Service Manual
™
Perfecto
2
Oxygen Concentrator
®
(HomeFill Compatible)
Model IRC5PO2 (Sensored)
Model IRC5P (Non-Sensored)
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,
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TABLE OF CONTENTS
TABLE OF CONTENTS
Important Safeguards...............................................................................................................................10
Radio Frequency Interference...............................................................................................................11
Verification of Battery Free Power Loss Alarm................................................................................12
Sequence of Operation...........................................................................................................................12
SensO Oxygen Sensor Technology - Ceramic Zirconia Sensor .................................................13
2
Technical Description.........................................................................................................................13
Operating Sequence............................................................................................................................13
Replacing Sieve Beds................................................................................................................................44
3
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TABLE OF CONTENTS
TABLE OF CONTENTS
Replacing Hour Meter.............................................................................................................................64
SensO Alarm Indicators........................................................................................................................71
2
Indicator Lights.....................................................................................................................................71
Autotuning.............................................................................................................................................73
4
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TABLE OF CONTENTS
TABLE OF CONTENTS
Leak Test....................................................................................................................................................76
4 Way Valve Function Test....................................................................................................................78
High Pressure Test..............................................................................................................................81
Disassembly...........................................................................................................................................86
5
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SPECIAL NOTES
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.
SIGNAL WORD
MEANING
Danger indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
DANGER
Warning indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
WARNING
CAUTION
Caution indicates a potentially hazardous situation which, if
not avoided, may result in property damage or minor injury
or both.
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
oxygen enriched air. Failure to observe this warning can result in severe fire, property
damage and cause physical injury or death.
6
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FEATURES
FEATURES
FRONT VIEW
Oxygen Purity Indicator
Lights / Fault and Power
Indicator Lights
Oxygen Outlet
Flowmeter
(SensO2 Model Only)
Circuit Breaker
Power Switch
Hour
Meter
ACCESSORIES (NOT SHOWN):
PreciseR ™ Pediatric Humidifier/Flowmeter Accessory ‐ IRCPF16
X
HomeFill home oxygen compressor ‐ IOH200
*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 ownerʹs manual, part
number 1100873, 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.
Outlet Fitting*
Power Cord
7
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TYPICAL PRODUCT PARAMETERS
TYPICAL PRODUCT PARAMETERS
Electrical Requirements:
120 VAC ± 10% (132 VAC/108 VAC), 60 Hz
Rated Current Input:
Perfecto2 5: 3 A
Sound Level:
Altitude:
Perfecto2 5: 44 ± 2 dBA Average
Perfecto2 5 - Up to 6,000 ft. (1828 meters) above sea level with-
out degradation of concentration levels. From 6,000 ft. (1828
meters) to 13,129 ft. (4000 meters) below 90% efficiency.
*Oxygen Output
All IRC5PO2/IRC5P models 95.6% to 87% at 0.5 to 5 L/min
Concentration Levels:
Maximum Outlet Pressure:
Flow Range:
Perfecto2 5: 5 psi ± 0.5 psi. (34.5 kPa ± 3.45 kPa.)
Perfecto2 5 - 0.5 to 5 L/min
For flowrates less than 1 L/min, we recommend the use of the
Invacare Pediatric Flowmeter IRCPF16 Accessory.
Low Flow Alarm:
Perfecto2 5 - 0 L/min to 0.5 L/min
Rapid Audible Alarm Beeping (No Accessories Connected).
Average Power
Consumption:
Perfecto2 5: 280 W (Operating @ 3 L/min)
Pressure Relief Mechanism Operational at:
35 psi ± 3.5 psi (241 kPa ± 24.1 kPa)
0.7 L/min
Change in maximum recommended flow
when back pressure of 7kPa is applied:
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. SensO2 Oxygen System (SensO2 Model)
Low Flow Alarm.
Width:
Height:
Depth:
Weight:
15 in. ± 3/8 in (38.1 cm ± 1 cm)
23 in. ± 3/8 in (58.4 cm ± 1 cm)
12 in. ± 3/8 in (30.5 cm ± 1 cm)
Perfecto2 5: 43 lbs ± 2 lbs (19.5 kg ± 1 kg)
Shipping Weight:
Perfecto2 5: 48 lbs ± 2 lbs (21.8 kg ± 1 kg)
Operating Ambient
Temperature:
50°F - 95°F (10°C - 35°C) at 20-60% relative humidity
Exhaust:
Perfecto2 5: Less than Ambient
+ 35°F (+19°C).
Oxygen Output:
Cabinet:
Perfecto2 5: Less than Ambient + 6°F (+3°C)
Impact Resistant flame-retardant plastic cabinet that conforms to
UL 94-V0.
Regulatory Listing:
Double Insulated Product ETL certified complying with UL 1097
ETL certified to CSA C22.2 No. 68.
8
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TYPICAL PRODUCT PARAMETERS
Electrical:
No extension cords.
Placement:
No closer than three inches from any wall, furniture, draperies,
or similar surfaces.
Tubing:
7 ft cannula with a maximum 50 ft of Crush-Proof Tubing (DO
NOT pinch).
Relative Humidity:
Time of Operation:
20 to 60%
Up to 24 hours per day.
Recommended Storage and Shipping Temper- -20°F to 150°F (-29°C to 65°C), at 15-95% relative humidity.
ature:
*NOTE: Stated concentration levels achieved after initial warm‐up period (approximately 30
minutes).
IRC5PO2 INDICATORS
LABEL
SYMBOL
O2 PURITY
INDICATOR LIGHTS
(LED)
SYSTEM OKAY
O2 over 85% (± 2%)
GREEN Indicator Light
O2
O2 Between 73% (± 3%) YELLOW Indicator light
A. YELLOW Solid
B. YELLOW Flashing Sensor
Failure
to 85% (±2%)
Call a qualified technician.
SYSTEM FAILURE
O2 Below 73% (±3%)
RED Indicator Light
Continuous Audible Alarm
Sieve-GARD Compressor Shut-
down.
IRC5P INDICATORS
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
9
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SECTION 1—IMPORTANT SAFEGUARDS
SECTION 1—IMPORTANT
SAFEGUARDS
Important Safeguards
In order to ensure the safe installation, assembly and operation of the Perfecto
concentrator these instructions MUST be followed.
2
CAUTION
“Caution: Federal law restricts this device to sale or rental by or on order of a physician,
or any other practitioner licensed by the law of the State in which he/she practices to use
or order the use of this device.”
ꢁ DANGER
The use of oxygen therapy requires that special care be taken to reduce the risk of fire.
Any materials that will burn in air, and some that will not, are easily ignited and burn
rapidly in high concentrations of oxygen. For safety concerns, it is necessary that all
sources of ignition be kept away from the product and out of the room in which it is
being used. NO SMOKING signs should be prominently displayed.
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.
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.
If the concentrator has a damaged cord or plug, if it is not working properly, if it has been
dropped or damaged, or dropped into water, call qualified technician for examination
and repair.
Keep the oxygen tubing, cord, and unit away from heated or hot surfaces, including space
heaters, blankets, stoves and similar electrical appliances.
DO NOT move or relocate concentrator by pulling on the cord.
NEVER drop or insert any object into any opening.
NEVER block the air openings of the product or place it on a soft surface, such as a bed
or couch, where the air opening may be blocked. Keep the openings free from lint, hair
and the like. Fill humidifier with water to the level shown by the manufacturer. DO NOT
overfill.
Keep unit at least three inches away from walls, draperies, furniture, and the like.
Invacare recommends that Crush‐Proof oxygen tubing be used with this product and not
exceed 50 ft. (15.2m) in length.
10
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SECTION 1—IMPORTANT SAFEGUARDS
Radio Frequency Interference
Most electronic equipment is influenced by Radio Frequency Interference (RFI). Caution
should be exercised with regard to the use of portable communications equipment in the
area around such equipment.
To Reduce The Risk Of Burns, Electrocution, Fire Or Injury
To Persons.
DO NOT come in contact with the concentrator while wet.
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 product should NEVER be left unattended when plugged in.
Use this product for only intended use as described in this manual.
DO NOT connect the concentrator in parallel or series with other oxygen concentrators or
oxygen therapy devices.
Use of some administration accessories or certain humidifiers not specified for use with
oxygen concentrator may impair the performance.
This equipment is to be used as an oxygen supplement and is not considered life
supporting or life sustaining.
Avoid creation of any spark near medical oxygen equipment. This includes sparks from
static electricity created by any type of friction.
11
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SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
SECTION 2—INSTALLATION/
SEQUENCE OF OPERATION
Verification of Battery Free Power Loss Alarm
Check the Perfecto2 concentrator 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 120 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 wobble pistons in the compressor to a pressure of 21 p.s.i. (144.79
kPa).
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 five p.s.i. (34.4 kPa), enters an accurate flow‐measuring
device, flows through Outlet HEPA filter and check valve, then out to the patient.
12
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SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
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 21
p.s.i. (144.79 kPa) output flows 4 L/min and above or 16 p.s.i. (110.32 kPa) 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 ʺBEEPʺ, 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
SensO Oxygen Sensor Technology - Ceramic Zirconia
2
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 SensO circuit will wait five minutes
2
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.
13
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SECTION 2—INSTALLATION/SEQUENCE OF OPERATION
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 O and wait for a maximum of 30 minutes from start‐up to reach
2
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.
14
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SECTION 3—PNEUMATIC DIAGRAM
SECTION 3—PNEUMATIC
DIAGRAM
Perfecto2 Oxygen Concentrator
Ouput
HEPA Filter
Output
Check
Valve
Flowmeter
Patient
Output
Oxygen Sensor
(SensO2 models Only)
Pressure
Regulator
Pressure Sensor
P.S.I.
O
2
P.C. Board
Product
Tank
Check
Valves
Air Inlet
Cabinet
Filter
Compressor
Inlet Filter
Sieve
Bed
Sieve
Bed
P.E. Valve
4-way
Valve
Compressor
Solenoid
Pilot
Relief
Valve
Exhaust
Muffler
Heat
LEGEND Pneumatic Connections
Electrical Connections
15
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SECTION 4—TROUBLESHOOTING
SECTION 4—TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE
SOLUTION
Normal Operation:
Internal Status Indicators:
RED: Off
No Problems.
