Invacare Perfecto2IRC5PO2AW User manual

Service Manual
DEALER: Keep this manual. The procedures in this manual
MUST be performed by a qualified technician.
For more information regarding
Invacare products, parts, and services,
please visit www.invacare.eu.com
Perfecto2™
Oxygen Concentrator
(HomeFill®Compatible)
Model IRC5PO2AW (Sensored)
Model IRC5PAW (Non-Sensored)
0120

Perfecto2™2Part No 1154245
 WARNING
DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND
UNDERSTANDING THIS MANUAL. IF YOU ARE UNABLE TO UNDERSTAND
THE WARNINGS, CAUTIONS, AND INSTRUCTIONS, CONTACT INVACARE
TECHNICAL SERVICES BEFORE ATTEMPTING TO USE THIS EQUIPMENT -
OTHERWISE SERIOUS INJURY OR PROPERTY DAMAGE MAY RESULT.
 WARNING
Invacare products are specifically designed and manufactured for use in conjunction
with Invacare accessories. Accessories designed by other manufacturers have not
been tested by Invacare and are not recommended for use with Invacare products.
PERFECTO2PARTS COMPATIBILITY
The Platinum concentrator and the Perfecto2concentrator share many similar
components. However, there are some components that are NOT cross compatible
and they are specific to each model.
Parts that can be used for Perfecto2repairs are listed in the Perfecto2parts catalog,
form number 08_076. Please reference this catalog before replacing any parts. Use
of incorrect parts could result in injury or property damage.

TABLE OF CONTENTS
Part No 1154245 3Perfecto2™
TABLE OF CONTENTS
SPECIAL NOTES ................................................................................ 5
FEATURES ........................................................................................ 6
TYPICAL PRODUCT PARAMETERS .................................................... 7
SECTION 1—IMPORTANT SAFEGUARDS ............................................ 9
Important Safeguards.................................................................................................................................9
Radio Frequency Interference ...............................................................................................................10
SECTION 2—INSTALLATION/SEQUENCE OF OPERATION .................. 11
Verification of Battery Free Power Loss Alarm ................................................................................11
Sequence of Operation ...........................................................................................................................11
SensO2Oxygen Sensor Technology - Ceramic Zirconia Sensor .................................................12
Technical Description .........................................................................................................................12
Operating Sequence ............................................................................................................................12
SECTION 3—PNEUMATIC DIAGRAM ............................................... 14
SECTION 4—TROUBLESHOOTING .................................................... 15
SECTION 5—CABINET .................................................................... 22
Removing Cabinet ....................................................................................................................................22
SECTION 6—PREVENTIVE MAINTENANCE ...................................... 23
Cleaning the Cabinet Filter ....................................................................................................................23
Replacing the Outlet HEPA Filter.........................................................................................................24
Check the Outlet HEPA Filter..........................................................................................................24
Replace the Outlet HEPA Filter .......................................................................................................24
Replacing the Compressor Inlet HEPA Filter ....................................................................................25
Replacing the Muffler Assembly ............................................................................................................25
Cleaning the Heat Exchanger.................................................................................................................28
SECTION 7—COMPRESSOR .............................................................. 30
Replacing Compressor Assembly .........................................................................................................30
Replacing Capacitor .................................................................................................................................32
Rebuilding the Thomas Model 2660 Compressor............................................................................33
Removing Compressor and Compressor Heads .........................................................................34
Rebuilding the Compressor...............................................................................................................37
SECTION 8—P.E. VALVE .................................................................. 41
Replacing P.E. Valve..................................................................................................................................41
SECTION 9—SIEVE BEDS ................................................................. 43
Replacing Sieve Beds................................................................................................................................43
SECTION 10—CHECK VALVES ......................................................... 45
Replacing Check Valves...........................................................................................................................45
SECTION 11—REGULATOR .............................................................. 47
Replacing Regulator..................................................................................................................................47
Adjusting Regulator..................................................................................................................................49
SECTION 12—HEAT EXCHANGER ASSEMBLY .................................. 50
Replacing Heat Exchanger Assembly ...................................................................................................50

