SERVICE MANU AL D ANGER – NO SMOKING
Contents
1. Sieve Bed Check gt gt _ _ _ _ lad da ERR FIGURES DIAGRAMS AND VIEWS a dn s Exterior VIEWS H aaa Interior VIEWS edu D HERR Pneumatic and Wiring Diagrams WARRANTY INFORMATION npn tr ERE ER CREER ER ORDERING INFORMATION AND PARTS LIST Ordering Information ec P Parts Retuin and Ordering Policy 5 vasaa aug arts ISC DER SPECIFICATIONS ce aaa ea LT 2023 2 GENERAL INFORMATION INTRODUCTION This service manual was designed to provide DeVilbiss Healthcare qualified service technicians and homecare providers with the proper maintenance service safety and repair procedures for the DeVilbiss Oxygen Concentrator Read and understand all the information contained in this service manual before attempting to operate or perform any maintenance on the concentrator An oxygen concentrator is a device that delivers highly concentrated oxygen for therapeutic applications Room air is a mixture of 7896 nitrogen 2196 oxygen 1 argon and oth2. sau sre An e rite Socket Dome i crescent wrench m N M H AC DC test light 1 4 Ratchet wrench EN E i amme Tie Alen bi nan Ea m li ic 10mm Socket 1 4 Drive 1 4 Drive extension Plastic storage case Plastic error indicator tool Pressure Vacuum gauge part PVO2D 601 8 Duckbill pliers T 10 Bit Test Fittings part 303DZ 637 Pt ora creer wt Tool box In addition to the Service Kit an oxygen analyzer part O2ANA is needed to periodically check oxygen concentration levels A voltmeter will be needed for more accurate voltage testing NOTE Be sure to read all of the steps involved before beginning any of the procedures in this manual NOTE After repairing or replacing a component run the unit for 20 minutes check the oxygen concentration and test for leaks Test for leaks using a certified leak detection solution such as SWAGELOK MS Snoop or equivalent must not contain ethylene glycol Apply leak test solution to all fittings and hose connections with the unit running If an air leak is present the solution will bubble All leaks should be repaired before putting the concentrator back in service CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly When servicing the DeVilbiss Oxygen Concentrator be absolutely certain that the correct tools are used and that the
3. Standard intervals are noted below Service interval may be more or less frequent than stated below provided that the Home Care Provider establishes and documents appropriate protocols BETWEEN PATIENT MAINTENANCE Discard oxygen tubing cannula amp humidifier bottle Wash or replace the cabinet air filter Wash the concentrator cabinet Check oxygen concentration If the unit falls within specification the extended life intake bacteria filter does not need to be replaced between patients PREVENTATIVE MAINTENANCE SUMMARY Patient Daily Clean the humidifier bottle if used Weekly Clean air filter on back of unit Clean exterior of cabinet Other Clean and replace cannula mask and tubing as instructed by manufacturer Homecare Provider 2 years Inspect Replace intake bacteria filter as necessary Check audible alert and indicator lights Check oxygen concentration Wash Replace cabinet filter 3 years Inspect Replace final bacteria filter 5 years Inspect Replace the compressor filter 7 LT 2023 TROUBLESHOOTING SYSTEM OPERATION The DeVilbiss Oxygen Concentrator uses a pressure swing adsorption system The air is drawn into the unit through air filters and into a double head compressor A pneumatic diagram of the system is shown in Figure 17 The compressed air passes through a rotary valve Figure 5 which is cycled at a pre determined rate and is directed into one of two sieve beds
4. DeVilbiss HEALTHCARE DeViLBISS 5 LITER COMPACT OXYGEN CONCENTRATOR SERVICE MANUAL DANGER NO SMOKING For Product Numbers 525DS 525KS CAUTION Federal U S A law restricts this device to sale by or on the order of a physician TABLE OF CONTENTS GENERAL INFORMATION Intr duetion z n mans ET Important Safety Precautions and General UNPACKING AND SETUP Initial 005 oa ca aaa aa da cai ca KAKKA SKA td aid Patient Operating Instructions MAINTENANCE Patient Alert System isis sssesessssscsessesuss s sn aaa acad catia EES ETS Routine Patient Maintenari e ree rtr ett ha ete STA KUN KAAN a audit e ROS VET nich Bin bata Periodic Homecare Provider Preventative Maintenance 2 00 2 1 Between Patient 0 211 11 nana eee se SEEEN EEEn aan eneee enee Preventative Maintenance Summary sse nn e n ana eaa e aan n en initi a ea initi a a tenente TROUBLESHOOTING System
5. 1500 4000 M 4921 13123 ft No degradation in performance expected Operating Environment Range No degradation in performance 5 C to 40 C humidity range across the operating of 1096 to 9596 voltage range Power Consumption 310 Watts Average 230V 50 Hz 312 Watts Average 275 Watts 2 5 LPM amp below 230V 50 Hz 296 Watts Average 2 5 LPM amp below 230V 60 Hz 387 Watts Average 230V 60 Hz 369 Watts Average 2 5 LPM amp below Weight 36 Ibs 16 3 Kilograms Sound Level ISO 8359 1996 from front 48 dbA overall average 50Hz Dimensions 24 5 H x 13 5 W x 12 D 62 2 x 34 2 x 30 4 cm Pressure Relief Valve 40 psig 5psig 276 kPa 34 5 kPa Operating System Time Cycle Pressure Swing The visible low oxygen indicator 8496 296 will activate at the following level At less than 6096 the red service required light will activate Storage Conditions 40 to 70 C humidity range of 1096 to 10096 including condensation Equipment Class and Type Class Equipment Double Insulated i Type B Applied Part Approval Body CSA TUV and CAN CSA C22 2 No 601 1 90 EN 60601 Al 2 Safety Standard 1508359 1996 EMC Compliance To EN60601 1 2 Typical Accumulator Pressure at Maximum Recommended Flow Sea Level 22 27 psig 150 190 kPa 9 750 M 2460 Ft 20 25 psig 138 172 kPa 1500 M 4921 Ft 18 22 psig 120 145 kPa NOTE The OSD performance at 5 C t
6. 3 Attach the 5 32 4 mm I D oxygen tubing part OST07 OSTI5 OST25 or OST50 not to exceed 50 feet 15 meters directly to the humidifier bottle outlet fitting NOTE For optimum performance the DeVilbiss Oxygen Concentrator has a preset nominal output pressure of 8 5 psi 58 6 kPa Use only bubble type humidifiers Do not use jet type humidifiers NOTE Condensation from the humidifier may occur in longer lengths of tubing or if the tubing is laying on a cold floor When ready for operation Attach the nasal cannula catheter or face mask to the oxygen tubing per the manufacturer s directions 2 Follow the Operating Instructions on the next page LT 2023 4 UNPACKING AND SETUP OPERATING INSTRUCTIONS Remove the power cord completely from the strap Make sure the power switch is in the Off position 2 115 Volt Units Insert the plug into an electrical outlet The DeVilbiss Oxygen Concentrator uses a two prong polarized plug and is double insulated to protect against electric shock 220 240 Volt Units Ensure it is connected to the unit before inserting plug into an appropriate electrical outlet The plug on the DeVilbiss 525DS concentrators has one blade wider than the other To reduce the risk of electric shock this plug is intended to fit in a wall outlet only one way Do not attempt to defeat this safety feature Improper use of the power cord and plugs can cause a burn fire or other electric
7. Allen bit No adjustment can be made without loosening the set screw 6 The DeVilbiss oxygen concentrator is now ready for use PATIENT ALERT SYSTEM The DeVilbiss Oxygen Concentrator patient alert system will detect unit component failure This system is comprised of both visible and audible alerts which signal the patient if a malfunction should occur DeVilbiss OSD Operation The OSD is a device within DeVilbiss concentrators that monitors the oxygen produced by the unit The OSD operates as follows Normal Oxygen green light oxygen purity normal e Low Oxygen yellow light oxygen purity low requires servicing the oxygen purity continues to fall an audible signal will sound intermittently If the oxygen purity continues to fall to a low enough level the yellow Low Oxygen light will turn off and the red Service Required light will turn on NOTE Refer to Specifications for specific alert settings NOTE After Power On the OSD conducts a continuous diagnostic evaluation to check for a fault in the piezo electronics If this condition is detected by the OSD electronics at any time during concentrator operation the green Normal Oxygen OSD light will turn off and the beeping audible alert and blinking red Service Required light activate Otherwise for the first fifteen minutes of operation the green Normal Oxygen light will remain illuminated during the oxygen stabilization process After that time the OS
