Nidek Mark 5 Plus Service manual
Mark 5 Plus Oxygen Concentrator
Domestic Models –115V; 60Hz
Configurations 1373-31100 and 1373-71100 (Part 1)
Configurations 1373-31103 and 1373-71103 (Part 2)
2010-1010QD Rev A
Mark 5 Plus Oxygen Concentrator
Domestic Models –115V; 60Hz
Configurations 1373-31100 and 1373-71100 (Part 1)
Configurations 1373-31103 and 1373-71103 (Part 2)
Introduction.................................................................................................... 1-1
Specifications................................................................................................ 1-1
Safety Information......................................................................................... 1-2
Principles of Operation.................................................................................. 1-3
Pneumatic Diagram..................................................................................... 1-4
Component Function................................................................................... 1-4
Initial Setup Instruction.................................................................................. 1-5
Precautions and Safe Practices.................................................................... 1-6
Preventive Maintenance................................................................................ 1-7
Trouble Shooting........................................................................................... 1-8
Test Port Diagram....................................................................................... 1-8
System Diagnosis Chart.............................................................................. 1-9
Trouble Shooting Guide.............................................................................. 1-10
Component Replacement.............................................................................. 1-11
Reference Material
Electrical Schematic.................................................................................... 1-13
Illustrations and Part Numbers.................................................................... 1-14
Oxygen Monitoring System Information
Price List/Sample Forms/Reference Material
Nidek Medical Products, Inc.
3949 Valley East Industrial Drive
Birmingham, AL 35217 U.S.A.
(800) 822-9255
Phone (205) 856-7200
Fax (205) 856-0533
2010-1010QD Rev. A
See Section Two
➋
➌ See Section Three
Introduction
Thank you for purchasing the Mark 5 Plus Oxygen Concentrator.
The Mark 5 Plus Concentrator is the latest in the high quality Mark series of
concentrators manufactured by Nidek Medical Products, Inc. It is a reliable concentrator,
requiring very little maintenance and is designed to operate efficiently for a long period of
time. We have accomplished this by combining real world experience with the latest of
control and process technology.
We believe that the Mark 5 Plus is the best machine available in today’s market and
will operate to your complete satisfaction. We invite your comments on our devices and
our service. The Mark5 Plus is manufactured under the controls of FDA-GMP’s and ISO9001 and EN46001 Quality Management Systems.
Anand Chitlangia
President & CEO
Nidek Medical Products, Inc.
This edition of the Mark5 Plus Maintenance Manual is effective for
configuration models 1373-31100 and 1373-71100 beginning with
serial number 992-18378. See Section 2 for configurations 137331103 and 1373-71103.
Specifications (Stated at 70°F (20° C) and 1 Atm.)
Height. ............................................................................ 26 in / 660 mm
Width............................................................................... 15 in / 380 mm
Depth.............................................................................. 15 in / 380 mm
Weight............................................................................. 60 lbs / 27 kg
Output............................................................................. 90% +/- 3% @ 5 lpm
Voltage............................................................................ 115 V; 60 Hz
Average Power Consumption.......................................... 420W @ 60 Hz
Cooling Air Temperature Rise.........................................
Less than 30°F / 16°C
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Safety
Oxygen Safety
Oxygen does not burn, but it does cause fire to burn more rapidly. Any material that
will burn in air will ignite more rapidly and burn more violently in an oxygen-enriched
atmosphere. While the oxygen concentrator does not contain a large volume of oxygen at
any one given time, oxygen hazards can occur. If the output is allowed to return to the
atmosphere no real hazard is likely; however, if the output hose is under a chair cushion
or a pile of shop rags, these materials may become saturated with oxygen and could burn
violently if ignited. The possibility of fire is the most serious hazard associated with the use
of oxygen equipment. Observe the following precautions to prevent the possibility of a fire
occurring in the vicinity of the oxygen outlet from this unit.