TABLE OF CONTENTS
Perfecto2™4Part No 1154245
TABLE OF CONTENTS
SECTION 13—CONTROL PANEL ...................................................... 52
Removing Control Panel.........................................................................................................................52
SECTION 14—COOLING FAN ........................................................... 54
Replacing Cooling Fan .............................................................................................................................54
SECTION 15—P.C. BOARD .............................................................. 57
Replacing P.C. Board................................................................................................................................57
SECTION 16—TRANSFORMER ......................................................... 60
Replacing the Transformer.....................................................................................................................60
SECTION 17—ON/OFF SWITCH ......................................................... 61
Replacing On/Off Switch.........................................................................................................................61
SECTION 18—FLOWMETER .............................................................. 62
Replacing Flowmeter ...............................................................................................................................62
SECTION 19—HOUR METER ............................................................ 63
Replacing Hour Meter.............................................................................................................................63
SECTION 20— 4-WAY VALVE/MANIFOLD ASSEMBLY ........................ 64
Replacing 4-Way Valve and/or Manifold Assembly...........................................................................64
Replacing Pilot Valve Poppets and O-Rings........................................................................................67
SECTION 21—PURITY INDICATORS ................................................ 70
SensO2Alarm Indicators ........................................................................................................................70
Operation ..............................................................................................................................................70
IRC5PO2AW Indicator Lights Explanation....................................................................................70
IRC5PAW Indicator Lights Explanation..........................................................................................70
SECTION 22—TIMING ..................................................................... 72
Autotuning (Model IRC5PO2AW Only)........................................................................................72
Manual Tuning (Model IRC5PAW Only)........................................................................................74
SECTION 23—LEAK TEST ................................................................ 75
Leak Test ....................................................................................................................................................75
4 Way Valve Function Test....................................................................................................................77
SECTION 24— ALARM TEST ............................................................ 79
Alarm and Sensor Tests..........................................................................................................................79
Power Loss Alarm ...............................................................................................................................79
Low Pressure Test...............................................................................................................................79
Time-Out Test......................................................................................................................................80
High Pressure Test ..............................................................................................................................80
Oxygen Sensor .....................................................................................................................................81
P.E. Valve Coil Test .............................................................................................................................83
SECTION 25— SIEVE BED PRESSURE CHECK ..................................... 84
Checking Sieve Bed Pressure.................................................................................................................84
Disassembly...........................................................................................................................................84
Pressure Testing...................................................................................................................................84
CUSTOMER SERVICE AND WARRANTY INFORMATION ................... 87

SPECIAL NOTES
Part No 1154245 5Perfecto2™
SPECIAL NOTES
Signal words are used in this manual and apply to hazards or unsafe practices which
could result in personal injury or property damage. Refer to the table below for
definitions of the signal words.
NOTICE
THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO
CHANGE WITHOUT NOTICE.
 DANGER
DO NOT SMOKE while using this device. Keep all matches, lit cigarettes, candles,
or other sources of ignition out of the room in which this product is located and
away from where oxygen is being delivered.
NO SMOKING signs should be prominently displayed. Textiles and other materials
that normally would not burn are easily ignited and burn with great intensity in oxy-
gen enriched air. Failure to observe this warning can result in severe fire, property
damage and cause physical injury or death.
SIGNAL WORD MEANING
 DANGER Danger indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
 WARNING Warning indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION
Caution indicates a potentially hazardous situation which, if
not avoided, may result in property damage or minor injury
or both.

FEATURES
Perfecto2™6Part No 1154245
FEATURES
FRONT VIEW
Power Inlet
Outlet Fitting*
Oxygen Outlet
Flowmeter
Oxygen Purity Indicator
Lights / Fault and Power
Indicator Lights (SensO2
Model Only)
Power Switch
Circuit Breaker
Hour
Meter
ACCESSORIES (NOT SHOWN):
PreciseRX™ Pediatric Flowmeter Accessory - IRCPF16AW
HomeFill home oxygen compressor - IOH200AW
*NOTE: This outlet fitting is to be used only
for filling oxygen cylinders with the HomeFill
home oxygen compressor. The outlet fitting
does not affect concentrator performance.
Refer to the HomeFill owner's manual, part
number 1145804 - Northern, 1145805 -
Southern, 1145806 - Scandinavian, for
connection and operating instructions. When
not in use, the plug provided with the
concentrator should be inserted into the outlet
fitting. For more information about the
HomeFill, contact your Invacare dealer.

