DeVilbiss 525DS User manual
DANGER – NO SMOKING
CAUTION-Federal (U.S.A.) law restricts this device to sale by or on the order of a physician.
DeVilbiss®5-liter Oxygen COnCentratOr
serViCe Manual
MODEL 525DS
MODEL 525DS-Q
MODEL 525KS
MODEL 525KS-LT
MODEL 525PS
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TABLE OF CONTENTS
GENERAL INFORMATION
Introduction............................................................................................................................................................................................................................. 3
Important Safeguards............................................................................................................................................................................................................. 3
Safety Precautions and General Warnings ............................................................................................................................................................................ 3
UNPACKING AND SETUP
Initial Inspection...................................................................................................................................................................................................................... 5
Patient Setup.......................................................................................................................................................................................................................... 5
Operating Instructions ............................................................................................................................................................................................................ 5
MAINTENANCE
Patient Alert System............................................................................................................................................................................................................... 7
Routine Patient Maintenance ................................................................................................................................................................................................. 7
Periodic Homecare Provider Preventative Maintenance........................................................................................................................................................ 7
Warranty ................................................................................................................................................................................................................................. 8
Provider's Notes ..................................................................................................................................................................................................................... 8
Return and Disposal............................................................................................................................................................................................................... 8
Preventative Maintenance Summary ..................................................................................................................................................................................... 8
TROUBLESHOOTING
System Operation................................................................................................................................................................................................................... 9
Normal Operating Sequence.................................................................................................................................................................................................. 9
Simplified Troubleshooting ................................................................................................................................................................................................... 10
Troubleshooting Chart A....................................................................................................................................................................................................... 11
Troubleshooting Chart B ...................................................................................................................................................................................................... 12
Troubleshooting Chart C ...................................................................................................................................................................................................... 12
Troubleshooting Chart D ...................................................................................................................................................................................................... 12
Troubleshooting Chart E ...................................................................................................................................................................................................... 13
Troubleshooting Chart F....................................................................................................................................................................................................... 13
COMPONENT TESTING, REPAIR, AND REPLACEMENT
Proper Repair Procedures.................................................................................................................................................................................................... 14
Cabinet Removal.................................................................................................................................................................................................................. 14
Accumulator Pressure Test .................................................................................................................................................................................................. 15
Auxiliary Oxygen Port........................................................................................................................................................................................................... 16
Capacitor .............................................................................................................................................................................................................................. 16
Check Valves/Manifold ......................................................................................................................................................................................................... 16
Compressor.......................................................................................................................................................................................................................... 16
Cooling Fan.......................................................................................................................................................................................................................... 18
Flow Meter............................................................................................................................................................................................................................ 18
Hour Meter ........................................................................................................................................................................................................................... 19
Manifold................................................................................................................................................................................................................................ 19
Molecular Sieve Beds........................................................................................................................................................................................................... 20
Power Cord .......................................................................................................................................................................................................................... 20
Power Switch........................................................................................................................................................................................................................ 20
Pressure Regulator .............................................................................................................................................................................................................. 21
Printed Circuit Board (PC Board)......................................................................................................................................................................................... 21
Rotary Valve ......................................................................................................................................................................................................................... 21
FIGURES, DIAGRAMS AND PARTS LIST
525DS Unit - Serial #F & 525DS / 525DS-Q Units - Serial #J (115V Units)........................................................................................................................ 23
525DS Unit - Serial #N & 525DS-Q Unit - Serial #R (115V Units with Auxiliary Oxygen Port) ........................................................................................... 25
525KS Unit - Serial #F & 525KS / 525KS-LT Units - Serial #J (220/230/240V Units)......................................................................................................... 28
525KS-LT Unit - Serial #N & 525KS Unit - Serial #R (220/230/240V Units with Auxiliary Oxygen Port) ............................................................................ 30
525PS Unit - Serial #F & 525PS Unit - Serial #J (220/230/240V Units).............................................................................................................................. 33
Accessories and Tools.......................................................................................................................................................................................................... 35
Pneumatic and Wiring Diagrams.......................................................................................................................................................................................... 36
ORDERING INFORMATION AND PARTS RETURN
Ordering Information ............................................................................................................................................................................................................ 38
Parts Return ......................................................................................................................................................................................................................... 38
SPECIFICATIONS................................................................................................................................................................................................................ 39
GUIDANCE AND MANUFACTURER’S DECLARATION.................................................................................................................................................... 40
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GENERAL INFORMATION
INTRODUCTION
This service manual was designed to provide DeVilbiss Healthcare qualied
service technicians and homecare providers with the proper maintenance,
service, safety, and repair procedures for the DeVilbiss Oxygen Concentrator.
Read and understand all the information contained in this service manual before
attempting to operate or perform any maintenance on the concentrator.
An oxygen concentrator is a device that delivers highly concentrated oxygen for
therapeutic applications.
Room air is a mixture of 78% nitrogen, 21% oxygen, 1% argon and other gases.
The concentrator draws in room air, separates the nitrogen from the oxygen, and
delivers concentrated oxygen to the patient through an oxygen port.
For more in-depth classroom type training, 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
DANGER
NO SMOKING
Read all instructions before operating the oxygen concentrator. Important
information is highlighted by these terms:
WARNING: Safety information for hazards that might cause serious injury
or death.
CAUTION–Information for preventing damage to the product.
NOTE–Information to which you should pay special attention.
SAFETY PRECAUTIONS AND GENERAL
WARNING:
A warning indicates the possibility of injury to the user or the
operator.
• Oxygen causes rapid burning. Do not smoke while your oxygen
concentrator is operating, or when you are near a person utilizing oxygen
therapy. Keep the oxygen concentrator and cannula at least 5 feet (1.6m)
from hot, sparking objects or naked sources of ame.
• Electric shock hazard. Do not remove cabinet. The cabinet should only be
removed by a qualied 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.
• Do not use oils, greases, or any petroleum-based solvents/cleaners on or
near the unit. Use only materials that are compatible with oxygen.
• 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.
• To ensure you receive the therapeutic amount of oxygen delivery according
to your medical condition, 525 Oxygen Concentrator must:
• be used only after one or more settings have been individually
determined or prescribed for you at your specic activity levels.
• be used with the specic combination of parts and accessories that are
in line with the specication of the concentrator manufacturer and that
were used while your settings were determined.
• For your safety, the oxygen concentrator must be used according to the
prescription determined by your physician.
• Equipment not suitable for use in the presence of a ammable anesthetic
mixture with air or with oxygen or nitrous oxide.
• This device contains electrical and/or electronic equipment. Follow local
governing ordinances and recycling plans regarding disposal of device
components.
• Installation of 515LF-607 low output ow meter package will cause the low
ow alarm to not work.
• Use only water-based lotions or salves that are oxygen-compatible before
and during oxygen therapy. Never use petroleum or oil-based lotions or
salves to avoid the risk of re and burns.
• Do not lubricate ttings, connections, tubing, or other accessories of the
oxygen concentrator to avoid the risk of re and burns.
• Use only spare parts recommended by the manufacturer to ensure proper
function and to avoid the risk of re and burns.
• Use of this device at an altitude above 4000 meters or above a
temperature of 95˚F (35˚C) or greater than 95% relative humidity may
affect the ow rate and the percentage of oxygen and consequently the
quality of the therapy. Refer to specications for details regarding
parameters tested.
