW beds. Severe sieve contamination can occur if uncapped beds are exposed to air.

8. Remove plastic caps from the top and bottom fittings of the NEW sieve beds.

9. Install NEW sieve beds reversing STEPS 3-7.

I E V E

B E D S

NOTE: After replacing sieve beds, retiming may be necessary. (Refer to PROCEDURE 18 TIMING OF THE INV ACARE 5 CONCENTRATOR).

10. Run unit and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

11. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

P.E. Valve Assembly

(

5LX/5LXO2/5LXO2T

6LXO2/6LXO2T

Sieve Bed Tubing

Sieve Bed

Adjustable Clamp Hangers

Reinforced Tubing

(Sieve Bed

Plastic Clamp

)

Ty-wraps

)

P.E. Valve Tubing

(5LX/5LXO2/5LXO2T 6LXO2/6LXO2T)

Plastic Caps

Adjustable Clamp

FIGURE 1 - REPLACING SIEVE BEDS

PROCEDURE 5 CHECK VALVES PROCEDURE 5 - REPLACING CHECK VALVES (FIGURE 1)

C H

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM

ELECTRICAL OUTLET BEFORE SERVICING.

CAUTION

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET)

NOTE: Replace one or both check valves when performing this procedure. The check valves are

one-way directional and can be checked by passing air through them. Air should flow in one

direction ONLY.

3. Loosen adjustable clamp on product tank and slide clamp down below the adjustable clamp hanger to

E S

access check valve(s).

4. Remove ty-wraps from top and bottom of the check valve(s) and disconnect check valve(s) from tygon tubing.

CAUTION The check valves are one-way directional and MUST be installed correctly. The letters VAC are printed on the bottom half of the check valves and should be installed with V AC to the underside of the check valve. Low system pressures and eventual bed contamination will result if not properly installed.

5. Install the NEW check valve(s) into the tygon tubing. NOTE: Ensure proper orientation of check valves when installing.

6. Secure the check valve(s) by installing new ty-wraps to the tygon tubing where previously removed.

NOTE: If tygon tubing is damaged in any way , replace the section of tygon tubing before installing check valve(s).

7. Run unit and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

8. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Ty-wraps

Underside of Check Valve

Check Valve

Tygon Tubing

Check Valve

(2 per Check

Valve).

Product Tank

Adjustable Clamp

FIGURE 1 - REPLACING CHECK V ALVES

REGULATOR PROCEDURE 6 PROCEDURE 6 - REPLACING / ADJUSTING REGULATOR

Replacing Regulator (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Loosen adjustable clamp on product tank and slide clamp down below the adjustable clamp hanger.

4. Pull product tank back and up to access regulator.

5. Remove the four (4) mounting screws that secure regulator to product tank cap.

6. Remove regulator from product tank cap ensuring that the "O" rings are removed.

NOTE: Clean mounting surface of product tank lid. Ensure that the two (2) "O" rings for the NEW regulator are installed onto the ports (underside) of the NEW regulator before installation.

CAUTION Ensure proper installation of regulator. Note flow arrow on regulator. This MUST face toward the front of unit or flow will be interupted causing system shutdown.

7. Install new regulator onto product tank by reversing STEP 5.

8. Torque mounting screws to 5

+ 1 inch lbs.

R E

9. Re-install product tank and secure with the adjustable clamp.

10. Adjust regulator pressure if necessary (Refer to ADJUSTING REGULATOR (FIGURE 2) in this PROCEDURE).

11. Run unit and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

12. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Mounting Screws

Regulator

"O" Rings

(To Bottom of

Regulator).

Adjustable Clamp

Product Tank

Regulator Flow Arrow

Sieve Beds

(for Reference only .)

FIGURE 1 - REPLACING REGULA T OR

PROCEDURE 6 REGULATOR PROCEDURE 6 - REPLACING / ADJUSTING REGULATOR

Adjusting Regulator (FIGURE 2)

1. Turn unit ON.

R E

2. Install pressure gauge onto oxygen outlet.

NOTE: Check O2 pressure at oxygen outlet. It should read a steady 5 p.s.i.

not in specification, proceed to STEP 3. If difficulty is encountered in adjusting or maintaining

5 p.s.i.

sure does fall within specification, operate normally.

+ 0.5 p.s.i., refer to the TROUBLESHOOTING GUIDE in this manual for assistance. If pres-

+ 0.5 p.s.i. If pressure is

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM

ELECTRICAL OUTLET BEFORE SERVICING.

3. Unplug unit.

4. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

5. Move product tank back to access regulator (Refer to PROCEDURE 6 - REPLACING/ADJUSTING REGULATOR - Replacing Regulator [FIGURE 1]).

6. Plug unit in and turn power switch ON.

CAUTION

7. Locate the pressure adjustment screw in center of regulator.

8. Insert a 3/32-inch Allen wrench into the pressure adjustment screw.

9. While reading pressure gauge, turn pressure adjustment screw: a) Clockwise to increase output pressure or; b) Counterclockwise to decrease output pressure.

10. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Pressure Regulator

Product Tank

Pressure Adjustment Screw (3/32-inch

Adjustable Clamp

Allen Wrench).

FIGURE 2 - ADJUSTING REGULA T OR

Sieve Beds

(Removed for Clarity)

COMPRESSOR PROCEDURE 7 PROCEDURE 7 - REPLACING COMPRESSOR ASSEMBLY OR CAPACITOR

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

Replacing Compressor Assembly (FIGURE 1)

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Disconnect intake and exhaust hoses from compressor assembly.

NOTE: If resonator is aluminum can design, leave it intact on compressor assembly until compressor has been removed from concentrator.

4. Disconnect molex connector from compressor assembly.

5. Disconnect ground (green) wire (NOT SHOWN) from back of sound box and pull wire through grommet.

Base (Underside)

6. Cut and remove ty-wraps.

7. Remove the four (4) mounting screws securing compressor brackets to base.

8. Tilt compressor assembly toward front of unit and lift out.

NOTE: If replacing capacitor only, proceed to Replacing Capacitor (FIGURE 2).

9. If resonator is aluminum can design, remove it from existing compressor and install on NEW compressor.

10. Reverse STEPS 3-8 to install new compressor assembly.

11. Run unit and inspect for leaks (Refer to PRO- CEDURE 19 - LEAK TEST).

12. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Grommet

Intake Resonator

Ground (Green) Wire

C O M P R E S S O R

Intake Hose

(NOT SHOWN)

Tilt Compressor Forward and Remove.

Compressor Mounting Screws

FIGURE 1 - REPLACING COMPRESSOR ASSEMBLY

Replacing Capacitor (FIGURE 2)

1. Remove compressor. (Refer to Replacing Compressor Assembly (FIGURE 1).

2. Remove terminal boot on wires (if present).

3. Disconnect the wires to the capacitor.

4. Remove ty-wraps and capacitor from bottom of Compressor Mounting Bracket.

5. Install NEW capacitor by reversing STEPS 2-4.

Ty-wraps

Molex Connector

Exhaust Hose

(NOT SHOWN)

8. Reinstall compressor assembly. (Refer to Replacing Compressor Assembly) (FIGURE 1).

Compressor Mounting Bracket

Capacitor

6. If applicable, transfer the unterminated terminals from the OLD capacitor to the NEW capacitor.

7. Reconnect spade connectors from compressor to connectors on capacitor.

Ty-wraps

Remove/ Connect Wires Here.