8. FIGURES DIAGRAMS AND VIEWS Figure 3 Exterior Side View Rear Cover Cabinet Screw Power Cord Strap Power Cord Caster Exhaust Grill LT 2023 22 Figure 4 Front with Cover Removed Bib Service Required Light Serial Number Label Light Panel OSD Indicator Lights Power Light Green EN meme FIGURES DIAGRAMS AND VIEWS Figure 5 Interior Front View PC Board Pressure Regulator Accumulator Tank Left Sieve Bed E Right Sieve Bed Sieve Bed Cable Ties Check Valve Rotary Valve LT 2023 24 FIGURES DIAGRAMS AND VIEWS Figure 6 Interior Front Lower View 1 8 ID Hose Fixed Orifice Check Valves Bib Mounting Slot Sieve Bed Cable Tie Rotary Valve Rotary Valve Wire Harness Ladder Clamp Plastic Hose Clamp 2 ID Silicone Hose 25 LT 2023 Figure 7 Interior Front Upper View Accumulator Tank PC Board Communication Harness 1 8 ID Hose Circuit Breaker amp 4 u gt Power Switch s Wires Main Wire Harness FIGURES DIAGRAMS AND VIEWS Figure 8 PC Board Valve Wire Harness Connector Hour Meter Connector Communication Harness Connector OSD Alert Capacitor for Power Fuse Fail Alert 27 LT 2023 Figure 9 Interior Top View Intake Bacteria PC Board Filter Hour Meter Pressure Regulator 1 8 I
9. parts are free of oil and grease or any material not compatible with oxygen Teflon tape is recommended and must be applied to the male threads omitting the first thread to eliminate the possibility of tape particles entering the oxygen system Electric shock hazard Do not remove cabinet The cabinet should only be removed by a qualified DeVilbiss homecare provider Disconnect the power cord from the wall outlet before attempting repairs on the unit Extra care should be taken if it is necessary to operate the unit with the cabinet removed Teflon is a registered trademark of DuPont is a registered trademark of SWAGELOK 13 LT 2023 COMPONENT TESTING REPAIR AND REPLACEMENT CABINET REMOVAL To remove front and back cabinets Fig 3 Ensure the unit is unplugged from the wall outlet 2 Using a screwdriver remove the six screws that hold the back cabinet to the internal structure and the bib six screws are the same size 3 Remove the back cabinet by sliding it toward the rear until clear Remove the front cabinet by pushing the top shoulders toward the back of the unit then outward away from behind the bib Tilt the top of the front cabinet forward until it can be pulled out of the base of the unit 5 To reassemble reverse steps 2 4 The majority of all the servicing and repairs can be done without removing the front bib However to gain access to the components behind the bib it may be
10. OFF ON Other Symptoms Possible Cause Possible Remedy Fan operating Main wiring harness disconnected defective Reconnect replace wiring harness Loose compressor wire Tighten or attach wire Defective capacitor Replace capacitor Defective compressor Replace compressor Unit warm to the touch and cannot Compressor overheated due to be restarted for several minutes Occluded filters Clean or replace filters 2 Restricted input or output air passage 2 Remove obstruction 3 Low or high line voltage 3 Check line voltage use alternate circuit independent of other appliances Defective cooling fan Replace cooling fan Defective compressor Replace compressor lI LT 2023 TROUBLESHOOTING TROUBLESHOOTING CHART E Visible Alarm Audible Alarm Compressor Power Light ON ON ON ON Other Symptoms Possible Cause Possible Remed Fluctuating or no flow System pressure below 9 psi 62 1 kPa due to Leak in system Check for leaks in all hoses and fittings 2 Defective compressor Replace compressor TROUBLESHOOTING CHART F Visible Alarm Audible Alarm Compressor Power Light See below See below ON ON Other Symptoms Possible Cause Possible Remed No OSD lights are illuminated Defective OSD Check concentration with an oxygen analyzer If the concentration is within specification replace the PC board No OSD lights are illuminated Oxygen level is low Check concentratia with an oxygen analyzer but red Service
11. compressor exhaust and filter 7 Reconnect the compressor electrical connector COOLING FAN The cooling fan provides a constant air flow to cool the compressor The cooling fan is located in the bottom of the unit below the compressor Figure 14 A defective cooling fan may cause the compressor s internal thermo protective device to activate and shut the compressor off Should this condition occur the compressor will require several minutes for the thermo protective device to reset If the cooling fan is defective it must be replaced Make sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets 3 Remove the compressor 4 Disconnect the cooling fan terminals 5 Note the position of the fan and fan guard before removing the four retaining screws that secure the fan to the base of the unit 6 Remove the defective fan and secure the replacement fan in position with the four retaining screws NOTE When installing the fan be sure the air flow directional arrow on the side of the fan is directed away from the compressor and fan guard is reinstalled properly 7 Reconnect the electrical connector 8 Reinstall the compressor FINAL CHECK VALVE This check valve is located between the final bacteria filter and the oxygen outlet fitting This check valve allows oxygen to flow only out of the unit When the unit is turned off and oxygen flow stops the check valve closes to prevent water
12. loosened or removed To loosen the bib Figure 11 Remove the two screws located directly above the hour meter that hold the bib to the unit s internal structure This will allow access to the components behind the bib To remove the bib completely Figure 11 Remove the two screws as above 2 Disconnect the ribbon connector from the PC board 3 Disconnect the lines from the power switch and circuit breaker Mark these wires accordingly 4 Tilt the top of the bib forward to release it from the slot in the body of the concentrator 5 Remove the hose connected to the bottom of the flow meter To reassemble bib Reconnect the wires and hose 2 Insert the bib tab into the slot above the rotary valve and push until it snaps into place 3 Secure bib with two screws ACCUMULATOR PRESSURE TEST To check accumulator pressures l Make sure the unit is Off 2 Remove front and back cabinets 3 Use the pressure vacuum gauge part PVO2D 601 and pressure test assembly part 303DZ 637 included in the Service Kit 4 Remove the tubing cap from the accumulator tank fitting and attach the 1 16 1 6 mm diameter tubing from the gauge to the accumulator tank fitting just vacated above 5 Turn the unit On with the flow rate set to maximum recommended flow During each timed cycle the average pressure in the oxygen accumulator will rise and fall NOTE Normal pressures observed depend on altitude and flo
13. oxygen patient unless prescribed by a physician and then only a bubble type humidifier should be used D Do not connect the oxygen concentrator to an electrical outlet controlled by a wall switch the outlet should be independent of other appliances E Do not use an electrical adapter or extension cord with the oxygen concentrator F Only operate the oxygen concentrator with all filters in place do not operate if the air filter is wet G WARNING Electric shock hazard Do not remove cabinet The cabinet should only be removed by a qualified DeVilbiss homecare provider H WARNING Disconnect the power cord from the wall outlet before attempting repairs on the unit Extra care should be taken if it is necessary to operate the unit with the cabinet removed WARNING Do not use oils greases or petroleum based solvents cleaners on or near the unit Use only materials that are compatible with oxygen WARNING Electric Shock Hazard When replacing the capacitor do not touch the terminals or allow metal objects to come in contact with the terminals on the capacitor The capacitor may hold a charge for several days after the unit is turned off The capacitor is located in the base of the unit next to the cooling fan K Use only DeVilbiss concentrator replacement parts and accessories L Do not use regenerated sieve material 3 LT 2023 UNPACKING AND SETUP INITIAL INSPECTION It is suggested that an initial inspectio
14. shock hazards Do not use the unit if the power cord is damaged Oxygen promotes rapid burning Do not smoke when using this unit or when near a person receiving oxygen therapy Do not operate the oxygen concentrator within a minimum of five feet 1 6m from hot sparking or burning objects or naked flames Do not use in rooms heated by paraffin or portable gas heaters 3 Press the power switch to the On position When the unit is turned On all four indicator lights Power Service Required Low Oxygen and Normal Oxygen on the front panel will briefly illuminate and an audible signal will sound the patient alert system momentarily After a few seconds only the Power and Normal Oxygen lights will remain on 4 Slowly turn the flow meter knob until the flow meter ball is centered on the line next to the appropriate flow rate NOTE When the flow meter knob is turned clockwise the flow decreases and eventually will shut off the oxygen flow When the knob is turned counter clockwise the flow increases NOTE Use low output flow meter part 515LF 607 for flow rates under 1 Ipm NOTE The unit may require up to 20 minutes for the oxygen concentration and flow rate to stabilize The flow rate should be monitored and readjusted if necessary 5 The flow meter has a locking device If it is necessary to preset and lock in the prescribed flow rate tighten the set screw located on the hex nut just below the control knob using a 1 16
