Sunrise Medical DeVilbiss 505DZ User manual

CAUTION-Federal (U.S.A.) law
restricts this device to sale by or
on the order of a physician.
Service
Manual
DeVilbiss 5 Liter Oxygen Concentrator
Models 505DZ, 505DS, 505CZ, & 505CS

2
TABLE OF CONTENTS
General Information
Introduction .............................................................................................................................................................................................3
Important Safeguards.............................................................................................................................................................................3
Safety Precautions and General Warnings........................................................................................................................................3
Theory of Operation.............................................................................................................................................................................3
Operation/Installation
Operation.................................................................................................................................................................................................4
Microprocessor-Controlled Pressure-Sensing System...................................................................................................................4
OSD Option ............................................................................................................................................................................................4
Exterior and Interior Parts Figures....................................................................................................................................................5
Operating the DeVilbiss Oxygen Concentrator ..........................................................................................................................11
Performing Initial Inspection..............................................................................................................................................................11
Suggested Patient Setup......................................................................................................................................................................12
Maintenance
Routine Patient Maintenance ...........................................................................................................................................................13
Periodic Homecare Provider Preventative Maintenance ............................................................................................................13
Between Patient Maintenance...........................................................................................................................................................14
Patient Alert & Diagnostic System
Patient Alert System ............................................................................................................................................................................15
Diagnostic System ................................................................................................................................................................................15
Troubleshooting
Normal Operating Sequence.............................................................................................................................................................18
Simplified Troubleshooting..................................................................................................................................................................19
Troubleshooting Chart........................................................................................................................................................................20
OSD Troubleshooting Chart..............................................................................................................................................................23
Component Testing, Repair, and Replacement
Proper Repair Procedures .................................................................................................................................................................24
Leak Testing............................................................................................................................................................................................25
Cabinet Removal ..................................................................................................................................................................................25
Power Cord...........................................................................................................................................................................................27
Flow Meter ............................................................................................................................................................................................28
Power Switch.........................................................................................................................................................................................28
Hour Meter ...........................................................................................................................................................................................28
Pressure Regulator...............................................................................................................................................................................28
Sieve Bed Check Valves.......................................................................................................................................................................29
Final Check Valve ..................................................................................................................................................................................31
Molecular Sieve Beds...........................................................................................................................................................................32
Compressor...........................................................................................................................................................................................34
Cooling Fan............................................................................................................................................................................................41
Four-Way Valve......................................................................................................................................................................................41
Purge Valve .............................................................................................................................................................................................46
Pilot Pressure System..........................................................................................................................................................................47
Manifold Assembly................................................................................................................................................................................48
Printed Circuit Board..........................................................................................................................................................................49
Capacitor................................................................................................................................................................................................50
OSD (oxygen sensing device) ..........................................................................................................................................................50
Pneumatic Diagram ...............................................................................................................................................................................51
Wiring Diagram .......................................................................................................................................................................................52
Specifications.............................................................................................................................................................................................53
Ordering Information............................................................................................................................................................................54
Parts List......................................................................................................................................................................................................55
Warranty Information...........................................................................................................................................................................56

