Invacare Perfecto 2 SeriesIRC5PO2AW 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.eu.com

Perfecto

™

Series

Oxygen Concentrator

(HomeFill

Compatible)

Model IRC5PO2AW

Model IRC5PO2VAW

0120

Summary of Contents for Perfecto 2 SeriesIRC5PO2AW

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 eu com Perfecto2 Series Oxygen Concentrator HomeFill Compatible Model IRC5PO2AW Model IRC5PO2VAW 0120 ...

Page 2: ...n 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 Platinum concentrator and the Perfecto2 Series concentrator share many similar components However there are some components that are NOT cross compatible and they are specific to each model Parts that can b...

Page 3: ...VENTIVE MAINTENANCE 24 Cleaning the Cabinet Filter 24 Replacing the Outlet HEPA Filter 25 Check the Outlet HEPA Filter 25 Replace the Outlet HEPA Filter 25 Replacing the Compressor Inlet HEPA Filter 26 Replacing the Muffler Assembly 26 Cleaning the Heat Exchanger 29 SECTION 7 COMPRESSOR 31 Replacing Compressor Assembly 31 Replacing Capacitor 33 Rebuilding the Thomas Model 2660 Compressor 34 Removi...

Page 4: ...WMETER 70 Replacing Flowmeter 70 SECTION 19 HOUR METER 71 Replacing Hour Meter 71 SECTION 20 4 WAY VALVE MANIFOLD ASSEMBLY 72 Replacing 4 Way Valve and or Manifold Assembly 72 Replacing Pilot Valve Poppets and O Rings 75 SECTION 21 PURITY INDICATORS 78 SensO2 Alarm Indicators 78 Operation 78 IRC5PO2AW IRC5PO2VAW Indicator Lights Explanation 78 SECTION 22 TIMING 80 Autotuning 80 SECTION 23 LEAK TES...

Page 5: ...RE CHECK 91 Checking Sieve Bed Pressure Model IRC5PO2AW Only 91 Disassembly 91 Pressure Testing 91 Checking Sieve Bed Pressure Model IRC5PO2VAW Only 93 Disassembly 93 Installation 93 Pressure Testing 94 After Testing 94 CUSTOMER SERVICE AND WARRANTY INFORMATION 95 ...

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 oxy gen enriched air Failure to observe this warning can result in severe fire property damage and cause physical injury or death SIGNAL WORD MEANING DANGER Danger indicates an imminently hazardous situation ...

Page 7: ...e oxygen compressor IOH200AW NOTE This outlet fitting is to be used only for filling oxygen cylinders with the HomeFill home oxygen compressor The outlet fitting does not affect concentrator performance Refer to the HomeFill owner s manual part number 1145804 Northern 1145805 Southern 1145806 Scandinavian for connection and operating instructions When not in use the plug provided with the concentr...

Page 8: ...g alert this alert is deactivated when acces sories are connected May be associated with a flow setting of 0 5 L min or less Power Consumption Perfecto2 AW 300 W 5 L min 280 W 3L min Perfecto2 VAW 320 W 5 L min Pressure Relief Mechanism Operational at 241 kPa 24 1 kPa 35 psi 3 5 psi Change in maximum recommended flow when back pressure of 7kPa is applied 0 7 L min Filters Cabinet Outlet HEPA and C...

Page 9: ...ing DO NOT pinch Relative Humidity 20 to 60 Time of Operation Up to 24 hours per day Recommended Storage and Shipping Temperature 29 C to 65 C 20 F to 150 F at 15 95 relative humidity Environment Smoke and soot free No confined spaces Example No closets Standards and Regulatory Listing IEC EN61000 3 2 IEC EN61000 3 3 IEC EN 60601 1 A1 A2 IEC EN 60601 1 2 ISO8359 MDD 93 42 EEC Annex I and IX CE mar...

Page 10: ...may occur if oil grease or greasy substances come in contact with oxygen under pressure These substances MUST be kept away from the oxygen concentrator tubing and connections and all other oxygen equipment DO NOT use any lubricants unless recommended by Invacare Operating Information For optimum performance Invacare recommends that each concentrator be on and running for a minimum of 30 minutes at...

Page 11: ...e above standards To determine if the emissions from the concentrator is causing the interference turn the concentrator Off If the interference with the other device s stops then the concentrator is causing the interference In such rare cases interference may be reduced or corrected by one of the following measures Reposition relocate or increase the separation between the equipment Connect the eq...