15. with your company name address phone number and account number The return authorization number should also be written on the outside of the package To expedite your order for warranty or non warranty parts the following information should be given to the representative Catalog number Serial number Hour meter reading for each concentrator e Account number name and address Description of problem LT 2023 40 ORDERING INFORMATION AND PARTS LIST Accessories Tools Pressure Test Assembly 303DZ 637 Pressure Vacuum Gauge PVO2D 601 Components 525DS 525 EEE E ym E eee I E E RN IE 41 LT 2023 ORDERING INFORMATION AND PARTS LIST Components continued Em rr N KH J us Lg Do n LT 2023 42 SPECIFICATIONS DEVILBISS 5 LITER COMPACT CONCENTRATOR Catalog Number 525DS 525KS Delivery Rate Lower delivery rates to 5 LPM available for low flow applications Maximum Recommended Flow 5 LPM Outlet Pressure 8 5 psig 58 6 kPa Electrical Rating 115V 60 Hz 3 3 Amp 220 230 V 50 Hz 1 55 Amp 230 V 60 Hz 1 9 Amp Operating Voltage Range 97 127 60 Hz 187 255 V 50 Hz 195 255 V 60 Hz Oxygen Percentage 1 5 LPM 93 3 Operating Altitude tested at 21 C only Across the voltage range 0 1500 M 0 4921 ft No degradation of performance Tested at nominal voltage only
16. Choisille FRANCE 33 247 55 44 00 Sunrise Medical Pty Limited 15 Carrington Road Unit 7 Castle Hill NSW 2154 AUSTRALIA 61 2 9899 3 144 DeVilbiss Healthcare 100 DeVilbiss Drive Somerset PA 15501 USA 814 443 488 800 338 1988 In Canada 800 263 3390 2008 DeVilbiss Healthcare 03 08 LT 2023 Rev A DeVilbiss Healthcare is a division of Sunrise Medical HHG Inc
17. D Hose Accumulator Tank Test Point Fitting Sieve Bed Test Point Sieve Bed Test Point Sieve Sieve Bed Bed Figure 10 Interior Behind Bib Final Bacteria Plastic Filter Elbow Power Switch 1 8 ID s Hose Es Flow Meter Circuit Final Check Light Panel Breaker Valve Ribbon Connector Switch Detail Red Wire Brown Wire or 2 Black Wires Red Wire 2 Black Wires Brown Wire Either red wire can be connected to either left hand terminal of the switch Figure Interior Rear View Bib Screws Pressure Regulator Accumulator Tank Intake Bacteria Filter Communicatio Port Intake a Compressor Silencer Filter Compressor Compressor Connector Strain Relief Power Cord 115V Units Figure 12 Interior Rear Lower View Intake Silencer 1 2 ID Braided Hose LII IVA gt Pressure gt Relief Valve Compressor Wire Harness Compressor Connector Grommet Ladder Clamps Motor Mount EN Exhaust Fitting Compressor Housing 1 2 ID Silicone Hose Figure 13 Compressor Housing Rear View Exhaust Muffler Ladder lt Clamp m m Compressor Housing 1 2 ID Silicone Hose Thermostat 220 240 Volt Units Compressor Rear View of Connector Rotary Valve Figure 14 Interior Base View Cooling Fan Guard Compressor Mountin
18. D will begin monitoring the oxygen purity every second 5 LT 2023 MAINTENANCE Alerts The visible alert located on the front panel reads Service Required The audible alert system is internally powered no batteries are required When the indicator lights illuminate or the audible alert sounds other than during unit start up a problem has occurred Power Failure Blinking red Service Required light and pulsing audible alert Low Flow Below 0 5 Continuous red Service Required light and audible alert Below Normal Oxygen 84 to 7596 yellow Low Oxygen light 7596 to 6096 yellow Low Oxygen light and beeping audible alert Less than 6096 red Service Required light and beeping audible alert Refer to Specifications for specific alert settings The visible and audible alerts will activate for approximately 15 minutes in a no power situation If the unit is turned On without power or power is removed later no alert will sound for the first 10 seconds After that time the alert will produce an audible pulse every few seconds while the visible alert blinks Power for this alert is provided by a capacitor on the PC board the concentrator has been unused for an extended period the unit must run several minutes before the power fail alert will activate The PC printed circuit board Figure 5 is responsible for controlling the system and alerts NOTE A high pressure condition is indicated b
19. Operation Normal Operating Sequence rrr 060 nein ina atei aaa acida XR aaa oda asuen dala da Simplified Troubleshooting Mt uae ru DERE Troubleshooting Chart me Troubleshooting Troubleshooting Chart Dieci sn evcessscavess dun Troubleshooting Chart inin a A ee Troubleshooting Chart COMPONENT TESTING REPAIR AND REPLACEMENT M Cabinet Removal aa Taa Accumulator Pressure E echo COmMpressor erm E E E E di a TR ERN Molec lar Sieve eror v rw Re Fe UND E TETTE Powei SWitehi seceta aaa dl dada cca se Pressure Regulator Printed Circuit Board Board
20. Remove rod screw from top of piston Remove the cup retainer plate Discard defective cup seal Place new cup seal into position Replace cup retainer plate mo ang Secure with screws 7 Reposition sleeve on piston NOTE n some cases it may be easier to position sleeve on piston before installing a new cup seal and retainer plate LT 2023 COMPONENT TESTING REPAIR AND REPLACEMENT 8 Place valve plates on the compressor so that heads of reed valve screws are aligned with the indentation in top of pistons 9 Install the compressor heads so that the holes in the heads are aligned with the holes in the compressor housing 10 Secure compressor heads with the screws To replace the compressor CAUTION 7he 52505 concentrators use a GSE compressor with a 22 mfd capacitor The 525KS concentrators use a GSE compressor with a 10 mfd capacitor If replacement is necessary be sure the correct capacitor is installed Inspect the motor mounts Replace if damaged Attach mounts to compressor feet 2 Inspect the capacitor to determine if replacement is necessary If capacitor is wrong value for compressor or replacement is desired refer to Capacitor section 3 Reconnect hose to the compressor intake fitting Position compressor on the base of the unit so that the studs on the motor mounts protrude through the holes in the base of the unit 5 Secure motor mounts with hex nuts Reconnect hoses to the fittings at
21. Replacement section for details on attaching the gauge A defective compressor will be indicated by slowly rising pressure Pressure may only reach a certain level and then stop If these conditions are observed then e unit filter s may be occluded check the air filter compressor filter and intake filter for occlusions There may be a severe leak in the system check for air leaks using a leak detection solution such as Snoop or equivalent must not contain ethylene glycol CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly e compressor reed valves cup seal or the compressor itself may be defective If the filters are not occluded and no leaks are found the compressor must then be removed and repaired or replaced To remove the compressor Make sure the unit is unplugged from the wall outlet 2 Disconnect the compressor wires by disconnecting the compressor electrical connector Figure 1 3 Remove the ladder clamp and hose from the exhaust fittings on the compressor head Figure 2 and compressor filter 4 Carefully place the concentrator on its front side From the bottom of the unit remove the four 10 mm hex nuts that secure the motor mounts 5 Lift compressor partially out of the compressor housing area and loosen ladder clamp securing hose to the intake fitting then remove hose 6 Compressor may now be removed from the c
22. Required light is illuminated accompanied by a beeping audible alarm If the concentration is within specification replace the PC board If the concentration is low refer to low oxygen concentration symptom in Troubleshooting Chart A Both OSD lights are illuminated Defective OSD Replace PC board Yellow Low Oxygen light Oxygen level is low Check concentration with an oxygen analyzer is illuminated If the concentration is within specification replace the PC board If the concentration is low refer to low oxygen concentration symptom in Troubleshooting Chart A Yellow Low Oxygen light Oxygen level is low Check concentratia with an oxygen analyzer is illuminated and an intermittent audible alarm sounds every few seconds If the concentration is within specification replace the PC board If the concentration is low refer to low oxygen concentration symptom in Troubleshooting Chart A Refer to Specifications page for oxygen purity levels LT 2023 12 COMPONENT TESTING REPAIR AND REPLACEMENT PROPER REPAIR PROCEDURES The DeVilbiss Oxygen Concentrator is designed for ease of service To aid service personnel a Service Kit part 444 501 is available which contains the necessary gauges tools and testing instruments to properly service the oxygen concentrator On parts that are sold separately the part number is indicated in parenthesis The following parts are included in the Service Kit