System Okay.
GREEN: Off
Unit plugged in, power switch
on. Single beep on start up.
Power loss:
Internal Status Indicators:
RED: Off
No Problems.
Battery Free Circuit drained. Plug in cord
and turn power switch ON () to
recharge.
GREEN: Off
Unit unplugged, power
switch on, alarm off.
Power loss:
Internal Status Indicators:
RED: Off
No power at outlet.
Check electrical outlet with a table lamp
or voltmeter set on 50-200 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.
GREEN: Off
Unit plugged in, power switch
, alarm off, battery Free
circuit drained.
Power cord:
a. Frayed.
a. Reattach cord.
b. Broken or damaged spade.
b. Replace power cord connectors on
plug.
c. Spade connector from power
cord loose or disconnected
(inside back of unit).
c. Reattach connector.
Check all electrical connections to the
On/Off (
) switch.
ON/OFF (
) switch for any
a. Disconnected wire.
disconnected wires.
b. Faulty switch.
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.
16
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SECTION 4—TROUBLESHOOTING
SOLUTION
SYMPTOM
PROBABLE CAUSE
Power Loss:
P.C. board.
(Continued)
Internal Status Indicators:
RED: Off
a. P.C. board damaged.
b. Repair or replace connector.
b. Loose or damaged connector.
GREEN: Off
Unit plugged in, power
switch, alarm off. Battery
Free circuit drained
Internal Power
Loss Senso2:
Internal Status Indicators:
RED: Off
Transformer assembly.
a. Faulty.
b. Reattach connector.
b. Connector loose or
disconnected.
c. Faulty wiring.
GREEN: Off
Alarm may or may not be on.
Control Panel Indicators:
RED: Off
YELLOW: Off
GREEN: Off
Fan operates, Compressor
not operating.
P.C. board faulty.
Replace P.C. board. Unit requires retiming
after P.C. board replacement. Refer to
High Pressure:
P.C. board:
Internal Status Indicators:
a. Malfunction
a. Set flow to max L/min. for
concentrator. Check voltage across
Pilot Valve 1 on 200 volt 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.
RED: One Flash
GREEN: Two Flashes
b. Disconnected wire.
Unit plugged in, power switch
on, continuous alarm.
Compressor shut down.
c. Replace P.C. board. Unit requires
retiming after P.C. board
c. Shifting valve at pressures greater
than 25 p.s.i. for Perfecto2.
replacement. Refer to Replacing P.C.
4-way Valve:
a. Not shifting.
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
c. Coil should read 175 ohm ± 20.
b. Bad coil.
c. Coil resistance.
Compressor inlet filter dirty or
plugged.
Replace compressor inlet filter. Refer to
17
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SECTION 4—TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE
SOLUTION
LOW PRESSURE:
Compressor:
Internal Status Indicators:
RED: One Flash
GREEN: One Flash
Or
RED: One Flash
GREEN: Three Flashes
a. Leaks at fittings or tubing
b. Leaking or defective relief valve.
c. Insufficient voltage at outlet.
a. Replace or repair.
b. Repair leak or replace.
c. DO NOT use extension cords. Use
another outlet.
d. Worn cup seals or gaskets.
Heat exchanger:
Control Panel Indicators:
RED: On
YELLOW: Off
GREEN: Off
a. Leak at tubing or body chamber.
b. Inspect tubing and heat
exchanger.
a. Replace or retighten.
b. Replace or retighten tubing. Replace
Replace P.E. Valve. Check voltage at P.E.
valve connector on 24 volt D.C. scale. The
P.E. Valve activates or energizes
Unit plugged in, power switch
on, continuous audible alarm.
Compressor shut down
(Failure to cycle due to low
pressure).
Regulator cracked or leaking.
P.E. valve leaking.
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
on page 58. If the P.C. board voltage acts
normally, replace the P.E. valve. Refer to
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:
Defective main valve coil.
Connector loose.
Defective P.E. valve coil. (Resistance
80 ohm’s ± 10.)
a. Replace main valve.
Internal Status Indicators:
RED: One Flash GREEN: Five
Flashes
b. Replace main valve coil.
Reattach connector.
Replace P.E. coil if shorted or open on
resistance check. Refer to Replacing P.E.
Replace P.E. valve. Refer to Replacing P.E.
Reattach connector.
Replace P.C. board. Refer to Replacing
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 P.E. valve.
Connector loose.
Defective P.C. board.
18
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SECTION 4—TROUBLESHOOTING
SOLUTION
SYMPTOM
PROBABLE CAUSE
Unit not operating: Alarm:
On or Off
P.C. board Failure.
Replace P.C. board.Refer to Replacing P.C.
Internal Status Indicators:
RED: Two Flashes
GREEN: Four Flashes Or
RED: Two Flashes GREEN:
Five Flashes
Low Concentration: NOTE: Cabinet filters dirty.
Check for O2 purity using a
calibrated Oxygen Analyzer
at Test Point 1 (oxygen
Clean or replace. Refer to Cleaning the
outlet) of the concentrator.
Compressor inlet filter dirty.
Replace inlet filter. Refer to Replacing the
Internal Status Indicators:
RED: Two Flashes
GREEN: One Flash73%
Shutdown Control Panel
Indicators: SensO2 ONLY:
Compressor:
a. Defective.
b. Faulty capacitor.
c. Replace compressor.
RED: On
YELLOW: Off
GREEN: Off
c. Bad motor windings.
d. Worn seals.
For SensO2 units, the RED
indicator will signal extremely
low purity and will be
accompanied by a continuous
audible alarm and a system
shutdown. Repairs are
required.
e. Bad bearings.
e. Replace compressor.
f. Replace fittings or tubing.
g. Replace relief valve.
f. Leak at fittings or tubing.
g. Leaky or defective relief valve.
h. Insufficient voltage (outlet).
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
Regulator cracked or leaking.
Replace. Refer to Replacing Regulator on
Exhaust muffler dirty or plugged.
Replace. Refer to Replacing the Muffler
Fan:
a. Not operating. Unit overheating.
a. Leads to fan disconnected.
Reconnect.
b. Faulty fan.
b. Replace.Refer to Replacing Cooling
Sieve beds defective.
Tubing kinked or blocked.
Replace. Refer to Checking Sieve Bed
Repair or replace.
19
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SECTION 4—TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE
SOLUTION
Low Concentration
(Continued)
P.C. board:
a. Shifts at wrong pressures.
Check pressure at product tank. Pressure
should rise to 21 p.s.i. at shift point. If not,
Flowmeter:
a. Flowmeter opened beyond
maximum flow rate.
a. Return flow to maximum setting.
b. Cracked or broken fitting.
c. Input tubing leaking or loose.
b. Replace fitting.
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
P.E. valve:
a. Bad coil.
a. Replace P.E. valve.
b. Restrictor blockage.
Inspect P.C. board restrictor tubing
for kinks or tears.
Replace P.C. board. Unit may need
retiming after board replacement. Refer to
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
Outlet HEPA filter:
a. Dirty or plugged
a. If low flow conditions persist, replace
outlet HEPA filter. Refer to Replacing
Unit Excessively Loud:
Pneumatic exhaust:
a. Muffler cracked, damaged or
missing.
b. Reconnect or replace tubing.
b. Muffler tubing disconnected or
damaged.
Compressor inlet filter missing and/or
orange sticker removed.
Compressor removed.
Incorrect style of inlet filter
(aftermarket).
a. Replace with factory OEM sound
reduced style inlet HEPA filter.
20
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SECTION 4—TROUBLESHOOTING
SOLUTION
SYMPTOM
PROBABLE CAUSE
Unit Overheats:
Base exhaust vent plugged or
restricted.
Place unit at least 3-inches from any wall.
DO NOT place unit on pile or shag car-
peting that may restrict air flow.
Clean or replace. Refer to Cleaning the
Cabinet filters dirty or blocked.
Fan:
a. Leads to fan disconnected.
b. Defective fan.
a. Reconnect leads.
c. Fan installed upside down.
c. Install fan with air flow arrow pointing
down.
Heat exchanger:
a. Dirty or plugged.
b. Damaged.
a. Clean heat exchanger.
Compressor:
a. Defective.
b. Faulty capacitor.
c. Bad motor windings.
d. Worn seals.
e. Bad bearings.
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
P.C. board defective.
P.C. Board on page 58. Unit may need
retiming after P.C. board replacement.
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.
Unit Not Operating,
Internal Status Indicators:
RED: Off
Transformer assembly:
a. Assembly connector
disconnected.
a. Reattach connector.
GREEN: Off
Control Panel Indicators:
RED: Off
b. Faulty transformer assembly.
YELLOW: Off
GREEN: Off
Power Switch ON.
Continuous audible alarm.
21
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SECTION 4—TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE
SOLUTION
Unit Operating,
Internal repairs required.
Replace SensO2 circuit board. Refer to
Internal Status Indicators:
RED: Three Flashes
GREEN: One Flash
Control Panel Indicators:
RED: Off
YELLOW: Flashing
GREEN: On
Low-Flow Alarm does not
activate on flows less than 0.5
L/min.
System leak.
Repair leak in product tank, regulator,
tubing, fittings, or flow meter.
Replace check valves. Refer to Replacing
Defective check valves.
22
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SECTION 5—CABINET
SECTION 5—CABINET
Removing Cabinet
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 5.1.
1. Unplug unit.
2. Remove the four mounting screws that secure cabinet assembly to the base assembly.
3. Lift the cabinet straight up.
NOTE: When required, vacuum inside of the cabinet and exposed foam insulation.
4. To re‐install cabinet, reverse STEPS 2‐3.
L
Cabinet Assembly
Mounting
Screws
Mounting
Screws
Base Assembly
23
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SECTION 6—PREVENTIVE MAINTENANCE
SECTION 6—PREVENTIVE
MAINTENANCE
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: The Perfecto Concentrators are specifically designed to minimize routine preventive
2
maintenance at intervals of once per year. In places with high dust or soot levels, maintenance may
need to be performed more often. The following MUST be performed at a minimum of one year in
filter symptoms. Power should be disconnected before beginning preventive maintenance on the
Invacare concentrator.