Page 12: ...ies 230 VAC to the compressor motor hour meter transformer cooling fan and the printed circuit P C board Room air enters the compressor via the cabinet filter and the compressor inlet filter The air is compressed by the WOB L pistons in the compressor to a pressure of 144 79 kPa 21 psi As increased pressure creates increased temperature a heat exchanger is used to lower the temperature before the ...

Page 13: ...ced 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 oxyge...

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 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 r...

Page 15: ...tput 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 Bed Sieve Bed P E Valve 4 way Valve Compressor Relief Valve Heat Solenoid Pilot Exhaust Muffler LEGEND Pneumatic Connections Electrical Connections ...

Page 16: ...tension cords Move to another outlet or circuit Power cord a Frayed b Broken or damaged spade c Spade connector from power cord loose or disconnected inside back of unit a Reattach cord b Replace power cord connectors on plug c Reattach connector On Off switch a Disconnected wire b Faulty switch Check all electrical connections to the ON OFF switch for any disconnected wires If the concentrator do...

Page 17: ... Replacing P C Board on page 65 High Pressure Internal Status Indicators RED One Flash GREEN Two Flashes Unit plugged in power switch on continuous alarm Compressor shut down P C board a Malfunction b Disconnected wire c Shifting valve at pressures greater than 25 p s i for Perfecto2 a Set flow to max L min for concentrator Check voltage across Pilot Valve 1 on volt DC scale If meter reads 0 volts...

Page 18: ...k voltage at P E valve connector on 24 volt D C scale The P E Valve activates or energizes approximately one second prior to the activation of the 4 way valve with approximately 24 volts If voltage is in excess of 24 volts consistently replace the P C board Refer to Replacing P C Board on page 65 If the P C board voltage acts normally replace the P E valve Refer to Replacing P E Valve on page 49 N...

Page 19: ...ief valve h Insufficient voltage outlet a Replace compressor Refer to Replacing Compressor Assembly on page 31 b Replace capacitor Refer to Replacing Capacitor on page 33 c Replace compressor d Rebuild top end of compressor Refer to Rebuilding the Thomas Model 2660 Compressor on page 34 e Replace compressor f Replace fittings or tubing g Replace relief valve h DO NOT use extension cords Heat excha...

Page 20: ... outlet Adjust regulator b If flow is still unstable check for leaks starting at the compressor outlet fitting through all pneumatic connections If no leaks are found and flow is still fluctuating replace the regulator If pressure at test point is within spec 5 p s i 0 5 max 34 4 kPa 6 89 replace flowmeter Refer to Replacing Flowmeter on page 70 Outlet HEPA filter a Dirty or plugged a If low flow ...

Page 21: ... on page 58 Compressor a Defective b Faulty capacitor c Bad motor windings d Worn seals e Bad bearings a Replace compressor Refer to Replacing Compressor Assembly on page 31 b Replace capacitor Refer to Replacing Capacitor on page 33 c Replace compressor d Replace compressor e Replace compressor Line voltage excessive surge Have line voltage inspected by certified electrician A voltage regulator m...

Page 22: ...y Refer to Replacing the Transformer on page 68 Unit Operating Internal Status Indicators RED Three Flashes GREEN One Flash Control Panel Indicators RED Off YELLOW Flashing GREEN On Internal repairs required Replace SensO2 circuit board Refer to Replacing P C Board on page 65 Potential Obstruction Alert does not activate on flows less than 0 5 L min System leak Repair leak in product tank regulato...

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 vacuum inside of the cabinet and exposed foam insulation 4 To re install cabinet reverse STEPS 2 3 L FIGURE 5 1 Removing Cabinet Cabinet Assembly Mounting Screws Base Assembly Mounting Screws ...

Page 24: ...vels maintenance may need to be performed more often Refer to Troubleshooting on page 16 for plugged filter symptoms and to Preventive Maintenance Record on page 30 Cleaning the Cabinet Filter NOTE For this procedure refer to FIGURE 6 1 on page 25 NOTE There is one cabinet filter located on the back of the cabinet 1 Remove the filter and clean as needed NOTE Environmental conditions that may requi...

Page 25: ...on page 16 Replace 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 Unplug the unit 2 Remove the cabinet Refer to Removing Cabinet on page 23 3 For easier access to the outlet HEPA filter remove the compressor inlet HEPA filter by grasping the compress...