TYPICAL PRODUCT PARAMETERS
Part No 1154245 7Perfecto2™
TYPICAL PRODUCT PARAMETERS
Electrical Requirements: 230 VAC ± 10% (253 VAC/207 VAC), 50 Hz
Rated Current Input: 1.4 A
Sound Level: 39.5 dBA Average
Altitude: Up to 1828 m (6,000 ft) above sea level without degradation of
concentration levels. Not recommended for use above 1828 m
(6,000 ft)
Oxygen Output
Concentration Levels:
NOTE: Stated concentration levels achieved
after initial warm-up period (approximately 30
minutes).
95.6% to 87% at 0.5 to 5 L/min
Maximum Outlet Pressure: 34.5 kPa ± 3.45 kPa. (5 p.s.i. ± 0.5 p.s.i.)
Flow Range: 0.5 to 5 L/min
For flowrates less than 1 L/min, we recommend the use of the
Invacare Pediatric Flowmeter IRCPF16AW Accessory
Potential Obstruction Alert: The concentrator detects a condition that may indicate a poten-
tial obstruction of the output oxygen.
Rapid Audible Alarm Beeping (this alarm is deactivated when
accessories are connected). May be associated with a flow setting
of 0.5 L/min or less.
Average Power Consumption: 280 W (Operating @ 3 L/min)
Pressure Relief Mechanism Operational at: 241 kPa ± 24.1 kPa (35 p.s.i. ± 3.5 p.s.i.)
Change in maximum recommended flow
when back pressure of 7kPa is applied:
0.7 L/min
Filters: Cabinet, Outlet HEPA and Compressor Inlet
Safety System: Current overload or line surge shutdown. High temperature
compressor shutdown. High Pressure Alarm w/compressor shut-
down. Low Pressure Alarm w/compressor shutdown. Battery
Free Power Loss Alarm. SensO2Oxygen System (SensO2Model)
Potential Obstruction Alert
Width: 38.1 cm ± 1 cm (15 in. ± 3/8 in)
Height: 58.4 cm ± 1 cm (23 in. ± 3/8 in)
Depth: 30.5 cm ± 1 cm (12 in ± 3/8 in)
Weight: 21 kg ± 1 kg (45 lbs ± 2 lbs)
Shipping Weight: 23 kg ± 1 kg (50 lbs ± 2 lbs)
Operating Ambient
Temperature:
50°F - 95°F (10°C - 35°C) at 20-60% relative humidity
Exhaust: Less than Ambient +19°C (+ 35°F)
Oxygen Output: Less than Ambient +3°C (+ 6°F)
Cabinet: Impact Resistant flame-retardant plastic cabinet that conforms to
UL 94-V0

TYPICAL PRODUCT PARAMETERS
Perfecto2™8Part No 1154245
IRC5PO2AW INDICATORS
IRC5PAW INDICATORS
Electrical: No extension cords
Placement: No closer than 30,5 cm (12 inches) from any wall, furniture, drap-
eries, or similar surfaces
Tubing: 2.1 m (7 ft) cannula with a maximum 15.2 m (50 ft) of
Crush-Proof Tubing (DO NOT pinch)
Relative Humidity: 20 to 60%
Time of Operation: Up to 24 hours per day
Recommended Storage and Shipping Temper-
ature:
-29°C to 65°C (-20°F to 150°F), at 15-95% relative humidity
Standards and Regulatory Listing: IRC5PO2AW/IRC5PAW
IEC/EN61000-3-2
IEC/EN61000-3-3
IEC/EN 60601-1, A1, A2
IEC/EN 60601-1-2
IRC5PO2AW Models Only
ISO8359
MDD
CE marked model IRC5PO2AW
LABEL
SYMBOL
O2PURITY INDICATOR LIGHTS
(LED)
SYSTEM OKAY
O2over 85% (± 2%)
GREEN Indicator Light
O2Between 73% (± 3%)
to 85% (±2%)
YELLOW Indicator light
A. YELLOW Solid
B. YELLOW Flashing Sensor
Failure
Call a qualified technician.
SYSTEM FAILURE
O2Below 73% (±3%)
RED Indicator Light
Continuous Audible Alarm
Sieve-GARD Compressor Shut-
down.
LABEL
SYMBOL
STATUS INDICATOR LIGHTS
(LED)
SYSTEM OKAY GREEN Indicator Light
SYSTEM FAILURE RED Indicator light
Continuous Audible Alarm
Sieve-GARD™Compressor
Shutdown
Call a qualified technician
O
2
I/O