FIGURE 2 - REPLACING CAP ACITO R

PROCEDURE 8 HEAT EXCHANGER PROCEDURE 8 - REPLACING HEAT EXCHANGER (FIGURE 1)

H E A

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

T E

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

CAUTION

3. Remove compressor assembly (Refer to PROCEDURE 7 - REPLACING COMPRESSOR ASSEM-

H A N

BL Y OR CAP ACIT OR).

NOTE: Concentrator can be laid down to more easily access heat exchanger.

4. Cut the four (4) ty-wraps that secure the heat exchanger to the four (4) ty-wrap mounts under the top of the sound box.

CAUTION

If applicable, use care not to damage fins of heat exchanger when installing, removing or cleaning.

5. Loosen the adjustable clamps on the compressor output and valve manifold input hoses at the front and rear of the heat exchanger.

6. Move the heat exchanger out to access the hoses and remove them from the heat exchanger.

7. Remove heat exchanger.

8. Ensure that protective (paper) cover is installed onto the front of finned heat exchanger. If NEW heat exchanger is being installed, discard protective paper cover.

9. Reverse STEPS 4-6 to install new heat exchanger.

10. Torque adjustable clamps to heat exchanger to 6.5

11. Run unit and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

12. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Ty-wrap Mounts (4)

(Removed for Clarity ONL Y. DO NOT REMOVE.)

Sound Box

FINS

+ 1 inch lbs.

Adjustable Clamp

Compressor Output Hose

(To Heat Exchanger from Compressor.)

Ty-wraps (4)

Heat Exchanger. NOTE: Fins not present on all models.

FIGURE 1 - REPLACING HEA T EXCHANGER

Adjustable Clamp

Protective (Paper) Cover. NOTE: Protective paper cover not necessary for unfinned models.

Valve Manifold Input Hose

(From Heat Exchanger to 4-way Valve Manifold.)

CONTROL PANEL PROCEDURE 9 PROCEDURE 9 - REMOVING CONTROL PANEL (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove the two (2) upper mounting screws that secure the control panel.

4. Loosen the two (2) lower mounting screws that secure the control panel.

5. Cut the ty-wraps that secures the 1/8-inch I.D. transducer tubing to the product tank and remove tubing from the top of the product tank.

6. Remove the 1/4-inch I.D. pressure regulator tubing from the tee fitting behind the control panel.

7. Disconnect the 9-pin molex connector from P.C. Board.

8. Disconnect the 8-pin molex connector from P.C. Board.

9. Disconnect the 4-pin connector to interface cable from P.C. Board (Telemetry Unit ONLY).

10. Remove and code connectors from circuit breaker, hour meter and On/Off switch. (Jumper wire har-

ness from On/Off switch to circuit breaker does not have to be removed).

P A N E

11. Remove control panel.

12. Reverse STEPS 3-10 to re-install control panel.

13. Run unit and check for leaks at transducer tubing on product tank cap (Refer to PROCEDURE 19 -

LEAK TEST).

14. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Circuit Breaker

(8 Amp)

Jumper Wire

(On/Off Switch to Circuit Breaker.)

Hourmeter

9-Pin Connector

On/Off Switch

Flowmeter Tubing

Upper Mounting Screws

(2 ea. - 1 per side.)

Control Panel

(Lower front of Control Panel.)

8-Pin Connector

1/4" I.D. Regulator Tubing (To Product

Tank.)

1/8" I.D.Transducer

Tee

Fitting

Tubing

(To Product Tank.)

FIGURE 1 - REMOVING CONTROL PANEL

Lower Mounting Screws

(2 ea. - 1 per side.)

PROCEDURE 10 FAN PROCEDURE 10 - REPLACING COOLING FAN (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove compressor assembly (Refer to PROCEDURE 7 - REPLACING COMPRESSOR ASSEMBL Y OR CAPACITOR).

5. Remove heat exchanger (Refer to PROCEDURE 8 - REPLACING HEA T EXCHANGER).

NOTE:Before removing the four (4) mounting clips, note their position. These clips must be properly reinstalled to secure heat exchanger.

6. Remove the four (4) mounting screws located under sound box and remove mounting clips.

7. Move fan to access the wires connected to fan.

8. Disconnect wires from spade connectors on back side of fan.

9. Remove GREEN ground wire from rear of fan by removing self-tapping screw on fan assembly.

10. Remove existing fan.

WARNING Fan must be positioned properly so air from the fan blows DOWN onto the compressor (see air flow arrow on back of fan) or damage to the unit will occur.

11. Reverse STEPS 6-9 to install NEW fan.

12. Reinstall heat exchanger (Refer to PROCEDURE 8 - REPLACING HEAT EXCHANGER).

13. Reinstall compressor (Refer to PROCEDURE 7 - REPLACING COMPRESSOR ASSEMBLY OR

CAP ACITOR).

14. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

15. Plug unit in and check for leaks (Refer to PROCEDURE 19 - LEAK TEST).

NOTE:Run unit for at least 1/2 hour . If unit runs properly, replace cover. If not, call Invacare Technical Service.

16. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

FAN PROCEDURE 10 (continued) - REPLACING COOLING FAN (FIGURE 1)

Self Tapping Screw

GREEN

Ground Wire

Cooling Fan

(See Drawing for Rear Detail.)

Mounting Clips (4)

Spade Connectors

(Rear of Fan.)

PROCEDURE 10

Air Flow Arrow

(Rear of Fan.)

F A N

Spade Connectors

Mounting Screws

(4)

Ty-wraps (4)

Heat Exchanger.

NOTE: Fins not present on all models.

FIGURE 1 - REPLACING COOLING FAN

Adjustable Clamp

Compressor Output Hose

(To Heat Exchanger from Compressor.)

Valve Manifold Input Hose

(From Heat Exchanger to 4-way Valve Manifold.)

Fan Detail

(Rear of Fan)

PROCEDURE 11 P.C. BOARD REPLACEMENT PROCEDURE 11 - REPLACING P.C. BOARD(S) (FIGURE 1)

CAUTION

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM

ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

A R D

ONL Y QUALIFIED SERVICE TECHNICIANS SHOULD MAKE ANY CHANGES TO THIS EQUIPMENT.

These are precautions that should be followed to prevent damage to the P. C. boards: Before handling any P. C. boards, you need to be properly grounded to prevent static damage to the components of the board. A Static Cuff must be worn and properly grounded using an alligator clip. Electrical conduit or a water pipe is normally sufficient when a known good ground is not available. Care should be taken to ensure that alligator clip contact with bare metal surface.

When removing quick disconnects, DO NOT pull on wire itself as damage to the connector or solder joint may occur. Hold down the P. C. board with one hand and use an upward force with a slight rocking motion to remove the terminals.

WARNING

Before installing any P. C. boards, ensure that all insulators are in place.

4. Remove Sensor Wiring Harness Jumper (P2) from P.C. board(s) to be replaced.

5. Disconnect the following:

CAUTION DO NOT remove sensor tubing from P.C. Board. Remove from tee fitting ONLY. Damage to sensor assembly could occur.

3LX, 5LX and 5LXO2 before S/N97JXXXX

Sens

O2 (T op) P .C. Board (5LXO2 ONL Y):

a) Sensor tubing from "T" fitting behind control panel (Refer to PROCEDURE 9 - REMOVING

CONTROL PANEL).