Page 26: ...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 FIGURE 6 3 Replacing the Compressor Inlet HEPA Filter Rep...

Page 27: ...URE 6 4 Replacing the Muffler Assembly 6 Push the muffler assembly down through the opening in the sound box 7 Cut the two tie wraps around the muffler assembly 8 Separate the muffler assembly 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 muffle...

Page 28: ... 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 Wrap Exhaust Canister 8 Tie Wrap Exhaust Muffler Grommet Muffler Body Tie Wraps ...

Page 29: ...t before servicing NOTE For this procedure refer to FIGURE 6 6 on page 29 1 Unplug unit 2 Remove cabinet Refer to Removing Cabinet on page 23 CAUTION Use care not to deform heat exchanger when installing removing or cleaning 3 Remove excess dirt using compressed air or vacuum 4 Reinstall cabinet Refer to Cabinet on page 23 FIGURE 6 6 Cleaning the Heat Exchanger Heat Exchanger ...

Page 30: ...s Check Prescribed L min Flow Rate Check Oxygen Concentration Clean Replace Cabinet Filter s Check Outlet HEPA Filter Check Compressor Inlet Filter Check Power Loss Alarm NOTE Refer to Preventive Maintenance section of Service Manual NOTE 26 280 hours are equivalent to usage 24 hours per day 7 days per week for 3 years UNITS WITH SensO 2 ON EACH INSPECTION DURING PREVENTIVE MAINTENANCE SCHEDULE OR...

Page 31: ...or 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 concentrator 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 concentrator pull heat exchanger with vinyl tube out of base assembly Det...

Page 32: ...245 FIGURE 7 1 Replacing Compressor Assembly Intake Hose Mounting Screws Brass Nut Capacitor DETAIL B DETAIL C DETAIL D Compressor Mounting Screws Grommets DETAIL A Tie Wrap Compressor Capacitor Wires attach here Clamp Vinyl Tube Manifold Assembly ...

Page 33: ...se 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 7 Re install the cabinet Refer to Removing Cabinet on page 23 FIGURE 7 2 Replacing Capacitor Capacitor Capacitor Terminals Spade Connectors connect here T...

Page 34: ...ew 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 s...

Page 35: ... head screws 3 Note head placement before removing compressor head plate 4 Remove the compressor head plate Valve Plates NOTE For this procedure refer to FIGURE 7 3 1 Note the position of the plates before removing 2 Lift off the valve plate on one side 3 Repeat for the other side NOTE Note the position of the tab on valve plate for reassembly NOTE To avoid confusion ONLY service one end of the co...

Page 36: ...nd 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 c...

Page 37: ...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 the plate with a clean soft cloth Gasket NOTE For this procedure refer to FIGURE 7 6 1 Remove the old gasket from the top of the valve plate and discard 2 Clean the valve plate with a clean soft cloth ...

Page 38: ...r 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 UP 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 1 36 N M 12 inch lbs Piston Cup NOTE For this procedure...

Page 39: ...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 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 i...

Page 40: ...on 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 1 Reinstall compressor Refer to Replacing Compressor Assembly on page 31 2 Run unit and check for leaks around compressor hoses and compressor tubes Refer to Leak Test on page 82 3 Take pressure reading...

Page 41: ...iston 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 Keeper Strip 12 Valve Flapper Intake Exhaust 13 Valve Plate 14 Screw Valve Flapper 15 O Ring Valve Plate 16 Fan Gray 17 Fan Black NOTE Compressor is shown assembled Compressor parts are shown exploded along direction of arrows ...

Page 42: ...h with Newton Meter scale Torx T 25 drive for torque wrench Two Flat head screwdrivers Rubber Mallet Phillips screwdriver attachment for torque wrench Disassembly Compressor 1 Unplug the concentrator and carefully remove compressor from concentrator Refer to Replacing Compressor Assembly on page 31 Compressor Head and Valve Plates NOTE For this procedure refer to FIGURE 7 8 DESCRIPTION QUANTITY Cy...

Page 43: ...screws from compressor head 3 Remove compressor head and head seal o rings 4 Remove both valve plates and valve plate o rings 5 Using two flat head screw drivers remove fan from motor shaft by gently prying under the center housing CAUTION DO NOT pry under the fan blades otherwise damage may occur Head Screws Compressor Head Head Seal O ring not shown Valve Plate Valve Plate O ring Compressor Fan ...