SECTION 1—IMPORTANT SAFEGUARDS
Part No 1154245 9Perfecto2™
SECTION 1—IMPORTANT
SAFEGUARDS
Important Safeguards
In order to ensure the safe installation, assembly and operation of the Perfecto2
concentrator these instructions MUST be followed.
 WARNING
This section contains important information for the safe operation and use of this
product.
 DANGER
Risk of electric shock. DO NOT disassemble. Refer servicing to qualified service
personnel. No user serviceable parts.
TO REDUCE THE RISK OF BURNS, ELECTROCUTION, FIRE OR INJURY TO
PERSONS.
DO NOT place or store product where it can drop into water or other liquid.
DO NOT reach for product that has fallen into water. Unplug IMMEDIATELY.
A spontaneous and violent ignition may occur if oil, grease or greasy substances come
in contact with oxygen under pressure. These substances MUST be kept away from the
oxygen concentrator, tubing and connections, and all other oxygen equipment. DO
NOT use any lubricants unless recommended by Invacare.
Operating Information
For optimum performance, Invacare recommends that each concentrator be on and
running for a minimum of 30 minutes at a time. Shorter periods of operation may reduce
maximum product life.
A product should NEVER be left unattended when plugged in. Make sure the Perfecto2
is Off when not in use.
DO NOT connect the concentrator in parallel or series with other oxygen concentrators or
oxygen therapy devices.
Keep the oxygen tubing, cord, and unit out from under such items as blankets, bed
coverings, chair cushions, clothing and away from heated or hot surfaces, including space
heaters, stoves and similar electrical appliances.

SECTION 1—IMPORTANT SAFEGUARDS
Perfecto2™10 Part No 1154245
Radio Frequency Interference
This equipment has been tested and found to comply with EMC limits specified by IEC/
EN 60601-1-2. These limits are designed to provide a reasonable protection against
electromagnetic interference in a typical medical installation.
Other devices may experience interference from even the low levels of electromagnetic
emissions permitted by the above standards. To determine if the emissions from the
Perfecto2is causing the interference, turn the Perfecto2Off. If the interference with the
other device(s) stops, then the Perfecto2is causing the interference. In such rare cases,
interference may be reduced or corrected by one of the following measures:
• Reposition, relocate, or increase the separation between the equipment.
• Connect the equipment into an outlet on a circuit different from that to which the
other device(s) is connected.
Avoid creation of any spark near medical oxygen equipment. This includes sparks from
static electricity created by any type of friction.

SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
Part No 1154245 11 Perfecto2™
SECTION 2—INSTALLATION/
SEQUENCE OF OPERATION
Verification of Battery Free Power Loss Alarm
Check the Perfecto2concentrator for proper operating conditions.
1. If the unit has been in below-freezing temperatures, allow it to warm up to room
temperature before operating.
2. The concentrator may need to be turned on for four to five seconds to charge the
Battery Free Power Loss Alarm. Connect power cord to outlet and turn the
concentrator on. Turn flow control knob counterclockwise and flow will begin
IMMEDIATELY. Set flow rate to five L/min. Let the unit run for 30 minutes, then turn
unit off.
3. Unplug the power cord and press On/Off ( )switch to the On ( ) position. An
intermittent audible alarm will sound. This confirms proper operation of the Battery
Free Power Loss Alarm. Turn On/Off switch Off ( ).
4. Connect power cord to outlet and turn on concentrator. Unit will beep on start-up.
5. Check the oxygen concentration per specifications after 30-40 minutes running time.
Sequence of Operation
Turning On ( ) the power switch applies 230 VAC to the compressor motor, hour meter,
transformer, cooling fan and the printed circuit (P.C.) board.
Room air enters the compressor via the cabinet filter and the compressor inlet filter. The
air is compressed by the WOB-L pistons in the compressor to a pressure of 144.79 kPa (21
p.s.i.).
As increased pressure creates increased temperature, a heat exchanger is used to lower
the temperature before the air enters the 4-way valve. It is then channeled to a sieve bed
containing the adsorption material. Restriction downstream of the sieve bed causes
pressure to build up inside the sieve bed which is necessary for the adsorption process. A
small amount of relatively pure oxygen enters the top of the second bed through a
restrictive leak in the pressure equalization (P.E.) valve with the balance entering a storage
tank. The nitrogen removed is exhausted back from the bed through the 4-way valve into
room air. A muffler is located at the exhaust end of the valve to muffle the sound of the
exhaust as it exits the concentrator.
The oxygen not being used to exhaust is channeled into the storage tank. The pressurized
oxygen is regulated down to 34.4 kPa (5 p.s.i.), enters an accurate flow-measuring device,
flows through Outlet HEPA filter and check valve, then out to the patient.
I/O
I/
/O
I/

SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
Perfecto2™12 Part No 1154245
The electrical activation of the 4-way Valve is accomplished every 8 to 15 seconds by the
pressure sensor and P.C. Board electronics when the pressure reaches a set point of 144.79
kPa (21 p.s.i.) output flows 4 L/min and above or 110.32 kPa (16 p.s.i.) output flows 3 L/
min and below. The time between cycles is dependent on altitude, flow rate and internal
environmental factors.
A P.E. valve opens just prior to the shift of the 4-way valve. This allows highly
concentrated oxygen to enter the just exhausted bed from the top. This additional
pressure allows the bed to start its cycle at a higher pressure. The P.E. valve will close just
after the shift of the 4-way valve.
If main power is lost, the Battery Free Power Loss Alarm will sound a short "BEEP", with
a long pause after. All units are equipped with a diagnostic alarm system that signals if
the pneumatic pressure or electrical systems malfunction. The troubleshooting guide in
this manual explains the alarm system signals and reasons, in detail. Refer to
Troubleshooting on page 15.
SensO2Oxygen Sensor Technology - Ceramic Zirconia
Sensor
Technical Description
The oxygen being produced by the concentrator flows out of the product tank and into
the flowmeter. A small flow of oxygen produced by the unit is sent through a precision
orifice to the oxygen sensor mounted on the printed circuit board.
As the oxygen enters the sensor, it passes through a screen and contacts the sensing disk.
Electric current flowing through a metal film resistor heats the disk in excess of 300°C.
Oxygen molecules contact the electrode of the disk and pick-up extra electrons to become
oxygen ions. These oxygen ions are attracted to the electrode on the bottom of the zirconia
sensing disk. Because of the crystal structure of the zirconia, only oxygen ions can pass
through. When the oxygen ions reach the bottom electrode, the extra electrons are
released from the oxygen ions and oxygen molecules return to the air. The number of
electrons is directly related to the oxygen concentration. The electrons travel to the P.C.
board where they are counted and the oxygen concentration reading is calculated.
A microprocessor on the P.C. board contains software that interprets the signal being
received from the sensor. It compares the signal to clinically acceptable limits. Signals
outside of the clinically acceptable limits generate responses in the form of lights, audible
indicators, and/or system shut-down.
Operating Sequence
Once the power switch has been turned on ( ), the SensO2circuit will wait five minutes
for the concentrator to begin producing clinically acceptable oxygen and the oxygen
sensor to stabilize. The GREEN light will illuminate (indicating normal system operation)
while the oxygen sensor is warming up.
I/

SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
Part No 1154245 13 Perfecto2™
After five minutes, if the oxygen purity exceeds 85% ± 2%, the GREEN light will continue
to illuminate.
If the oxygen level is not above 85% ± 2% after the first five minutes, the system will
continue to monitor the O2and wait for a maximum of 30 minutes from start-up to reach
85% ± 2% before activating an alarm. Environmental factors such as low voltage, high
altitude, or age of the machine will affect the time required to reach 85% ± 2%.
If the oxygen level is not above 85% ± 2% within the first 30 minutes, the oxygen
concentration alarm sequence will activate and the unit will shut down.
When oxygen concentration is above 85% ± 2%, the sensor measures oxygen purity every
10 minutes. If a reading falls below 85% ± 2%, a YELLOW light will illuminate. If the
oxygen purity falls below 73% ± 3% the RED light/Alarm/Shut-Down mode will activate.

SECTION 3—PNEUMATIC DIAGRAM
Perfecto2™14 Part No 1154245
SECTION 3—PNEUMATIC DIAGRAM
Perfecto2Oxygen Concentrator
Flowmeter
Ouput
HEPA Filter
Output
Check
Valve
Patient
Output
Oxygen Sensor
(SensO2models Only)
Pressure Sensor
p.s.i. O2
P.C. Board
Pressure
Regulator
Product
Tank
Check
Valves
Air Inlet
Cabinet
Filter
Compressor
Inlet Filter
Sieve
Bed
Sieve
Bed
P.E. Valve
4-way
Valve
Compressor
Relief
Valve
Heat
Solenoid
Pilot
Exhaust
Muffler
LEGEND Pneumatic Connections Electrical Connections

SECTION 4—TROUBLESHOOTING
Part No 1154245 15 Perfecto2™
SECTION 4—TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE SOLUTION
Normal Operation:
Internal Status Indicators:
RED: Off
GREEN: Off
Unit plugged in, power switch
on. Single beep on start up.
No Problems. System Okay.
Power loss:
Internal Status Indicators:
RED: Off
GREEN: Off
Unit unplugged, power
switch on, alarm off.
No Problems. Battery Free Circuit drained. Plug in cord
and turn power switch ON ()to
recharge.
Power loss:
Internal Status Indicators:
RED: Off
GREEN: Off
Unit plugged in, power switch
, alarm off, battery Free
circuit drained.
No power at outlet. Check electrical outlet with a table lamp
or voltmeter set on VAC scale. If outlet
isn't working, check protective device in
home's electrical panel or consult an
electrician. Also ensure that unit is
properly plugged in. DO NOT use
extension cords. Move to another outlet
or circuit.
Power cord:
a. Frayed.
b. Broken or damaged spade.
c. Spade connector from power
cord loose or disconnected
(inside back of unit).
a. Reattach cord.
b. Replace power cord connectors on
plug.
c. Reattach connector.
On/Off ()switch.
a. Disconnected wire.
b. Faulty switch.
Check all electrical connections to the
ON/OFF ()switch for any
disconnected wires.
If the concentrator does not come on at all
and wiring is intact, color code and
remove wires one at a time. Remove and
replace with new one. Transfer wires from
old switch to new switch one at a time to
the matching contact.
Circuit breaker tripped. Reset breaker.
NOTE: Breaker may trip to safeguard
concentrator during a power surge.
If breaker trips IMMEDIATELY, there is a
probable short in the unit. Check for
pinched or charred wires. If the breaker
does not trip, run unit for approximately
two hours. The circuit breaker should be
less than 10 ohms. If breaker trips again,
there is an internal problem. Contact
Invacare Technical Service.
I/
I/O
I/O