CAUTION
Eliminate Sources of Flame, Heat and Sparks
A fire can be started by almost anything that produces flame, heat and sparks. Do not
permit the use of matches, cigarette lighters, burning tobacco, candles, or other flame
sources in rooms where oxygen is used or stored. Electrical heaters or equipment that
gets hot or sparks during operation can be a source of ignition.
Keep Flammable Materials Away From Oxygen
It is not possible to completely eliminate the presence of combustible materials such as
clothing, bedding, and even parts of the therapy equipment itself, but the presence of
highly flammable materials can and must be avoided. Do not lubricate oxygen equipment.
Oil and grease, including petroleum jelly such as Vaseline ignite very easily and burn
vigorously in the presence of oxygen.
Prevent Accumulation of Oxygen
Since any material that will burn in air will burn more vigorously in an oxygen-enriched
atmosphere, prevent any local accumulation of oxygen that may saturate combustibles. All
connections on the apparatus should be made carefully and observed for leakage.
Sect. 1 Pg.2_________________________________________________________9/99
Principles of Operation
The Mark 5 Plus Concentrator takes in room air that contains 21% oxygen, 78%
nitrogen and trace amounts of inert gases. The air is filtered, compressed and passed
through one of the two molecular sieve beds which allows the oxygen to pass but traps
most of the nitrogen. Before the nitrogen saturates the molecular sieve in the first bed it is
vented to the atmosphere and purged with oxygen while air is fed to the second bed. This
process of alternate feeding and venting of beds is continued thus producing oxygen
enriched gas at one end and exhaust at the other end of the sieve beds. The oxygen
produced is then filtered, regulated, and set at a given flow rate for delivery to the patient.
The operation of the Mark 5 Plus can be grouped into three distinct systems; the
compressed air system, the process system and the delivery system.
Compressed Air System
Air enters the system through filters which prevent dust and other particles from
entering and potentially damaging the air compressor. The compressor is a reciprocating
two cylinder positive displacement type that compresses the air to the necessary pressure.
The compressed air is then routed through a heat exchanger to reduce its temperature and
then to the air surge tank. The surge tank reduces air pressure swing and traps moisture.
The wick assembly, located at the bottom of the surge tank, allows the moisture to be
evaporated to atmosphere. The system also has a safety relief valve to prevent pressure
buildup should a blockage occur and a test port for measuring system pressure.
Process System
The process system consist of two sieve beds and a rotary poppet valve. The valve
controls the process by alternately feeding air into and exhausting nitrogen from the sieve
beds. The valve utilizes a gear motor to cause a cam action to alternately open and close
feed and exhaust poppets. Thus, what normally is a complex control system in other
concentrators is reduced to a simple and easily understandable mechanical control in the
Mark 5 Plus.
Delivery System
exits the beds. In order to provide a stable flow, the oxygen, after passing through a
bacterial filter to remove any contaminants, is passed through a regulator to establish a
fixed delivery pressure. A flow control valve consisting of multiple orifices then establishes
a fixed flow rate to the patient. The use of a vacuum relief breaker and check valve in this
section prevents the possibility of contaminants entering the system from the outside. Two
pressure switches monitor the oxygen pressure and cause an alarm to sound if the
pressure is high or low. An Oxygen Monitoring System for continuously monitoring oxygen
purity is available as an option. The operation of the Oxygen Monitoring System is
described separately in Section ➋ .
The cyclic process described above causes pressure variations in the oxygen as it
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Component Function
A brief description of the principal function of each of the major components is
provided below:
CABINET FILTER..............................................................Filters dust from cooling air
INLET FILTER................................................Filters Particles To Protect Compressor
COMPRESSOR.................................................................Pumps Air Into The System
RELIEF VALVE...............................................Safety Device To Limit System Pressur
HEAT EXCHANGER....................... ................................Cools Air After Compression
WICK ASSY............................................Removes Moisture from the Compressed Air
IR SURGE TANK..................................................Reduces air pressure fluctuations
IR TEST PORT.......................................................A Connection For System Testin
ROTARY POPPET VALVE...............................Controls The Pressure Swing Process
SIEVE BEDS...................................