• Oxygen makes it easier for a re to start and spread. Do not leave the
nasal cannula or mask on bed coverings or chair cushions if the oxygen
concentrator is turned on but not in use, the oxygen will make the materials
ammable. Turn the oxygen concentrator off when not in use to prevent
oxygen enrichment.
• If you feel discomfort or are experiencing a medical emergency while
undergoing oxygen therapy, seek medical assistance immediately to avoid
harm.
• Geriatric, pediatric or any other patient unable to communicate discomfort
can require additional monitoring and/or a distributed alarm system to
convey the information about the discomfort and/or the medical urgency to
the responsible caregiver to avoid harm.
• Smoking during oxygen therapy is dangerous and is likely to result in facial
burns or death. Do not allow smoking within the same room where the
oxygen concentrator or any oxygen carrying accessories are located. If you
intend to smoke, you must always turn the oxygen concentrator off, remove
the cannula and leave the room where either the cannula or mask or the
oxygen concentrator is located. If unable to leave the room, you must wait
10 minutes after you have turned off the oxygen concentrator before
smoking.
• Open ames during oxygen therapy are dangerous and are likely to result
in re or death. Do not allow open ames within 2 m of the oxygen
concentrator or any oxygen carrying accessories.”
• The Device is classied as IPX0 which means it does not provide
protection from water ingress. Keep the device dry.
• Do not service or clean this device while in use with a Patient.
• Under certain circumstances, oxygen therapy can be hazardous. Seek
medical advice before using an oxygen concentrator.
• When device is used under extreme operating conditions, the temperature
near the exhaust vents on the bottom of the unit may reach 145˚F (63˚C).
Keep body parts a minimum of 32” away from this area.
• Improper use of the power cord and plugs can cause a burn, re, or other
electric shock hazards. Do not use the unit if the power cord is damaged.
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GENERAL INFORMATION
• The DeVilbiss oxygen concentrators manufactured since July 1, 2012
are equipped with a re mitigating outlet tting that prevents propagation
of re into the unit. DeVilbiss oxygen concentrators manufactured prior
to July 1, 2012 must be retrotted by your provider with the re
mitigating outlet tting.
• In order to prevent a re propagating from the patient through the
cannula towards the unit, a means of protection should be located as
close to the patient as practicable. Please contact your provider for this
means of protection.
• Before attempting any cleaning procedures, turn the unit “Off.”
• Use of harsh chemicals (including alcohol) is not recommended. If
bactericidal cleaning is required, a non-alcohol based product should be
used to avoid inadvertent damage.
• Medical Electrical Equipment needs special precautions regarding EMC
and needs to be installed and put into service according to the
Electromagnetic Compatibility [EMC] information provided in the
accompanying documents.
• Portable and Mobile RF Communications Equipment can affect Medical
Electrical Equipment.
• The equipment or system should not be used adjacent to or stacked with
other equipment and that if adjacent or stacked use is necessary, the
equipment or system should be observed to verify normal operation in
the conguration in which it will be used.
CAUTION:
A Caution indicates the possibility of damage to the device.
• Federal (U.S.A.) law restricts this device to sale by or on the order of a
physician.
• It is very important to follow your oxygen prescription. Do not increase or
decrease the ow of oxygen – consult your physician.
• To prevent product damage, do not attempt to operate the unit without
the air lter or while the lter is still damp.
• Do not place a humidier with an oxygen patient unless prescribed by a
physician and then only a bubble-type humidier should be used.
• Do not connect the oxygen concentrator to an electrical outlet controlled
by a wall switch; the outlet should be independent of other appliances.
• Do not use an electrical adapter or extension cord with the oxygen
concentrator.
• Only operate the oxygen concentrator with all lters in place; do not
operate if the air lter is wet.
• Use only DeVilbiss concentrator replacement parts and accessories.
• Do not use regenerated sieve material.
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UNPACKING AND SETUP
INITIAL INSPECTION
It is suggested that an initial inspection be performed upon receiving the oxygen
concentrator.
1. After removing the DeVilbiss Oxygen Concentrator from the carton,
examine it for any external damage. If shipping damage has occurred,
contact the DeVilbiss Customer Service Department at 1-800-338-1988
(814-443-4881) for specic instructions. Save the carton for possible later
return; note the position of the unit and placement of the packing material.
2. Open the lter door and record the number of hours on the hour meter.
Check to make sure the air lter is in place.
3. Check to be sure the intake bacteria lter is in place.
4. Plug the unit into an electrical outlet, turn the unit “On,” and check the
audible and visible alerts.
5. Set the ow meter to maximum recommended liter ow and let the unit run
for at least 20 minutes.
6. Use an oxygen analyzer to check the concentration.
7. With unit still running, unplug to test the power fail alarm.
NOTE–If the unit fails to operate properly (oxygen concentration not within
specication) or if internal damage is found, contact the DeVilbiss Customer
Service Department at 1-800-338-1988 (814-443-4881).
PATIENT SETUP
1. Position the unit near an electrical outlet in the room where the patient
spends most of his or her time.
NOTE–Do not connect to an electrical outlet controlled by a wall switch.
2. Position the unit at least 6 inches (16 cm) from walls, draperies, or any
other objects that might prevent the proper ow of air in and out of the
oxygen concentrator.
3. Locate the unit a minimum of 5 feet (1.6 meters) from replaces, radiators,
heaters, and hot-air registers.
WARNING
Oxygen causes rapid burning. Do not smoke while your oxygen
concentrator is operating, or when you are near a person utilizing oxygen
therapy. Keep the oxygen concentrator and cannula at least 5 feet (1.6m)
from hot, sparking objects or naked sources of ame.
Electric Shock Hazard. Only qualied DeVilbiss Healthcare homecare
providers may remove the cabinet.
4. Attach the appropriate oxygen accessories (oxygen tubing or humidier) 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 humidier is allowed between the concentrator and the
patient.
NOTE–The oxygen supply accessory (patient tubing) shall be
equipped with a means that in case of re stops the delivery
of oxygen to the patient. This means of protection should be
located as close to the patient as practicable.
Oxygen Tubing Only Connection
1. Thread the cannula tting onto the oxygen outlet port.
2. Attach the 5/32” (4 mm) I.D. oxygen tubing.
Oxygen Tubing with Humidification
Connection
If the physician has prescribed an oxygen humidier as part of the patient’s
therapy, follow these steps (If using a prell, go to Step 3.):
1. Fill the humidier bottle with distilled, demineralized, or boiled water. Do not
overll.
2. Thread the wing nut located on the top of the humidier bottle to the
oxygen outlet port so that it is suspended. Make sure it is securely
tightened.
3. Attach the 5/32" (4 mm) I.D. oxygen tubing, not to exceed 50 feet (15
meters), directly to the humidier bottle outlet tting.
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”
humidiers. Do not use “jet-type” humidiers.
NOTE–Condensation from the humidier may occur in longer lengths of tubing
or if the tubing is laying on a cold oor.
When ready for operation
1. Attach the nasal cannula to the oxygen tubing (per the manufacturer’s
directions).
2. Follow the Operating Instructions.
OPERATING INSTRUCTIONS
1. 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.
220/230/240 Volt Units – Ensure cord is connected to the unit before
inserting plug into an appropriate electrical outlet.
WARNING
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 t 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, re, or other
electric shock hazards. Do not use the unit if the power cord is damaged.