Page 44: ...r reinforced washer valve flapper keepers and valve flapper 2 From the bottom of valve plate remove and discard the valve plate screw square washer and valve flapper 3 Clean the top and bottom of the valve plate with a clean soft cloth Valve Plate Valve Plate Screw Square Washer Reinforced Washer Valve Flapper Keeper Strip Metal Valve Flapper Valve Flapper Square Washer Valve Plate Screw Valve Fla...

Page 45: ...wn located in the back of the compressor housing 4 Loosen the set screw 1 4 turn 5 Rotate the connecting rod to top dead center 180 and slide the connecting rod eccentric and bearing assembly off the shaft through the opening in the compressor housing 6 Secure the connecting rod eccentric and bearing assembly in a fixture 7 Remove the torque screw from the piston cup retainer keep for assembly 8 R...

Page 46: ...ew hole 4 Secure piston cup retainer using torque screw Tighten torque screw to 4 0 N M 35 4 inch lbs 5 With gloved hand or clean cloth pre form cylinder if necessary 6 Gently slide cylinder up and over piston cup seal to fully form it 7 With bearing side of connecting rod eccentric and bearing assembly facing the center motor of the compressor slide the assembly onto the compressor shaft bringing...

Page 47: ...cross pattern to 4 0 N M 35 4 inch lbs WARNING Risk of Injury or 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 don t feel suction or the fan does not turn freely DO NOT connect the unit to a power source R...

Page 48: ... Piston Cup Seal 3 Torque Screw 4 Piston Cup Retainer 5 Cylinder 6 Head 7 Head Screw 8 Valve Plate Assembly 9 Valve Flapper Screw 10 Square Washer 11 Reinforced Washer 12 Valve Flapper Keeper Strip Metal 13 Valve Flapper Keeper Strip Plastic 14 Valve Flapper Top 15 Valve Plate 16 Valve Plate O Ring round 17 Valve Flapper Bottom 18 Head Seal O Ring 19 Fan ...

Page 49: ... 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 8 Reinstall the compressor inlet HEPA filter Refer to Replacing the Compressor Inlet HEPA Filter on page 26 NOTE Retiming of the concentrator ...

Page 50: ...rfecto2 50 Part No 1154245 FIGURE 8 1 Replacing P E Valve OUT 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 Attach Here are not shown ...

Page 51: ...eck 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 contaminati...

Page 52: ...raps are located HERE Check Valve Tubing P E Valve Tubing Sieve Bed Tie Wraps P E Valve Assembly Reinforced Tubing attaches HERE not shown NOTE Compressor Inlet HEPA Filter removed from illustration for clarity Tie Wraps are located HERE Check Valve Tubing P E Valve Tubing Sieve Bed Tie Wraps Clamp ...

Page 53: ...ING 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...

Page 54: ... Run units and check for leaks Refer to Leak Test on page 82 11 Reinstall cabinet Refer to Removing Cabinet on page 23 FIGURE 10 1 Replacing Check Valves Tie wrap Check Valve Product Tank Location of Product Tank Check Valve Regulator Outlet Tubing Flow Arrow Upper Inlet Tubing Connect to barb on sieve bed Regulator Lower Inlet Tubing Connect to product tank ...

Page 55: ... O rings are removed 6 Clean 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 Note flow arrow on regulator This MUST face toward the regulator outlet tubing or flow will be interrupted causing system shutdown 8 Install new regulator onto product tank...

Page 56: ... inch Allen Wrench Pressure Regulator Top Pressure Regulator 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 concentrators and before 09 01 12 for non sensored concentrators DETAIL A REGULATORS AFTER 07 01 12 SENSORED AND 09 01 12 NON SENSORED ...

Page 57: ...ne 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 12 Non Sensored Insert a 3 32 2 5 mm Allen wrench into the pressure adjustment screw 8 While reading pressure gauge do one of the following Turn pressure adjustment screw clockwise to increase output pres...

Page 58: ...move 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 the compressor Detail A 4 On the backside of the concentrator loosen the clamp that secures the vinyl tube to the manifold assembly and remove the vinyl tube from the manifold assembly Detail B 5 Remo...