Control (Bottom) P .C. Board (3LX, 5LX, 5LXO2):

a) Wiring Harness from 9-Pin Wiring Harness Connector (P1). b) Wiring Harness from 8-Pin Wiring Harness Connector (P5). c) Transformer connector (P3). d) Pressure transducer tubing from product tank.

Integrated Board (5LXO2/5LXO2T/6LXO2/6LXO2T) After

a) Wiring Harness from 9-Pin Wiring Harness Connector (P1). b) Wiring Harness from 8-Pin Wiring Harness Connector (P5). c) Transformer connector (P3). d) Pressure transducer tubing from product tank. e) Oxygen Sensor tubing from "T" fitting behind control panel (Refer to PROCEDURE 9 - REMOVING

CONTROL PANEL).

f) Wiring Harness from 4-pin wiring harness connector (P6) [5LXO2T, 6LXO2T Telemetry Unit ONLY].

S/N97JXXXX

Remote Display Board

a) Sensor wiring harness if not disconnected in STEP 1.

6. Pinch end of each stand-off with needle-nose pliers and remove the P.C. Board(s).

P.C. BOARD PROCEDURE 11

PROCEDURE 11 (continued)- REPLACING P.C. BOARD(S) (FIGURE 1)

7. Position NEW P.C. board(s).

8. Snap P.C. Board(s) into place.

9. 3LX, 5LX and 5LXO2 after S/N 97JXXXX. Connect the following:

Sens

O2 or Integrated (T op) P.C. Board (5LXO2 ONL Y):

a) Sensor tubing to "T" fitting behind control panel (Refer to PROCEDURE 9 - REMOVING

CONTROL PANEL).

Control (Bottom) P.C. Board (IRC3LX, IRC5LX, IRC5LXO2):

a) Wiring Harness to 9-Pin Wiring Harness Connector (P1). b) Wiring Harness to 8-Pin Wiring Harness Connector (P5). c) Transformer connector (P3).

10. Reinstall Sensor Wiring Harness Jumper (P2) to P.C. board(s).

11. Reconnect P6 (4-pin connector) on wiring harness on Telemetry Units ONLY.

12. Set timing switch to position "F" for 3LX.

13. Run unit and ensure that concentrator operates to specification.

NOTE: After replacing P.C. Board(s), retiming may be necessary. (Refer to PROCEDURE 18 TIMING THE INV ACARE OXYGEN CONCENTRATO R.

P C

A R D S

14. Check for leaks at transducer tubing on product tank cap (Refer to PROCEDURE 19 - LEAK TEST in this manual.

15. Reinstall control panel (Refer to PROCEDURE 9- REMOVING CONTROL PANEL).

16. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

INTEGRATED SETUP

5LXO2 After S/N97JXXXX

P2 (Remove Sensor Wiring Harness Jumper.)

Sensor Wiring Harness Jumper

9 Pin Wiring Harness Connector (To P1)

Sens

O2 (T op) P.C. BOARD (5LXO2, 5LXO2T, 6LXO2, 6LXO2T ONL Y)

(P1)

(P5)

LED2

LED1

(P3)

Control Panel

REAR

Stand-off for SensO2 Board

Sensor

Sensor Tubing

Pressure Transducer

Stand-offs

Transformer

Stand-offs

Transducer Tubing

8-Pin Wiring Harness Connector (To P5)

P2 (Remove Sensor Wiring Harness Jumper.)

CONTROL (Bottom) P.C. BOARD

(3LX, 5LX, 5LXO2, 5LXO2T, 6LXO2, 6LXO2T)

FIGURE 1 - REPLACING P. C. BOARD(S)

PROCEDURE 12 TRANSFORMER PROCEDURE 12 - REPLACING TRANSFORMER ASSEMBLY (FIGURE 1)

T R

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

CAUTION

1. Unplug unit.

S F

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Locate the transformer assembly in the upper right corner on the back of control panel.

5. Unplug the transformer connector from the Control (bottom) P.C. Board.

E R

6. Remove the two (2) keps nuts that secure transformer to the back of the control panel.

7. Reverse STEPS 5-6 to install NEW transformer.

8. Torque keps nuts to 13.5

9. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

10. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

+ 1 in. lbs.

Transformer P.C. Board Connector (All Models)

Transformer Assembly

Keps Nut

Transformer Connector

Control Panel

Control (Bottom) P.C. Board (Typical)

Keps Nut

FIGURE 1 - REPLACING TRANSFORMER ASSEMBLY

ON/OFF SWITCH PROCEDURE 13 PROCEDURE 13 - REPLACING ON/OFF SWITCH (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove and code the four (4) wires from back of existing On/Off switch.

5. Compress retaining grips on back of existing On/Off switch and push switch out through front of panel.

CAUTION DO NOT install the On/Off switch upside down. Universal OFF symbol should be at bottom and Universal ON symbol should be at the top. Possible damage to the concentrator may result if not properly installed.

NOTE: Ensure proper orientation of the On/Off switch and wiring connections before installation. See Detail A and Detail B below.

F F

T C H

6. Reverse STEPS 4-5 to secure NEW On/Off switch.

7. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

8. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Control Panel

On/Off Switch

(See Detail A and Detail B for proper Switch installation.)

Brown Jumper Wire

(From Circuit Breaker)

OFF

Detail A - Front of

On/Off Switch -

Universal ON and OFF

Symbols.

Brown

Black

On/Off Switch

Switch Wiring Orientation

FIGURE 1 - REPLACING ON / OFF SWITCH

Detail B - Back of

ON/OFF Switch -

PROCEDURE 14 FLOWMETER

PROCEDURE 14 - REPLACING FLOWMETER (FIGURE 1)

CAUTION

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove tygon tubing from the top and bottom fittings on back of flowmeter.

5. Remove palnuts from rear of flowmeter.

6. Remove flowmeter from front of control panel.

7. Install new flowmeter reversing STEPS 4-5.

8. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

9. Run unit and check for leaks where tygon tubing engages flowmeter fittings (Refer to PROCEDURE

19 - LEAK TEST).

10. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Flowmeter

Flowmeter Fittings

(Back of Flowmeter)

Palnuts

Control Panel

FIGURE 1 - REPLACING FLOWMETER

HOUR METER PROCEDURE 15 PROCEDURE 15 - REPLACING HOUR METER (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove and code the two (2) wires connected to back of hour meter.

5. Spread retaining clips on hour meter housing that secure hour meter to control panel.

6. Remove hour meter by pushing meter through front of control panel.

7. Install new hour meter reversing STEPS 4-6.

8. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

9. Reinstall cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Hour Meter Housing

Hour Meter

H O U R

E T E

Retaining Clips

(Hour Meter Housing)

Back of Control Panel

FIGURE 1 - REPLACING HOUR METER

Hour Meter Connectors

4-WAY V AL VEPROCEDURE 16

PROCEDURE 16 - REPLACING 4-WAY VAL VE/MANIFOLD ASSEMBLY/PILOT V ALVES

TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM

ELECTRICAL OUTLET BEFORE SERVICING.

Replacing 4-way Valve (FIGURE 1)

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove the four (4) mounting screws that secure the 4-way valve to the manifold assembly.

5. Position NEW 4-way valve onto manifold assembly and loosely install mounting screws through 4-way

valve and into manifold assembly.

Torque sequence and specification MUST BE adhered to or possible damage to the 4-way valve could result.