Oxygen causes rapid burning. Do not smoke while your oxygen
concentrator is operating, or when you are near a person utilizing oxygen
therapy. Keep the oxygen concentrator and cannula at least 5 feet (1.6m)
from hot, sparking objects or naked sources of ame.
WARNING
The DeVilbiss oxygen concentrators manufactured since July 1, 2012 are
equipped with a re mitigating outlet tting that prevents propagation of
re into the unit. DeVilbiss oxygen concentrators manufactured prior to
July 1, 2012 must be retrotted by your dealer with the re mitigating outlet
tting.
In order to prevent a re propagating from the patient through the cannula
towards the unit, a means of protection should be located as close to the
patient as practicable. Please contact your dealer for this means of
protection.
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 briey illuminate and an audible signal will
sound (the patient alert system) momentarily. After a few seconds, only the
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UNPACKING AND SETUP
“Power” and “Normal Oxygen” lights will remain on.
NOTE– DeVilbiss recommends for optimal service life that the DeVilbiss
Oxygen Concentrator to be operated for at least 30 minutes after it is
powered on. Shorter periods of operation may affect the long term reliable
operation of the product.
4. Slowly turn the ow meter knob until the ow meter ball is centered on the
line next to the appropriate ow rate.
NOTE–When the ow meter knob is turned clockwise, the ow decreases
(and eventually will shut off the oxygen ow). When the knob is turned
counter-clockwise, the ow increases.
NOTE–Use low output ow meter (part #515LF-607) for ow rates under 1
lpm.
NOTE–The unit may require up to 20 minutes for the oxygen concentration
and ow rate to stabilize. The ow rate should be monitored and
readjusted if necessary.
5. The ow meter has a locking device. If it is necessary to preset and lock in
the prescribed ow rate, tighten the set screw located on the hex nut just
below the control knob using a 1/16" Allen bit. No adjustment can be made
without loosening the set screw.
6. The DeVilbiss oxygen concentrator is now ready for use.
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MAINTENANCE
PATIENT ALERT SYSTEM
The DeVilbiss Oxygen Concentrator patient alert system will detect unit
component failure. This system is comprised of both visible and audible 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
• Low Oxygen (yellow light) - oxygen purity low–requires servicing
NOTE–If the oxygen purity continues to fall, an audible signal will sound
intermittently. If the oxygen purity continues to fall to a low enough level, the
yellow “Low Oxygen” light will turn off and the red “Service” light will turn on.
NOTE–Refer to the Alerts section below for specic 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” light will activate. Otherwise for the rst fteen minutes of operation,
the green “Normal Oxygen” light will remain illuminated during the oxygen
stabilization process. After that time, the OSD will begin monitoring the oxygen
purity every second.
Alerts:
There are two visible service alerts located on the front panel.
For serial numbers starting with
J, N or R For serial numbers starting with F
Low O2%Service Low O2%Service
The audible alert system is internally powered; no batteries are required. If the
indicator lights illuminate or the audible alert sounds other than during start-up,
a problem has occurred
• Power Failure (Blinking red “Service” light and pulsing audible alert)
• Low Flow (Below 0.5 lpm) (Continuous red “Service” light and audible
alert)
• Below Normal Oxygen (84% to 75%, yellow “Low Oxygen” light. 75% to
60%, yellow “Low Oxygen” light and beeping audible alert. Less than 60%,
red “Service” light and beeping audible alert.)
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 rst 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.
NOTE–If 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 is responsible for controlling the system and
alerts.
NOTE–A high pressure condition is indicated by the audible (a “popping” sound)
release of pressure from a pressure relief valve located on the compressor
head.
NOTE–Installation of 515LF-607 low output ow meter package will cause the
low ow alarm not to work.
ROUTINE PATIENT MAINTENANCE
DeVilbiss recommends using only original DeVilbiss parts and lters in order to
guarantee a reliable operation of the product.
The oxygen patient should perform the following maintenance:
Cannula, Tubing, and Humidifier Bottle
The patient should clean and replace the cannula, tubing, and humidier bottle
according to the manufacturer’s instructions.
Air Filter and Oxygen Outlet Connector
The air lter and oxygen outlet connector should be cleaned at least once a
week by the patient. To clean, these steps should be followed:
1. Remove the air lter located in the door on the back of the unit. Remove
the oxygen outlet connector (if used) from oxygen outlet port.
2. Wash in a solution of warm water and dishwashing detergent.
3. Rinse thoroughly with warm tap water and towel dry. The lter should be
completely dry before reinstalling.
WARNING
Do not attempt to operate the unit without the air lter or while the lter is
still damp.
NOTE–The air lter 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 lter will prematurely occlude the intake bacteria
lter and cause a decrease in the unit performance.
Exterior Cabinet
The patient should clean the concentrator exterior cabinet by using a damp cloth
or sponge with a mild household cleaner and wiping it dry.
WARNING
Do not apply liquids directly to the cabinet or utilize any petroleum-based
solvents or cleaning agents.
PERIODIC HOMECARE PROVIDER
PREVENTATIVE MAINTENANCE
Use only DeVilbiss concentrator replacement parts and accessories.
Every DeVilbiss Oxygen Concentrator is tested at the factory. To assure
continued trouble-free performance, the following preventative maintenance
should be performed by the homecare provider during periodic oxygen patient
visits. Failure to properly maintain the unit will void the warranty.
1. Check the oxygen concentration with an oxygen analyzer (part #R217P62
or R218P12)—every 3 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 concentrator.
b. Power the unit, set the ow meter to 5 LPM and connect the analyzer
to the unit’s oxygen outlet port.
c. Wait 20 minutes for the display to stabilize. The concentrator must
operate for a minimum of 20 minutes before checking the oxygen
concentration.
d. Record the reading.
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MAINTENANCE
2. Check the audible alert and indicator lights during every service. 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 lter (part #MC44D-605) during every PM Check. Replace
as necessary.
a. Open the lter door and replace lter as required.
4. Inspect the nal bacteria lter (part #PV5LD-651) during every compressor
service. Replace as necessary.
a. Use the Cabinet Removal instructions found under CABINET
REMOVAL in this manual to remove and attach the cabinets.
b. Remove the hose from each end of the lter and discard the lter.
c. Install the new nal bacteria lter with the “IN” tting toward the ow
meter.
5. Inspect the compressor lter during every compressor service. Replace as
necessary.
NOTE–A change was made to the type of compressor lter used in the 525
series concentrator. The unit may have one of two different types of compressor
lters depending on when the concentrator was manufactured. The original one
is a white plastic lter (part #525D-622) that is located near the compressor. The
newer style is a sintered bronze lter (525DD-626) that is installed in one end of
the compressor exhaust hose near the rotary valve. All models of the 525 series
are now being manufactured with the sintered bronze compressor lter. See
gure below.
Sintered Bronze Compressor Filter
(525DD-626)
NOTE– This PM Schedule reects:
• 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 specic operating environment.
* 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.
WARRANTY
DeVilbiss provides warranty for this device. Use only DeVilbiss approved original
spare parts for maintenance and repair to retain warranty. Using unapproved or
non-original spare parts would void warranty.
PROVIDER’S NOTES - Cleaning and
Disinfection When There is a Patient
Change
When medical devices have already been used with a patient, contamination
with human pathogenic germs should be assumed (unless there is evidence to
the contrary), and the next patient, user or third party should be protected by
appropriate handling and preparation.