MUFFLER...............................................................................Reduces Exhaust Noise
OXYGEN TEST PORT............................................A Connection For System Testing
PRESSURE SWITCHES...........................Activates Alarm For High Or Low Pressure
BACTERIAL FILTER....................... .....................Removes contaminant from oxygen
VACUUM BREAKER...........................................................Prevents System Vacuum
REGULATOR................................................................Sets A Fixed Output Pressure
FLOW CONTROL VALV..E.............
CHECK VALVE......................................Prevents Any Reverse Flow Into The System
OUTLET..........................................
.....Separates Gases As Air Is Moved In And Out
................Sets The Flow Rate To ASpecific Flow
...Provides A Connection For Hose Or Humidifie
Sect. 1 Pg.4_________________________________________________________9/99
Operating Instructions
The operating instructions for the Mark 5 Plus Concentrator are provided in a
separate booklet written for the patient's use. Maintenance personnel must make
themselves familiar with the contents of this book and use it for all questions that relate to
the operation of the unit.
Initial Setup
Preparing a new Mark 5 Plus Concentrator for patient use consists of little
more than taking it out of its shipping carton. After completing the Carton Unpacking
Instructions found in the shipping carton follow these important checks to insure that
shipping damage has not occurred and unit is performing properly.
Step One: Flow Control Limit Adjustment
The flow control setting on the Mark 5 Plus Concentrator may be locked to
limit the maximum output available to the user. This limit is preset at the factory to 5 liters
per minute but may be changed to any flow setting. From the front of the unit remove the
flow control knob by pulling the knob straight off its shaft. The back of the knob assembly
has a flow locking disc. To reset the flow, remove the screw from the locking disc, lift and
rotate the disc in the desired flow setting, reinstall the screw and replace the flow control
knob.
Step Two: Alarm Test
Before connecting power to the unit, press the ON button to test the battery and power
failure alarm. It should sound when the switch is on and the power disconnected. If there
is no alarm, check the 9-volt battery inside the front cabinet on switch plate and replace if
necessary.
With the unit is plugged-in, push the ON button. The audible alarm should sound and the
Service Required light should be lit and the compressor should run. After approximately
15 seconds both the alarm and the Serviced Required light should turn off.
Step Three: Purity Test
With unit running connect an oxygen Analyzer (Example: OxyChek) to oxygen outlet and
verify results of 90% +/- 3% @ 5 LPM.
Mark 5 Plus Oxygen Concentrator is ready to be placed in service.
9/99__________________________________________________________Sect 1 Pg5
Precautions and Safe Practices
The following precautions and safe practices are specifically directed to personnel
who are experienced in the service of medical oxygen equipment. The device covered
by these instructions is an electro-mechanical device that deserves all the respect inherent
in servicing such equipment. Operation of this equipment also requires an awareness of
all the potential hazards associated with handling and using oxygen.
Maintenance Safety
Maintenance personnel must be properly trained in the service of
oxygen concentrators. Electrical shock hazards exist inside the cabinet of this equipment.
Good shop practices must be observed at all times.
Use only approved replacement parts. Medical oxygen equipment
should be repaired with parts supplied by the manufacturer. Substitution of unauthorized
parts can effect the performance of the unit. All parts that will come in contact with oxygen
must be thoroughly cleaned. Remember, human health is affected by the end product of
this device and a foreign substance left by maintenance could be inhaled by a patient.
Thread sealant and lubricants used on oxygen equipment must be of approved quality for
such use.
Always follow printed instructions when maintaining or repairing this equipment.
Repair procedures may involve special techniques that must be followed when performing
such work.