6. Tighten mounting screws in the sequence described below (FIGURE 1).

7. Pre-torque the mounting screws to 10

8. The mounting screws can be now be torqued to 27

CAUTION

+ 2 in. lbs. using the torque sequence.

+ 3-in. lbs. in the same sequence.

STOP! THIS IS A MAINTENANCE FREE VALVE. OPENING THE V AL VE WILL

VOID ANY AND ALL W ARRANTIES APPLICABLE T O THE VALVE.

4-way Valve Face

4-way Valve

Mounting

Screws

FIGURE 1 - REPLACING 4-WAY V ALVE

Replacing 4-way Valve Manifold Assembly (FIGURE 2)

1. Unplug unit.

2. Remove cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Remove control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

4. Remove the ty-wraps from the sieve bed hoses to top of manifold assembly.

5. Remove hoses from manifold assembly.

6. Remove and code the four (4) spade connectors - two (2) each from the two (2) valve pilots on top of the manifold assembly.

Manifold Assembly

MOUNTING SCREW TORQUE SEQUENCE

Pre-torque to 10 + 2-in. lbs., then Torque

to 27 + 3-in. lbs.

7. Remove the mounting screw(s) that secures muffler canister assembly to rear of sound box (Refer to PROCEDURE 2 - PREVENTIVE MAINTENANCE).

8. Remove muffler from muffler canister.

9. Loosen the adjustable clamp that secures valve manifold input hose to front of heat exchanger.

10. Remove hose from front of heat exchanger.

PROCEDURE 164-WAY V AL VE

PROCEDURE 16 - REPLACING 4-WAY VAL VE/MANIFOLD ASSEMBLY/PILOT V ALVES

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

Ty-wraps

(STEP 4)

Spade Connectors

(STEP 6)

4-way Valve

(STEP 13)

Compressor Output Hose

(STEP 17)

Muffler Canister w/Exhaust Hose

(STEP 15)

Sieve Bed Hoses (STEP 5)

Mounting Screw

Washer

Sound Box

Top

Mounting Detail for Manifold

Assembly (STEP 1 1)

Adjustable Clamp

(STEP 16)

Ty-wraps

(STEP 14)

Bushing

(2) per side

Heat Exchanger (Typical)

Adjustable

Clamp

Valve Manifold

Input Hose

(STEP 9)

NOTE: NEW Heat Exchanger does NOT have fins.

V A

L V E

FIGURE 2 - REPLACING 4-WAY VALVE MANIFOLD ASSEMBLY

11. Remove the two (2) mounting screws, washer and bushings from manifold securing 4-way valve assembly to top of sound box.

12. The 4-way valve/manifold assembly can be removed from the concentrator by lifting the assembly straight up through the cutout in the sound box.

13.Remove 4-way valve from manifold assembly. (Refer to PROCEDURE 16 - REPLACING 4-WAY V AL VE/MANIFOLD ASSEMBLY) (FIGURE 1).

14. Remove ty-wraps from the muffler canister hoses on the bottom outside fittings of manifold assembly (Refer to PROCEDURE 2 - PREVENTIVE MAINTENANCE).

15. Remove muffler canister w/hoses from manifold.

16. Loosen the adjustable clamp on output hose to bottom center port of manifold assembly.

17. Remove hose from bottom center port of manifold assembly.

18. Reverse STEPS 13-17 to re-install.

19. Slide 4-way/manifold assembly complete through the cutout in top of sound box then install the two (2) mounting screws, washer and bushings into the manifold to secure the 4-way valve assembly to the top of sound box.

20. Reverse STEPS 4-10.

21. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

22. Plug unit in and turn power ON.

23. Run unit and check for leaks at hose connections (Refer to PROCEDURE 19 - LEAK TEST).

4-WAY V AL VEPROCEDURE 16

PROCEDURE 16 (continued) - REPLACING 4-WAY VAL VE/MANIFOLD ASSEMBLY/PILOT VALVES

Replacing 4-way Valve Manifold Assembly (continued) (FIGURE 2).

24. Check for proper system operation. (Refer to the SPECIFICATION section of this manual).

25. Re-install cabinet (Refer to PROCEDURE 1 - REMOVING CABINET).

Replacing Pilot Valve Poppets and "O" Rings (FIGURES 3 & 4). NOTE: Both pilot valves can be accessed while the 4-way valve and sieve bed hoses are intact on

the concentrator.

A L

NOTE: DO NOT remove spade connectors from pilot valve coils. Simply lay coils with spade connectors aside while performing this installation.

V E

1. Hold pilot valve stem with the flat blade screwdriver and turn the 9/16-inch locknut counterclockwise one (1) complete turn.

2. Unscrew the pilot valve stem assembly from the manifold while leaving the coil with yoke and locknut intact on stem.

3. Remove pilot valve poppet from inside the pilot valve stem.

STOP! DO NOT REMOVE THE COIL YOKE FROM THE COIL.

The Washer between the Bottom of the Y oke and the Bottom of Coil IS NOT DESIGNED TO BE REMOVED and difficulty in reassembly will be encountered that could cause damage to components.

4. Set aside the coil with yoke and pilot valve stem assembly with the wires still intact.

CAUTION DO NOT use sharp tools to remove "O" ring from plastic manifold opening. Damage to the plastic manifold and/or plastic manifold airflow passage could occur (FIGURE 3).

5. Remove "O" ring from manifold opening.

6. Discard old poppet and "O" ring.

Manifold

"O" Ring

Air Flow

Passage

FIGURE 3 - REMOVING/INSTALLING "O" RINGS

Opening

7. Install NEW "O" ring into the opening in the plastic manifold housing.

CAUTION DO NOT overtighten pilot valve stem when installing it into plastic manifold. Damage to the rubber "O" ring and/or plastic manifold may occur.

8. Install NEW slotted poppet into the bottom of the pilot valve stem with tapered end facing to the bottom

(FIGURE 3).

9. Install pilot valve stem and NEW slotted poppet with coil with yoke and locknut intact into manifold opening.

PROCEDURE 164-WAY V AL VE

PROCEDURE 16 (continued) - REPLACING 4-WAY VAL VE/MANIFOLD ASSEMBLY/PILOT VALVES

Sieve Bed Hoses

LEAVE

TOGETHER

Yoke

Pilot Valve Stem

Locknut

Spade Connectors

(Leave Wire Connectors

Intact).

Tapered End

Slotted Poppet

Pilot Valve Coil

Yoke

Pilot Valve

Valve Body

(Reference)

New Label

Pilot Valve

Stem

Locknut

Valve Body

(Reference)

Label

New

Coil

A Y

V A

L V E

Manifold

Manifold Opening

"O" Ring

FIGURE 4 - REMOVING/INST ALLING PILOT VALVE POPPETS AND "O" RINGS

10. Use the flat blade screwdriver and tighten pilot valve stem clockwise until snug. (Reference: Torque to 25-inch lbs. + 5-inch lbs.).

11. Install NEW label onto pilot valve coil yoke.

12. Position pilot valve coil with yoke at an approximate 60

angle to the left (as viewed from the front of

valve) to ensure spade connectors are not pulled or tensioned after reinstallation.

13. Use the flat blade screwdriver and hold the pilot valve stem in place.

14. Tighten locknut clockwise with the 9/16-inch wrench until snug to secure the stem and coil with yoke.

DO NOT OVERTIGHTEN. (Reference: Torque to 20-inch lbs.

+ 3-inch lbs.).