23. The sieve beds contain molecular sieve material which is a synthetically produced inorganic silicate It is very porous and has the unique ability to selectively adsorb nitrogen from the air as it passes through the sieve bed As one bed is being pressurized the other bed is quickly depressurized This allows the nitrogen that was adsorbed during its pressurization cycle to be exhausted from the sieve material The nitrogen is released through exhaust ports located on the rotary valve assembly The ports are connected to a single piece of hose running from the valve to the exhaust muffler Also during each bed pressurization a small amount of oxygen flows through an orifice Figure 6 from the pressurized bed into the depressurizing bed The orifice is clamped inside a long piece of blue tubing connecting the outlets of the two sieve beds This helps purge the nitrogen from the depressurizing bed The beds will continue to be alternately pressurized and depressurized as the unit operates Oxygen leaving the sieve beds is directed through a check valve to the accumulator tank A pressure regulator Figure 9 on the tank controls the oxygen pressure as it leaves the accumulator and enters the flow meter The flow meter allows the oxygen flow to be controlled and adjusted to the level prescribed by the patient s physician From the flow meter the oxygen passes through the final bacteria filter Figure 10 a check valve and finally the oxygen outlet po
24. asket cup seal These components are included in the Compressor Rebuild Kit part 525DZ 643 NOTE A built in thermal cutoff switch will shut the compressor off if it becomes overheated This protects the compressor from damage caused by heat build up Some models have an auxiliary thermostat mounted within the compressor compartment NOTE A pressure relief PR valve is located on the pressure head to prevent high pressure build up in the system should a component malfunction occur To test the compressor operating voltage Fig 11 The compressor requires line voltage to operate If the compressor does not start when the unit is turned on the voltage input must be tested This voltage be checked at the compressor connector using a voltmeter or test light connected to the brown and blue wires The voltmeter is the best way to test 2 If no voltage is detected disconnect power and check for loose or broken wires between the compressor connector and switch or wire harness 3 If there is voltage at the compressor connector then either the capacitor or the compressor itself is defective To test the compressor for proper output the compressor is not providing a high enough output the patient alert system may be activated Remove the front and back cabinets 2 Connect pressure vacuum gauges to the sieve bed test points See the Sieve Bed Pressure Test in the Component Testing Repair and
25. concentrator goes into its turn down mode the cycle time is shortened 5 If any of these readings are not obtained check for loose or broken wires in the harness If wire harness is okay replace the main PC board 6 If proper voltages are obtained replace valve To replace the rotary valve Make sure the unit is unplugged from the wall outlet Remove the front cabinet and loosen the bib Unplug valve wire harness from the valve DUMPS Loosen speedy clamps and remove bed hoses from each side of valve 5 Loosen ladder clamps and remove pressure intake and exhaust hoses from backside of valve 6 Install the new rotary valve by reversing the above procedure SIEVE BED CHECK VALVES A check valve Figure 6 located between the outlet of each sieve bed and the accumulator tank allows oxygen to pass through the sieve beds to the accumulator tank when the bed pressure is greater than the accumulator tank pressure These valves also prevent reverse flow of oxygen from the accumulator to the sieve beds Run the Accumulator Pressure Test described in the Component Testing Repair and Replacement section It covers details of attaching the gauge Acceptable pressure swing ranges at various altitudes are included in the Specifications A defective check valve will result in a decrease in oxygen concentration and lower accumulator pressures To replace a defective check valve remove the tubing on either side of it and insta
26. e YOSSIYANOI QM aay YOLIDY AVO Y MOSS3MdWOO 3mg 40 ALIM NNA SOLON 1 134 3078 3LIHM SLINN ASI 1 1v1SOWM3HL AJAdINDI LON ST300W 304 ama YO gt gt OVE I 31IHM UNOH am 3AWA an 29 20 qavoa S IOMLNOO OINOHLO3T3 TANVd LHS ana S 9 140d NOILVOINNNWOI 3LIHM NMOYA YIAVIYD LINII ana L3INI Mov 18 SIINN L IOA SLL 303 38 LT 2023 WARRANTY INFORMATION DEVILBISS 525DS COMPACT OXYGEN CONCENTRATOR LIMITED WARRANTY DeVilbiss Healthcare warrants the DeVilbiss 52505 Compact Oxygen Concentrators under the conditions and limitations stated below DeVilbiss warrants this equipment to be free from defects in workmanship and materials for five 5 years from date of factory shipment to the original purchaser typically the healthcare provider This warranty is limited to the Buyer of new equipment purchased directly from DeVilbiss or one of its Providers Distributors or Agents DeVilbiss s obligation under this warranty is limited to 1 product repair parts and labor at its factory or at an Authorized Service Center or 2 supplying a replacement for component part s This warranty does not cover any labor charges incurred i
27. e instructions Unqualified service personnel conduct routine maintenance servicing or warranty repairs Unauthorized parts or components i e regenerated sieve material are used to repair or alter the equipment Unapproved filters are used with the unit THERE IS NO OTHER EXPRESS WARRANTY IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THE EXPRESS LIMITED WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED THIS IS THE EXCLUSIVE REMEDY AND LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE LIMITATION OR EXCLUSION OF CONSEQUENTIAL OR INCIDENTAL DAMAGE SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other rights that vary from state to state NOTE nternational warranties may vary 39 LT 2023 ORDERING INFORMATION AND PARTS LIST ORDERING INFORMATION When ordering components instruction guides or service manuals the following must be provided Unit Catalog Number Unit Serial Number P art Number Quantity Required DeVilbiss Compact Concentrator 5 Liter Series Instruction Guide e A 525 525DS English Spanish French e SE 525 525DS amp 525KS Engl
28. e internal discs to turn and direct pressure to the proper sieve bed If the rotary valve does not shift properly the same bed may continue to pressurize causing the pressure relief valve to release the excess pressure There are several reasons why the rotary valve could malfunction therefore the cause of failure must be determined before corrective action can be taken To test the rotary valve Figures 9 amp 16 Remove the front cabinet 2 Connect pressure gauges to the test points at the top of the sieve LT 2023 beds in order to observe unit cycling and bed pressures Refer to the section on Normal Operating Sequence 3 fitis determined that the valve did not shift properly or the bed pressures are uneven continue testing with step 4 4 The stepper motor on the rotary valve has multiple windings so there are several voltage readings that need to be checked in order to determine if the problem is being caused by the PC board or the valve itself Testing for proper voltage is done at the wire harness connectors on the valve or on the PC Board using a voltmeter Below are the valve voltage test positions and voltages that should be present at each one Negative Lead Voltage Reading Yellow or White 12 VDC 5 VDC intermittent Black or Green or Yellow or White 2 3 VDC Red or Blue intermittent NOTE The 2 3 Volt reading will go on and off as the valve cycles 525 Series have a fixed cycle time However when the
29. e unit is unplugged from the wall outlet Cut the plastic cable ties that secure the sieve beds to the internal structure of the unit Remove the tubing from the fittings at the top of each sieve bed 5 Remove the hose clamps and hose from the bottom of the sieve beds 6 Install new sieve beds in reverse order using new plastic cable ties Position the new beds so that the bed serial number label is at the top of the unit NOTE Make sure that the sealing caps remain on the new sieve beds until just prior to connecting hoses and tubing 7 Leak test all connections with a certified leak detection solution such as Snoop or equivalent must not contain ethylene glycol Apply leak test solution to all fittings and hose connections with unit running If an air leak is present the solution will bubble All leaks should be repaired before putting the unit back in service CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly POWER CORD To replace the power cord 115 volt units only Fig 11 amp 14 Make sure the unit is unplugged from the wall outlet 2 Remove the back cabinet 3 Disconnect the power cord connector NOTE Loosening or removing the compressor mounting plate may make it easier to service the power cord Note wire colors and socket locations before removing wires 5 Using a pair of duckbill pliers squeeze the power cord strain relief and pull it out