Cleaning the Cabinet Filter
NOTE: For this procedure, refer to FIGURE 6.1.
NOTE: There is one cabinet filter located on the back of the cabinet.
1. Remove the filter and clean at least once a week depending on environmental
conditions.
NOTE: Environmental conditions that may require more frequent cleaning of the filters include
but are not limited to: high dust, air pollutants, etc.
2. Clean the cabinet filter with a vacuum cleaner or wash in warm soapy water and rinse
thoroughly.
3. Dry the filter thoroughly before reinstallation.
CAUTION
DO NOT operate the concentrator without the filter installed.
24
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SECTION 6—PREVENTIVE MAINTENANCE
Replacing the Outlet HEPA Filter
Check the Outlet HEPA Filter
NOTE: The outlet HEPA filter can be checked by performing the following procedure.
1. Turn the concentrator on and adjust the flowmeter to the maximum flow of the unit.
2. Observe the flowmeterʹs flow indicator while connecting a fifty foot cannula tube to
the outlet barb of the concentrator (not shown).
Replace the Outlet HEPA Filter
NOTE: For this procedure, refer to FIGURE 6.2.
NOTE: Perform this procedure as needed depending on the outlet HEPA filter check results.
1. Unplug the unit.
3. For easier access to the outlet hepa filter, remove the compressor inlet hepa filter by
grasping the compressor inlet filter, pull outward and up until filter is dislodged from
rubber base (FIGURE 6.3).
4. With a flat head screwdriver, remove the tubing from both sides of the existing outlet
HEPA filter by prying the tubing away from the outlet HEPA filter.
5. Discard existing outlet HEPA filter.
6. Connect tubing to both sides of the new outlet HEPA filter as shown below.
Tubing
Outlet HEPA Filter
Tubing
25
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SECTION 6—PREVENTIVE MAINTENANCE
Replacing the Compressor Inlet HEPA Filter
NOTE: For this procedure, refer to FIGURE 6.3 on page 26.
NOTE: Perform this procedure as needed depending upon the environment the concentrator is
used in.
1. Unplug the unit.
2. Remove the filter access panel by pressing down on center tab and pulling panel out.
3. Grasp the compressor inlet HEPA filter, pull outward and up until filter is dislodged
from rubber base.
4. Discard the existing compressor inlet HEPA filter.
5. Install new compressor inlet filter by inserting the filter into the rubber base.
6. Push the filter down until the rubber base touches the edge of the filter.
7. Reinstall the filter access panel.
Compressor Inlet HEPA Filter
Center Tab
Filter Access
Panel
Rubber Base
Replacing the Muffler Assembly
NOTE: The following should be performed at 20,000 hour intervals although these procedures can
be performed as needed depending upon the environment the concentrator is exposed to.
1. Unplug unit.
3. Cut tie wrap that secures the bottom of the manifold exhaust tube to the “F” tube.
26
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SECTION 6—PREVENTIVE MAINTENANCE
4. Remove the bottom of the manifold exhaust tube from the “F” tube.
5. Disconnect and remove the top of the manifold exhaust tube from the grommet.
Top of Manifold
Exhaust Tube
Tie-Wrap
Rubber
Grommet
Bottom of Manifold
“F” Tube
Exhaust Tube
6. Push the muffler assembly down through the opening in the sound box.
7. Cut the two tie wraps around the muffler assembly.
9. Inspect the components to ensure they are clear.
10. Do one of the following:
• Replace exhaust canister and throttling muffler if plugged or restricted.
• Install only new throttling muffler if exhaust canister is in good condition.
11. Install new/existing muffler assembly by reversing 2‐10.
27
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SECTION 6—PREVENTIVE MAINTENANCE
12. Reinstall cabinet. Refer to Removing Cabinet on page 23.
Top of Manifold
Exhaust Tube
Sound Box
Rubber Grommet
Tie Wraps
Throttling Muffler
Exhaust Canister
DETAIL “A”
Muffler Body
8” Tie-Wrap
Throttling
Muffler
Assembly
Exhaust
Muffler
Muffler
Grommet
Grommet
Exhaust
Canister
8” Tie-Wrap
28
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SECTION 6—PREVENTIVE MAINTENANCE
Cleaning the Heat Exchanger
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 6.6.
1. Unplug unit.
CAUTION
Use care not to deform heat exchanger when installing, removing or cleaning.
3. Remove excess dirt using compressed air or vacuum.
Heat Exchanger
29
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SECTION 6—PREVENTIVE MAINTENANCE
MODEL NO. IRC
SERIAL NO.
FIGURE 6.7 Preventative Maintenance Record
30
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SECTION 7—COMPRESSOR
SECTION 7—COMPRESSOR
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
Replacing Compressor Assembly
1. Unplug unit.
3. Cut the tie wrap that secures the intake hose to the compressor assembly (Detail “A”).
4. Disconnect intake hose from compressor assembly (Detail “A”).
5. Remove compressor wires from wire clamps or tie‐wraps (not shown).
6. Disconnect compressor connector from the main harness connector (not shown).
7. Disconnect capacitor wires from the top of the capacitor (Detail “B”).
8. Disconnect brass nut from compressor (Detail “B”).
9. On the backside of the Perfecto2, loosen the clamp that secures the vinyl tube to the
manifold assembly and remove the vinyl tube from the manifold assembly (Detail
“C”).
10. On the front side of the Perfecto2, pull heat exchanger with vinyl tube out of base
assembly (Detail “D“).
11. Remove the four mounting screws that secure the compressor to the base assembly
(Detail “D”).
12. Tilt compressor assembly forward and lift out.
13. Reverse STEPS 3‐12 to install new compressor assembly.
14. Secure compressor to base assembly with four screws and springs. Torque screws to
30 ± 5 in‐lbs.
15. Reinstall the cabinet. Refer to Removing Cabinet on page 23.
16. Run unit and inspect for leaks. Refer to Leak Test on page 76.
31
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SECTION 7—COMPRESSOR
DETAIL “A”
DETAIL “B”
Tie-Wrap
Brass Nut
Capacitor
Compressor
Capacitor Wires
attach here
Compressor
Intake Hose
DETAIL “C”
DETAIL “D”
Mounting Screws
Mounting
Screws
Grommets
Vinyl
Tube
Clamp
Manifold
Assembly
32
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SECTION 7—COMPRESSOR
Replacing Capacitor
NOTE: For this procedure, refer to FIGURE 7.2 on page 33.
1. Unplug the unit.
3. Using needlenose pliers, disconnect the spade connectors from the capacitor
terminals.
4. Cut the tie wrap that secures the capacitor to the base of the concentrator.
5. Remove the capacitor from the concentrator base.
6. Install new capacitor by reversing STEPS 3‐6.
Capacitor
Tie Wrap
Capacitor Terminals (Spade
Connectors connect here)
33
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SECTION 7—COMPRESSOR
Rebuilding the Thomas Model 2660 Compressor
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: This kit is designed for rebuilding the Thomas Model 2660 Series compressor. The model
number is located on the front of the compressor. Compressor numbers for this kit are 2660CE32,
2660CE37, and 2660CE50. If the compressor has a different model number than those listed, this
kit will not work.
The Thomas 2660 Series Compressor Rebuild Kit (p/n 1109235) contains the following:
DESCRIPTION QUANTITY
DESCRIPTION
Teflon®Piston Cups
Aluminum Piston Sleeves
Flapper Valves - Intake and Exhaust
Valve Keepers
QUANTITY
2
2
4
4
2
2
8
4
2
2
O-Ring - Sleeve
Valve Plate Gaskets
Head Mounting Screws
Valve Screws
Valve Restraints
Piston Cup Retainer Screws
Tools Required:
• Torque wrench that has an inch‐pound scale (for head screws, set screws, flapper
valve screw, and pipe plugs)
• Torx® T‐25 drive for torque wrench (for head screws)
• Torx T‐27 drive for torque wrench (for retainer screws)
• 1/8‐inch Allen wrench attachment for torque wrench (for eccentric set screw)
• 5/32‐inch Allen wrench attachment for torque wrench
• Flat blade screwdriver attachment or 1/4‐inch hex socket for torque wrench (for
flapper valve screw)
• Two flat blade screwdrivers
• Rubber Mallet
• Phillips screwdriver attachment for torque wrench (for retainer screws)
34
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SECTION 7—COMPRESSOR
CAUTION
DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a
precision sealed bearing. Therefore, additional lubrication is not necessary.
Removing Compressor and Compressor Heads
Compressor
Compressor Head Plate
NOTE: For this procedure, refer to FIGURE 7.3.
1. Clean loose dirt from the outside of the
Head Screws
Head
Screws
compressor.
2. Use the Torx T‐25 torque wrench and
loosen the eight head screws.
3. Note head placement before removing
compressor head plate.
Compressor
Head
Plate
4. Remove the compressor head plate.
Valve Plates
NOTE: For this procedure, refer to
FIGURE 7.3.
Valve
Plate
1. Note the position of the plates before
removing.
Valve
Plate
2. Lift off the valve plate on one side.
3. Repeat for the other side.
Compressor
NOTE: Note the position of the tab on valve
plate for reassembly.
NOTE: To avoid confusion, ONLY service one
end of the compressor at a time.
Head Plate - Valve Plates
35
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SECTION 7—COMPRESSOR
Fan
NOTE: For this procedure, refer to FIGURE 7.4.
1. Using two flat blade screwdrivers, pry the fan off of the motor shaft under the center
housing. DO NOT pry under the fan blades.
NOTE: Note position/orientation of fan for reassembly.
Connecting Rod and Eccentric Assembly
NOTE: For this procedure, refer to FIGURE 7.4.
1. Rotate shaft to align the eccentricʹs set screw with the access hole in the bottom of the
compressor housing.