CAUTION DO NOT overtighten locknut when installing it onto pilot valve stem. Damage to the plastic manifold may occur.

15. Repeat the STEPS 1 through 14 for other pilot valve.

16. Reinstall control panel (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

CAUTION Ensure that hoses behind control panel DO NOT contact cooling fan after control panel reinstallation.

17. Plug power cord in and turn concentrator on to ensure proper operation.

18. Reinstall cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

19. If any difficulties are encountered in this installation, contact Invacare Technical Service at

(800) 832-4707 or in Florida 1 - (407) 321-5630.

PROCEDURE 17 PURITY SWITCH PROCEDURE 17 - SENSO2 ALARM INDICATORS AND SWITCH

P U

TO PREVENT ELECTRICAL SHOCK, ALWAYS

DISCONNECT CONCENTRATOR FROM ELEC-

TRICAL OUTLET BEFORE SERVICING.

CAUTION

Operation

The Invacare 5 and 6 with SensO2 is equipped with an oxygen purity indicator. This feature monitors

the purity level of the oxygen generated by the

concentrator. If purity falls below alarm thresholds,

indicator lights on the control panel will illuminate.

C H

NOTE: Concentrator can be used during initial warm-up time (approx. 30 minutes). When the unit is initially turned ON, no oxygen purity lights will illuminate. Within 5 to 30 minutes after initial startup, a GREEN light will illuminate in the Oxygen Purity Section of the Control Panel if the concentration level is in specification. Any other indicator light illuminating will signal a condition that requires service. The concentrator may be used while waiting for a light to illuminate.

Indicator Lights (FIGURE 1) GREEN LIGHT - Normal Operation.

YELLOW LIGHT - You may continue to use the

concentrator unless instructed otherwise by your supplier. Call Supplier IMMEDIATELY. Be certain that BACKUP OXYGEN is nearby.

RED LIGHT - Total unit shutdown. Switch IMMEDIATELY to BACKUP OXYGEN supply. Call Supplier IMMEDIATELY.

Oxygen Purity

Auto Shut - Down

Use Backup

Below Normal

Call Supplier

Normal

FIGURE 1 - INDICA TOR LIGHTS

Purity Indicator Switch

1. Unplug unit.

2. Remove cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Locate purity switch on upper left corner of Sensor Board.

4. Set the indicator switch to either 73% or 85%. (Switch

is factory preset at 73%). (Refer to Alarm Thresholds in the SPECIFICATION section of this manual).

5. Plug in power cord.

6. Run unit and check the indicator lights for operation in accordance with specifications set forth in this PROCEDURE.

7. If problems exist, call Invacare Technical Support.

8. Refer to Operating Sequence in the INST ALLA- TION AND SEQUENCE OF OPERATION portion of this manual.

9. If operation is within specification, reinstall cabinet.

(Refer to PROCEDURE 1 - REMOVING CABINET).

- If Installed (FIGURE 2)

RED

YELLOW

GREEN

GREEN LIGHT - with YELLOW LIGHT FLASHING

- Oxygen sensor malfunctioning; you may continue to use the concentrator. Call Supplier IMMEDI-

A TELY. NOTE: If your Invacare Concentrator

board is equipped with an alarm threshold switch then you can set the level at which the purity indicators will activate. The switch is located on the sensor board near the top of the unit. (See PURITY INDICA TOR SWITCH graphic) (FIGURE 2).

Refer to - Alarm Thresholds in the SPECIFICATION section of this manual.

NOTE: Indicator lights are visible only when lit.

Sens

O2 P .C.

TOP-LEFT

73%

FIGURE 2 - PURITY INDICA TOR SWITCH

Purity Switch Settings

85%

Sensor Board

TIMING PROCEDURE 18

PROCEDURE 18 - TIMING THE INVACARE 5 AND 6 CONCENTRATORS (FIGURE 1)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

To accommodate for varying tolerances when replacing components, an adjustable timer is used to control the shifting of the INVACARE 5 and 6 Pressure Equalization (P.E.) Valve. Retiming of a unit involves increasing or decreasing the switch located on the lower right side of the bottom P.C. Board.

1. Unplug unit.

2. Remove cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

3. Plug concentrator in, and turn power on, set flow at 5 L/min. for the IRC5LX/IRC5LXO2.

4. Run unit for 20 minutes.

5. Take O2 reading.

6. If oxygen concentration is within specification, retiming is not necessary.

7. Unplug unit and reinstall cabinet.

UNITS WITH CONTROL BOARD OR LX SMT BOARD IRC5LX/5LXO2

1. If retiming is needed, perform the following:

a) Unplug unit. b) Remove or loosen control Panel. (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL). c) Locate the timing switch on the lower right side of the bottom P.C. Board.

WARNING Use extreme care when making adjustments to the timing switch. DO NOT allow screwdriver or your hands to contact the P.C. Board when unit is plugged in and ON. Turn unit OFF and unplug before adjusting timing switch. Electrical shock is possible.

Control Panel

Timing Switch

Control Panel

Adjustment Screw

FIGURE 1 - TIMING THE INV ACARE 5 CONCENTRATOR - IRC 5LX/5LXO2

PROCEDURE 18 TIMING PROCEDURE 18 UNITS WITH CONTROL BOARD OR LX SMT BOARD IRC5LX/5LXO2 (FIGURE 1)

(CONTINUED)

d) Insert a small common or flathead screwdriver into the adjustment screw of the timing switch.

e) Set the timing switch initially at the number 7 position.

2. Turn unit on.

3. If after 10 minutes of run time the concentration is below specification, change setting to a number

I N G

one (1) position lower than the previous setting.

4. Let unit run another 10 minutes. If concentration is lower still, change the switch to a number two (2) positions higher.

NOTE: You will find that the concentrator will perform better at either the higher or lower setting. The normal adjustment range is between 3 and A.

5. Continue to change setting one (1) step at a time (up or down) until the concentration is the highest value achievable. (Refer to CONCENTRA TION LEVELS Chart in this PROCEDURE of the Manual.)

6. Once concentration has reached specification, retiming is complete.

7. Reinstall inlet filter.

8. Reinstall control panel. (Refer to PROCEDURE 9 - REMOVING CONTROL PANEL).

9. Reinstall cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

TIMING IRC5LXO2/5LXO2T/6LXO2/6LXO2T - UNITS WITH INTEGRATED OR TELEMETRY BOARDS (FIGURE 1)

To accomodate the varying tolerances when replacing components, an adjustable timer is used to control the shift time of the pressure equlization (P. E.) valve. The integrated and telemetry boards allow for either manual or automatic (microprocessor controlled) adjustments of the P.E. shift times.

If manual adjustments is preferred, please refer to SECTION A of this procedure. Automatic adjustment is performed by the onboard microprocessor to optimize the oxygen output concentration.

Unattended operation is possible without the use of any additional manual adjustments.

1. Turn power OFF and unplug the unit.

2. Remove cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

3. a. If the intergrated or telemetry board has beeen replaced, set the timing switch to position "0". b. If the intergrated or telemetry board has NOT beeen replaced, set the timing switch to position "F".

4. Replace the cabinet. Plug concentrator in, and turn power on, set flow at 5 L/min. for the IRC5LXO2/IRC5LXO2T and 6 L/min. for the IRC6LXO2/IRC6LXO2T.

NOTE: The flow MUST be at rated output for optimum adjustment of oxygen output for all flow ranges.