Therefore, when there is a patient change, people must be protected during the
transport and handling of the device, and the device must be fully processed,
i.e., cleaned and disinfected, by suitably trained personnel before reuse to
protect the next patient. The complete processing may only be done by the
manufacturer or by a qualied DeVilbiss provider/service technician.
NOTE–If the following described complete processing of the concentrator by a
qualied DeVilbiss provider/technician is not possible, the device must not be
used by another patient!
DeVilbiss Healthcare recommends that at least the following procedures be
carried out by the manufacturer or a qualied third party between uses by
different patients.
NOTE–If preventative maintenance is due at this time, these procedures should
be carried out in addition to the servicing procedures.
1. Dispose of all accessory components that are not suitable for reuse, i.e.,
particularly the oxygen tubing, the nasal cannula/mask, oxygen outlet
connector and humidier bottle.
2. CAUTION–the concentrator must be disconnected from the power
supply for this step: Open the concentrator and remove all dust deposits
inside the cabinet with an appropriate vacuum cleaner.
3. Clean and disinfect all parts of the cabinet inside and outside and the
power cord with a suitable disinfecting agent, e.g., Microbac Forte,
Terralin®, Aldahol, Cidex OPA or Peract.
4. Check the cord, the plug on the back of the device, the power switch, the
fuse holder and the indicator light for possible damage.
5. Replace all damaged or worn components.
6. Replace the cabinet air lter on the back of the device.
7. Check the oxygen concentration. If the device is within specications, the
intake bacteria lter does not need to be replaced between patients. If the
concentration is not within specications, the provider should refer to the
service manual section on Troubleshooting.
RETURN AND DISPOSAL
This device may not be disposed of with household waste. After use of the
device, please return the device to the dealer for disposal. This device contains
electrical and/or electronic components that must be recycled per EU Directive
2012/19/EU-Waste Electrical and Electronic Equipment (WEEE). Non-infectious
used accessories (e.g. nasal cannula) can be disposed of as residential waste.
The disposal of infectious accessories (e.g. nasal cannula from an infected user)
must be made via an approved waste disposal company. Names and addresses
can be obtained from the local municipality.
PREVENTATIVE MAINTENANCE SUMMARY
Patient / Caregiver
Clean and replace oxygen tubing, cannula / mask, and humidier bottle (if used)
according to manufacturer’s instructions.
Homecare Provider
During each inspection
Wash/Replace cabinet lter.
Check audible alert and indicator lights.
During each PM check – every 3 years for the 525 series
Inspect/Replace intake bacteria lter as necessary.
Check oxygen purity.
During compressor service
Inspect/ Replace nal bacteria lter.
Inspect/ Replace the compressor lter
9
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TROUBLESHOOTING
SYSTEM OPERATION
The DeVilbiss Oxygen Concentrator uses a pressure swing adsorption system.
The air is drawn into the unit through air lters and into a double-head
compressor.
A pneumatic diagram of the system is shown on Page 36.
The compressed air passes through a rotary valve, which is cycled at a pre-
determined rate, and is directed into one of two sieve beds. The sieve beds
contain molecular sieve material which is a synthetically-produced inorganic
silicate. It is very porous and has the unique ability to selectively adsorb nitrogen
from the air as it passes through the sieve bed.
As one bed is being pressurized, the other bed is quickly depressurized. This
allows the nitrogen that was adsorbed during its pressurization cycle to be
exhausted from the sieve material.
The nitrogen is released through exhaust ports located on the rotary valve
assembly. The ports are connected to a single piece of hose running from the
valve to the exhaust mufer.
Also during each bed pressurization, a small amount of oxygen ows through an
orice from the pressurized bed into the depressurizing bed. 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 on the tank controls the oxygen pressure
as it leaves the accumulator and enters the ow meter. The ow meter allows the
oxygen ow to be controlled and adjusted to the level prescribed by the patient’s
physician. From the ow meter the oxygen passes through the nal bacteria lter
and nally the oxygen outlet port to the patient.
The DeVilbiss Oxygen Concentrator operates on a timed cycle (3.6 sec. @
5LPM) that 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. Low ow, system
abnormality, and power failure are indicated by audible and visible alerts. A high
pressure condition will be indicated with a “popping” type sound produced by
release of pressure from a pressure relief valve on the compressor head.
The 525 operating system incorporates “turn-down” technology. The PC board
constantly monitors the ow rate and will decrease the cycle time whenever the
ow rate is less than 1.2 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 a pressure gauge to the manifold or accumulator tank test
point.
1. The 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. The pressure exhausts through an exhaust
mufer 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 to pressurize rst while the
left bed depressurizes.
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. A 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.
5. A 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. The cycle then repeats with step 2.
NOTE–In the “turn-down” mode, the xed cycle time is decreased to less than 2
seconds.
LT-2023
10
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— Purity Issues (Low Purity Indicator Light
and/or an audible alert is activated or the Pressure
Relief Valve releases pressure with a ‘popping’ sound).
WARNING
Electric Shock Hazard. Extra care should be taken if it is necessary to
operate the unit with the cabinet removed.
WARNING
Mechanical Hazard. Keep ngers, loose clothing, etc. away when working
on compressor.
Observe the pressure cycle at the oxygen tank.
1. Connect a calibrated pressure gauge to the unit’s oxygen tank test point or
manifold.
2. Set the unit’s ow meter to 5 LPM.
3. Power the unit and allow it to operate for a minimum of 5 minutes before
observing the pressure cycle.
4. Compare the high pressures and low pressures to those expected for the
current elevation and use the following chart to nd the appropriate action.
All consecutive high pressures should be within 1 psi of each other and all
consecutive low pressures should be within 1 psi of each other.
NOTE–For normal system pressures refer to Specications.
NOTE–Check for leaks using a certied leak detection solution such as Snoop®
or equivalent (must not contain ethylene glycol). Apply leak test solution to all
ttings 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.
Pressure Diagnostic Chart
If Pressure Reading Is Do This To This
Higher than expected and/
or pressure relief valve
has a ‘popping’ noise
Replace Sieve beds (2)
Lower than expected
Inspect and replace, as
needed Filters
Inspect and correct or replace,
as needed Tubing connections
Troubleshoot
Compressor
See Component Testing,
Repair and Replacement
As expected Inspect and correct, as
needed
Leaks from sieve beds to
oxygen outlet port
Dropping too low during
cycle change Replace Check valves or manifold
Uneven - high pressures
& low pressures are not
consistent during cycle
Inspect and replace, as
needed Rotary valve wire harness
Troubleshoot or replace
Rotary valve or PC board.
See Component Testing,
Repair and Replacement
Type II—Operation Issues (Service Indicator
Light and/or an audible alert is activated or the
Pressure Relief Valve releases pressure with a
‘popping’ sound)
WARNING
Electric Shock Hazard. Extra care should be taken if it is necessary to
operate the unit with the cabinet removed.
WARNING
Mechanical Hazard. Keep ngers, loose clothing, etc. away when working
on compressor.
NOTE–Check for leaks using a certied leak detection solution such as Snoop®
or equivalent (must not contain ethylene glycol). Apply leak test solution to all
ttings 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.
Operation Alarm Chart
If this is happening It’s because of this Do this to resolve
Pressure relief valve has a
‘popping’ noise with
possible uneven tank
pressure.
Rotary valve not cycling
properly.
Test rotary valve. Refer to
page 21.