2. Insert the 1/8‐inch Allen wrench into the access hole in the bottom of the compressor
3. Loosen the set screw ¼ turn.
4. Rotate connecting rod to top dead center (180°) and slide the connecting rod/eccentric
assembly off the shaft through the opening in the housing.
5. Secure the rod assembly in a fixture.
6. Remove the sleeve from the connecting rod and discard.
Piston Cup
NOTE: For this procedure, refer to FIGURE 7.4.
1. Remove the torque screw (discard) from the piston cup retainer (retain for reassembly).
2. Remove the piston cup (discard) and wipe debris from the top of the connecting rod
with a clean damp cloth.
NOTE: As the piston travels
DETAIL “A” - BOTTOM OF
COMPRESSOR
up and down it will also rock
from side‐to‐side. This is a
feature of the WOB‐L Piston.
Cylinder Sleeve
Eccentric Set Screw Access Hole
Torque Screw
Retainer
Piston Cup
Rod Top
Eccentric
Fan
Connecting
Set Screw
(hidden)
Rod
36
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SECTION 7—COMPRESSOR
O-ring, Intake Valve Keeper and Valve Keeper Strip
NOTE: For this procedure, refer to FIGURE 7.5.
1. Remove the O‐ring, intake valve
flapper and valve keeper strip from the
bottom of the valve plate. Discard all.
Valve Flapper
Screw
2. Clean the bottom of the valve plate
with a clean, soft cloth.
Valve
Keeper Strip
O-Ring
Intake Valve
Flapper
Exhaust Valve Flapper, Valve Restraint and Valve Keeper Strip
NOTE: For this procedure, refer to FIGURE 7.6.
1. Remove the exhaust valve flapper,
valve restraint and valve keeper strip
from the top of the valve plate. Discard
all.
Gasket
ValveFlapper
Screw
Valve
Keeper Strip
2. Clean the top of the plate with a clean,
soft cloth.
Exhaust Valve
Flapper
Gasket
NOTE: For this procedure, refer to
Valve
Restraint
1. Remove the old gasket from the top of
the valve plate and discard.
Restraint and Valve Keeper Strip
2. Clean the valve plate with a clean, soft
cloth.
37
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SECTION 7—COMPRESSOR
Rebuilding the Compressor
NOTE: Before reassembly, wipe any residue from all components with a clean soft cloth.
Gasket
NOTE: For this procedure, refer to FIGURE 7.6 on page 37.
1. Install new gasket; seating the gasket firmly in the groove at the top of the valve plate
with your finger or blunt object.
CAUTION
Make sure that the gasket is not twisted when seated in the groove of the top of the valve
plate.
Exhaust Valve Flapper, Valve Restraint and Valve Keeper Strip
NOTE: For this procedure, refer to FIGURE 7.6 on page 37.
1. Install the new exhaust valve flapper, valve restraint and valve keeper strip to the top
of the valve plate with the valve flapper screw.
NOTE: Torque flapper screws to 12 inch‐lbs.
O-ring, Intake Valve Flapper and Valve Keeper Strip
NOTE: For this procedure, refer to FIGURE 7.5 on page 37.
1. Install the new valve keeper strip on top of the new intake valve flapper so that the
word ʺUPʺ is visible. Fasten with the valve flapper screw.
2. Install the new O‐ring, seating it firmly into the groove with your finger or blunt
object.
NOTE: Torque flapper screws to 12 inch‐lbs.
Piston Cup
NOTE: For this procedure, refer to FIGURE 7.4 on page 36.
1. Place cylinder sleeve over rod top with smooth edge facing up.
2. Place piston cup on rod top making sure it is centered.
3. Place retainer on top of piston cup and seat retainer in rod top pocket, making sure the
retainer and cup align properly along with screw holes.
4. Insert new screw into rod top and torque to 30 inch‐lbs.
Connecting Rod/Eccentric Assembly
NOTE: For this procedure, refer to FIGURE 7.4 on page 36.
1. With gloved‐hand or clean cloth, pre‐form piston cup if necessary.
2. Gently slide cylinder sleeve up and over cup to fully form it.
38
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SECTION 7—COMPRESSOR
CAUTION
DO NOT lubricate or use oil on any moving parts. The compressor eccentric uses a
precision sealed bearing.
DO NOT crimp the piston cup when you replace the sleeve. If the cup is crimped, it MUST
be replaced.
3. With bearing side of connecting rod/eccentric assembly facing the center (motor) of
the compressor, slide the assembly onto the shaft bringing it flush to the motor
bearing.
NOTE: Make sure the eccentric set screw is positioned over the flat of the shaft.
5. Hold the sleeve down to the housing with one hand and slowly rotate the eccentric
with the other hand to ensure all the components are aligned properly.
Fan
NOTE: For this procedure, refer to FIGURE 7.4 on page 36.
1. Reinstall the fan onto the shaft in original orientation. Secure into position using a
rubber mallet.
Valve Plate
NOTE: For this procedure, refer to FIGURE 7.3 on page 35.
1. With the sleeve located and firmly seated on the housing, replace the valve plate in the
same manner as it was.
2. Repeat step 1 for other valve plate.
NOTE: Make sure the top edge of the sleeve locates in the O‐ring groove in the bottom of the valve
plate.
CAUTION
Make sure that the O‐ring is not twisted when seated in the groove of the bottom of the
valve plate.
Compressor Heads
NOTE: For this procedure, refer to FIGURE 7.3 on page 35.
1. Place the heads on top of the valve plates.
2. Tighten the head screws in a criss‐cross pattern to 40 inch‐lbs.
39
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SECTION 7—COMPRESSOR
Compressor
ꢀ WARNING
To avoid personal injury or property damage, rotate the fan by hand prior to connecting
the unit to a power source. Check for suction at the air inlet by placing your finger over
the port as you rotate the fan. You should feel a slight suction with each rotation of the
fan. If you DO NOT feel a suction but you feel or hear a thump as you turn the fan, DO
NOT connect the unit to a power source. Review the assembly procedure for possible
error.
NOTE: For this procedure, refer to FIGURE 7.7 on page 41.
FIELD SERVICE PARTS LIST FOR THOMAS 2660 SERIES COMPRESSOR
ITEM PART
QTY.
QTY.
NO.
NO.
See Chart
624277
625776
626175
618114
See Chart
623143
625175
621591
638574
617177
617562
621485
621641
625094
623137
638281
638282
PER ASM PER UNIT
DESCRIPTION
Connecting Rod, Eccentric & Bearing Assembly
Piston Cup
1
2
3
4
5
6
7
8
9
—
1
2
2
2
2
2
1
2
8
2
1
2
4
4
2
4
2
1
1
1
Screw - Piston Cup Retainer
Piston Cup Retainer
Cylinder Sleeve
1
1
—
—
—
—
—
1
Head
O-Ring - Head Gasket
Screw - Head
Valve Plate Assembly
Valve - Pressure Relief-Not Shown (115 V)
Valve Restraint
10
11
12
13
14
15
16
17
2
Valve Keeper Strip
2
Valve Flapper - Intake & Exhaust
Valve Plate
1
2
Screw - Valve Flapper
O-Ring Valve Plate
—
—
—
Fan - Gray
Fan - Black
2660CE37-989 COMPRESSOR
ITEM
PART NO.
607731
QTY.
DESCRIPTION
Connecting Rod, Eccentric & Bearing Assembly
Head
1
6
2
1
665167
40
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SECTION 7—COMPRESSOR
COMPRESSOR PARTS LEGEND
1. Connecting Rod, Eccentric & Bearing Assembly
10. Valve Restraint
2. Piston Cup
11. Valve Keeper Strip
3. Screw - Piston Cup Retainer
4. Piston Cup Retainer
5. Cylinder Sleeve
6 Head
7. O-Ring - Head Gasket
8. Screw - Head
12. Valve Flapper - Intake & Exhaust
13. Valve Plate
14. Screw - Valve Flapper
15. O-Ring Valve Plate
16. Fan - Gray
17. Fan - Black
9. Valve Plate Assembly
FIGURE 7.7 Compressor Exploded View
41
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SECTION 8—P.E. VALVE
SECTION 8—P.E. VALVE
Replacing P.E. Valve
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 8.1 on page 43.
1. Unplug unit.
4. Remove spade connectors from P.E. valve terminals.
5. Remove tie‐wraps from P.E. valve tubing.
6. Remove P.E. valve assembly from tubing.
CAUTION
If P.E. valve is not to be installed IMMEDIATELY, plug the P.E. valve tubing to prevent
sieve bed contamination.
7. Install new P.E. Valve assembly IMMEDIATELY, by reversing STEPS 3‐5.
NOTE: Retiming of the concentrator is necessary. Refer to Timing on page 73.
NOTE: To ensure proper orientation, the “out” port barb should face to the left side sieve bed when
viewing from behind the unit.
10. Reinstall cabinet. Refer to Removing Cabinet on page 23.
42
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SECTION 9—SIEVE BEDS
SECTION 9—SIEVE BEDS
Replacing Sieve Beds
ꢀ DANGER
To prevent electrical shock, AWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 9.1 on page 45.
NOTE: ALWAYS replace sieve beds in pairs to ensure that both beds are in optimum condition.
1. Unplug unit.
4. Remove tie wraps and disconnect P.E valve tubing and check valve tubing from top
of sieve beds.
5. Remove the four large tie‐wraps (two on each sieve bed).
6. Tilt sieve beds back and lift up. Rest sieve beds on rear of base.
7. Using a hose clamp tool, remove the clamp and reinforced tubing from bottom of both
sieve beds and remove sieve beds.
CAUTION
DO NOT remove plastic caps from new sieve bed fittings until ready to install new beds.
Severe sieve contamination can occur if uncapped beds are exposed to air.
8. Remove plastic caps from the top and bottom fittings of the new sieve beds.
9. Install new sieve beds reversing STEPS 3‐7.
NOTE: After replacing sieve beds, retiming is necessary. Refer to Timing on page 73.