5. After the FIRST valve shift, the front panel Red LED will slowly blink. This indicates that the unit is in the autotune mode. The microprocessor automatically adjusts the length of the P.E. valve timing up or down to provide maximum value of oxygen concentration for the unit at rated flow.

6. a. If the switch is set to position "0", the auto-tune will take a minimum of three (3) hours to complete. b. If the switch is set to position "F", the auto-tune will take a minimum of 45 minutes to complete.

7. If the front panel Red LED does NOT blink or the unit alarms immediately, check the timimg switch position.

8. When the auto-tune procedure is completed, the alarm will sound every 3-4 seconds and the front panel Red LED will change from slowly blinking to rapid flashing. Count the number of Red LED flashes between the pauses. This indicates the P.E. timing value the microprocessor has determined as optimum for maximum

PROCEDURE 18TIMING

oxygen production. This Red LED count corresponds to the same numbers on the timing switch in the manual mode. Record this number.

9. If the timing switch was in position "0" at the start, turn the unit OFF and then BACK on. The unit will now function normally. The timimg value is stored in the microprocessor's memory and is recalled everytime the unit is turned back ON.

10. If the timing switch was in position "F" at the start, remove the cabinet and change the position to "0". The alarm should stop sounding and the Red LED will stop flashing. The unit will now function normally. The timimg value is stored in the microprocessor's memory and is recalled everytime the unit is turned back ON.

11. The timing switch MUST be in position "0" for the automatic control of the P.E. valve time by the unit's microprocessor for maximum oxygen concentration. The timing switch can be changed to manual control by selecting position "1" to "E". Verification of oxygen production MUST be performed according to SECTION A of this procedure.

CONCENTRATION LEVELS CHART - (IRC5LX/5LXO2/6LXO2)

L/Min. O2 Level

1 L/min. 95.6% to 93% 2 L/min. 95.6% to 93%

I N G

3 L/min. 95.6% to 93% 4 L/min. 95.6% to 91% 5 L/min. 95.6% to 87% 6 L/min. 95.6% to 87%

PROCEDURE 19 LEAK TEST PROCEDURE 19 - LEAK TEST

(FIGURES 1-3)

TO PREVENT ELECTRICAL SHOCK, ALWAYS

DISCONNECT CONCENTRATOR FROM

ELECTRICAL OUTLET BEFORE SERVICING.

CAUTION

Leak Test

1. Unplug unit.

2. Remove cabinet. (Refer to PROCEDURE 1 REMOVING CABINET).

3. Turn the concentrator on.

4. Let concentrator run for 20 minutes.

CAUTION Apply small amount of leak test solution to fittings only . Avoid all other components. DO NOT leak test 4-way Valve body. Carefully leak test for pressure leaks around Sieve Bed Hoses at 4-way Valve. DO NOT allow leak test solution to enter into 4-way Valve and system.

5. With "leak-test" or equivalent soapy water, leak test the following:

a) The two (2) sieve bed hoses at the top of

4-way Valve and hose to bottom center port on 4-way Valve (FIGURE 1).

NOTE: Refer to PROCEDURE 2 - PREVENTIVE MAINTENANCE for maintenance of heat exchanger and filters.

b) Hose connections to top and bottom fittings of

sieve beds.

c) P.E. Valve hose connections on top of sieve

beds - IRC 5LX/IRC5LXO2 (FIGURE 2).

d) Hose fittings at product tank cap and check

valves (FIGURE 2).

Sieve Bed Hoses to 4-way Valve

(STEP 5-a).

Hose Fitting on Bottom Center Port of 4-way Valve

(STEP5-a).

FIGURE 1 - 4-WAY V ALVE HOSES

Hose Connections to

P.E. Valve Fittings

[5LX/5LXO2/6LXO2 ONLY.] (STEP 5-c.)

All Hoses to Product Tank Cap

(STEP 5-d).

Top Fittings of Sieve Beds (STEP 5-b).

Hose Connections to Bottom Fittings of Sieve Beds (STEP 5-b).

FIGURE 2 - SIEVE BED AND PRODUCT T ANK

HOSES

Heat Exchanger (Typical) Hose Connections

(STEP 5-d).

Check Valve

Tubing

(STEP 5-d).

e) The front and rear fittings on heat exchanger

(FIGURE 3).

6. Replace any tubing that appears cracked, worn, etc.

7. Re-install cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET).

8. See SPECIFICATION section of this manual for Concentration Levels. If low concentrations are observed, refer to the TROUBLESHOOT-

ING GUIDE in this manual.

NOTE: NEW heat exchanger does NOT have fins.

FIGURE 3 - HEA T EXCHANGER HOSES

PROCEDURE 20 - ALARM AND SENSOR TEST

PROCEDURE 20ALARM TEST

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

CAUTION

CHECK ALARMS PERIODICALL Y FOR PROPER FUNCTION.

To check each alarm, perform the following:

1. POWER LOSS - With the unit running, remove the line cord from power source. The power loss alarm

mode should sound the audible alarm immediately or within 30 seconds.

NOTE: With the unit unplugged and inoperable for a short period of time, the Battery Free will be drained. If power failure alarm does not sound with unit unplugged and power switch on, the Battery FreeTM circuit is drained. It will recharge when unit is plugged in and switched on.

2. LOW PRESSURE TEST- There are two (2) seperate failure modes for Low Pressure. a. Low product tank pressure (pressure in tank drops below a preset value, typically 7 p.s.i).

b. Failure to reach the set point pressure within a prescribed time limit, or Timeout Failure.

Test each in the following manner: Low Pressure Test (FIGURE 1).

circuit

L A R M

c1. With unit running, set flow at maximum rating. When the main valve switches, pull the stem on the

compressor relief valve out as far as it will go and hold it. The low pressure alarm should activate within 30 seconds. (Refer to FIGURE 5 for Shutdown Mode.)

c2. With unit running, set flow at maximum rating. Remove the P.C. board tubing (tywrap) from the top

of the product tank The low pressure alarm should activate within 30 seconds. (Refer to FIGURE 5 for

Shutdown Mode.) Replace tubing and tywrap.

Time-Out Test (FIGURE 1)

d. With unit OFF, disconnect the compressor connector from the main wiring harness. Plug

unit in and turn power ON. The Time-Out Failure alarm should activate within 40 seconds. (Refer

to FIGURE 5 for Shutdown Mode.)

NOTE: If any alarm fails to perform to specification, contact Invacare Technical Service.

Compressor

Compressor Molex Connector

[Disconnect from Harness(STEP 2-b)].

Relief Valve Stem

[Pull Out to Simulate Leak (STEP 2-a)].

Compressor

FIGURE 1 - LOW PRESSURE TEST

PROCEDURE 20 ALARM TEST

3. HIGH PRESSURE - Occurs when pressure in product tank rises beyond a preset value, typically

23 p.s.i.

Test in the following manner:

High Pressure Test (FIGURE 2).

3-a. With unit running and flow set at 3 L/min. for 3LX, 5 L/min. for 5LX/5LXO2 or 6 L/min. for 6LXO2,

3-b. Set flow at 3 l/min. for 3LX, 5 L/min. for 5LX/5LXO2 or 6 L/min. for 6LXO2. Turn unit OFF and

T E S T

NOTE: If any alarm fails to perform to specification, contact Invacare Technical Service.