3
GENERAL INFORMATION
Introduction
This service manual was created for Sunrise Medical qualified
service technicians to define the proper maintenance, service,
and repair procedures on the DeVilbiss 5 Liter Oxygen
Concentrator. For more in-depth classroom-type training,
Sunrise Medical holds oxygen concentrator service schools. For
service school information, contact the Service Department at
1-800-338-1988.
IMPORTANT SAFEGUARDS
When using electrical products, especially when children are present,
basic safety precautions should always be followed. Read all instruc-
tions before using. Important information is highlighted by these
terms:
DANGER - urgent safety information for hazards that will
cause serious injury or death.
WARNING - important safety information for hazards that
might cause serious injury.
CAUTION - information for preventing damage to the prod-
uct.
NOTE - information to which you should pay special attention.
READ ALL INSTRUCTIONS
BEFORE USING.
Safety Precautions and
General Warnings
A. Federal (U.S.A.) law restricts this device to sale by or on
the order of a physician.
B. Oxygen promotes rapid burning. Do not smoke when
using this unit or when near a person receiving oxygen
therapy. Do not operate the oxygen concentrator within a
minimum of five feet (1.5 meters) from hot, sparking, or
burning objects or naked flames. Do not use in rooms
heated by paraffin or portable gas heaters.
C. Do not place a humidifier with an oxygen patient unless
prescribed by a physician and then only a bubble-type
humidifier should be used.
D. Do not connect the oxygen concentrator to an electrical
outlet controlled by a wall switch; the outlet should be
independent of other appliances.
E. Do not use an electrical adapter or extension cord with
the oxygen concentrator.
F. Only operate the oxygen concentrator with all filters in
place; do not operate if the air filter is wet.
G. Electric shock hazard. Do not remove cabinet.The cabinet
may only be removed by a qualified Sunrise Medical
homecare provider.
H. 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.
I. Do not use oils, greases, or any petroleum-based
solvents/cleaners on or near the unit. Use only materials
that are compatible with oxygen.
J. When replacing the capacitor, do not touch the terminals
or allow metal objects to come in contact with the
terminals on the capacitor.
K. Use only DeVilbiss concentrator replacement parts and
accessories.
L. Do not use regenerated sieve material.
Theory of Operation
An oxygen concentrator is a device that delivers highly concen-
trated oxygen for therapeutic applications.
Room air is a mixture of 78% nitrogen, 21% oxygen, 1% argon
and other gases.The concentrator draws in the air, separates
the nitrogen from the oxygen, and allows delivery of the con-
centrated oxygen to the patient through the oxygen port.

4
OPERATION/INSTALLATION
Operation/Installation
DeVilbiss 5 Liter Oxygen Concentrator Operation
The DeVilbiss 5 Liter Oxygen Concentrator uses a pressure swing adsorption system.The air is drawn into the unit through the air
filter and into a double-head compressor.
The compressed air passes through a four-way valve 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 pressur-
ization cycle to be exhausted from the sieve material.
The nitrogen is released through an exhaust muffler located on the back of the manifold assembly. Also during each bed pressuriza-
tion, a small amount of oxygen flows through an orifice located in the manifold into the depressurizing bed.This helps purge the nitro-
gen from the bed.
A purge valve will also open momentarily during each cycle change to allow high purity oxygen to flow into the bed that is just begin-
ning its pressurization cycle.This helps to maintain the proper concentration levels, especially at high-flow rates. Once the purge valve
closes, the nitrogen is exhausted from the sieve beds.
The beds will continue to be alternately pressurized and depressurized as the unit operates.This cycling process will vary in length
depending on altitude and oxygen output flow rate. Refer to specifications.
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 flow meter.The flow meter allows the oxygen flow to be controlled
and adjusted to the level prescribed by the patient's physician. From the flow meter, the oxygen passes through the final bacteria filter,
check valve, and outlet port to the patient.
Microprocessor-Controlled Pressure-Sensing System
The DeVilbiss 5 Liter Oxygen Concentrator operates on a microprocessor-controlled pressure-sensing system to cycle the unit.The
cycling is controlled and monitored by the PC board.This is accomplished by use of a pressure transducer mounted on the PC board.
The transducer is connected to the accumulator tank by 1/16" diameter tubing and allows the PC board to sense the oxygen pres-
sure and cycle time at this point.
A cycle change takes place when the pressure in the accumulator tank reaches 25.5 PSI (175 kPa).The PC board will send 12-15 VDC
to the four-way valve causing the valve to activate.At the same time, the green “4-way” indicator light on the PC board will illuminate.
With the four-way in the activated position, compressed air is directed to the left sieve bed.When the PC board senses 25.5 PSI (175
kPa) in the oxygen accumulator tank, the PC board removes the 12-15 VDC from the four-way.This causes the four-way to deactivate
or go to the “rest” position and compressed air is then directed to the right sieve bed.The green “4-way” indicator light on the PC
board is not illuminated when the voltage is removed from the valve.
This cycling process is repeated every time the PC board senses 25.5 PSI (175 kPa) in the oxygen accumulator tank.
The PC board also activates the alarm system whenever it senses a low or high pressure condition or when the cycle time has
exceeded its preset minimum or maximum limits.The alarm system will also activate in the case of a power failure and electrical or
pneumatic component failure.
OSD Option
The DeVilbiss 5 Liter Oxygen Concentrator with the optional OSD (oxygen sensing device) monitors the concentration of oxygen
leaving the accumulator tank. There are two additional indicator lights on the front panel.
• 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 intermittent audible signal will also sound.
NOTE – Refer to specifications for specific alarm settings.
DeVilbiss 5 Liter Overview
This service manual was designed to supply homecare providers with the proper maintenance, service, and safety procedures for the
DeVilbiss 5 Liter Oxygen Concentrator. Read and understand all the information contained in this service manual before attempting
to operate or perform any maintenance on the concentrator.
NOTE – Sunrise Medical reserves the right to alter or change the design of the DeVilbiss Oxygen Concentrator series. Hence,
slight differences in construction or components may exist than what is described herein.