10. Run unit and check for leaks. Refer to Leak Test on page 76.
11. Reinstall cabinet. Refer to Removing Cabinet on page 23.
44
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SECTION 9—SIEVE BEDS
P.E. Valve
Assembly
Check Valve Tubing
Tie-Wraps
Check Valve Tubing
Tie-Wraps
Tie-Wrap
P.E. Valve
Tubing
P.E. Valve
Tubing
Tie Wraps
Tie-Wrap
Clamp
Sieve Bed
Reinforced Tubing attaches
HERE (not shown)
NOTE: Compressor Inlet HEPA Filter removed from illustration for clarity.
45
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SECTION 10—CHECK VALVES
SECTION 10—CHECK VALVES
Replacing Check Valves
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 10.1 on page 47.
1. Unplug unit.
NOTE: Replace one or both check valves when performing this procedure. The check valves are one‐
way directional and can be checked by passing air through them. Air should flow in one direction
only.
4. Remove tie‐wraps from top and bottom of the check valve(s) and disconnect check
valve(s) from ¼‐inch PVC tubing.
ꢀ WARNING
The check valves are one‐way directional and MUST be installed correctly. The letters
“VAC” are printed on the check valves. The check valves MUST be installed with the
“VAC” on the underside of the check valve. Low system pressures and eventual bed
contamination will result if check valves are not properly installed.
CAUTION
DO NOT put a check valve on the regulator outlet tubing. Otherwise, damage may result.
The regulator outlet tubing is identified by the flow arrow on the side of the regulator
which points to it.
5. Install the new check valve(s) into the ¼‐inch PVC tubing on inlet tubing only.
6. Make sure “VAC” is on the underside of the check valve to ensure proper orientation
of check valves when installing.
7. Secure the check valve(s) by installing new tie‐wraps to the ¼ inch PVC tubing where
previously removed.
NOTE: If ¼ inch PVC tubing is damaged in any way, replace the section of ¼ inch PVC tubing
before installing check valve(s).
NOTE: Ensure check valves are not crossed. Left barb product tank check valve goes to left barb on
sieve bed. Right barb product tank check valve to right barb on sieve bed.
46
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SECTION 10—CHECK VALVES
10. Reinstall cabinet. Refer to Removing Cabinet on page 23.
Location of Product Tank
¼ PVC Inlet Tubing
Check Valves
Regulator Outlet Tubing
Tie-wrap
Tie-wrap
Check Valves
Tie-wrap
Regulator
Tie-wrap
Flow Arrow
Product Tank
47
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SECTION 11—REGULATOR
SECTION 11—REGULATOR
Replacing Regulator
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 11.1 on page 49.
1. Unplug unit.
NOTE: On concentrator models with the SensO unit ONLY, remove the 1/8‐inch tubing to
2
oxygen sensor housing.
3. Remove the four mounting screws that secure regulator to product tank cap.
4. Remove regulator from product tank lid ensuring that the O‐rings are removed.
NOTE: Clean mounting surface of product tank cap. Ensure that the two ʺOʺ rings for the NEW
regulator are installed onto the ports (underside) of the NEW regulator before installation.
ꢀ WARNING
Ensure proper installation of regulator. Note flow arrow on regulator. This MUST face
toward the regulator outlet tubing or flow will be interrupted causing system shutdown.
5. Install new regulator onto product tank by reversing STEPS 3 and 4.
6. Torque mounting screws to 5 ± 1 inch‐lbs.
NOTE: On units with SensO , reinstall 1/8‐inch tubing to oxygen sensor housing.
2
48
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SECTION 11—REGULATOR
Pressure Regulator
(Top)
Pressure
Adjustment Screw
(5/32-inch Allen
Wrench)
Pressure
Regulator
Mounting
Screws
Pressure
Sensor Tubing
Product
Tank
Location of
Product Tank
NOTE: For adjusting the regulator there is no
need to remove the control panel.
Adjusting Regulator
NOTE: For this procedure, refer to FIGURE 11.1 on page 49.
1. Turn unit on ( ).
2. Install pressure gauge onto oxygen outlet.
NOTE: Use a 0 ‐ 30 p.s.i. pressure gauge.
NOTE: Check O2 pressure at oxygen outlet. It should read a steady five p.s.i. ± 0.5 p.s.i. If pressure
is not in specification, proceed to STEP 3. If pressure falls within specification, no adjustment is
needed.
3. Unplug unit.
5. Plug unit in and turn power switch on ( ).
6. Using the access hole located on the control panel, locate the pressure adjustment
screw in center of pressure regulator top.
7. Insert a 5/32‐inch Allen wrench into the pressure adjustment screw.
8. While reading pressure gauge, do one of the following:
• Turn pressure adjustment screw or adjustment knob, clockwise to increase output
pressure; or
• Turn pressure adjustment screw or adjustment knob, counterclockwise to decrease
output pressure.
49
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SECTION 11—REGULATOR
9. Adjust until pressure reads a steady five p.s.i. ± 0.5 p.s.i.
10. Once required pressure is achieved, reinstall cabinet. Refer to Removing Cabinet on
± 0.5 p.s.i.
NOTE: After ten minutes of run time, retest output pressure of concentrator to insure proper
operation and/or spec levels.
50
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SECTION 12—HEAT EXCHANGER ASSEMBLY
SECTION 12—HEAT EXCHANGER
ASSEMBLY
Replacing Heat Exchanger Assembly
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 12.1 on page 52.
NOTE: The heat exchanger assembly contains three components: heat exchanger, nine inch vinyl
tube and connecting component.
1. Unplug unit.
CAUTION
Use care not to deform heat exchanger when installing, removing or cleaning.
3. Disconnect brass nut that secures the heat exchanger assembly to the compressor
(Detail “A”).
4. On the backside of the Perfecto2, loosen the clamp that secures the vinyl tube to the
manifold assembly and remove the vinyl tube from the manifold assembly. (Detail
“B”).
5. Remove heat exchanger assembly by pulling vinyl tube through sound box.
6. Reverse STEPS 3‐5 to install new heat exchanger.
51
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SECTION 13—CONTROL PANEL
SECTION 13—CONTROL PANEL
Removing Control Panel
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 13.1 on page 54.
Tools Required:
• Diagonal cutters
• Flathead screwdriver
• ¼‐inch ratchet, ¼‐inch socket, and ¼‐inch extension
• Pliers
• Tie‐wraps
1. Unplug unit.
3. Cut the two tie wraps that secure the control panel to the sieve beds (Detail “A”).
4. Cut the two tie wraps that secure the P.E. valve assembly to the control panel (not
shown).
5. Remove the two mounting screws that secure the control panel to the sound box
(Detail “B”).
6. Remove the ¼‐inch I.D. tubing from the top and bottom barbed fittings of the
flowmeter (Detail “B”).
7. Cut tie wrap and remove ¼‐inch I.D. tubing from the patient outlet barbed fitting
behind the control panel (Detail “B”).
8. Remove the two mounting screws that secure the P.C. board to the control panel.
NOTE: Before performing STEP 9, code all wires to ensure correct reinstallation.
9. Remove spade connectors from circuit breaker, hour meter and On/Off ( ) switch.
(Jumper wire harness from On/Off switch to circuit breaker does not have to be
removed).
10. Remove the hour meter. Refer to Replacing Hour Meter on page 64.
12. Remove the circuit breaker by twisting the locknut on the outside of the control panel.
13. Discard existing control panel.
14. Install new control panel by reversing STEPS 3‐12.
53
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SECTION 13—CONTROL PANEL
15. Run unit and check for leaks at pressure sensor tubing on product tank cap. Refer to
16. Reinstall cabinet. Refer to Removing Cabinet on page 23.
DETAIL “B”
DETAIL “A”
Tie
Mounting Screws
(STEP 5)
Control
Panel
Wrap
Tie
Wrap
¼ Tubing
(STEP 6)
Control Panel
¼ Tubing (STEP 7)
Control Panel
Circuit Breaker
(STEP 9)
Hour Meter
(STEP 9)
On/Off Switch
(STEP 9)
P.C. Board
Mounting
Screws
54
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SECTION 14—COOLING FAN
SECTION 14—COOLING FAN
Replacing Cooling Fan
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 14.1 on page 57.
1. Unplug unit.
5. Remove the three mounting screws that secure the resonator housing to the soundbox.
Two mounting screws are installed in the top. The other mounting screw is located on
the backside of the housing near the bottom (Detail “A”).
6. Move the resonator housing back slightly for access to the cooling fan. Disconnect the
intake hose on the compressor assembly if necessary (Detail “A”).
7. Disconnect spade connectors from fan terminals on side of cooling fan.
NOTE: The cooling fan is fastened to the soundbox with four rubber grommets on each corner.
8. Lift cooling fan up and dislodge the rubber grommets from the soundbox (Detail “B”).
9. Remove the rubber grommets from the existing cooling fan (Detail “C”).
10. Note the orientation of the installed rubber grommets. There are two recessed areas
on the rubber grommet. The larger recessed area of the grommet is installed in the fan.
The smaller recessed area is installed in the sound box.
11. Inspect rubber grommets for damage. If damage is found, do not use. Order new
rubber grommets before installing fan.
12. Install rubber grommets into new cooling fan with larger recessed area installed in the
fan. (Detail “C”).
CAUTION
Fan MUST be positioned properly so air from the fan blows DOWN onto the compressor
(see air flow arrow on back of fan) or damage to the unit will occur.
13. Position cooling fan onto soundbox (Detail “B).
14. Pull rubber grommets down into the sound box. (Detail “D”).
55
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SECTION 14—COOLING FAN
15. Connect spade connectors to fan terminals on side of cooling fan (Detail “B”).
16. Move resonator housing back into position (Detail “A”).
17. Secure the resonator housing to the soundbox with the three mounting screws. Two in
the top and one on the back near the bottom of the housing (Detail “A”).
18. if necessary, reconnect the intake valve on the compressor assembly.
19. Reinstall control panel. Refer to Removing Control Panel on page 53.
20. Reinstall compressor inlet HEPA filter. Refer to Replacing the Compressor Inlet HEPA
21. Plug unit in and check for leaks. Refer to Leak Test on page 76.
22. Run unit for at least 30 minutes. If unit runs properly, replace cover. If not, call
Invacare Technical Service.
