Invacare Perfecto2 V IRC5PO2V 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 IRC5PO2V (Sensored)

Summary of Contents for Perfecto2 V IRC5PO2V

Page 1: ...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 Perfecto2 V Oxygen Concentrator...

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 V PARTS COMPATIBILITY The Plat...

Page 3: ...l Description 13 Operating 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 Fil...

Page 4: ...l Panel 53 SECTION 14 COOLING FAN 55 Replacing Cooling Fan 55 SECTION 15 P C BOARD 58 Replacing P C Board 58 SECTION 16 TRANSFORMER 61 Replacing the Transformer 61 SECTION 17 ON OFF SWITCH 62 Replacin...

Page 5: ...ction Test 78 SECTION 24 ALARM TEST 80 Alarm and Sensor Tests 80 Power Loss Alarm 80 Low Pressure Test 80 Time Out Test 81 High Pressure Test 81 Oxygen Sensor 82 P E Valve Coil Test 84 SECTION 25 SIEV...

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: ...IRCPF16 Accessory Low Flow Alarm 0 L min to 0 5 L min Rapid Audible Alarm Beeping No Accessories Connected Average Power Consumption 325 W Pressure Relief Mechanism Operational at 35 psi 5 psi 241 kPa...

Page 9: ...or similar surfaces Tubing 7 ft cannula with a maximum 50 ft of Crush Proof Tubing DO NOT pinch Relative Humidity 20 to 60 Time of Operation Up to 24 hours per day Recommended Storage and Shipping Te...

Page 10: ...t 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...

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: ...plies 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: ...fore 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 firs...

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...

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: ...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 P...

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: ...or 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 Ref...

Page 20: ...uating 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 compr...

Page 21: ...1 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 elect...

Page 22: ...Flashing GREEN On Internal repairs required Replace SensO2 circuit board Refer to Replacing P C Board on page 58 Low Flow Alarm does not activate on flows less than 0 5 L min System leak Repair leak i...

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: ...age 16 for plugged 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...

Page 25: ...edure refer to FIGURE 6 2 NOTE Perform this procedure as needed 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 easi...

Page 26: ...sor 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 C...

Page 27: ...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...

Page 28: ...moving Cabinet on page 23 FIGURE 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 Throttl...

Page 29: ...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 r...

Page 30: ...R COMES FIRST Check Oxygen Concentration Clean Replace Cabinet Filter s Check Outlet HEPA Filter Check Compressor Inlet Filter Check Power Loss Alarm AS REQUIRED Clean Heat Exchanger Replace Exhaust M...

Page 31: ...r wires from the top of the capacitor Detail A 8 Disconnect brass nut from compressor Detail A 9 On the backside of the Perfecto2V loosen the clamp that secures the vinyl tube to the manifold assembly...

Page 32: ...o 1164934 FIGURE 7 1 Removing Replacing Compressor Assembly Intake Hose Mounting Screws Brass Nut Capacitor DETAIL B DETAIL C Vinyl Tube Clamp Manifold Assembly Mounting Screws Grommets DETAIL A Tie W...

Page 33: ...edlenose 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...

Page 34: ...ound scale for head screws eccentric set screws valve flapper screws and pipe plugs T 25 Torx torque wrench for head screws piston cup seal retainer and connecting rod eccentric Two flat blade screwdr...

Page 35: ...rews NOTE Note placement of the head before removing 3 Carefully remove the compressor head and head seal o ring not shown Valve Plates NOTE For this procedure refer to FIGURE 7 3 NOTE Note the positi...

Page 36: ...oosen the set screw turn 5 Rotate connecting rod to top dead center 180 and slide the connecting rod eccentric assembly off the shaft through the opening in the housing 6 Secure the rod assembly in a...

Page 37: ...emoving Compressor and Compressor Heads Rebuilding the Compressor Bottom Intake Valve Flapper Removal Top Exhaust Valve Flapper Removal NOTE For this procedure refer to FIGURE 7 5 1 Remove valve flapp...

Page 38: ...cedure refer to FIGURE 7 5 on page 37 1 Install the new valve flapper screw square washer and valve flapper NOTE Torque flapper screws to 12 inch lbs Top Exhaust Valve Flapper Installation NOTE For th...