SECTION 4—TROUBLESHOOTING
Perfecto2™16 Part No 1154245
Power Loss:
(Continued)
Internal Status Indicators:
RED: Off
GREEN: Off
Unit plugged in, power
switch, alarm off. Battery
Free circuit drained.
P.C. board.
a. P.C. board damaged.
b. Loose or damaged connector.
a. Replace P.C. Board. Refer to
Replacing P.C. Board on page 57.
b. Repair or replace connector.
Internal Power
Loss Senso2:
Internal Status Indicators:
RED: Off
GREEN: Off
Alarm may or may not be on.
Control Panel Indicators:
RED: Off
YELLOW: Off
GREEN: Off
Fan operates, Compressor
not operating.
Transformer assembly.
a. Faulty.
b. Connector loose or
disconnected.
c. Faulty wiring.
a. Replace. Refer to Replacing the
Transformer on page 60.
b. Reattach connector.
c. Replace transformer assembly. Refer
to Replacing the Transformer on
page 60.
P.C. board faulty. Replace P.C. board. Unit requires retiming
after P.C. board replacement. Refer to
Replacing P.C. Board on page 57.
High Pressure:
Internal Status Indicators:
RED: One Flash
GREEN: Two Flashes
Unit plugged in, power switch
on, continuous alarm.
Compressor shut down.
P.C. board:
a. Malfunction
b. Disconnected wire.
c. Shifting valve at pressures greater
than 25 p.s.i. for Perfecto2.
a. Set flow to max L/min. for
concentrator. Check voltage across
Pilot Valve 1 on volt DC scale. If
meter reads 0 volts when unit is
turned on, replace P.C. board
b. Check spade connectors on pilot
valves 1 or 2 and connectors on P.C.
board.
c. Replace P.C. board. Unit requires
retiming after P.C. board
replacement. Refer to Replacing P.C.
Board on page 57.
4-way Valve:
a. Not shifting.
b. Bad coil.
c. Coil resistance.
a. Check voltage. If voltage rises to
approximately 24 volts D.C. when
unit shuts down, P.C. board is
functioning properly. Replace the
valve if shorted or open. Refer to
Replacing 4-Way Valve and/or
Manifold Assembly on page 64.
b. Replace 4-way valve. Refer to
Replacing 4-Way Valve and/or
Manifold Assembly on page 64.
c. Coil should read 175 ohms ± 20.
SYMPTOM PROBABLE CAUSE SOLUTION