Continuous red light with a
pulsing audible alert while
compressor is operating.
Low ow alert – ow setting
below 0.5 lpm.
Correct setting and educate
user and / or install low ow
meter, if prescription is
below 1 lpm. See section on
the ow meter.
Continuous red light with a
continuous audible alert
and unit is warm to touch.
Internal temperature is too
high.
Move unit to cooler location.
Ensure unit vents are clear.
Ensure unit lters are clean.
Ensure cooling fan is
operating, replace as
needed.
Ensure there is proper
voltage to the unit. If voltage
is correct, replace capacitor
or compressor.
Continuous red light with a
pulsing audible alert and
fan is operating but
compressor is not.
Internal power failure to
compressor.
Test voltage at compressor
connector. If no voltage,
replace main wire harness. If
voltage present, replace
capacitor or compressor.
Blinking red light with a
pulsing audible alert and
compressor and fan not
operating.
External OR Internal power
failure.
Ensure voltage is correct
and / or the part is functional
for the following: AC outlet,
power cord, IEC connector
or cord connection, main
wire harness, circuit breaker;
correct as needed. If issue
persists, replace power
switch.
Blinking red light with a
pulsing audible alert and
compressor and fan are
operating. Pressure relief
valve has a ‘popping’
noise.
Internal power failure at valve
wire harness or PC board.
Inspect wire harness and
replace as needed.
Inspect fuse, if blown,
replace fuse or PC board.
Type III—The concentrator runs and
continues to cycle but has low oxygen
concentrations and no alarms are
activated.
This problem is similar to Type I in the way it is diagnosed. Observe pressure
cycle at oxygen tank as recommended in Type I.
11
LT-2023
TROUBLESHOOTING
OTHER SYMPTOMS POSSIBLE CAUSE POSSIBLE REMEDY
Pulsating air noise Intake filter not in place or defective Check filter and replace if necessary
Compressor intake hose disconnected Reconnect hose
Excessive noise Loose or defective motor mounts Replace motor mounts
Defective compressor Replace compressor
Defective cooling fan Replace cooling fan
Fluctuating oxygen ow Occluded humidier Clean or replace humidier
Use of improper humidier Use only a bubble-type humidier
Occluded filters Clean or replace filters
Occluded or defective cannula and tubing Detach cannula from oxygen delivery tubing. If proper flow is not
attained, check tubing for kinks or other obstructions. Clean or straighten
as required or replace tubing if necessary
Use of excess oxygen tubing The unit is designed to deliver 5 lpm with a cannula on 50 feet (15
meters) of approximately 5/32” (4 mm) inside diameter tubing. Smaller
diameter tubing or the addition of any other ow restriction may prevent
obtaining the desired ow rate.
Defective ow meter Replace ow meter
Leak in system Check for leaks in all hoses and ttings
Defective compressor Replace compressor
Defective compressor reed valve Replace compressor reed valve
Defective check valve Replace check valve or manifold
Pressure regulator not adjusted properly or defective Adjust or replace pressure regulator
Little or no oxygen ow Flow meter not adjusted properly Adjust ow meter
Hose disconnected to ow meter Reconnect hose
Oxygen delivery tubing is kinked or blocked Straighten tubing or remove obstruction
Occluded humidier Clean or replace humidier
Low oxygen concentration Leak in system Check for leaks in all hoses and ttings
Defective sieve bed check valve Replace check valve or manifold
Defective compressor reed valve Replace compressor reed valve
Defective compressor Replace compressor
Rotary valve not operating correctly Replace valve
Occluded lters Clean or replace lters
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”
Defective PC board Replace PC board
Pressure relief valve activated “popping” sound PC board connectors not properly latched Be sure tabs are pushed completely into place
Defective PC board Replace PC board
Defective rotary valve Replace valve
Service Required light does not illuminate when
unit is turned “On”
PC board connectors not properly latched Be sure tabs are pushed completely into place
Defective PC board Replace PC board
Defective light panel Replace light panel
Visible Alarm Audible Alarm Compressor Power Light
OFF OFF ON ON
TROUBLESHOOTING CHART A
LT-2023
12
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 220/230/240
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 unit is
disconnected Reconnect quick-connect terminal
Defective power switch Replace power switch
Defective circuit breaker Replace circuit breaker
TROUBLESHOOTING CHART C
Visible Alarm Audible Alarm Compressor Power Light
Blinking Pulsing ON ON/OFF
OTHER SYMPTOMS POSSIBLE CAUSE POSSIBLE REMEDY
Fan and compressor operating
Pressure relief valve activated – “popping”
sound
Connector on PC board not connected Connect connector
Blown fuse on PC board Replace fuse
Defective PC board Replace PC board
TROUBLESHOOTING CHART D
Visible Alarm Audible Alarm Compressor Power Light
ON ON 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 be
restarted for several minutes
Compressor overheated due to:
1. Occluded lters 1. Clean or replace lters
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
13
LT-2023
TROUBLESHOOTING
TROUBLESHOOTING CHART E
Visible Alarm Audible Alarm Compressor Power Light
ON ON ON ON
OTHER SYMPTOMS POSSIBLE CAUSE POSSIBLE REMEDY
Fluctuating or no ow System pressure below 9 psi (62.1 kPa) due to:
1. Leak in system 1. Check for leaks in all hoses and ttings
2. Defective compressor 2. Replace compressor
TROUBLESHOOTING CHART F
Visible Alarm Audible Alarm Compressor Power Light
See Below See Below ON ON
OTHER SYMPTOMS POSSIBLE CAUSE POSSIBLE REMEDY
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, but red
“Service Required” light is illuminated
accompanied by a beeping audible alarm
Oxygen level is low* Check concentration with an oxygen analyzer. If the concentration is
within specication, 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 is illuminated. Oxygen level is low* Check concentration with an oxygen analyzer. If the concentration is
within specication, replace the PC board. If the concentration is low,
refer to low oxygen concentration symptom in Troubleshooting Chart A.
Yellow Low Oxygen light is illuminated and
an intermittent audible alarm sounds every
few seconds.
Oxygen level is low* Check concentration with an oxygen analyzer. If the concentration is
within specication, replace the PC board. If the concentration is low,
refer to low oxygen concentration symptom in Troubleshooting Chart A.
*Refer to Alerts page for oxygen purity levels.
NOTE-If unit does not run or perform to specication, verify the proper AC input voltage and frequency are being used.
LT-2023
14
COMPONENT TESTING, REPAIR AND REPLACEMENT
PROPER REPAIR PROCEDURES
WARNING
When servicing the DeVilbiss Oxygen Concentrator, be absolutely certain
that the correct tools are used and that the parts are free of oil and grease
or any material not compatible with oxygen. Teon® tape is recommended
and must be applied to the male threads omitting the rst 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 qualied 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.
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.
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. See list below.
In addition, you will also need an oxygen analyzer (part #R217P62 or R218P12)
to periodically check oxygen concentration levels and leak test solution.
WARNING
A certied leak detection solution, such as SWAGELOK #MS-Snoop® or
equivalent, is needed to test for system leaks. The solution 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.
NOTE–Apply leak test solution to all ttings 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.