30. ective compressor Replace compressor Defective cooling fan Replace cooling fan Fluctuating oxygen flow Occluded humidifier Clean or replace humidifier Use of improper humidifier Use only a bubble type humidifier Occluded filters Clean or replace filters Occluded or defective cannula and tubing Detach cannula from oxygen delivery tubing If proper flow is not attained check tubing for kinks or other obstructions Clean or straighten as required or replace tubing if necessary Use of excess oxygen tubing The unit is designed to deliver 5 with a cannula on 50 feet 15 meters of approximately 5 32 4 mm inside diameter tubing Smaller diameter tubing or the addition of any other flow restriction may prevent obtaining the desired flow rate Defective flow meter Replace flow meter Leak in system Check for leaks in all hoses and fittings Defective compressor Replace compressor Defective compressor reed valve Replace compressor reed valve Defective check valve Replace check valve Pressure regulator not adjusted properly or defective Adjust or replace pressure regulator Little or no oxygen flow Flow meter not adjusted properly Adjust flow meter Hose disconnected to flow meter Reconnect hose Oxygen delivery tubing is kinked or blocked Straighten tubing or remove obstruction Occluded humidifier Clean or replace humid
31. er gases The concentrator draws in room air separates the nitrogen from the oxygen and delivers concentrated oxygen to the patient through an oxygen port For more in depth classroom type training DeVilbiss holds oxygen concentrator service schools For service school information contact the Respiratory Technical Service Department at 1 800 338 1988 814 443 4881 NOTE DeVilbiss reserves the right to alter or change the design of the DeVilbiss Oxygen Concentrator series Hence slight differences in construction or components may exist between the unit in hand and what is described in this manual IMPORTANT SAFEGUARDS Read all instructions before operating the oxygen concentrator Important information is highlighted by these terms WARNING Safety information for hazards that might cause serious injury or death CAUTION nformation for preventing damage to the product NOTE nformation to which you should pay special attention DANG E R NO SMOKING SAFETY PRECAUTIONS AND GENERAL WARNINGS A CAUTION Federal U S A law restricts this device to sale by or on the order of a physician B WARNING Oxygen promotes rapid burning Do not smoke when using this unit or when near a person receiving oxygen therapy Do not operate the oxygen concentrator within a minimum of five feet 1 6m from hot sparking or burning objects or naked flames Do not use in rooms heated by paraffin or portable gas heaters C Do not place a humidifier with an
32. from being drawn into the unit A defective final check valve may allow water to be drawn in from the humidifier bottle when the unit is turned off This may occlude the final bacteria filter and or the flow meter causing a restriction of flow and making it difficult to adjust the flow rate LT 2023 To replace the final check valve Figure 10 Make sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets and loosen or remove the bib 3 Remove the hose from the outlet side of the final bacteria filter 4 Remove the two screws from the back of the oxygen outlet fitting assembly and remove the assembly sa Remove the hose from each end of the final check valve 6 Attach the hoses to a new check valve Make sure that the flat side of the check valve is directed toward the oxygen outlet fitting 7 Replace the outlet fitting assembly and connect the hose to the filter 8 Replace the bib and front and back cabinets FLOW METER The pressure compensated flow meter has an accuracy level of 5 at full scale exception 0 5 at 5 Ipm The flow meter on the DeVilbiss Oxygen Concentrator is designed for use at 8 5 psi 58 6 kPa at flow rates up to 5 Ipm To check for leaks in the flow meter tubing Check for leaks using a certified leak detection solution such as Snoop or equivalent must not contain ethylene glycol 2 Apply leak test solution to all fittings and hose connections wi
33. g Supports PP Cooling Fan Fan Mounting Screw Power Cord Connector Compressor 28 Connector Capacitor Cooling Capacitor Fan Wires Wires Figure 15 GSE Compressor Head Screw Intake Fitting Pressure Relief Valve Exhaust Fitting Modei No ZW28002 75 1 ARev A 115v 60 MZ 237951 C Do not lubncate Electrical Connector Figure 15A GSE Compressor With Head Removed Rod beneath Spacer 2 cup retainer Sleeve Cup Seal Rod Screw Cup Retainer Valve Plate Retainer Reed Valve or Flapper Exhaust Fitting PR Valve Sleeve Compressor Head Intake Fitting Connecting Head Gasket Tubes FIGURES DIAGRAMS AND VIEWS Figure 16 Rotary Valve LT 2023 Stepper Motor Left Sieve Right Bed Fitting Sieve Bed Fitting Valve Wire Harness Front View Pressure Exhaust Fitting Pressure Intake Fitting Rear View 36 n 3 gt 2 u gt lt 4 a FIGURES Figure 17 Pneumatic Diagram OL SASTS 8 SQSCS 9NIMOTIO3 JHL OL SINdAVY OILVW3HOS OILVAINIJNA SIHL Miri ViM310VH TYNII 4 r o 9154 1 K 5 35 ZO LT 2023 OA 954 OF una NOSS3HdWOD0 37 au n gt gt 2 4 gt a lt FIGURES Figure 18 Wiring Diagram aay o
34. he pressure vacuum gauge reads anything other than 8 5 5 psi 58 6 5 9 kPa with gauge outlet blocked adjustment to the pressure regulator may be required If so call DeVilbiss Service Department at 800 338 1988 814 443 4881 NOTE Make sure no leaks exist before adjusting the pressure regulator by using a certified leak detection solution such as Snoop or equivalent must not contain ethylene glycol CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly A malfunction in the pressure regulator will cause either a loss or fluctuation in the oxygen flow which will be seen on the flow meter or a decrease in oxygen concentration LT 2023 COMPONENT TESTING REPAIR AND REPLACEMENT To replace the pressure regulator Figure 9 Make sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets 3 Remove the tubing clamp and tubing from the pressure regulator 4 Unscrew the regulator from the accumulator tank 5 Install a new regulator on the accumulator tank and attach the tubing and tubing clamp 6 Replace the front and back cabinets PRINTED CIRCUIT BOARD The printed circuit PC board is responsible for monitoring and controlling the DeVilbiss Oxygen Concentrator The PC board has preset alerts for low flow and power failure Should any of the alert values be exceeded the patient alert system will activate the concentra
35. ifier Low oxygen concentration Leak in system Check for leaks in all hoses and fittings Defective sieve bed check valve Replace check valve Defective compressor reed valve Replace compressor reed valve Defective compressor Replace compressor Rotary valve not operating correctly Replace valve Occluded filters Clean or replace filters Contaminated sieve beds Replace sieve beds Audible alarm does not sound during power failure Unit has not been used for an extended period of time NOTE If the concentrator has been unused for an extended period the unit must run several minutes before the power fail alarm will activate Allow unit to run for 20 minutes and retry Defective PC board Replace PC board Defective power switch Replace power switch Defective wire harness Replace wire harness Audible alarm does not sound when unit is turned On Pressure relief valve activated popping sound Defective PC board PC board connectors not properly latched Replace PC board Be sure tabs are pushed completely into place Defective PC board Replace PC board Service Required light does not illuminate when unit is turned On LT 2023 Defective rotary valve PC board connectors not properly latched Replace valve Be sure tabs are pushed completely into place Defective PC board Replace PC board Defective light Re
36. ish Spanish French German Italian Dutch Portuguese DeVilbiss Compact Concentrator 5 Liter Series Service Manual 17 2023 525DS amp 525KS English e 17 2024 525DS amp 525KS Spanish e 11 2025 525DS amp 525KS Portuguese DeVilbiss Oxygen Concentrator Service Log A 1007 All English Orders may be placed by calling Customer Service 800 338 1988 W arranty parts U S A 800 338 1988 Canada 905 660 2459 or 800 263 3390 International Department 814 443 4881 PARTS RETURN AND ORDERING POLICY ALL DEFECTIVE COMPONENTS THAT ARE STILL UNDER WARRANTY MUST BE RETURNED TO THE FACTORY IN SOMERSET PA WITHIN 30 DAYS AFTER SHIPMENT OF THE NEW COMPONENTS IF THE COMPONENTS ARE NOT RECEIVED WITHIN THIS PERIOD AN INVOICE WILL BE ISSUED TO YOUR ACCOUNT REBUILT EXCHANGE PARTS PRICING IS AVAILABLE ONLY WITH THE RETURN OF DEFECTIVE PARTS WITHIN 30 DAYS COMPONENTS WILL THEN BE BILLED AT THE REBUILT COST THERE WILL BE A CHARGE FOR SHIPPING IF THE DEFECTIVE COMPONENT IS NOT RECEIVED WITHIN 30 DAYS THEN A NEW COMPONENT INVOICE WILL BE ISSUED TO YOUR ACCOUNT COMPONENTS THAT ARE OUT OF WARRANTY AND NOT ON A REBUILT EXCHANGE PROGRAM DO NOT HAVE TO BE RETURNED TO THE FACTORY Before returning parts or units to the factory call the DeVilbiss Healthcare Customer Service Department 800 338 1988 or 814 443 4881 to obtain a return authorization number Include in the package a note indicating the return authorization number along