23. Reinstall cabinet. Refer to Cabinet on page 23.
56
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SECTION 14—COOLING FAN
DETAIL “B”
DETAIL “A”
Rubber
Cooling Fan
Grommet
Mounting
Screws
Mounting
Screw
Fan Terminals
(Spade Connectors
attach here)
Intake
Hose
Soundbox
Resonator
Housing
Compressor
Assembly
DETAIL “D”
Cooling
Fan
NOTE: Sieve Beds are not shown for clarity.
DETAIL “C”
Cooling
Fan
Soundbox
Rubber
Grommets
Rubber Grommets
Larger recessed area
to be installed in fan.
NOTE: Cooling fan removed from
rubber grommets to show proper
installation of grommets in
Smaller recessed area to be
installed in soundbox.
57
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SECTION 15—P.C. BOARD
SECTION 15—P.C. BOARD
Replacing P.C. Board
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
CAUTION
Follow these pre‐cautions to prevent damage to the P.C. boards:
Before handling any P.C. boards, you need to be properly grounded to prevent static
damage to the components of the board. A Static Cuff MUST be worn and properly
grounded using an alligator clip. Electrical conduit or a water pipe is normally sufficient
when a known good ground is not available. Care should be taken to ensure that the
alligator clip contacts with bare metal surface.
When removing quick disconnects terminals, DO NOT pull on wire itself as damage to
the connection may occur. Hold down the P.C. board with one hand and use an upward
force with a slight rocking motion to remove the terminals.
Before installing any P.C. boards, ensure that all insulators are in place.
NOTE: For this procedure, refer to FIGURE 15.1 on page 60.
1. Unplug unit.
4. Do the following:
A. Disconnect wiring harnesses from PC board.
ꢀ WARNING
DO NOT remove oxygen sensor tubing from P.C. board. Remove from regulator ONLY.
DO NOT remove the pressure sensor tubing from P.C. board. Remove from top of
product tank only. Damage to oxygen sensor assembly or pressure sensor could occur. A
faulty sensor may result in improper oxygen delivery and harm to the user.
B. Disconnect pressure sensor tubing from product tank, not P.C. Board.
C. For concentrators that have O2 sensor, disconnect the oxygen sensor tubing from
regulator fitting. Refer to Replacing Regulator on page 48.
5. Remove the two mounting screws on top corners of P.C. board.
6. Position new P.C. board.
58
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SECTION 15—P.C. BOARD
7. Secure new P.C. board in place with existing mounting screws. Be sure all tie‐wraps
removed from tubing connections are replaced.
8. Do the following:
A. Connect wiring harnesses to P.C. board.
B. Connect pressure sensor tubing to product tank.
C. For concentrators that have O2 sensor, Connect the oxygen sensor tubing to
regulator fitting.
10. Run concentrator to ensure unit operates to specifications.
12. Check for leaks at pressure sensor tubing on product tank cap. Refer to Leak Test on
13. Reinstall cabinet. Refer to Removing Cabinet on page 23.
59
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SECTION 16—TRANSFORMER
SECTION 16—TRANSFORMER
Replacing the Transformer
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 16.1 on page 61.
1. Unplug unit.
3. Locate the transformer located on the sound box.
4. Code all wires before disconnecting for proper re‐connections.
5. Remove the two mounting screws that secure the transformer to the soundbox.
6. Note orientation of transformer on soundbox before removing for proper
reinstallation
7. Remove the existing transformer and discard.
8. Install new transformer in orientation noted in STEP 7.
9. Connect all wires as noted from STEP 4.
10. Reinstall cabinet. Refer to Cabinet on page 23.
Location of
DETAIL “A”
Transformer
Transformer
Mounting
Assembly
Screws
61
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SECTION 17—ON/OFF SWITCH
SECTION 17—ON/OFF SWITCH
Replacing On/Off Switch
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 17.1 on page 62.
1. Unplug unit.
4. Remove and code the four spade connectors from back of existing On/Off switch.
5. Compress retaining grips on back of existing On/Off switch and push switch out
through front of control panel.
NOTE: Ensure proper orientation of the On/Off ( ) switch and wiring connections before
CAUTION
DO NOT install the On/Off (I/O) switch upside down. Universal Off (O) symbol should
be at bottom and Universal On (I) symbol should be at the top. Possible damage to the
concentrator may result if not properly installed.
6. Reverse STEP 4 to secure new On/Off ( ) switch.
DETAIL “A”
ON
Front View
On/Off
OFF
(
)
Switch
DETAIL “B”
On/Off (
)
Spade Connector
from Brown Wire
attached here
Switch
Back View
Brown Jumper
Wire (From
Circuit Breaker)
Spade Connectors
from White Wires
attached here
62
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SECTION 18—FLOWMETER
SECTION 18—FLOWMETER
Replacing Flowmeter
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 18.1 on page 63.
1. Unplug unit.
3. Note the location of the PVC tubing for accurate replacement after new flowmeter is
installed.
5. Remove palnuts that secure flowmeter to the control panel.
6. Remove flowmeter from front of control panel.
7. Install new flowmeter reversing STEPS 4‐5.
9. Run unit and check for leaks where ¼‐inch PVC tubing engages flowmeter barbed
fittings. Refer to Leak Test on page 76.
10. Reinstall cabinet. Refer to Removing Cabinet on page 23.
Flowmeter Barbed
Fittings (Back of
Flowmeter)
Palnuts
Flowmeter
Control Panel
63
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SECTION 19—HOUR METER
SECTION 19—HOUR METER
Replacing Hour Meter
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 19.1.
1. Unplug unit.
4. Remove and label the two hour meter connectors and wires connected to back of hour
meter.
5. Spread retaining clips on hour meter housing that secure hour meter to control panel.
6. Remove hour meter by pushing meter through front of control panel.
7. Install new hour meter reversing STEPS 4‐6.
Hour Meter
Hour Meter
Housing
Hour Meter
Connectors
Wires
Hour Meter
Back of
Control Panel
Retaining Clips (Hour
Meter Housing)
64
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
SECTION 20— 4-WAY VALVE/
MANIFOLD ASSEMBLY
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
CAUTION
This is a maintenance free valve. Opening the valve will void any and all warranties
applicable to the valve.
Replacing 4-Way Valve and/or Manifold Assembly
NOTE: For this procedure, refer to FIGURE 20.1 on page 67.
1. Unplug unit.
3. Cut the one tie wrap that secures the manifold exhaust tube to the “F” tube.
4. Remove the manifold exhaust tube from the “F” tube.
5. Cut the two tie wraps that secure the “F” tube to the 4 way valve/manifold assembly.
6. Remove the “F” tube from the 4 way valve/manifold assembly.
7. Using a hose clamp tool, remove the clamps that secure the vinyl tubes to the 4‐way
valve/manifold assembly.
8. Remove the vinyl tubes from both sides of the 4 way valve/manifold assembly.
9. Note the orientation of the 4‐way valve/manifold assembly before removing for
correct re‐installation.
10. Lift 4‐way valve/manifold assembly up and out of the base of the concentrator.
11. Disconnect spade connectors located on the side of the 4 ‐way valve assembly (Not
shown).
12. Remove the four mounting screws that secure the 4‐way valve/manifold assembly
together (Detail “A”).
13. Replace the necessary component(s). (i.e. ‐ 4‐way valve, manifold or both).
14. Loosely install mounting screws through 4‐way valve and into manifold assembly.
NOTE: Ensure the manifold gasket is in place on 4‐way valve before installing.
65
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
CAUTION
Torque sequence and specification MUST be adhered to or possible damage to the 4‐way
valve could result.
15. Tighten mounting screws in the sequence described below (Detail “B”).
16. Pre‐torque the mounting screws to 10 ± 2 inch‐lbs using the torque sequence.
17. The mounting screws can be now be torqued to 22 ± 2 inch‐lbs in the same sequence.
18. Connect spade connectors located on the side of the 4 ‐way valve assembly.
19. Position the 4‐way valve/manifold assembly in the base of the concentrator on the
foam block in the orientation noted in STEP 9.
20. Slide the vinyl tubes onto each side of the manifold/valve assembly.
21. Using a hose clamp tool, secure the vinyl tubes to the 4‐way valve/manifold assembly
with the clamps.
22. Install the “F” tube into the 4‐way valve/manifold assembly.
23. Secure the “F” tube to the 4 way valve/manifold assembly with two tie wraps.
24. Install the manifold exhaust tube into the “F” tube.
25. Secure the manifold exhaust tube to the “F” tube with a tie wrap.
26. Install cabinet. Refer to Removing Cabinet on page 23.
66
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
Tie
Wrap
Manifold
Exhaust
Tube
Vinyl Tube
“F” Tube
Clamp
Tie Wrap
Tie
Wrap
Clamp
4 Way Valve/
Manifold Assembly
Vinyl Tube
DETAIL “B”
DETAIL “A”
4-Way Valve/
Manifold
Manifold
Assembly
Assembly
4-Way Valve
2
4
1
3
NOTE: The Numbers above
indicate the MOUNTING SCREW
TORQUE SEQUENCE:
Mounting
Screws
pre‐torque to 10 + 2 inch‐lbs.,
then torque to 22 + 2 inch‐lbs.
67
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
Replacing Pilot Valve Poppets and O-Rings
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 20.2 on page 70.
1. Unplug unit.
4. Locate pilot valve on 4‐way valve/manifold assembly.
5. Hold pilot valve stem with the flat blade screwdriver and turn the 9/16‐inch locknut
counterclockwise one complete turn.
6. Unscrew the pilot valve stem assembly from the manifold while leaving the coil with
yoke and locknut intact on stem.
7. Remove pilot valve poppet from inside the pilot valve stem.
CAUTION
DO NOT remove the coil yoke from the coil. The washer between the bottom of the yoke
and the bottom of the coil MUST not be removed. Otherwise, components may be
damaged in reassembly.
8. Set aside the coil with yoke and pilot valve stem assembly with the wires still intact.
ꢀ WARNING
DO NOT use sharp tools to remove O‐ring from plastic manifold opening. Damage to the
plastic manifold and/or plastic manifold airflow passage may occur. Damage to airflow
may result in improper oxygen delivery and harm to the user. Refer to Detail “A ” in
FIGURE 20.2.
9. Remove poppet and O‐ring from manifold opening (Detail “A”).
10. Discard old poppet and O‐ring.
11. Install new O‐ring into the opening in the plastic manifold housing (Detail “A”).
CAUTION
DO NOT overtighten pilot valve stem when installing it into plastic manifold. Damage to
the rubber ʺOʺ ring and/or plastic manifold may occur.
68
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
12. Install new slotted poppet into the bottom of the pilot valve stem with tapered end
facing to the bottom.
13. Install pilot valve stem and new slotted poppet with coil (with yoke and locknut
intact) into manifold opening.
14. Use a flat blade screwdriver, and tighten pilot valve stem clockwise until snug. Torque
to 25 inch‐lbs. ± 5 inch‐lbs.
15. Install new label onto pilot valve coil yoke.
16. Position pilot valve coil with yoke at an approximate 90° angle to the right as viewed
from the front of valve.
17. Use the flat blade screwdriver and hold the pilot valve‐stem in place.
18. Tighten locknut clockwise with the 9/16‐inch wrench until snug to secure the stem and
coil with yoke. DO NOT overtighten. Torque to 20 inch‐lbs ± 3 inch‐lbs.
CAUTION
DO NOT overtighten locknut when installing it onto pilot valve stem. Damage to the
plastic manifold may occur.
19. Plug power cord in and turn concentrator ON (I) to ensure proper operation.
20. Reinstall cabinet. Refer to Removing Cabinet on page 23.
21. If any difficulties are encountered in this installation, contact Invacare Technical
Service at (800) 832‐4707.
69
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SECTION 20—4-WAY VALVE/MANIFOLD ASSEMBLY
Manifold
Opening
DETAIL “A”
O-Ring
Air Flow Passage
Exploded View
Assembled View
NOTE: DO NOT disassemble.
Spade Connectors attach here
(Leave Wire Connectors Intact)
Locknut
Coil
Valve
Pilot Valve Stem
Slotted
Poppet
Pilot Valve
Stem
Yoke
Tapered
End
Valve
New
Label
O-Ring
Manifold
70
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SECTION 21—PURITY INDICATORS
SECTION 21—PURITY INDICATORS
SensO Alarm Indicators
2
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
NOTE: For this procedure, refer to FIGURE 21.1 on page 72.
Operation
The Perfecto2 with SensO2 Concentrator is equipped with an oxygen purity indicator.
This feature monitors the purity level of the oxygen generated by the concentrator. If
purity falls below alarm thresholds, indicator lights on the control panel will illuminate.
NOTE: Concentrator may be used during the initial start warm‐up time (approximately 30
minutes) while waiting for the O purity to reach maximum.
2
When the unit is turned on, the GREEN light will come on (SYSTEM OK/O greater than
2
85%). After five minutes, the oxygen sensor will be operating normally and will control
the indicator lights depending on oxygen concentration values. The explanation of the
indicator light functions are as follows:
Indicator Lights
NOTE: Indicator lights are visible only when lit.
GREEN light (O2) ‐ Normal Operation.
YELLOW light ( )‐ Call supplier IMMEDIATELY. You may continue to use the
concentrator unless instructed otherwise by your supplier. Be certain that backup oxygen
is nearby.
RED light ( )‐ Total unit shutdown. Switch IMMEDIATELY to backup oxygen supply.
Call supplier IMMEDIATELY.
GREEN light ‐ with YELLOW light flashing ‐ Call supplier IMMEDIATELY. Oxygen
sensor malfunctioning; you may continue to use the concentrator. Indicators ‐ If your unit
does not feature the O Sensor
2
LX Models Indicator Light Explanation
RED light ( )‐ Total Unit Shut‐Down. Switch IMMEDIATELY to a back‐up oxygen
supply. Call Supplier IMMEDIATELY.
GREEN light ( ) ‐ On/Off. System okay.
71
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SECTION 22—TIMING
SECTION 22—TIMING
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
Use extreme care when making adjustments to the timing switch. DO NOT allow
screwdriver or your hands to contact the P.C. Board when unit is plugged in and/or on.
Turn unit off and unplug before adjusting timing switch. Electrical shock is possible.
To accommodate the varying tolerances when replacing components, an adjustable timer
is used to control the shift time of the pressure equalization (P.E.) valve. The SensO board
2
allows for automatic (microprocessor controlled) adjustments of the P.E. shift times. Non‐
SensO2boards allow for manual adjustment.
Autotuning
ꢀ WARNING
DO NOT push the autotune button while powering up. Otherwise, the factory settings
will be erased.
NOTE: For this procedure, refer to FIGURE 22.1 on page 74.
1. Turn power off ( ) and unplug the unit.
3. Plug the unit in and turn the power on ( ).
4. Locate the P.C. board.
5. Wait for the main valve shift to indicate one of the following:
• If the P.C. board is new, the front panel RED indicator light will slowly blink,
indicating autotune has initiated.
• If the P.C. board is used and has performed autotuning before, press and release
the small push button on the P.C. board. The front panel RED indicator light will
slowly blink, indicating the unit is autotuning and automatically adjusting the P.E.
valve timing.
6. Set the output flow to 5.0 L/min.
7. The GREEN (onboard) diagnostic light will flash the current value of the P.E. valve
timing number.
8. Place the cover back on the unit but DO NOT install the cover screws. Let the unit run
until autotuning is completed.
9. When autotuning is complete, the RED front panel indicator light will change from a
slow blinking to a flashing of the final P.E. valve timing number.
73
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SECTION 22—TIMING
10. Turn the unit off and then back on. The timing value is stored in memory for future
use.
11. If the unit is turned off before an autotune cycle is completed, the P.E. valve timing
will not be stored or updated. If the board is new, autotuning MUST be successfully
completed before the unit can be placed into service.
12. After a successful autotune, run the unit for 30 minutes and verify that the oxygen
concentration output of the unit is within specification.
13. If the oxygen output concentration is not within specification, rerun the autotune
again.
14. Reinstall the cover screws.
Autotune Push Button Switch
NOTE: PC board is exploded
away from control panel for
clarity. there is no need to
remove P.C. Board from
P.C. Board
control panel.
74
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SECTION 22—TIMING
Manual Tuning
NOTE: For this procedure, refer to FIGURE 22.2.
1. Turn power off ( ) and unplug the unit.
3. Plug unit in but DO NOT turn on ( ) until instructed to below.
4. Locate the timing switch on the P.C. board.
5. Insert a small common or flathead screwdriver into the adjustment screw of the timing
switch.
6. Set the timing switch initially at the number “7” position.
7. Turn unit on ( ) and wait 15 minutes for unit to stabilize.
8. If after 15 minutes of run time the concentration is below specification, change setting
to a number one position lower than the previous setting.
9. Let unit run ten minutes. If concentration is lower still, change the switch to number
two positions higher.
NOTE: You will find that the concentrator will perform better at either the higher or lower setting.
The normal adjustment range is between timing positions 3 and A.
10. Continue to change setting one step at a time (up or down) until the concentration is
the highest value achievable.
11. Once concentration has reached specification, retiming is complete.
12. Reinstall cabinet. Refer to Removing Cabinet on page 23.
Control Panel
P.C. Board
Manual Timing
Switch
75
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SECTION 23—LEAK TEST
SECTION 23—LEAK TEST
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
Leak Test
NOTE: For this procedure, refer to FIGURE 23.1 on page 77.
1. Unplug unit.
3. Plug in unit.
4. Turn the concentrator on ( ).
5. Let concentrator run for 20 minutes.
ꢀ WARNING
Apply small amount of leak test solution to fittings only. Avoid all other components. DO
NOT leak test 4‐way valve body. Carefully leak test for pressure leaks around sieve bed
hoses at 4‐way valve. DO NOT allow leak test solution to enter into 4‐way valve and
system.
6. With ʺleak‐test” solution or equivalent soapy water, leak test the following:
A. The two sieve bed hose connection at the 4‐way valve/manifold assembly
(Detail”A”).
B. Leak test the hose fitting on center port of 4‐way valve/manifold assembly.
C. Hose connections to top and bottom fittings of sieve beds.
D. P.E. valve hose connections.
E. Hose fittings at product tank cap and check valves (Detail “B”).
F. Both fittings on heat exchanger assembly (Detail “C”).
7. Replace any tubing that appears cracked, worn, etc.
concentrations are observed, refer to Troubleshooting on page 16.
76
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SECTION 23—LEAK TEST
DETAIL “A”
P.E. Valve Hose
Connections (STEP 6D)
P.E. Valve Hose
Connections (STEP 6D)
Hose
Connections
to Top Fittings
of Sieve Beds
(STEP 6C)
Hose Connections to
Top Fittings of Sieve
Beds (STEP 6C)
Sieve Bed
Hose fitting on
Center Port of 4-
way Valve/
Sieve Bed
ManifoldAssembly
(STEP 6B)
Hose
Hose
Connections to
Bottom Fittings
of Sieve Beds
(STEP 6C)
Connections to
Bottom Fittings
of Sieve Beds
(STEP 6C)
Sieve Bed Hose
Connection At 4-way
Valve/manifold
Assembly (STEP 6A)
4-Way Valve/
Manifold
DETAIL “B”
Check
Valves
Assembly
DETAIL “C”
Fitting
Heat Exchanger
Assembly
Product Cap Tank
(Check all hoses/
valves attached)
Fitting
77
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SECTION 23—LEAK TEST
4 Way Valve Function Test
NOTE: For this procedure, refer to FIGURE 23.1 on page 77.
The 4‐way valve used in the Perfecto2 Series Concentrators does have an acceptable
®
tolerance of leakage per RexRoth .
By nature of the valve design it is possible for the valve to experience small leaks, and still
operate without affecting the overall performance of the unit. The valve is assembled
where the components that make up the valve “Snap” together. The only screws in the
valve are for securing the valve to the manifold assembly.