The following parts are included in the Service Kit:
1Slotted bit
1#1 Phillips bit
1#2 Phillips bit
1Crescent wrench
18” Duckbill pliers
1 Voltmeter
2Pressure/Vacuum gauge
1Tool box
2Test Fittings
1Torx screwdriver w/bits
1Channel Lock Pliers
11/4” Ratchet wrench
110mm Socket l/4” Drive
11/4” Drive extension
1Plastic storage case
CABINET REMOVAL
For units with Serial Numbers starting with J,
N or R
To remove back cabinet:
The majority of all the servicing and repairs can be done without removing the
front cabinet completely. However, it may be loosened or removed to gain access
to the components behind it.
1. Unplug the unit from the wall outlet.
2. Remove the six screws that secure the back cabinet – 2 behind handle, 2
near the bottom, and 1 on each side.
NOTE–All six screws are the same size.
3. Remove the back cabinet by sliding it toward the rear until clear.
4. To reassemble, reverse steps 2-3.
To loosen the front cabinet:
5. Remove the two screws (located directly above the hour meter) that hold
the front cabinet to the unit’s internal structure.
6. Remove the screw located near the bottom of the recessed humidier
compartment on the front of the unit. The top of the front cabinet can now
be tilted forward to allow access to the components behind it.
To remove the front cabinet completely:
7. Tilt cabinet forward and disconnect the ribbon connector from the PC
board.
8. Before disconnecting the wires from the power switch and circuit breaker
note their positions in order to reconnect them properly; then disconnect
the wires.
9. Disconnect the hose at the bottom of the ow meter and remove cabinet.
10. To reassemble reverse steps 5 – 9 making sure bottom of cabinet is
inserted securely in base of unit.
NOTE–All 525 models are now being built using Plastite cabinet screws. These
are special thread forming screws; so do not over tighten. They should be
torqued to 18 – 20 in-lbs. The original cabinet screw has much ner threads and
is not a thread forming screw.
These screws are not interchangeable, so be sure to order the correct part
number. See gure below.
Plastite Cabinet
Screw
Original Cabinet
Screw (525DD-628)
For units with Serial Numbers starting with F
To remove front and back cabinets:
1. Ensure the unit is unplugged from the wall outlet.
2. Remove the six screws that secure the back cabinet – 2 behind handle, 2
near the bottom, and 1 on each side.
NOTE–All six screws are the same size.
3. Remove the back cabinet by sliding it toward the rear until clear.
4. Remove the front cabinet by pushing the top shoulders toward the back of
the unit, then outward away from behind the bib. Tilt the top of the front
cabinet forward until it can be pulled out of the base of the unit.
5. To reassemble, reverse steps 2-4.
The majority of all the servicing and repairs can be done without removing the
front bib. However, it may be loosened or removed to gain access to the
components behind it.
15
LT-2023
COMPONENT TESTING, REPAIR AND REPLACEMENT
To loosen the bib:
6. Remove the two screws (located directly above the hour meter) that hold
the bib to the unit’s internal structure. The bib can now be tilted forward to
allow access to the components behind it.
To remove the bib completely:
7. Disconnect the ribbon connector from the PC board.
8. Before disconnecting the wires from the power switch and circuit breaker
note their positions in order to reconnect them properly; then disconnect
the wires.
9. Tilt the top of the bib forward to release it from the slot in the body of the
concentrator.
10. Disconnect the hose at the bottom of the ow meter and remove bib.
11. To reassemble reverse steps 6 – 10 making sure bottom of front cabinet is
inserted securely in base of unit.
NOTE–The bib tab must be inserted into the slot above the rotary valve before
securing bib.
NOTE–All 525 models are now being built using Plastite cabinet screws. These
are special thread forming screws; so do not over tighten. They should be
torqued to 18 – 20 in-lbs. The original cabinet screw has much ner threads and
is not a thread forming screw.
These screws are not interchangeable, so be sure to order the correct part
number. See gure below.
Plastite Cabinet
Screw
Original Cabinet
Screw (525DD-628)
ACCUMULATOR PRESSURE TEST
To check accumulator pressures:
1. Make sure the unit is “Off.”
2. Use the Cabinet Removal instructions listed previously to open the unit for
testing.
3. Use the pressure gauge (part #PVO2D-601) and pressure test assembly
(part #303DZ-637) included in the Service Kit.
Pressure Gauge
Pressure Test
Assembly
4. Remove the tubing cap from the accumulator tank tting or from the
manifold attached to the tank, and attach the 1/16" (1.6 mm) diameter
tubing from the gauge to the accumulator tank tting just vacated above.
See Figures below showing pressures being checked at accumulator tank "T"
tting and manifold.
ManifoldAccumulator "T" Fitting
5. Turn the unit “On” with the ow rate set to maximum recommended ow,
which is usually 5 lpm. Allow the unit to run for 5 minutes before observing
the pressures. During each timed cycle, the average pressure in the
oxygen accumulator will rise and fall. The high pressures should be
consistent and the low pressures should be consistent.
NOTE–Pressure drop will be 4-5 psi each cycle.
NOTE–Expected normal pressures observed depend on altitude and ow rate.
See the Expected Accumulator Tank Pressure Range chart below.
• Increases in altitude and ow rate will slightly decrease accumulator
pressures.
• Lower altitudes and ow rates will slightly increase accumulator pressures.
NOTE–A defective check valve, in either the purge harness or the manifold, may
cause a rapid drop in accumulator pressure below the minimum value.
EXPECTED ACCUMULATOR TANK PRESSURE RANGE @ 5LPM
Altitude Psi kPa
0 to 457 m
0 to 1500 ft. 23-32 159-221
457 to 914 m
1500 to 3000 ft. 21-29 145-200
914 to 1524 m
3000 to 5000 ft. 20-27 138-186
Includes a pressure drop of 4-5 psi and 27-34 kPa during the pressure cycle.
6. Refer to the Type 1 – Purity Issues, found under Simplied Troubleshooting,
to determine the appropriate action to take in resolving abnormal pressure
cycles.
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 may 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.
LT-2023
16
COMPONENT TESTING, REPAIR AND REPLACEMENT
AUXILIARY OXYGEN PORT
All 525 series concentrators are now being manufactured with an auxiliary
oxygen port located on the back of the unit. Concentrators with the auxiliary port
have serial numbers starting with “N” or “R”.
To ll oxygen cylinders:
This external port can be used to ll oxygen cylinders with an FDA-cleared
cylinder lling device that is designed to use oxygen from a concentrator to ll a
cylinder. The port is only for use with FDA-cleared lling devices with compatible
oxygen input specications.The ow meter should be set at 3 LPM or less when
the concentrator is being used during cylinder ll. The port does not affect
concentrator performance if properly used. See gures below.
Auxiliary Port Output Specications:
Outlet Pressure .................................. 8.5±0.5 psi
Outlet Flow ...................................... 2.5±0.5 LPM
Outlet Oxygen ..............................................>90%
Operation Time ...................................Continuous
Refer to the cylinder lling device instruction guide for the oxygent input/output
specications, connection and operating instructions.
Transfill Hose
(PF1100TUB) Auxiliary Port Transfiller Caddy
(525DD-650)
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 525DS concentrators use a GSE compressor with a 22 mfd
capacitor. If replacement is necessary, be sure the correct capacitor is installed.
CAUTION–The 525KS/525PS concentrators use a GSE compressor with a 10
mfd capacitor. If replacement is necessary, be sure the correct capacitor is
installed.
WARNING
Electric Shock Hazard. When replacing the capacitor, do not touch the
terminals or allow metal objects to come in contact with the terminals on
the capacitor. The capacitor may hold a charge for several days after the
unit is turned off.