SECTION 4—TROUBLESHOOTING
Part No 1154245 17 Perfecto2™
LOW PRESSURE:
Internal Status Indicators:
RED: One Flash
GREEN: One Flash
Or
RED: One Flash
GREEN: Three Flashes
Control Panel Indicators:
RED: On
YELLOW: Off
GREEN: Off
Unit plugged in, power switch
on, continuous audible alarm.
Compressor shut down
(Failure to cycle due to low
pressure).
Compressor inlet filter dirty or
plugged.
Replace compressor inlet filter. Refer to
Replacing the Compressor Inlet HEPA
Filter on page 25.
Compressor:
a. Leaks at fittings or tubing
b. Leaking or defective relief valve.
c. Insufficient voltage at outlet.
d. Worn cup seals or gaskets.
a. Replace or repair.
b. Repair leak or replace.
c. DO NOT use extension cords. Use
another outlet.
d. Rebuild top end of compressor. Refer
to Rebuilding the Thomas Model
2660 Compressor on page 33.
Heat exchanger:
a. Leak at tubing or body chamber.
b. Inspect tubing and heat
exchanger.
a. Replace or retighten.
b. Replace or retighten tubing. Replace
heat exchanger. Refer to Replacing
Heat Exchanger Assembly on
page 50.
Regulator cracked or leaking. Replace regulator. Refer to Replacing
Regulator on page 47.
P.E. valve leaking. Replace P.E. Valve. Check voltage at P.E.
valve connector on 24 volt D.C. scale. The
P.E. Valve activates or energizes
approximately one second prior to the
activation of the 4 way valve with
approximately 24 volts. If voltage is in
excess of 24 volts consistently, replace the
P.C. board. Refer to Replacing P.C. Board
on page 57. If the P.C. board voltage acts
normally, replace the P.E. valve. Refer to
Replacing P.E. Valve on page 41.
Note: Check for leaks starting at the
compressor output through all the
pneumatic connections. Major leaks will
cause system pressures to remain below
adequate shift (exhaust) pressures and will
cause compressor shutdown.
Defective Parts:
Internal Status Indicators:
RED: One Flash GREEN: Five
Flashes
Or
RED: Two Flashes
GREEN: Three Flashes
Control Panel Indicators:
RED: On
YELLOW: Off
GREEN: Off
Unit plugged in, power switch
on, continuous audible alarm.
Compressor shut down.
Defective main valve coil. a. Replace main valve.
b. Replace main valve coil.
Connector loose. Reattach connector.
Defective P.E. valve coil. (Resistance
80 ohms ± 10.)
Replace P.E. coil if shorted or open on
resistance check. Refer to Replacing P.E.
Valve on page 41.
Defective P.E. valve. Replace P.E. valve. Refer to Replacing P.E.
Valve on page 41.
Connector loose. Reattach connector.
Defective P.C. board. Replace P.C. board. Refer to Replacing
P.C. Board on page 57.
SYMPTOM PROBABLE CAUSE SOLUTION

SECTION 4—TROUBLESHOOTING
Perfecto2™18 Part No 1154245
Unit not operating: Alarm:
On or Off
Internal Status Indicators:
RED: Two Flashes
GREEN: Four Flashes Or
RED: Two Flashes GREEN:
Five Flashes
P.C. board Failure. Replace P.C. board.Refer to Replacing P.C.
Board on page 57.
Low Concentration: NOTE:
Check for O2purity using a
calibrated Oxygen Analyzer
at Test Point 1 (oxygen
outlet) of the concentrator.
Internal Status Indicators:
RED: Two Flashes
GREEN: One Flash73%
Shutdown Control Panel
Indicators: SensO2ONLY:
RED: On
YELLOW: Off
GREEN: Off
For SensO2units, the RED
indicator will signal extremely
low purity and will be
accompanied by a continuous
audible alarm and a system
shutdown. Repairs are
required.
Cabinet filters dirty. Clean or replace. Refer to Cleaning the
Cabinet Filter on page 23, Replacing the
Outlet HEPA Filter on page 24, and
Replacing the Compressor Inlet HEPA
Filter on page 25.
Compressor inlet filter dirty. Replace inlet filter. Refer to Replacing the
Compressor Inlet HEPA Filter on page 25.
Compressor:
a. Defective.
b. Faulty capacitor.
c. Bad motor windings.
d. Worn seals.
e. Bad bearings.
f. Leak at fittings or tubing.
g. Leaky or defective relief valve.
h. Insufficient voltage (outlet).
a. Replace compressor. Refer to
Replacing Compressor Assembly on
page 30.
b. Replace capacitor. Refer to Replacing
Capacitor on page 32.
c. Replace compressor.
d. Rebuild top end of compressor. Refer
to Rebuilding the Thomas Model
2660 Compressor on page 33.
e. Replace compressor.
f. Replace fittings or tubing.
g. Replace relief valve.
h. DO NOT use extension cords.
Heat exchanger:
a. Leak at tubing or body chamber.
b. Inspect tubing and heat
exchanger.
a. Replace or retighten.
b. Replace or retighten tubing. Replace
heat exchanger. Refer to Replacing
Heat Exchanger Assembly on
page 50.
Regulator cracked or leaking. Replace. Refer to Replacing Regulator on
page 47.
Exhaust muffler dirty or plugged. Replace. Refer to Replacing the Muffler
Assembly on page 25.
Fan:
a. Not operating. Unit overheating.
b. Faulty fan.
a. Leads to fan disconnected.
Reconnect.
b. Replace.Refer to Replacing Cooling
Fan on page 54.
Sieve beds defective. Replace. Refer to Checking Sieve Bed
Pressure on page 84.
Tubing kinked or blocked. Repair or replace.
P.C. board:
a. Shifts at wrong pressures.
Check pressure at product tank. Pressure
should rise to 144.79 kPa (21 p.s.i.) at shift
point. If not, replace P.C. Board. Refer to
Replacing P.C. Board on page 57.
SYMPTOM PROBABLE CAUSE SOLUTION