According to RexRoth there is an acceptable leak specification of 60 cc per minute at 20
psi on each valve. Valves that have leaks within this specification will function properly
without any adverse effects to the performance of the concentrator. A leak in the amount
of 60 cc or less would be indicative of the type of small leak you would notice where the
end caps connect to the main body or where the three pieces of the main body connect
together. A 60 cc leak would not be noticeable when examining the system pressure
swings.
Leaks greater than 60 cc are indicative of cracks in the end caps, or a blown seal where the
end cap connects to the main body of the valve. These leaks are detected by either reading
the system swing pressures, noticing two consecutive swings not being equal or by
hearing an audible leak every other cycle. Leaks of this extreme nature indicate the valve
needs to be replaced.
Valves should only need to be replaced when the following conditions exist:
1. A visible crack is noted on either of the end caps or main body of the 4 way valve,
regardless of the amount of leak.
2. A large leak is present on the valve that causes an imbalance in the sieve bed swing
pressures. Example: Sieve Bed 1 pressure swings from 14 psi to 16 psi, within 7‐20
seconds and Sieve Bed 2 pressure swings from 13 psi to 16 psi slowly, and may take
as long as 25‐30 seconds before shifting (times over 30 second will shut down
automatically).
3. Valve will not shift and the pilot valve solenoid and circuit board are working
properly.
NOTE: The concentrator’s P.C.B. should exhibit an error code for High Pressure Failure (1 Red/
2 Green).
NOTE: The best method to test the 4‐way valve operation is by measuring the unit pressure
swings. This can easily be done at the HomeFill port with a 0‐30 psi pressure gauge and a ¼” fill
line adapter. Upon starting the unit should build pressure up to 16 psi for output flows 3 L/min
and below or 21 psi for output flows 4 L/min and above before its initial shift. After the initial shift
the unit should shift consistently in equal amounts of time +/‐ 1 second (time recorded in seconds).
78
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SECTION 23—LEAK TEST
Check each end cap
for cracks and for
major leaks. You
should NOT use
leak detector on the
valve.
4 Way Valve
Use a 0-30 psi pressure gauge to monitor
system pressure swings, and also record the
amount of time it takes to achieve a shift (full
charge and full purge).
79
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SECTION 24—ALARM TEST
SECTION 24— ALARM TEST
Alarm and Sensor Tests
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
Check alarms periodically for proper function.
Power Loss Alarm
With the unit running, remove the line cord from power source. The power loss alarm
mode should sound the audible alarm IMMEDIATELY or within 30 seconds.
NOTE: With the unit unplugged and inoperable for a short period of time, the battery free circuit
will be drained. If power failure alarm does not sound with unit unplugged and power switch on,
the battery free circuit is drained. It will recharge when unit is plugged in and switched on.
Low Pressure Test
NOTE: For this procedure, refer to FIGURE 24.1 on page 81.
1. There are two separate failure modes for Low Pressure:
• Low product tank pressure. (Pressure in tank drops below a preset value, typically
7 p.s.i.).
• Failure to reach the set point pressure within a prescribed time limit, or Timeout
Failure.
Test One
1. With unit running, set flow at maximum rating.
2. When the main valve switches, pull the stem on the compressor relief valve out as far
as it will go and hold it.
Threshold on page 83 for shutdown mode.
Test Two
1. With unit running, set flow at maximum rating.
2. Remove the pressure sensor tubing (tie‐wrap) from the top of the product tank (not
shown).
Threshold on page 83 for shutdown mode.
80
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SECTION 24—ALARM TEST
4. Replace tubing and tie wrap.
Time-Out Test
NOTE: For this procedure, refer to FIGURE 24.1.
1. With unit off ( ), disconnect the compressor connector from the main wiring harness.
2. Plug unit in and turn power on ( ).
Threshold on page 83 for shutdown mode.
4. Replace tubing and tie wrap.
NOTE: If any alarm fails to perform to specification, contact Invacare Technical Service.
Relief Valve (Pull Out
Stem to Simulate Leak)
Compressor
High Pressure Test
NOTE: For this procedure, refer to FIGURE 24.2 on page 82.
• High Pressure ‐ Occurs when pressure in product tank rises beyond a preset value,
typically 23 p.s.i. ± 1 p.s.i. for 5 liter and 27 p.s.i. ± 1 p.s.i. for 10 liter.
• Main Valve Coil ‐ Alarm sequence occurs when the main valve coil, connection or
P.C. board circuitry has failed.
1. With the unit running and flow set at 5 L/min., disconnect in‐line connector shown in
3. Replace tubing and tie wrap.
NOTE: If any alarm fails to perform to specification, contact Invacare Technical Service.
81
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SECTION 24—ALARM TEST
Location of In-Line
Connector
In-Line Connector
Oxygen Sensor
NOTE: For this procedure, refer to FIGURE 24.3 on page 83.
Alarm sequence occurs when concentration levels fall below a preset value, typically 73%
± 3% or 85% ± 2%. This failure indicates a catastrophic failure of any component
mechanical or electrical.
1. Turn unit on ( ). Set output flow at 5 L/min.
2. Monitor the O level.
2
3. With the O level greater than 85% after five minutes, the GREEN panel indicator light
2
will remain illuminated.
82
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SECTION 24—ALARM TEST
4. Slowly adjust flow beyond maximum rated flow until you can achieve a concentration
level greater than 75% but less than 84%. Within 30 minutes the YELLOW panel
indicator light will illuminate and the unit will continue to run.
5. Clamp off the 1/8‐inch oxygen sensor tubing between the oxygen sensor and the
product tank regulator.
ꢀ WARNING
Use care not to cut oxygen sensor tubing when clamping the oxygen sensor tubing.
6. Within 30 minutes, the Oxygen Sensor Alarm should activate and the RED panel light
indicator will illuminate. The compressor will shut down with the alarm.
1/8-inch I.D. Oxygen Sensor Tubing
(Clamp Off Flow)
SENSO ALARM THRESHOLD
2
LABEL
STATUS
INDICATOR LIGHTS
SYMBOL
SYSTEM OKAY
GREEN Indicator Light
O over 85% (± 2%)
O2
2
O Between 73% (± 3%)
YELLOW Indicator light
A. YELLOW Solid
2
to 85% (±2%)
B. YELLOW Flashing Sensor Failure
Call a qualified technician.
SYSTEM FAILURE
RED Indicator light
O Below 73% (±3%)
Continuous Audible Alarm Sieve-GARD™Compressor
Shutdown
2
Call a qualified technician
83
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SECTION 24—ALARM TEST
P.E. Valve Coil Test
NOTE: For this procedure, refer to FIGURE 24.4.
NOTE: P.E. Valve Coil ‐ Alarm sequence occurs when the P.E. Valve Coil, connection or P.C.
Board Circuitry has failed.
1. With the unit running and flow set at 5 L/min., remove one YELLOW wire from the
P.E. valve coil. The P.E. valve coil alarm should activate within 10 seconds.
NOTE: If any alarm fails to perform to specification, contact Invacare Technical Service.
NOTE: If problems arise during test, contact Invacare Technical Service for further assistance.
P.E. Valve Coil
Yellow Wires
when preventive maintenance was performed on the concentrator or any repairs made.
84
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SECTION 24—ALARM TEST
85
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SECTION 25—SIEVE BED PRESSURE CHECK
SECTION 25— SIEVE BED PRESSURE
CHECK
Checking Sieve Bed Pressure
ꢀ DANGER
To prevent electrical shock, ALWAYS disconnect concentrator from electrical outlet
before servicing.
Disassembly
NOTE: For this procedure, refer to FIGURE 25.1.
1. Turn power off ( ) and unplug unit.
3. Turn unit so the back faces you.
Check Valve
Cut PVC Tubing below
Check Valve to install
Product
Tank
Tap-in Kit
Pressure Testing
NOTE: For this procedure, refer to FIGURE 25.2 on page 87.
1. Connect pressure gauge to the ¼ x 2‐inch silicone tubing with connector (p/n 1131392).
2. Remove plug in HomeFill port in back of concentrator.
3. Connect ¼ x 2‐inch silicone tubing with connector to HomeFill port.
86
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SECTION 25—SIEVE BED PRESSURE CHECK
4. Check each connection to make sure it is tight.
5. Turn the concentrator On ( ).
NOTE: Adjust the concentrator to MAXIMUM rated liter flow to 5 L/min.
NOTE: Wait approximately five minutes to allow system pressures to achieve proper equilibrium
before testing.
6. The pressure in the concentrator should rise within 20 seconds to 21 p.s.i.g. ± 0.3 and
shift the 4‐way valve to the opposite sieve bed.
7. After the 4‐way valve shift, the pressure in the concentrator will drop to 12 p.s.i.g. ± 2
before rising within 20 seconds to 21 p.s.i.g. ± 0.3 and shift the 4‐way valve to the
opposite sieve bed.
8. If pressure reading is 21 p.s.i.g. ± 0.3 when both valve shifts are made, proceed to STEP
10.
9. If pressure in the concentrator does not fall into the specifications listed above, refer
10. Turn the concentrator off (O).
11. Disconnect pressure gauge from the HomeFill port and reinstall plug.
Pressure
Gauge
Back of
Concentrator
¼ x 2-inch
Silicone Tubing
with Connector
Plug
HomeFill Port
87
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LIMITED WARRANTY
For warranty information, please refer to the original ownerʹs manual which came with
this product, or contact Invacare for more information.
Invacare Corporation
USA
Canada
All rights reserved. Trademarks are
One Invacare Way
Elyria, Ohio USA
44036-2125
570 Matheson Blvd E Unit 8 identified by ™ and ®.
Mississauga Ontario
L4Z 4G4 Canada
800-668-5324
All trademarks are owned by or licensed
to Invacare Corporation or its subsidiaries
unless otherwise noted.
800-333-6900
Teflon is a registered trademark of DuPont
Corp.
Torx is a registered trademark of Textron,
Inc.
RexRoth is a registered trademark of
BOSCH REXROTH AG, GERMANY
© 2009 Invacare Corporation
Part No 1148070
Rev D - 04/09
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