If a defective capacitor is suspected, a new one must be installed. The capacitor
is strapped into a well molded into the bottom of the unit next to the cooling fan.
To replace the capacitor:
1. Make sure the unit is unplugged from the wall outlet.
2. Remove the back cabinet. Use the Cabinet Removal instructions listed
previously.
3. Remove the compressor. Use the To Remove the Compressor instructions
listed under Compressor.
4. Disconnect the two wires from the terminals on the capacitor.
5. Cut the nylon cable tie holding the capacitor in place and remove the
capacitor.
6. Reconnect the wires to the new capacitor.
7. Install the new capacitor and secure with a new cable tie.
8. Replace the compressor and reassemble cabinet.
9. Replace the back cabinet and secure with the six screws.
CHECK VALVES/MANIFOLD
Manifold And Sieve Bed Check Valves
The manifold check valves, located in the manifold attached to the accumulator
tank, and the sieve bed check valves, located in the purge harness, between the
outlet of each sieve bed and the accumulator tank, allow oxygen to pass from the
sieve beds to the accumulator tank, when the bed pressure is greater than the
accumulator tank pressure. These valves also prevent reverse ow of oxygen
from the accumulator tank to the sieve beds.
The manifold also directs a small amount of pressurized oxygen into the
discharging sieve bed to aid the nitrogen exhaust process. The purge harness
includes a xed orice that performs the same function.
A defective manifold or sieve bed check valve will result in lower oxygen
concentrations and accumulator pressures.
Use the Accumulator Pressure Test described in this section to troubleshoot
manifold or sieve bed check valves.
• To replace a defective sieve bed check valve, remove the tubing on either
side of it and install a new valve making sure the outlet end is toward the
accumulator tank.
• To replace a defective manifold check valve, replace the manifold.
NOTE– Also see manifold section on page 19.
Final Check Valve
The nal check valve is located, on older units, between the nal bacteria lter
and the oxygen outlet tting.
To replace the nal check valve:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Remove the hose from the outlet side of the nal bacteria lter.
4. Remove the two screws from the back of the oxygen outlet tting assembly
and remove the assembly.
5. Remove the hose from each end of the nal check valve.
6. Attach the hoses to a new check valve. Make sure that the at side of the
check valve is directed toward the oxygen outlet tting.
7. Replace the outlet tting assembly and connect the hose to the lter.
8. Reassemble the cabinet.
COMPRESSOR
The DeVilbiss Oxygen Concentrator uses a double-head, oil-free compressor.
The compressor is secured to the base with four motor mounts.
Electrical Connector
Exhaust Fitting
Intake Fitting
Pressure Relief Valve
17
LT-2023
COMPONENT TESTING, REPAIR AND REPLACEMENT
A compressor that is worn or defective may:
• cause pressure to rise slowly.
• cause excessive noise and/or vibration.
• cause lower oxygen concentrations.
A worn or defective compressor can be caused by a defective internal
component such as:
• reed valve
• o-ring
• gasket
• cup seal
These components are included in the Compressor Rebuild Kit (525D-643 and
525K-643).
Sleeve
Valve Plate
Rod Screw Rod (beneath
cup retainer)
Cup Seal
Cup
Retainer
Reed
Valve or
Flapper
Retainer
Intake
Fitting
PR Valve
Compressor
Head
Head
Gasket
Screw
Connecting
Tubes
O-Ring
Spacer
Sleeve
Exhaust
Fitting
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.) Should this condition occur, the compressor will require several
minutes for the thermo-protective device to reset.
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:
The compressor requires line voltage to operate. If the compressor does not start
when the unit is turned on, the voltage input must be tested:
1. This voltage can be checked at the compressor connector using a
voltmeter or test light connected to the brown and blue wires. The voltmeter
is the best way to test.
Testing Compressor Voltage
Voltmeter Leads
2. If no voltage is detected, disconnect power and check for loose or broken
wires between the compressor connector and switch or wire harness.
3. If there is voltage at the compressor connector, then either the capacitor or
the compressor itself is defective.
To test the compressor for proper output:
NOTE–If the compressor is not providing a high enough output the patient alert
system may be activated.
1. Use the Cabinet Removal instructions listed previously to open the unit for
testing.
2. Use the Accumulator Pressure Test listed previously to observe the high
pressures, low pressures and the pressure drop.
3. Refer to the Type 1 – Purity Issues, found under Simplied Troubleshooting,
to determine the appropriate action to take in resolving abnormal pressure
cycles.
NOTE–A compressor, which slowly builds pressure that remains below 25 psi,
indicates worn cup seals and/ or reed valves.
If these conditions are observed then:
• The unit lter(s) may be occluded—check the air lter, compressor lter,
and intake lter 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.
• The compressor reed valves, cup seal, or the compressor itself may be
defective.
If the lters are not occluded and no leaks are found, the compressor must then
be removed and repaired or replaced.
To remove the compressor:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Disconnect the compressor wires by disconnecting the compressor
electrical connector.
4. Remove the ladder clamp and hose from the exhaust ttings on the
compressor head and compressor lter if applicable.
5. 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.
LT-2023
18
COMPONENT TESTING, REPAIR AND REPLACEMENT
6. Lift compressor partially out of the compressor housing area and loosen
ladder clamp securing hose to the intake tting, then remove hose.
7. Compressor may now be removed from the compressor housing area.
CAUTION–If the unit has been running recently, the compressor may be hot.
8. Unscrew motor mounts from compressor feet by hand.
To inspect and/or replace internal
components:
1. Remove the eight screws that hold the compressor heads in place. When
removing the heads, be sure to keep each head and its components with
the correct compressor side.
2. Check for proper placement of or damage to the gaskets on the bottom of
the compressor heads. Replace if damaged.
3. Remove reed valve plates. A reed valve is located on each side of the
valve plate.
4. The compressor reed valves should be ush with the valve plate. If the
valve is broken or not ush 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:
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:
a. Remove rod screw from top of piston.
b. Remove the cup retainer plate.
c. Discard defective cup seal.
d. Place new cup seal into position.
e. Replace cup retainer plate.
f. Secure with screws.
7. Discard old sleeve and position new sleeve at 45 degree angle over the
piston. Carefully push it down as you rotate it slightly around the top of the
piston until it is in place.
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–The 525DS concentrators use a GSE compressor with a 22 mfd
capacitor. The 525KS/525PS concentrators use a GSE compressor with a 10 mfd
capacitor. If replacement is necessary, be sure the correct capacitor is installed.
1. 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 tting.
4. 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.
6. Reconnect hoses to the ttings at compressor exhaust and lter.
7. Reconnect the compressor electrical connector.
COOLING FAN
The cooling fan provides a constant air ow to cool the compressor. The cooling
fan is located in the bottom of the unit below the compressor.
A defective cooling fan may cause the compressor’s internal thermo-protective
(thermal cut off) device to activate and shut the compressor off. Should this
condition occur, the compressor will require several minutes for the thermo-
protective device to reset.
If the cooling fan is defective, it must be
replaced:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Use the To Remove the Compressor instructions listed under 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 ow 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.
FLOW METER
There are two ow meters available for the DeVilbiss 525 series oxygen
concentrators: a standard 5 lpm ow meter (505DZ-607) and a low output ow
meter (515LF-607). The low output ow meter should be used when the
prescribed ow rate is at or under 1 lpm.