SECTION 4—TROUBLESHOOTING
Part No 1154245 19 Perfecto2™
Low Concentration
(Continued)
Flowmeter:
a. Flowmeter opened beyond
maximum flow rate.
b. Cracked or broken fitting.
c. Input tubing leaking or loose.
a. Return flow to maximum setting.
b. Replace fitting.
c. Repair or replace. Refer to Replacing
Flowmeter on page 62.
Timing. To accommodate for varying tolerances
when replacing components, an adjustable
timer is used to control the shifting of the
Pressure Equalization (P.E.) valve. Refer to
Timing on page 72.
P.E. valve:
a. Bad coil.
b. Restrictor blockage.
a. Replace P.E. valve.
b. Replace P.E. valve. Refer to Replacing
P.E. Valve on page 41.
Inspect P.C. board restrictor tubing
for kinks or tears.
Replace P.C. board. Unit may need
retiming after board replacement. Refer to
Replacing P.C. Board on page 57.
Fluctuating Flow: Regulator/Flowmeter:
a. Incorrectly set regulator.
b. Flowmeter malfunction.
a. Check pressure at oxygen outlet.
Adjust regulator.
b. If flow is still unstable, check for leaks
starting at the compressor outlet
fitting through all pneumatic
connections. If no leaks are found
and flow is still fluctuating, replace
the regulator. If pressure at test point
is within spec (5 p.s.i. ± 0.5 max.
[34.4 kPa ± 6.89]), replace
flowmeter. Refer to Replacing
Flowmeter on page 62.
Outlet HEPA filter:
a. Dirty or plugged a. If low flow conditions persist, replace
outlet HEPA filter. Refer to Replacing
the Outlet HEPA Filter on page 24.
Unit Excessively Loud: Pneumatic exhaust:
a. Muffler cracked, damaged or
missing.
b. Muffler tubing disconnected or
damaged.
a. Replace. Refer to Replacing the
Muffler Assembly on page 25.
b. Reconnect or replace tubing.
Compressor inlet filter missing and/or
orange sticker removed.
a. Replace compressor inlet filter. Refer
to Replacing the Compressor Inlet
HEPA Filter on page 25.
Compressor removed. a. Replace Compressor. Refer to
Replacing Compressor Assembly on
page 30.
Incorrect style of inlet filter
(aftermarket).
a. Replace with factory OEM sound
reduced style inlet HEPA filter.
SYMPTOM PROBABLE CAUSE SOLUTION

SECTION 4—TROUBLESHOOTING
Perfecto2™20 Part No 1154245
Unit Overheats: Base exhaust vent plugged or
restricted. Place unit at least 30,5 cm (12-inches)
from any wall. DO NOT place unit on
pile or shag carpeting that may restrict
air flow.
Cabinet filters dirty or blocked. Clean or replace. Refer to Cleaning the
Cabinet Filter on page 23.
Fan:
a. Leads to fan disconnected.
b. Defective fan.
c. Fan installed upside down.
a. Reconnect leads.
b. Replace fan. Refer to Rebuilding the
Thomas Model 2660 Compressor on
page 33.
c. Install fan with air flow arrow pointing
down.
Heat exchanger:
a. Dirty or plugged.
b. Damaged.
a. Clean heat exchanger.
b. Replace heat exchanger. Refer to
Replacing Heat Exchanger Assembly
on page 50.
Compressor:
a. Defective.
b. Faulty capacitor.
c. Bad motor windings.
d. Worn seals.
e. Bad bearings.
a. Replace compressor. Refer to
Replacing Compressor Assembly on
page 30.
b. Replace capacitor. Refer to Replacing
Capacitor on page 32.
c. Replace compressor.
d. Replace compressor.
e. Replace compressor.
Line voltage excessive (surge). Have line voltage inspected by certified
electrician. A voltage regulator may be
required and is obtainable from your local
electric company.
Oxygen Purity:
Good
Internal Status Indicators:
Control Panel Indicators:
RED: Off
YELLOW: On
GREEN: On
After 30 minutes of
run time, unit operates
normally, oxygen purity
within normal range.
GREEN or YELLOW panel
indicator should illuminate.
P.C. board defective. Replace P.C. board. Refer to Replacing
P.C. Board on page 57. Unit may need
retiming after P.C. board replacement.
Refer to Timing on page 72.
SYMPTOM PROBABLE CAUSE SOLUTION