+ 1 p.s.i.

remove one (1) RED wire from the top of Pilot Valve 1. The high pressure alarm should activate within 40 seconds. (Refer to FIGURE 5 for Shutdown Mode.)

remove one (1) RED wire from the top of Pilot Valve 1. Turn unit ON. The high pressure alarm should activate within 30 seconds. (Refer to FIGURE 5 for Shutdown Mode.)

ORANGE

Wires

(DO NOT Remove).

Pilot Valve 2

4-way Valve

(SHOWN FOR REFERENCE)

FIGURE 2 - HIGH PRESSURE TEST

4. OXYGEN SENSOR (5LXO2/6LXO2) - Alarm sequence occurs when concentration levels fall below

a preset value, typically 73% component mechanical or electrical. This test is performed in a series of STEPS.

Test in the following manner: Oxygen Sensor Test (FIGURE 3)

+ 3% or 85% + 2%. This failure indicates a catastrophic failure of any

RED Wires [Remove Either Wire STEPS 3-a and 3-b)].

Pilot Valve 1

Ensure that Purity Switch (SW1) is set at 73%. (Refer to PROCEDURE 17 - SENSO2 ALARM INDICATOR AND SWITCH in this manual).

4-a. Turn unit ON. Set output flow at 5 L/min. (5LXO2) or 6 L/min. (6LXO2). 4-b. Monitor the O2 level. 4-c. With the O2 level greater than 85% after 5 minutes, the GREEN panel LED will illuminate. 4-d. Slowly adjust flow beyond maximum rated flow until you can achieve a concentration level greater

than 75% but less than 84%. Within 30 min. the YELLOW panel LED indicator will illuminate and the unit will continue to run.

4-e.

Use care not to cut oxygen sensor tubing when clamping the oxygen sensor tubing.

Clamp off the 1/8-inch oxygen sensor tubing between the oxygen sensor and the tee in the supply line from the product tank.

CAUTION

PROCEDURE 20ALARM TEST

4-f. Within 30 min., the Oxygen Sensor Alarm should activate.

NOTE: 85% Setting is NOT available on units without switch. 4-g. Repeat STEPS 4-a and 4-c with (SW1) set at 85%. (Refer to PROCEDURE 17 - SENSO2

ALARM INDICA TOR AND SWITCH in this manual).

4-h. Unit will again climb to an O2 level greater than 85% after 5 minutes and the GREEN

control panel LED will illuminate. (Refer to PROCEDURE 17 - SENSO2 ALARM

INDICATOR AND SWITCH in this manual).

L A R M

4-i. Repeat STEP 4-e. 4-j. Within 30 min., the Oxygen Sensor Alarm should activate. 4-k. Reset Purity Switch to desired setting per chart (FIGURE 3).

NOTE: If problems arise during test, contact Invacare Technical Service for further assistance.

4-l. Reinstall cabinet. (Refer to PROCEDURE 1 - REMOVING CABINET). 4-m. If any alarm fails to perform to specification, contact Invacare Technical Service. Your Invacare concentrator is now ready for an additional year. Use the PREVENTATIVE MAINTE-

NANCE RECORD in this manual to record date and number of hours when preventive maintenance was performed on the concentrator, or any repairs made.

1/8-inch I.D.

Oxygen Sensor Tubing

[Clamp Off Flow (STEP 4-e and 4-i)].

LED2

(GREEN)

Control (Bottom) P.C. Board

O2 Purity

Over 85% (+ 2%)

73% (+ 3%) to 85% (+2%)

Below 73% (+ 3%)

FIGURE 3 - OXYGEN SENSOR TEST

LED1 [RED (STEP 4-j)].)

Indicators

Internal Switch (If Present) *Set at 73%

GREEN Indicator Light

YELLOW Indicator Light

RED Indicator Light -

Continuous Audible Alarm Sieve GARD Compressor Shutdown

* Factory Preset at 73%

Internal Switch (If Present) Set at 85%

GREEN Indicator Light

RED Indicator Light -

Continuous Audible Alarm Sieve GARD Compressor Shutdown

N/A

PROCEDURE 20 ALARM TEST

5-a. P.E. Valve Coil (IRC5LXO2 after S/N 97JXXXX) - Alarm sequence occurs when the P.E. Valve

Coil, connection or P.C. Board Circuitry has failed.

Test in the following manner:

L A

P.E. Valve Coil Test (FIGURE 4)

5-b. With the unit running and flow set at 5 L/min., remove one (1) yellow wire from the P.E. Valve. The

P.E. Coil Alarm should activate within 10 seconds. (Refer to FIGURE 5 for Shutdown Mode.)

T E S

P.E. Valve Coil

Yellow Wires

FIGURE 4 - P.E. VALVE COIL TEST

ALARM MODES

3LX, 5LX, 5LXO2

(BEFORE S/N 97JXXXX)

INTERNAL LED

ALARM RED GREEN High Pressure On Off

Low Pressure On On Time-Out On On

(30 Secs.) Low O2 On Off

All alarms have Compressor Shutdown, Horn ON and IRC5LXO2 ONLY - RED Panel LED ON.

3LX, 5LX, 5LXO2/5LXO2T, 6LXO2/6LXO2T

(AFTER S/N 97JXXXX)

INTERNAL LED FLASHES

ALARM RED GREEN

Three (3) Beeps at 0 0 No Problems - System Startup OK

Short Beep, 0 0 Main Power Loss Long Pause

Continuous 1 1 Low Pressure:

Major Leak

Continuous 1 2 High Pressure:

No Switching

Continuous 1 3 Time-out Failure:

Compressor Continuous 1 4 Pilot Valve 1 Coil Continuous 1 5 Pilot Valve 2 Coil Continuous 2 1 73% Shutdown: Low O2 Continuous 2 3 PE Valve Coil Continuous 2 4 Eprom Failure Continuous 2 5 Ram Failure Continuous 3 1 Oxygen Sensor Failure

*No Shutdown, Unit continues to run. All alarms have Compressor Shutdown, Horn ON and 5LXO2/5LXO2T, 6LXO2/6LXO2T ONLY - RED Panel LED ON.

FIGURE 5 - ALARM MODES

SIEVE BED PRESSURE CHECK PROCEDURE 21 PROCEDURE 21 - SIEVE BED PRESSURE TAP-IN KIT INST ALLATION AND BED

PRESSURE CHECK (FIGURES 1, 2 & 3)

CAUTION TO PREVENT ELECTRICAL SHOCK, ALWAYS DISCONNECT CONCENTRATOR FROM ELECTRICAL OUTLET BEFORE SERVICING.

DISASSEMBLY

WARNING

Turn power OFF and unplug unit.

1. Remove the eight (8) 5/8-inch screws that secure the cabinet to the base and remove the cabinet from the base of the concentrator.

2. Turn unit so the back faces you.

3. Loosen and lower the adjustable clamp on the product tank.

4. Pull product tank up and back to access the check valve PVC tubing.

CAUTION 3LX and 5LX standard units (without SensO2) are equipped with a restrictor assembly located on the left top of the product tank as viewed from the rear. DO NOT remove tubing or restrictor . Install tap-in kit on the opposite side.