NOTE–Installation of a low output ow meter eliminates the low ow alert for ow
delivery under 0.5 lpm.
Locking Screw
Both pressure-compensated ow meters have an accuracy
level of ±5% at full scale (exception: +0% / -5% at 5 lpm)
and are designed for use at 8.5 psi (58.6 kPa). Both ow
meters can be locked using a 1/16th inch Allen wrench and
tightening the locking screw behind the ow meter knob.
To check for leaks in the flow meter tubing:
1. Check for leaks using a certied leak detection solution such as Snoop® or
equivalent (must not contain ethylene glycol).
2. Apply leak test solution to all ttings and hose connections with the unit
running.
CAUTION–Do not apply leak test solution to any part of the rotary valve or the
main PC Board assembly.
3. If an air leak is present, the solution will bubble. All leaks should be
repaired before putting the concentrator back in service.
WARNING
Electric Shock Hazard. Use caution when leak testing near electrical
connections.
19
LT-2023
COMPONENT TESTING, REPAIR AND REPLACEMENT
To replace the flow meter:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. From behind the bib/front cabinet, remove the 2 hoses from the ow meter.
4. While squeezing tabs on ow meter brackets, push the ow meter through
the bib/front cabinet or just unscrew ow meter ttings.
5. Install new ow meter and reconnect hoses.
To install or replace the low output flow
meter:
1. Ensure that the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Disconnect:
a. All wires, terminals and connectors attached to the PC board.
b. The 1/8 ID blue tubing from the Oxygen Sensing Device (OSD) and
from the ow meter.
c. The screw that secures the PC board to the unit.
4. Build the T-tting assembly. (Skip this step, if replacing an existing low
output ow meter.)
a. Cut the existing 1/8 inch blue tubing that connected the OSD and the
ow meter into two equal pieces.
b. Attach each piece of the cut tubing to the large ends of the T-tting,
included in the kit.
c. Attach one end of the 1/16 inch ID blue tubing, included in the kit, to
the small end of the T-tting.
5. Position the bleed-off orice and connect tubing.
21
Insert an opened paperclip through the hole in the case, behind where the PC board
was installed (Fig. 1), until it appears in the lter cavity (Fig. 2).
Place the orice tting, included in
the kit, onto the end of the paperclip
(Fig. 3).
Push the tting through the foam
until it’s inside the case. Remove
the paperclip and attach the 1/16
inch ID tubing (Fig. 4).
3 4
6. Replace the ow meter.
a. Remove all tubing from the current ow meter.
b. Unscrew white plastic connectors or ttings.
c. Remove the metal brackets and push the meter through the case.
Save the meter and metal brackets for later use, if desired.
d. Align the new metal brackets on the at surfaces of the new meter.
e. Push the ow meter into the case with the highest ow at the top.
7. Reassemble the unit.
a. Connect one end of the 1/8 inch blue tubing to the T-tting assembly
to the bottom of the ow meter and the other end to the bottom of the
OSD.
b. Reconnect the PC board wires, tubing, terminals and connectors.
HOUR METER
To replace the hour meter:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Remove PC board.
4. Squeeze locking tabs on both sides of hour meter while pushing upward to
remove meter.
5. Install a new hour meter by applying downward pressure until it snaps into
position.
6. Replace PC board and reconnect all wires, connectors and tubing.
CAUTION–Do not apply any force or ex the PC Board when connecting or
disconnecting electronic or pneumatic components. Damage to the electronic
assembly is possible.
MANIFOLD
The manifold is attached to the accumulator tank and performs the same function
as a purge harness. It directs a small amount of pressurized oxygen into the
discharging sieve bed to aid the nitrogen exhaust process while it ensures that
the majority of pressurized oxygen is directed into the accumulator tank. The
manifold also prevents reverse ow of oxygen from the accumulator to the sieve
beds.
See CHECK VALVES: MANIFOLD and SIEVE in this manual for additional
information.
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20
COMPONENT TESTING, REPAIR AND REPLACEMENT
MOLECULAR SIEVE BEDS
The build and release of pressure in the sieve beds indicates the health of the
sieve material and the operation of contributing components. Determine ‘good’ or
expected pressures for your altitude by testing bed pressures on multiple oxygen
concentrators that are producing at least 93% purity.
Check sieve bed pressures at the accumulator tank using the manifold test point
or the accumulator tank test point. See Figures below.
ManifoldAccumulator "T" Fitting
NOTE–The pressure will rise and fall as it cycles through the rotary valve.
Also consider the acceptable pressure range for various altitudes as shown
below.
EXPECTED ACCUMULATOR TANK PRESSURE RANGE @ 5 LPM
Altitude Psi kPa
0 to 457 m
0 to 1500 ft. 23-32 159-221
457 to 914 m
1500 to 3000 ft. 21-29 145-200
914 to 1524 m
3000 to 5000 ft. 20-27 138-186
Includes a pressure drop of 4-5 psi and 27-34 kPa during the pressure cycle.
To test sieve bed pressures:
1. Remove the plugged piece of 1/16" tubing from the manifold or the
accumulator tank.
2. Connect the pressure gauge to the test point and observe the cycling of
pressures. Refer to the section on Normal Operating Sequence and also
Accumulator Pressure Test.
a. If it is determined that the valve is not cycling the pressure, refer to
the section on Rotary Valve testing.
b. If the unit is cycling properly, allow it to operate for 20 minutes.
3. After 20 minutes of operation, observe the high and low pressures and
check the oxygen concentration level.
a. If the pressures are within the expected range and the oxygen
concentration is within specication, the sieve material is effective.
b. If pressures are not within the expected range and/or the oxygen
concentration is not within specication, refer to the Simplied
Troubleshooting Table in this manual to determine the proper
corrective action.
NOTE–If the molecular sieve material is found to be no longer effective, rst
search for the source of a malfunction in the system; then, for a cause for
contamination (such as leaks) and take corrective action.
To replace the molecular sieve beds:
NOTE–Make sure that the sealing caps remain on the new sieve beds until just
prior to connecting hoses and tubing.
1. Ensure any contamination problem has been corrected.
2. Ensure the unit is unplugged from the wall outlet.
3. Cut the plastic cable ties that secure the sieve beds to the internal structure
of the unit.
4. Remove the tubing from the ttings 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.
7. Leak test all connections with a certied leak detection solution such as
Snoop® or equivalent (must not contain ethylene glycol). Apply leak test
solution to all ttings 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:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
3. Disconnect the power cord connector.
4. Note wire colors and socket locations before removing wires.
5. Using a pair of duckbill pliers, squeeze the power cord strain relief and pull
it out of the base of the unit.
6. Insert a new power cord through the hole in the base of the unit and secure
with strain relief.
7. Insert sockets into connector housing and then reconnect the power cord
connector.
8. Replace back cabinet and secure with the six screws.
POWER SWITCH
To replace the power switch:
1. Make sure the unit is unplugged from the wall outlet.
2. Use the Cabinet Removal instructions listed previously to open the unit.
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 unit.
5. Install the new switch in the correct orientation making sure that it locks into
position.
6. Reconnect the wires to the switch terminals.
Brown Wire (or 2 Black Wires)
2 Black Wires (or 1 Brown Wire)
*Red Wire
*Red Wire
*Either red wire can be connected to either left hand terminal of the switch
Switch Detail
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