WARNING
The sieve beds of the concentrator covered by these instructions contain a highly
compressed spring. DO NOT ATTEMPT TO DISASSEMBLE a sieve bed or the
spring may eject parts with dangerous velocity sufficient to cause personal injury.
Sect. 1 Pg.6_________________________________________________________9/99
Preventive Maintenance
To ensure proper performance of the Mark 5 Plus Oxygen Concentrator purity
checks are recommended every three (3) months.
When operating under normal conditions the following maintenance schedule is
recommended and should be followed for proper operation of the unit. In severe conditions
such as high temperature, dusty and/or dirty atmosphere, it may be necessary to perform
the maintenance functions at more frequent intervals. Where procedures are involved, they
are shown elsewhere in this publication.
Preventive Maintenance Schedule
Mark 5 Plus Oxygen Concentrator
12 Months 24 Months 36 Months
Inlet Filter X X X
Bacterial Filter X X X
Battery X X X
Muffler X
Wick Assy x
Compressor
Rebuild or perform maintenance when oxygen
purity and/or operating pressure falls below
minimum specifications.
Note: In the Reference Material Section
Maintenance Record Check List sample for your convenience.
9/99__________________________________________________________Sect 1 Pg7
➌ of this manual we have provided a
Trouble Shooting
System Problem Diagnosis
With system problem isolation in mind, the Mark 5 Plus was designed
with two test ports that allow the monitoring of the system pressures at two
key points. The pressure swings / ranges at these test ports will provide
important diagnostic clues when used with the SYSTEM DIAGNOSIS chart.
Each port has a plug that is held into place by a quick disconnect fitting.
The plug may be removed by depressing the ring around the plug. A
suitable pressure gauge with ¼ diameter tube lead can then be connected
to the quick disconnect fitting to measure the pressure swings.
Normal Pressure Swings Are:
*20 – 30 psig (140-205 kPa) at Air Test Port; 5 – 6 psig (35-42 kPa)
difference between high pressure and low pressure
*10 – 15 psig (70-105 kPa) at Oxygen Test Port; 1 – 2 psig (7-15 kPa)
difference between high pressure and low pressure
Note: To obtain accurate readings please observe the following check list.
1. Make sure that the filters are clean.
2. Leak test all fittings and repair all leaks (a leak will distort all
measurements).
3. Make sure that the oxygen flow is set correctly at 5 lpm and that actual flow is 5
lpm with an accurate flowmeter..
4. Always be sure of the accuracy of your test instruments.
Sect. 1 Pg.8_________________________________________________________9/99
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System Diagnosis Chart
Symptom Possible Cause Corrective Action
Power Failure Alarm 1) No Electrical Power
Service Req'd Light 1) Low Oxygen Pressure
2) High Oxygen Pressure
Low Product Flow 1) System Leak A) Test Product Pressure
1) Clogged Bacterial
Filter
High Product Flow 1) Product Regulator A) Test Product Pressure
Noisy Compressor 1) Worn Piston Seals
2) Rods or Bearings
Compressor Turns Off
and Comes On
Fluctuating Flow 1) Dirty or Defective
The trouble shooting guide which follows has been prepared to provide a logical sequence
of measurements and evaluations that will lead to a probable conclusion as to the cause of
a problem. As with all diagnostic efforts, the more highly trained and experienced
individual is more likely to determine the root cause of any problem.
1) Compressor Thermal
Overload Switch
Activated Due to
Overheating
Regulator
2) Leak on Oxygen Side
3) Low Oxygen Pressure
) Check Power Source
) See Trouble Shooting
Guide
B) Adjust Regulator
C) Change Inlet Filter
B) Adjust Regulator
A) Replace Piston Seals
or Replace Compressor
A) Check Fan and
Cooling Airway Path
B) Replace Fan
C) Replace Compressor
) Check Operation
B) Clean or Replace
Regulator
C) See Trouble Shooting
Guide
9/99__________________________________________________________Sect 1 Pg9
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