37. ll a new valve making sure the outlet end is toward the accumulator tank FIGURES DIAGRAMS AND VIEWS FIGURES DIAGRAMS AND VIEWS INDEX Exterior Views The following figures show the exterior of the DeVilbiss 5 Liter Compact Concentrators Figure Front Figure 2 Rear Figure 3 Side Interior Views The following figures show the interior of the DeVilbiss 5 Liter Compact Concentrators Figure 4 Front with Cover Removed Figure 5 Front Figure 6 Front Lower close up Figure 7 Front Upper close up Figure 8 PC Board Figure 9 Top Figure 10 Behind Bib Figure Rear Figure 12 Rear Lower close up Figure 13 Rear Compressor Housing close up Figure 14 Base Other Figures Figure 15 GSE Compressor removed from base Figure ISA Compressor with head removed Figure 16 Rotary Valve Diagrams Figure 17 Pneumatic Diagram Figure 18 Wiring Diagram 19 LT 2023 Figure Exterior Front View Service Required Power Light OSD Indicator Lights Light Red Green Serial Number Label Power Switch Flow Meter Knob Light Panel Flow Meter Oxygen Outlet Port Circuit Bib Breaker Front Cover Caster Base Figure 2 Exterior Rear View Cabinet Screws Caution Warning Label Filter Door Air Filter Communication Port Cover Electrical Rating Label Rear Cover Cabinet Screws Power Cord Strain Relief 15V Units IEC Connector 220V 240V Units
38. n be performed upon receiving the oxygen concentrator After removing the DeVilbiss Oxygen Concentrator from the carton examine it for any external damage If shipping damage has occurred contact the DeVilbiss Customer Service Department at 800 338 1988 814 443 4881 for specific instructions Save the carton for possible later return note the position of the unit and placement of the packing material Open the filter door and record the number of hours on the hour meter Check to make sure the air filter is in place Check to be sure the intake bacteria filter is in place Plug the unit into an electrical outlet turn the unit On and check the audible and visible alerts Set the flow meter to maximum recommended liter flow and let the unit run for at least 20 minutes U N Use an oxygen analyzer to check the concentration NOTE f the unit fails to operate properly oxygen concentration not within specification or if internal damage is found contact the DeVilbiss Customer Service Department at 1 800 338 1988 814 443 4881 PATIENT SETUP Position the unit near an electrical outlet in the room where the patient spends most of his or her time NOTE Do not connect to an electrical outlet controlled by a wall switch The outlet should be independent of other appliances 2 Position the unit at least 6 inches 16 cm from walls draperies or any other objects that might prevent the proper flow of air in and out
39. n removing or replacing the warranted component part s by any other service personnel Routine maintenance items such as filters are not covered under this warranty Warranty Claims Submissions The original purchaser must submit any warranty claim to DeVilbiss or to an Authorized Service Center Upon verification of the warranty status instructions will be issued For component part s return s the original purchaser shall be responsible to remove the defective component part s For all returns the original purchaser must 1 properly package the unit or parts in a DeVilbiss approved shipping container 2 properly identify the claim with the Return Authorization Number and 3 send the shipment freight prepaid Service under this warranty must be performed by a qualified DeVilbiss provider and or an Authorized Service Center Labor costs incurred by a qualified DeVilbiss provider are excluded and will not be reimbursed Only labor costs incurred by an Authorized Service Center are reimbursed NOTE This warranty does not obligate DeVilbiss to provide loaner unit during the time that an oxygen concentrator is undergoing repair NOTE Replacement components are warranted for the unexpired portion of the original Limited Warranty This warranty shall be voided and DeVilbiss shall be relieved of any obligation or liability if equipment is operated or maintained outside the parameters indicated the DeVilbiss operating and servic
40. ncentrator b Setthe flow meter to 5 LPM The concentrator must operate for a minimum of 20 minutes before checking the oxygen concentration c Connect the analyzer to the unit s oxygen outlet port and wait until the display stabilizes d Record the reading 2 Check the audible alert and indicator lights every two years When the power switch is turned On listen for the audible alert and check to see if the front panel indicator lights are operating 3 Inspect intake filter part MC44D 605 every 2 years Replace as necessary a Open the filter door and replace filter as required 4 Inspect the final bacteria filter part PV5LD 651 every 3 years Replace as necessary or in conjunction with compressor service a Unplug the unit remove the cabinet and loosen the bib b Remove the hose from each end of the filter and discard the filter c Install the new final bacteria filter with the IN fitting toward the flow meter d Tighten the bib and replace the cabinet 5 Inspect the compressor filter part 525D 622 every 5 years Replace as necessary or in conjunction with compressor service NOTE This PM Schedule reflects 5000 hour usage equal to one year a normal clean operating environment The homecare provider is responsible for determining the condition of the concentrator operating environment determining a preventative maintenance interval frequency which takes into consideration the specific operating environment
41. o 40 C 95 through voltage range on the 52505 verified at 670m NOTE Turn down mode may cease at 0 5 LPM if a low output flow meter is not being used Specifications subject to change without notice DECLARATION OF CONFORMITY Manufacturer Sunrise Medical dba DeVilbiss Healthcare Safety Standards Applied no Respiratory Products Division 835921996 Address 100 DeVilbiss Drive Somerset PA 15501 2125 USA EMC Compliance To EN 60601 1 2 Product Designation Oxygen Concentrator Authorized Representative Sunrise Medical Ltd Catalog Number 525KS Sunrise Business Park High Street We herewith declare that the above mentioned product complies with the requirements Wollaston West Midlands DY8 4PS of EC directive 93 42 EEC and the following ENGLAND Class Rule 2 44 138 444 6688 Quality System Standards Applied 15013485 2003 C 0044 Notified body T V NORD MDD Annex II Applied 43 LT 2023 J 110155 HEALTHCARE DeVilbiss Healthcare 100 DeVilbiss Drive Somerset Pennsylvania 15501 USA 814 443 4881 Sunrise Medical Ltd Sunrise Business Park High Street Wollaston West Midlands DY8 4PS ENGLAND 44 138 444 6688 Sunrise Medical DeVilbiss Produkte Kahlbachring 2 4 D 69254 Malsch Heidelberg GERMANY 49 7253 980 460 Sunrise Medical Canada Inc 237 Romina Drive Unit 3 Concord Ontario L4K 4V3 CANADA 905 660 2459 Sunrise Medical Division Respiratoire 13 Rue de la Painguetterie 37390 Chanceaux
42. o pressurize first while the left bed depressurizes to approximately 2 PSI 14 kPa 3 Voltage is again applied to the valve for a short time The valve will stop for approximately a second During this time the sieve bed pressures are equalized 4 short DC voltage signal is again applied to the valve The valve will stop for several seconds causing the left bed to pressurize while the right bed depressurizes to approximately 2 PSI 14 kPa 5 short DC voltage signal is again applied to the valve The valve will stop for approximately a second During this time the sieve bed pressures are equalized 6 cycle then repeats with step 2 NOTE n the turn down mode the fixed cycle time is decreased to a few seconds and the bed pressure equalization time to less than a second NOTE High end sieve bed pressure should not exceed 1 2 PSI 4 kPa above high end accumulator pressures Refer to Specifications for normal pressures obtained during the cycle LT 2023 8 TROUBLESHOOTING SIMPLIFIED TROUBLESHOOTING The key to simple troubleshooting is to recognize which type of problem exists and select the most effective approach to solving the problem The different types of problems and the approaches for solutions are as follows Type I The unit runs but a low pressure and flow or high pressure condition exists NOTE Low pressure or flow are indicated by both a visible and audible alarm High pressure is indicated by a pop
43. of the oxygen concentrator 3 Locate the unit a minimum of 5 feet 1 6 meters from fireplaces radiators heaters and hot air registers Oxygen promotes rapid burning Do not smoke when using this unit or when near a person receiving oxygen therapy Do not operate the oxygen concentrator within a minimum of 5 feet 1 6 meters from hot sparking or burning objects or naked flames Do not use in rooms heated by paraffin or portable gas heaters Electric Shock Hazard Only qualified DeVilbiss Healthcare homecare providers may remove the cabinet 4 Attach the appropriate oxygen accessories oxygen tubing or humidifier to the oxygen outlet port NOTE A maximum of 50 feet 15 meters of tubing plus 7 feet 2 1 meters of cannula plus a bubble humidifier is allowed between the concentrator and the patient Oxygen Tubing Only Connection Thread the cannula fitting part 100 onto the oxygen outlet port 2 Attach the 5 32 4 mm I D oxygen tubing part OST07 5 15 OST25 or OST50 Oxygen Tubing with Humidification Connection If the physician has prescribed an oxygen humidifier as part of the patient s therapy follow these steps Fill the humidifier bottle part HUM 16 with distilled demineralized or boiled water Do not overfill If using a go to Step 3 2 Thread the wing nut located on the top of the humidifier bottle to the oxygen outlet port so that it is suspended Make sure it is securely tightened