INST ALLATION (FIGURE 2)

1. Insert the "T" fitting into the ends of the PVC tubing.

2. Secure 1/4-inch clamps to each end of the PVC tubing “T” fitting connection.

3. Attach the 1/4 x 2-inch silicone tubing to the NEW “T” fitting and secure with a 1/4-inch clamp.

4. Insert plug into the open end of the 1/4 x 2-inch silicone tubing.

5. Secure with a 1/4-inch clamp.

1/4" Clamp

"T" Fitting

PVC Tubing

1/4 x 2-inch Silicone Tubing

I E V

E B

E D

P R E S S U R E

5. Locate the check valve and PVC tubing to your right.

6. Cut in half the PVC tubing below the check valve.

Check Valve

Cut PVC Tubing

Restrictor

SHOWN for Clarity

Adjustable Clamp

below Check Valve to install Tap-in Kit

Product Tank

FIGURE 1 - DISASSEMBLY

Plug

1/4" Clamp

FIGURE 2 - INST ALLATION

PRESSURE TESTING (FIGURE 3)

1. Remove plug and Connect pressure gauge to the 1/4 x 2-inch silicone tubing and secure with a 1/4inch clamp.

2. Check each connection to make sure they are tight.

3. Turn the concentrator ON.

PROCEDURE 21 SIEVE BED PRESSURE CHECK PROCEDURE 21 - SIEVE BED PRESSURE TAP-IN KIT INSTALLATION AND BED

PRESSURE CHECK (FIGURES 1, 2 & 3)

I E V

NOTE: Adjust the concentrator to MAXIMUM

liter flow (3 liters for 3LX, 5 liters for 5LX/5LXO2 and 6 liters for 6LXO2).

NOTE: Wait approximately 5 minutes to allow

system pressures to achieve proper equallibrium before testing.

4. The pressure in the concentrator should rise

E S S

U R

within 20 seconds to 20 PSIG 97I) and 21 PSIG

+ .3 (AFTER 97I) and shift

the 4-way valve to the opposite sieve bed.

5. After the 4-way valve shift, the pressure in the concentrator will drop to 14 PSIG

+ .3 (BEFORE

+ 2 before rising within 20 seconds to 20 PSIG + .3 (BEFORE 97I) and 21 PSIG + .3 (AFTER 97I) and shift the 4-way valve to the opposite sieve bed.

AFTER TESTING (FIGURE 4)

1. Insert 1/4-inch plug and 1/4 x 2-inch silicone tubing onto the "T" fitting and secure with 1/4inch clamp.

2. Reinstall the cabinet onto the base of the concentrator.

Restrictor

SHOWN for Clarity

1/4-inch Plug

6. If pressure reading is 20 PSIG

+ .3 (BEFORE

97I) and 21 PSIG + .3 (AFTER 97I) when both valve shifts are made, proceed to STEP 9.

7. If pressure in the concentrator does not fall into

the specifications listed above, refer to the

TROUBLESHOOTING section in this manual.

8. Turn the concentrator OFF.

9. Unclamp the pressure gauge and remove it from the "T" fitting.

1/4-inch Clamp

STEP 1.

Pressure

Restrictor

SHOWN for Clarity

Adjustable Clamp

Product Tank

Gauge

1/4-inch Clamp

FIGURE 4 - AFTER TESTING

FIGURE 3 - PRESSURE TESTING

NOTES

N O

T E S

NOTES

LIMITED WARRANTY

LIMITED W ARRANTY

NOTE: THE WARRANTY BELOW HAS BEEN DRAFTED TO COMPLY WITH FEDERAL LAW APPLICABLE TO PRODUCTS MANUF ACTURED AFTER JUL Y 4, 1975.

This warranty is extended only to original purchaser of our products.This warranty gives you specific legal rights and you may also have other legal rights which may vary from state to state.

Invacare Corporation warrants its Oxygen Concentrators to be free from defects in materials and workmanship from date of purchase:

ALL Careguard 3LX Models for a period of three (3) years ALL Invacare 5LX, 5LXO2, and 6LXO2 Oxygen Concentrator Models for a period of five (5) years

The 4-way valve body carries a lifetime warranty from date of purchase. DO NOT OPEN OR ATTEMPT TO SERVICE V AL VE BODY. This will void any and all warranty applicable to the valve body. If within such warranty period any such product shall be proven to Invacare Corporation's satisfaction to be defective, such product shall be repaired or replaced, at Invacare Corporation's option. This warranty only applies to the labor for repairs performed by the Invacare Service Department or authorized Invacare dealers. It does not apply to the labor performed by the purchaser or user. This warranty does not include normal wear and tear or shipping charges incurred in replacement part installation or repair of any such product. Invacare Corporation's sole obligation and your exclusive remedy under this warranty shall be limited to such repair or replacement. Routine maintenance items, such as filters, are excluded from this warranty .

For warranty service, please contact Invacare Corporation's service department at the toll free number on the back cover during normal working hours.

I T E D

A R R A N T Y

Upon receiving notice of an alleged defect in a product, Invacare Corporation will issue a serialized return authorization. It shall then be the responsibility of the purchaser to return the entire unit or remove, at purchaser's cost, the defective component part(s) identified, pack the component part(s) in a manner to avoid shipping damage and to ship the component part(s) to either Invacare Corporation's plant or service center as specified by Invacare Corporation in advance. Defective component part(s) must be returned for warranty inspection using the serial number as identification within thirty (30) days of return authorization date. Do not return products to our factory without prior consent. C.O.D. shipments will be refused; please prepay shipping charges.

LIMIT ATIONS AND EXCLUSIONS: THE FOREGOING WARRANTY SHALL NOT APPLY TO PRODUCTS SUBJECTED TO NEGLIGENCE, ACCIDENT, IMPROPER OPERATION, MAINTENANCE OR STORAGE, SOOT OR SMOKE-FILLED ENVIRONMENTS, COMMERCIAL USE, OR OTHER THAN NORMAL APPLICA TION, USE OR SERVICE, OR TO PRODUCTS MODIFIED WITHOUT INV ACARE CORPORATION'S EXPRESS WRITTEN CONSENT (INCLUDING, BUT NOT LIMITED TO, MODIFICA TION THROUGH THE USE OF UNAUTHORIZED P ARTS OR A TT ACHMENTS) OR TO PRODUCTS DAMAGED BY REASON OF REP AIRS MADE TO ANY COMPONENT WITHOUT THE SPECIFIC CONSENT OF INV ACARE CORPORATION OR TO PRODUCTS DAMAGED BY CIRCUMST ANCES BEYOND INV ACARE CORPORA TION'S CONTROL.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES, IMPLIED WARRANTIES, IF ANY , INCLUDING THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE EXPRESS WARRANTY PROVIDED HEREIN, AND THE REMEDY FOR VIOLA TION OF ANY IMPLIED WARRANTY SHALL BE LIMITED TO REP AIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT PURSUANT T O THE TERMS CONT AINED HEREIN. INV ACARE CORPORATION SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENT AL DAMAGES WHA TSOEVER.

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGE, OR LIMITATION OF HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE EXCLUSION AND LIMIT A TION MA Y NOT APPLY TO YOU.

THIS WARRANTY SHALL BE EXTENDED T O COMPLY WITH ST A TE/PROVINCIAL LAWS AND REQUIREMENTS.

INV ACARE CORPORA TION

Respiratory Products Group

699 Aero Lane - Sanford, Florida 32771

Customer Service - Toll Free (800) 333-6900 l Technical Support - Toll Free (800) 832-4707

In Florida (407) 328-5900

Form No. 96-151 Part No. 2002728 Rev. E 10/01 Printed in USA

Invacare 3-6 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual