Invacare Perfecto 2 IRC5P Service Manual Download Page 1

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Service Manual

DEALER: Keep this manual. The procedures in this manual MUST be
performed by a qualified technician.

For more information regarding

Invacare products, parts, and services,

please visit www.invacare.com

Perfecto

™

Oxygen Concentrator

(HomeFill

Compatible)

Model IRC5PO2 (Sensored)

Model IRC5P (Non-Sensored)

Summary of Contents for Perfecto 2 IRC5P

Page 1: ...in this manual MUST be performed by a qualified technician For more information regarding Invacare products parts and services please visit www invacare com Perfecto2 Oxygen Concentrator HomeFill Comp...

Page 2: ...tion with Invacare accessories Accessories designed by other manufacturers have not been tested by Invacare and are not recommended for use with Invacare products PERFECTO2 PARTS COMPATIBILITY The Pla...

Page 3: ...ating Sequence 13 SECTION 3 PNEUMATIC DIAGRAM 15 SECTION 4 TROUBLESHOOTING 16 SECTION 5 CABINET 23 Removing Cabinet 23 SECTION 6 PREVENTIVE MAINTENANCE 24 Cleaning the Cabinet Filter 24 Replacing the...

Page 4: ...ION 15 P C BOARD 59 Replacing P C Board 59 SECTION 16 TRANSFORMER 62 Replacing the Transformer 62 SECTION 17 ON OFF SWITCH 63 Replacing On Off Switch 63 SECTION 18 FLOWMETER 64 Replacing Flowmeter 64...

Page 5: ...Function Test 79 SECTION 24 ALARM TEST 81 Alarm and Sensor Tests 81 Power Loss Alarm 81 Low Pressure Test 81 Time Out Test 82 High Pressure Test 82 Oxygen Sensor 83 P E Valve Coil Test 85 SECTION 25...

Page 6: ...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 e...

Page 7: ...cessory IRCPF16 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 aff...

Page 8: ...cted May be associated with flow setting of 0 5 L min or less 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 Cha...

Page 9: ...NOT pinch Relative Humidity 20 to 60 Time of Operation Up to 24 hours per day Recommended Storage and Shipping Temper ature 20 F to 150 F 29 C to 65 C at 15 95 relative humidity LABEL SYMBOL O2 PURITY...

Page 10: ...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 c...

Page 11: ...O 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 NO...

Page 12: ...lies 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...

Page 13: ...duced 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...

Page 14: ...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...

Page 15: ...put Check Valve Patient Output Oxygen Sensor SensO2 models Only Pressure Sensor P S I O2 P C Board Pressure Regulator Product Tank Check Valves Air Inlet Cabinet Filter Compressor Inlet Filter Sieve B...

Page 16: ...extension cords Move to another outlet or circuit Power cord a Frayed b Broken or damaged spade c Spade connector from power cord loose or disconnected inside back of unit a Reattach cord b Replace p...

Page 17: ...tors RED One Flash GREEN Two Flashes Unit plugged in power switch on continuous alarm Compressor shut down P C board a Malfunction b Disconnected wire c Shifting valve at pressures greater than 25 p s...

Page 18: ...ctivates or energizes approximately one second prior to the activation of the 4 way valve with approximately 24 volts If voltage is in excess of 24 volts consistently replace the P C board Refer to Re...

Page 19: ...essor a Defective b Faulty capacitor c Bad motor windings d Worn seals e Bad bearings f Leak at fittings or tubing g Leaky or defective relief valve h Insufficient voltage outlet a Replace compressor...

Page 20: ...r 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...

Page 21: ...Replace capacitor Refer to Replacing Capacitor on page 34 c Replace compressor d Replace compressor e Replace compressor Line voltage excessive surge Have line voltage inspected by certified electrici...

Page 22: ...g GREEN On Internal repairs required Replace SensO2 circuit board Refer to Replacing P C Board on page 59 Potential Obstruction Alert does not activate on flows less than 0 5 L min System leak Repair...

Page 23: ...ng 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 vacuu...

Page 24: ...ntenance may need to be performed more often Refer to Troubleshooting on page 16 for plugged filter symptoms and to Preventive Maintenance Record on page 31 Cleaning the Cabinet Filter NOTE For this p...

Page 25: ...the Outlet HEPA Filter NOTE For this procedure refer to FIGURE 6 2 NOTE Perform this procedure during preventive maintenance or between patients depending on the outlet HEPA filter check results 1 Un...

Page 26: ...e 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 fil...

Page 27: ...s procedure as needed depending upon the environment the concentrator is used in 1 Unplug unit 2 Remove cabinet Refer to Removing Cabinet on page 23 3 Cut tie wrap that secures the bottom of the manif...

Page 28: ...Detail A in FIGURE 6 5 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...

Page 29: ...RE 6 5 Replacing the Muffler Assembly Exhaust Canister Throttling Muffler Sound Box Top of Manifold Exhaust Tube Tie Wraps Rubber Grommet DETAIL A Muffler Grommet Throttling Muffler Assembly 8 Tie Wra...

Page 30: ...outlet before servicing NOTE For this procedure refer to FIGURE 6 6 1 Unplug unit 2 Remove cabinet Refer to Removing Cabinet on page 23 CAUTION Use care not to deform heat exchanger when installing re...

Page 31: ...HEPA Filter Check Compressor Inlet Filter Check Power Loss Alarm Clean Replace Cabinet Filter s Check Outlet HEPA Filter Check Compressor Inlet Filter Check Power Loss Alarm NOTE Refer to Preventive M...

Page 32: ...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...

Page 33: ...o 2 FIGURE 7 1 Replacing Compressor Assembly Intake Hose Mounting Screws Brass Nut Capacitor DETAIL B DETAIL C DETAIL D Compressor Vinyl Tube Clamp Manifold Assembly Mounting Screws Grommets DETAIL A...

Page 34: ...dlenose 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 b...

Page 35: ...s 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...

Page 36: ...the compressor 2 Use the Torx T 25 torque wrench and loosen the eight head screws 3 Note head placement before removing compressor head plate 4 Remove the compressor head plate Valve Plates NOTE For t...

Page 37: ...enter 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 discar...

Page 38: ...alve 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 2 Clean the top of t...

Page 39: ...apper and Valve Keeper Strip NOTE For this procedure refer to FIGURE 7 5 on page 38 1 Install the new valve keeper strip on top of the new intake valve flapper so that the word UP is visible Fasten wi...

Page 40: ...ate 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 37 1 Reinstall the fan onto the shaft in original orient...

Page 41: ...Test on page 77 3 Take pressure readings to ensure proper system pressures Refer to Checking Sieve Bed Pressure on page 86 FIELD SERVICE PARTS LIST FOR THOMAS 2660 SERIES COMPRESSOR 2660CE37 989 COMPR...

Page 42: ...ccentric Bearing Assembly 2 Piston Cup 3 Screw Piston Cup Retainer 4 Piston Cup Retainer 5 Cylinder Sleeve 6 Head 7 O Ring Head Gasket 8 Screw Head 9 Valve Plate Assembly 10 Valve Restraint 11 Valve K...

Page 43: ...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...

Page 44: ...erfecto 2 44 Part No 1148070 FIGURE 8 1 Replacing P E Valve OUT Tie Wrap P E Valve Tubing P E Valve Tubing P E Valve Assembly Sieve Bed Out Port Barb Tie Wrap P E Valve Terminals Spade Connectors Atta...

Page 45: ...ck 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 c...

Page 46: ...e Beds Sieve Bed Tie Wraps Check Valve Tubing P E Valve Tubing Tie Wraps P E Valve Assembly Reinforced Tubing attaches HERE not shown NOTE Compressor Inlet HEPA Filter removed from illustration for cl...

Page 47: ...NG 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 chec...

Page 48: ...10 Reinstall cabinet Refer to Removing Cabinet on page 23 FIGURE 10 1 Replacing Check Valves Lower Tie wrap Check Valves Product Tank Location of Product Tank Check Valves Regulator Outlet Tubing Flow...

Page 49: ...n mounting surface of product tank cap 7 Install the two O rings for the NEW regulator onto the ports underside of the NEW regulator before installation WARNING Ensure proper installation of regulator...

Page 50: ...t Screw 5 32 inch Allen Wrench Product Tank Mounting Screws NOTE For adjusting the regulator there is no need to remove the control panel NOTE Regulator shown was used before 07 01 12 for sensored con...

Page 51: ...m one of the following A Regulators before 07 01 12 Sensored or 09 01 12 Non Sensored Insert a 5 32 inch Allen wrench into the pressure adjustment screw B Regulators after 06 30 12 Sensored or 08 31 1...

Page 52: ...emove cabinet Refer to Removing Cabinet on page 23 CAUTION Use care not to deform heat exchanger when installing removing or cleaning 3 Disconnect brass nut that secures the heat exchanger assembly to...

Page 53: ...T EXCHANGER ASSEMBLY Part No 1148070 53 Perfecto 2 FIGURE 12 1 Replacing Heat Exchanger Assembly Sound Box Heat Exchanger Assembly Compressor DETAIL A DETAIL B Brass Nut Clamp Vinyl Tube Manifold Asse...

Page 54: ...o the sound box Detail B 6 Remove the inch I D tubing from the top and bottom barbed fittings of the flowmeter Detail B 7 Cut tie wrap and remove inch I D tubing from the patient outlet barbed fitting...