5
OPERATION/INSTALLATION
The following figures will help familiarize you with the exterior of the DeVilbiss 5 Liter Oxygen Concentrator.
Exterior Front View Figure 1
Oxygen outlet port
Light panel Power switch
Flow meter
Circuit breaker
Front cover
Bib

6
OPERATION/INSTALLATION
Exterior Back View Figure 2
Exterior Side View Figure 3
Cabinet screws
Cabinet screw
Air filter
Rating label
Filter door
Communication port
(OSD units only)
Rear cover
Cabinet screw
Line cord strap
Caster (locking) Caster (non-locking)
Line cord
Rear cover
Front cover

7
OPERATION/INSTALLATION
Interior Front View Figure 4
Hose clamp
1/4" I.D. hose
PC board
Hose clamp
Accumulator tank
Fitting
(top of sieve bed)
1/4" I.D. hose
Intake
silencer
valve wire
harness
Right
sieve bed
Fitting
(bottom of
sieve bed)
Caster
(locking)
Hose
clamp
Hose
clamp
Left
sieve
bed
Cable tie
Hex nut
(compressor
mounting plate)
1/2" I.D. hose
Hex nut
(compressor
mounting plate)

8
OPERATION/INSTALLATION
Interior Back View Figure 5
Hour meter
Accumulator tank
Compressor filter
Oxygen sensor
assembly
(OSD units only)
Communication port
(OSD units only)
Silicon tubing
Hose clamp
Screw
(mounting plate)
Screw
(mounting plate)
Cabinet base
Caster
(non-locking)
Line cord
Strain relief
Motor mount
Compressor
mounting plate
Compressor

9
OPERATION/INSTALLATION
Interior Right Side View Figure 6
Interior Left Side View Figure 7
Bib
Flow meter
OSD assembly
(OSD units only)
OSD wire harness
(OSD units only)
Communications wire harness
(OSD units only)
Left sieve bed
Cabinet base
Exhaust grill
Right sieve bed
Caster
(locking) Exhaust grill
Caster
(non-locking)
Housing
Bib tab
Screw (bib)
Pressure regulator
Accumulator tank
Tab connecting bib to
compressor housing

10
OPERATION/INSTALLATION
Behind Bib Figure 8
Compressor Housing Area & Bib Figure 9
Power switch
Circuit breaker
Final bacteria filter
Light panel ribbon
connector
Screw (outlet port)
Oxygen outlet port
1/8" I.D. hose
Flow meter
Bracket/Spring clip
1/8" I.D. hose
Plastic cable tie
Intake Hose
Capacitor
Power cord
Electrical power connector
Silicon tubing
Hose clamp
Wire harness
Exhaust muffler assembly
Grommet
Cooling fan
Compressor base
Wires to compressor
Electrical connector (fan)