44. of the base of the unit 6 Insert a new power cord through the hole in the base of the unit and secure with strain relief 7 Insert sockets into connector housing and then reconnect the power cord connector 8 Replace back cabinet and secure with the six screws POWER SWITCH To replace the power switch Figure 10 sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets and loosen the bib 3 Note the position of the wires and switch before removing the wires from the switch terminals 4 While squeezing the locking tabs on the sides of the switch push the switch out of the front of the bib 5 Install the new switch in the correct orientation making sure that it locks into position 6 Reconnect the wires to the switch terminals Switch Detail Red Wire ce Brown Wire or 2 Black Wires Red Wire 2 Black Wires or Brown Wire Either red wire can be connected to either left hand terminal of the switch PRESSURE REGULATOR The pressure regulator stabilizes the flow of oxygen to the patient and establishes back pressure on the system It is preset at 8 5 psi 58 6 kPa and should not have to be adjusted in the field To test the pressure regulator Turn the unit On 2 Setthe flow meter at 2 Ipm 3 Usea pressure vacuum gauge part PVO2D 601 and a fitting suitable to fit on the oxygen outlet or on a short piece of tubing connected to the outlet 4 W t
45. ompressor housing area CAUTION f the unit has been running recently the compressor may be hot 7 Unscrew motor mounts from compressor feet by hand To inspect and or replace internal components Figs 15 amp 15A Remove the eight screws that hold the compressor heads in place When removing the heads be sure to keep each head and its components with the correct compressor side 2 Check for proper placement of or damage to the gaskets on the bottom of the compressor heads Replace if damaged 3 Remove reed valve plates A reed valve is located on each side of the valve plate 4 The compressor reed valves should be flush with the valve plate If the valve is broken or not flush with the valve plate or foreign matter is detected inside the head clean or replace the compressor reed valves To replace the compressor reed valves Fig 15A a Remove the screw holding the compressor reed valves in position on the valve plate and discard the used reed valves b Position the new reed valves so that they are centered and completely cover the holes in the valve plate c Place the metal retainer on the reed valves and secure with the reed valve screw 5 Check for proper placement of or damage to the rubber o ring on the bottom of the valve plate Replace if damaged 6 Remove piston sleeves by pulling upward and inspect cup seal on pistons Replace if badly worn or damaged To replace cup seal Fig 15A a
46. ons Connect test gauges and check for higher or lower than normal bed pressures a High pressures indicate defective sieve beds b Low pressures indicate occluded filters leaks or defective compressor c Uneven bed pressures indicate valve is not operating correctly 2 Check for oxygen leaks at e sieve beds flow meter e accumulator tank final bacteria filter e pressure regulator final check valve outlet port NOTE Check for leaks using a certified leak detection solution such as Snoop or equivalent must not contain ethylene glycol Apply leak test solution to all fittings and hose connections with unit running If an air leak is present the solution will bubble All leaks should be repaired before putting the unit back in service CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly 3 Test accumulator tank pressure If pressure is lower than normal then sieve bed check valves are defective NOTE For normal system pressures refer to Specifications 9 LT 2023 TROUBLESHOOTING TROUBLESHOOTING CHART A Visible Alarm Audible Alarm Compressor Power Light OFF OFF ON ON Other Symptoms Possible Cause Possible Remedy Pulsating air noise Excessive noise Intake filter not in place or defective Check filter and replace if necessary Compressor intake hose disconnected Loose or defective motor mounts Reconnect hose Replace motor mounts Def
47. operate the unit without the air filter or while the filter is still damp NOTE The air filter should be monitored more closely in environments with abnormal amounts of dust and lint CAUTION Operation of the DeVilbiss Oxygen Concentrator in extreme environments or without the air filter will prematurely occlude the intake bacteria filter and cause a decrease in the unit performance Exterior Cabinet The patient should clean the concentrator exterior cabinet by using a damp cloth or sponge with a mild household cleaner and wiping it dry Do not apply liquids directly to the cabinet or utilize any petroleum based solvents or cleaning agents LT 2023 6 MAINTENANCE PERIODIC HOMECARE PROVIDER PREVENTATIVE MAINTENANCE Every DeVilbiss Oxygen Concentrator is tested at the factory To assure continued trouble free performance the following preventative maintenance should be performed by the homecare provider during periodic oxygen patient visits Failure to properly maintain the unit will void the warranty Check the oxygen concentration with an oxygen analyzer part O2ANA every two years a Calibrate the oxygen analyzer prior to checking the oxygen concentration The analyzer should be properly calibrated using the manufacturer s recommended procedure NOTE Changes in temperature altitude or humidity may affect the analyzer s oxygen concentration reading The analyzer should be calibrated in similar conditions to the location of the co
48. ping sound caused by the pressure relief valve Connect test gauges to sieve bed tests points Figure 9 2 Refer to the Normal Operating Sequence to make sure the unit is cycling properly 3 pressure is rising slowly check for occluded filters and severe leaks If filters are clean and there are no leaks then the compressor is defective 4 If the pressure relief valve is releasing pressure observe whether the unit is cycling not 5 If the unit is not cycling or has uneven bed pressures this indicates that the rotary valve is not operating correctly Refer to the Rotary Valve Testing described in the chapter Component Testing Repair and Replacement 6 Ifthe unit is cycling in conjunction with very high bed pressures this indicates defective sieve beds Type 11 compressor will not start when the unit is turned on Verify that the cooling fan is running if it is not determine where you are losing power Check for compressor voltage at the compressor connector If voltage is present then the capacitor or compressor is defective If voltage is not present the wire harness is defective JN WARNING Electric Shock Hazard Extra care should be taken if it is necessary to operate the unit with the cabinet removed Mechanical Hazard Keep fingers loose clothing etc away when working on compressor Type III concentrator runs and continues to cycle but has low oxygen concentrati
49. place light TROUBLESHOOTING TROUBLESHOOTING CHART B Visible Alarm Audible Alarm Compressor Power Light Blinking Pulsing OFF OFF Other Symptoms Possible Cause Possible Remedy Fan off Line cord not properly installed or defective Insert plug in receptacle or replace line cord On 220 240 Volt units check that the IEC connector on the back of the unit is attached No power at receptacle Check building circuit breaker or fuse or have house wiring checked by qualified electrician Circuit may be fully loaded with other appliances and another receptacle may be required Wall outlet should be independent of other appliances Oxygen concentrator circuit breaker activated Press the circuit breaker reset button If unit circuit breaker opens again check internal wiring Line cord quick connect terminal inside Reconnect quick connect terminal unit is disconnected Defective power switch Replace power switch Defective circuit breaker Replace circuit breaker TROUBLESHOOTING CHART C Visible Alarm Audible Alarm Compressor Power Light Blinking Pulsing ON ON OFF Other Symptoms Possible Cause Possible Remed Fan and compressor operating Connector on PC board not connected Connect connector Pressure relief valve activated Blown fuse on PC board Replace fuse popping sound Defective PC board Replace PC board TROUBLESHOOTING CHART D Visible Alarm Audible Alarm Compressor Power Light ON ON