Page 59: ...AT EXCHANGER ASSEMBLY Part No 1154245 59 Perfecto2 FIGURE 12 1 Replacing Heat Exchanger Assembly Sound Box Heat Exchanger Assembly Compressor DETAIL A DETAIL B Brass Nut Clamp Vinyl Tube Manifold Assembly Sound Box ...

Page 60: ...s Tie wraps Ground strap cuff 1 Unplug unit 2 Remove cabinet Refer to Cabinet on page 23 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 inch I D tubing from the top and botto...

Page 61: ... control panel by reversing STEPS 3 12 15 Run unit and check for leaks at pressure sensor tubing on product tank cap Refer to Leak Test on page 82 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 Control Panel DETAIL A Tie Wrap Tie Wrap Control Panel DETAIL B inch Tubing STEP 6...

Page 62: ...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 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...

Page 63: ...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 60 20 Reinstall compressor inlet HEPA filter Refer to Replacing the Compressor Inlet HEPA Filter on page 26 21 Plug unit in and check for leaks Refer to Leak Test on page 82 22 Run unit for at least 30 minutes If unit runs proper...

Page 64: ...ETAIL 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 grommets to show proper installation of grommets in soundbox Cooling Fan Rubber Grommets Soundbox Larger recessed area to be installed in fan Smaller recessed area to be installed in soundbox Back View Side View Compressor Assembl...

Page 65: ...d with other hand 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 67 1 Unplug unit 2 Remove cabinet Refer to Removing Cabinet on page 23 3 Remove control panel Refer to Removing Control Panel on page 60 4 Do the following A Disconnect wiring harnesses from PC board WAR...

Page 66: ...o 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 60 10 Run concentrator to ensure unit operates to specifications 11 After replacing P C board retiming may be necessary Refer to Timing on page 80 12 Check for leaks at pressure sensor tubing on product tank cap Refer to Leak...

Page 67: ...ION 15 P C BOARD Part No 1154245 67 Perfecto2 FIGURE 15 1 Replacing P C Board Control Panel Mounting Screw P C Board Oxygen Sensor Tubing Pressure Sensor Tubing Mounting Screw Wiring Harnesses Connect Here ...

Page 68: ...r 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 ...

Page 69: ...NOTE 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 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 Of...

Page 70: ...flowmeter is installed 4 Remove control panel Refer to Removing Control Panel on page 60 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 8 Reinstall control panel Refer to Removing Control Panel on page 60 9 Run unit and check for leaks where 1 4 inch tubing engages flowmeter barbed fittings Refe...

Page 71: ...move 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 8 Reinstall control panel Refer to Removing Control Panel on page 60 9 Reinstall cabinet Refer to Removing Cabine...

Page 72: ... 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 v...

Page 73: ...nectors 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 va...

Page 74: ...s above indicate the mounting screw torque sequence pre torque to 1 1 N M 0 2 N M 10 2 inch lbs then torque to 2 5 N M 0 2 N M 22 2 inch lbs Mounting Screws 4 Way Valve Manifold Assembly Manifold Exhaust Tube Tie Wrap F Tube 4 Way Valve Manifold Assembly Tie Wrap Tie Wrap Clamp Vinyl Tube Clamp Vinyl Tube DETAIL A DETAIL B 4 Way Valve Manifold Assembly ...

Page 75: ... 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 pl...

Page 76: ...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 2 26 34 N M 20 inch lbs 3 inch lbs CAUTION DO NOT overtighten locknut when installing it onto pilot valve...

Page 77: ...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 NOT disassemble Air Flow Passage Manifold Opening O Ring DETAIL A Valve Assembled View Exploded View ...

Page 78: ...the O2 purity to reach maximum When the unit is turned on the GREEN light will come on SYSTEM OK O2 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 functions are listed below IRC5PO2AW IRC5PO2VAW Indicator Lights Explanation NOTE Indicator lights are...

Page 79: ...SECTION 21 PURITY INDICATORS Part No 1154245 79 Perfecto2 FIGURE 21 1 Display Control Panel Auto Shut Down Below Normal Normal ...

Page 80: ... to FIGURE 22 1 on page 81 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 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 performe...

Page 81: ...sfully 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 FIGURE 22 1 Autotuning Autotune Push Button Switch P C Board NOTE PC board i...

Page 82: ...es 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 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 c...