Page 39: ...e access hole tighten set screw to 40 inch lbs Detail A of FIGURE 7 4 5 Hold the cylinder down to the housing with one hand and slowly rotate the eccentric with the other hand to ensure all the compon...

Page 40: ...ompressor Refer to Removing 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 76 3 Take pressure readings...

Page 41: ...etainer 4 Piston Cup Retainer 5 Cylinder 6 Head 7 Head Screw 8 Valve Plate Assembly 9 Valve Flapper Keeper Strip 10 Square Washer 11 Valve Flapper Top Bottom 12 Valve Plate 13 Valve Flapper Screw 14 F...

Page 42: ...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 43: ...rt No 1164934 43 Perfecto2 V 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 44: ...k 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 f...

Page 45: ...Wrap 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 clarity Tie Wrap P E Valve Tubing Tie Wrap...

Page 46: ...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...

Page 47: ...PA Filter on page 26 9 Run units and check for leaks Refer to Leak Test on page 76 10 Reinstall cabinet Refer to Removing Cabinet on page 23 FIGURE 10 1 Replacing Check Valves Tie wrap Check Valves Pr...

Page 48: ...moved NOTE Clean mounting surface of product tank cap Ensure that the two O rings for the NEW regulator are installed onto the ports underside of the NEW regulator before installation WARNING Ensure p...

Page 49: ...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...

Page 50: ...10 Once required pressure is achieved reinstall cabinet Refer to Removing Cabinet on page 23 11 Refer to Troubleshooting on page 16 if you are unable to adjust or maintain five p s i 0 5 p s i NOTE Af...

Page 51: ...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 52: ...EXCHANGER ASSEMBLY Perfecto2 V 52 Part No 1164934 FIGURE 12 1 Replacing Heat Exchanger Assembly Compressor Sound Box Heat Exchanger Assembly DETAIL A DETAIL B Brass Nut Clamp Vinyl Tube Manifold Asse...

Page 53: ...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 54: ...p Refer to Leak Test on page 76 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 Scre...

Page 55: ...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 56: ...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 53 20 Reinstall compressor in...

Page 57: ...Compressor 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...

Page 58: ...n 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 U...

Page 59: ...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 53 10 Run concentrator to...

Page 60: ...C BOARD Perfecto2 V 60 Part No 1164934 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...

Page 61: ...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 transforme...

Page 62: ...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...

Page 63: ...w flowmeter is installed 4 Remove control panel Refer to Removing Control Panel on page 53 5 Remove palnuts that secure flowmeter to the control panel 6 Remove flowmeter from front of control panel 7...

Page 64: ...53 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 65: ...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 assemb...

Page 66: ...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 67: ...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 Wra...

Page 68: ...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 69: ...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...

Page 70: ...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 71: ...rity 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 indicato...

Page 72: ...SECTION 21 PURITY INDICATORS Perfecto2 V 72 Part No 1164934 FIGURE 21 1 Display Control Panel Auto Shut Down Below Normal Normal Model IRC5P02V...

Page 73: ...or this procedure refer to FIGURE 22 1 on page 74 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 b...

Page 74: ...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 specificati...

Page 75: ...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 76: ...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 a...

Page 77: ...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 Connect...

Page 78: ...e 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 ind...

Page 79: ...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 80: ...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 b...

Page 81: ...Time Out Test 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...

Page 82: ...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...

Page 83: ...en 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 2...

Page 84: ...e coil alarm should activate within 10 seconds 2 Replace YELLOW wire and reinstall cabinet Refer to Removing Cabinet on page 23 NOTE If any alarm fails to perform to specification contact Invacare Tec...

Page 85: ...SECTION 24 ALARM TEST Part No 1164934 85 Perfecto2 V FIGURE 24 1 Alarm Diagnostic Label...

Page 86: ...Turn power off and unplug unit 2 Turn unit so the rear of the unit is facing you FIGURE 25 1 Post Pressure Check Pressure Testing NOTE For this procedure refer to FIGURE 25 2 on page 87 1 Connect pre...

Page 87: ...hift 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...

Page 88: ...ssissauga Ontario L4Z 4G4 Canada 800 668 5324 2010 Invacare Corporation All rights reserved Republication duplication or modification in whole or in part is prohibited without prior written permission...

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