50. rrect capacitor is installed Electric Shock Hazard When replacing the capacitor do not touch the terminals or allow metal objects to come in contact with the terminals on the capacitor The capacitor may hold a charge for several days after the unit is turned off If a defective capacitor is suspected a new one must be installed The capacitor is strapped into a well molded into the bottom of the unit Figure 14 next to the cooling fan To replace the capacitor sure the unit is unplugged from the wall outlet Remove the front and back cabinets gt gt Remove the compressor gt Disconnect the two wires from the terminals the capacitor m Cut the nylon cable tie holding the capacitor in place and remove the capacitor Reconnect the wires to the new capacitor Install the new capacitor and secure with a new cable tie Replace the compressor Replace the front and back cabinets and secure with the six screws COMPONENT TESTING REPAIR AND REPLACEMENT COMPRESSOR The DeVilbiss Oxygen Concentrator uses a double head oil free compressor The compressor is secured to the base with four motor mounts A compressor that is worn or defective may cause pressure to rise slowly cause excessive noise and or vibration cause lower oxygen concentrations A worn or defective compressor can be caused by a defective internal component such as e reed valve o ring e g
51. rt to the patient The DeVilbiss Oxygen Concentrator operates on a timed cycle The cycling is controlled by the PC board The PC board will send voltage to the valve causing it to shift and alternately pressurize the sieve beds The PC board also activates the electronic alert system high pressure condition will be indicated with a popping type sound produced by release of pressure from a pressure relief valve on the compressor head Low flow system abnormality and power failure are indicated by audible and visible alerts The 525 Model operating system incorporates turn down technology The PC board constantly monitors the flow rate and will decrease the cycle time whenever the flow rate is less than 2 5 LPM Therefore it turns down the cycle based on lower oxygen demand As a result the unit runs cooler and less power is consumed NORMAL OPERATING SEQUENCE When the concentrator is turned On the following cycling sequence can be observed by attaching pressure gauges to the sieve bed test points rotary valve is quickly cycled several times to relieve residual bed pressure preventing a static condition in the compressor This rapid cycling only happens on start up and is clearly heard as pressure is being quickly exhausted several times through the exhaust muffler that is connected to the valve 2 The PC board applies a short DC voltage signal to the valve The valve will stop for several seconds causing the right bed t
52. th the unit running CAUTION Do not apply leak test solution to any part of the rotary valve or the main PC Board assembly 3 fanair leak is present the solution will bubble leaks should be repaired before putting the concentrator back in service Electric Shock Hazard Use caution when leak testing near electrical connections To replace the flow meter Figure 10 Make sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets 3 From behind the bib remove the 2 hoses from the flow meter 4 While squeezing tabs on flow meter brackets push the flow meter through the bib 5 Install new flow meter bib and reconnect hoses HOUR METER To replace the hour meter Figure 9 sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets and loosen the bib 3 Disconnect the hour meter connector from the PC board 4 Remove the meter by carefully inserting a small flat screwdriver under the outer edge of meter and prying upward 5 Install a new hour meter by applying downward pressure until it snaps into position 6 Connect the hour meter to the PC board CAUTION Do not apply any force or flex the PC Board when connecting or disconnecting electronic or pneumatic components Damage to the electronic assembly is possible COMPONENT TESTING REPAIR AND REPLACEMENT MOLECULAR SIEVE BEDS The two molecular sieve beds alternately remove
53. the nitrogen from the air passing through them and provide the patient with a constant supply of oxygen The efficiency of the molecular sieve material will be impaired if it becomes contaminated by moisture Contamination causes the molecular sieve material to lose its nitrogen adsorbing properties resulting in a decrease in oxygen concentration The unit should run for a minimum of 20 minutes before turning Off to prevent problems associated with moisture contamination in the system To test the sieve beds Remove the 1 16 plugged piece of tubing from the top of each sieve bed 2 Connect the pressure vacuum gauges to the sieve bed test points Figure 9 in order to observe unit cycling and bed pressures Refer to the section on Normal Operating Sequence 3 fitis determined that the valve did not shift refer to the section on Rotary Valve testing However if the unit is cycling properly allow unit to run while observing the sieve bed pressures 4 After 20 minutes of operation check the oxygen concentration levels Low oxygen concentration and high pressures indicate contaminated sieve beds the molecular sieve material is found to be no longer effective first locate the source of the malfunction or cause such as leaks for contamination and take corrective action To replace the molecular sieve beds Figs 5 amp 6 Make sure any contamination problem has been corrected before replacing 2 Make sure th
54. tor has been unused for an extended period the unit must run 20 minutes before the power fail alert will be enabled This alert is powered by a capacitor on the PC board CAUTION Do not apply any force or flex to the PC Board when connecting or disconnecting electronic or pneumatic components Damage to the electronic assembly is possible To remove and replace the PC board Figs 5 amp 7 Make sure the unit is unplugged from the wall outlet 2 Remove the front and back cabinets and the bib 3 Disconnect all wires terminals and connectors 4 Remove the 1 8 3 2mm tubing attached to the sensor 5 Remove the screw that secures the board to the unit and remove the PC board 6 Install the new PC board and secure it using the screw NOTE Confirm PC Board is correct use only 525DS 622 on 525DS units and 525KS 622 on 525KS units 7 Reconnect all electrical wires terminals connectors and the tubing to the sensor 8 Replace the bib and front and back cabinets ROTARY VALVE The timed rotary valve alternately distributes pressure supplied by the compressor to the sieve beds While one bed is being pressurized the other bed is being exhausted through the valve Exhaust gases go through the valve exhaust port and exit through the exhaust muffler The valve contains two revolving discs powered by a stepper motor to cycle the pressure between the beds DC voltage is supplied by the PC board to the motor windings causing th
55. w rate Increases in altitude and flow rate will slightly decrease accumulator pressures Decreases in the two variables will slightly increase accumulator pressures Acceptable accumulator pressure swing ranges at various altitudes at the maximum recommended flow are identified in the Specifications LT 2023 NOTE A defective check valve may cause a rapid drop in accumulator pressure below the minimum value NOTE A defective compressor will be indicated by slowly rising pressure Pressure may only reach a certain level and then Stop Low oxygen concentration levels and accumulator pressures higher than normal may indicate defective sieve beds Severely contaminated beds may also cause the pressure relief valve on the compressor to open NOTE A malfunctioning rotary valve will also cause high accumulator tank pressure and activation of the pressure relief valve In this case it should be determined whether the problem is with the sieve beds valve or both CAPACITOR The capacitor enables the compressor to start and run by supplying voltage to the windings of the compressor motor A defective capacitor will result in the compressor running slower or not starting CAUTION The 5250 concentrators use a GSE compressor with a 22 mfd capacitor If replacement is necessary be sure the correct capacitor is installed CAUTION The 525KS concentrators use a GSE compressor with a 10 mfd capacitor If replacement is necessary be sure the co
56. y the audible a popping sound release of pressure from a pressure relief valve located on the compressor head ROUTINE PATIENT MAINTENANCE The oxygen patient should perform the following maintenance Oxygen Humidifier reusable bottles only The patient should clean the humidifier bottle daily The patient should follow the instructions supplied by the manufacturer If no cleaning instructions were supplied these steps should be followed Wash the humidifier bottle in a solution of hot water and dishwashing detergent 2 Soak the humidifier in a solution of one part white vinegar to three parts hot water for 30 45 minutes This solution acts as a germicidal agent 3 Rinse thoroughly with hot tap water and refill with distilled demineralized or boiled water for use Do not overfill Cannula Mask and Tubing The patient should clean and replace the cannula or mask and tubing as instructed by the manufacturer Air Filter and Oxygen Outlet Connector The air filter and oxygen outlet connector should be cleaned at least once a week by the patient To clean these steps should be followed Remove the air filter located in the door on the back of the unit Remove the oxygen outlet connector if used from oxygen outlet port 2 Wash a solution of warm water and dishwashing detergent 3 thoroughly with warm tap water and towel dry The filter should be completely dry before reinstalling Do not attempt to
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