Page 83: ... 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 Connections to Top Fittings of Sieve Beds STEP 6C Sieve Bed P E Valve Hose Connections STEP 6D P E Valve Hose Connections STEP 6D Product Cap Tank Check all hoses valves attached Check Valves DETAIL B DETAIL...

Page 84: ...icative 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 ...

Page 85: ...SECTION 23 LEAK TEST Part No 1154245 85 Perfecto2 FIGURE 23 2 4 Way Valve Function Test 4 Way Valve Check each end cap for cracks and for major leaks You should NOT use leak detector on the valve ...

Page 86: ...Low Pressure Test NOTE For this procedure refer to FIGURE 24 1 on page 87 1 There are two separate failure modes for Low Pressure Low product tank pressure Pressure in tank drops below a preset value typically 48 26 kPa 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 swit...

Page 87: ...Test High Pressure Test NOTE For this procedure refer to FIGURE 24 2 on page 88 High Pressure Occurs when pressure in product tank rises beyond a preset value typically 158 58 kPa 6 89 kPa 23 p s i 1 p s i 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 ...

Page 88: ...oncentration 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 O2 level 3 With the O2 level greater than 85 after five minutes the GREEN panel indicator light will remain illuminated In Line Connector Location of In Line Connector I ...

Page 89: ...g 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 FIGURE 24 3 Oxygen Sensor SENSO2 ALARM THRESHOLD LABEL SYMBOL STATUS INDICATOR LIGHTS SYSTEM OKAY O2 over 85 GREEN Indicator Light O2 Between 73 to 85 YELLOW Indicator light A YELLOW Solid B YELLOW Flashi...

Page 90: ...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 Service NOTE If problems arise during test contact Invacare Technical Service for further assistance FIGURE 24 4 P E Valve Coil Test Use the chart in Preventive Maintenance on page 24 to record date and nu...

Page 91: ...nplug unit 2 Remove cabinet Refer to Removing 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 Pressure Testing NOTE For this procedure refer to FIGURE 25 2 on page 92 1 Connect pressure gauge to the x 2 inch silicone tubing with connector p n 1131...

Page 92: ...he opposite sieve bed NOTE After the 4 way valve shift the pressure in the concentrator will drop to 82 74 13 79 12 p s i g 2 p s i g before rising within 20 seconds to 144 79 kpa 2 07 kPa 21 p s i g 0 3 and shift the 4 way valve to the opposite sieve bed 8 If pressure reading is 144 79 kpa 2 07 kPa 21 p s i g 0 3 p s i g when both valve shifts are made proceed to STEP 10 9 If pressure in the conc...

Page 93: ...t so the product tank faces you 4 Remove tie wrap from the end of the 1 8 pressure sensor hose that connects to the product tank 5 Remove pressure sensor hose from product tank Installation 1 Insert T fitting into the end of the pressure sensor hose that was connected to the product tank cap 2 Attach a piece of 1 8 tubing to the opposite leg of the T fitting 3 Connect the T fitting assembly to pro...

Page 94: ...e 4 way valve to the opposite sieve bed After the 4 way valve shifts the pressure in the concentrator will drop to 14 PSIG 2 before rising to 21 PSIG 3 and shifting the 4 way valve to the opposite sieve bed 5 If pressure reading is 21 PSIG 3 when the valve shifts are made proceed to STEP 6 NOTE If concentrator pressure DOES NOT fall into the specifications listed above Refer to Troubleshooting on ...

Page 95: ... Unit 5 Seatown Business Campus Seatown Road Swords County Dublin Ireland Tel 353 1 810 7084 Fax 353 1 810 7085 ireland invacare com www invacare ie Italia Invacare Mecc San s r l Via dei Pini 62 I 36016 Thiene VI Tel 39 0445 38 00 59 Fax 39 0445 38 00 34 italia invacare com www invacare it Nederland Invacare BV Celsiusstraat 46 NL 6716 BZ Ede Tel 31 0 318 695 757 Fax 31 0 318 695 758 nederland in...

Page 96: ...62586180 Fax 86 512 62586167 2014 Invacare Corporation All rights reserved Republication duplication or modification in whole or in part is prohibited without prior written permission from Invacare Trademarks are identified by and All trademarks are owned by or licensed to Invacare Corporation or its subsidiaries unless otherwise noted Teflon is a registered trademark of DuPont Corp Torx is a regi...

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Invacare Perfecto 2 SeriesIRC5PO2AW, Service Manual

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