Page 55: ...er to Leak Test on page 77 16 Reinstall cabinet Refer to Removing Cabinet on page 23 FIGURE 13 1 Removing Control Panel Circuit Breaker STEP 9 Hour Meter STEP 9 On Off Switch STEP 9 Mounting Screws Co...

Page 56: ...ecessary 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 u...

Page 57: ...he 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 54 20 Reinstall compressor in...

Page 58: ...ompressor Assembly DETAIL A DETAIL B Fan Terminals Spade Connectors attach here Cooling Fan Rubber Grommet DETAIL C Cooling Fan Rubber Grommets Soundbox DETAIL D NOTE Cooling fan removed from rubber g...

Page 59: ...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 61 1 Un...

Page 60: ...product tank C For concentrators that have O2 sensor Connect the oxygen sensor tubing to regulator fitting 9 Reinstall control panel Refer to Removing Control Panel on page 54 10 Run concentrator to...

Page 61: ...C BOARD Part No 1148070 61 Perfecto 2 FIGURE 15 1 Replacing P C Board Control Panel Mounting Screw P C Board Oxygen Sensor Tubing IRC5PO2 only Pressure Sensor Tubing Mounting Screw Wiring Harnesses C...

Page 62: ...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...

Page 63: ...OTE Ensure proper orientation of the On Off switch and wiring connections before installation Refer to FIGURE 17 1 Detail A and Detail B below CAUTION DO NOT install the On Off I O switch upside down...

Page 64: ...w flowmeter is installed 4 Remove control panel Refer to Removing Control Panel on page 54 5 Remove palnuts that secure flowmeter to the control panel 6 Remove flowmeter from front of control panel 7...

Page 65: ...4 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...

Page 66: ...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 assembl...

Page 67: ...e 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...

Page 68: ...NOTE The Numbers above indicate the MOUNTING SCREW TORQUE SEQUENCE pre torque to 10 2 inch lbs then torque to 22 2 inch lbs Mounting Screws 4 Way Valve Manifold Assembly Manifold Exhaust Tube Tie Wrap...

Page 69: ...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 re...

Page 70: ...oil 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...

Page 71: ...lve Poppets and O Rings Spade Connectors attach here Leave Wire Connectors Intact Pilot Valve Stem Yoke New Label Locknut Coil Pilot Valve Stem Valve Manifold Tapered End O Ring Slotted Poppet NOTE DO...

Page 72: ...2 greater than 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...

Page 73: ...SECTION 21 PURITY INDICATORS Part No 1148070 73 Perfecto 2 FIGURE 21 1 Display Control Panel Auto Shut Down Below Normal Normal Model IRC5P02 Model IRC5P...

Page 74: ...r this procedure refer to FIGURE 22 1 on page 75 1 Turn power off and unplug the unit 2 Remove cabinet Refer to Removing Cabinet on page 23 3 Plug the unit in and turn the power on 4 Locate the P C bo...

Page 75: ...fully 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 specificatio...

Page 76: ...5 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...

Page 77: ...s at 4 way valve DO NOT allow leak test solution to enter into 4 way valve and system 6 With leak test solution or equivalent soapy water leak test the following A The two sieve bed hose connection at...

Page 78: ...Valve Manifold Assembly STEP 6B Sieve Bed Hose Connection At 4 way Valve manifold Assembly STEP 6A 4 Way Valve Manifold Assembly Hose Connections to Bottom Fittings of Sieve Beds STEP 6C Hose Connecti...

Page 79: ...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 indi...

Page 80: ...Function Test 4 Way Valve Check each end cap for cracks and for major leaks You should NOT use leak detector on the valve Use a 0 30 psi pressure gauge to monitor system pressure swings and also recor...

Page 81: ...in and switched on Low Pressure Test NOTE For this procedure refer to FIGURE 24 1 on page 82 1 There are two separate failure modes for Low Pressure Low product tank pressure Pressure in tank drops b...

Page 82: ...gh Pressure Test NOTE For this procedure refer to FIGURE 24 2 on page 83 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...

Page 83: ...ncentration 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...

Page 84: ...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 FIGUR...

Page 85: ...The P E valve coil alarm should activate within 10 seconds 2 Reinstall cabinet Refer to Removing Cabinet on page 23 NOTE If any alarm fails to perform to specification contact Invacare Technical Servi...

Page 86: ...Cabinet on page 23 3 Turn unit so the back faces you 4 It may be necessary to remove compressor inlet HEPA filter Refer to Replacing the Compressor Inlet HEPA Filter on page 26 FIGURE 25 1 Disassembly...

Page 87: ...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 be...

Page 88: ...Canada 800 668 5324 2014 Invacare Corporation All rights reserved Republication duplication or modification in whole or in part is prohibited without prior written permission from Invacare Trademarks...

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