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Respironics Millennium Enhanced M600 Service And Technical Reference Manual Download Page 220

E

NHANCED

 M600/605; E

NHANCED

 M10600/M10605 R

EPAIR

 & R

EPLACEMENT

 - P

AGE

 13

1041897, R

EV

. 00

M

ILLENNIUM

 S

ERVICE

 & T

ECHNICAL

 I

NFORMATION

M

AIN

 PCB F

USE

 R

EPLACEMENT

To remove the Fuse 

1. Remove the Rear Cabinet.  Refer to the Rear Cabinet Replacement Section.  
2. Slide the Front Cabinet forward until it is clear from the Base Cabinet. 
3. Using a fuse extractor, remove the fuse from its receptacle on the Main PCB.  

F

IGURE

 M: F

USE

 L

OCATION

To install the Fuse 

1. Align the fuse with its receptacle on the Main PCB.
2. Carefully press the fuse into its receptacle until completely seated.  

Summary of Contents for Millennium Enhanced M600

Page 1: ...Millennium TM Oxygen Concentrators Service Technical Information ...

Page 2: ...COPYRIGHT WARRANTY PAGE 1 1041826 REV 00 MILLENNIUM SERVICE TECHNICAL INFORMATION 2007 Respironics Inc and affiliates All rights reserved ...

Page 3: ...y for economic loss loss of profits overhead or consequential damages which may be claimed to arise from any sale or use of this product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty is given in lieu of all other express or implied warranties including the implied warranties of mer...

Page 4: ...41905 00 5 5 2007 Initial Revision Maintenance 1041813 00 5 5 2007 Initial Revision Troubleshooting 1041814 00 5 5 2007 Initial Revision H600 605 Repair Replacement 1041895 00 5 5 2007 Initial Revision M600 605 Repair Replacement 1041896 00 5 5 2007 Initial Revision M10600 M10605 Repair Replacement 1041898 01 5 5 2007 Initial Revision Enhanced M600 M605 M10600 M10605 Repair Replacement 1041897 00 ...

Page 5: ...1041845 REV 01 PAGE 2 REVISION HISTORY MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally blank ...

Page 6: ...FICATIONS 2 M10600 M10605 ENHANCED M10600 M10605 SPECIFICATIONS 4 FRONT CABINET FEATURES 6 REAR AND SIDE CABINET FEATURES 6 CONTROL PANEL FEATURES 7 SYSTEM SETUP SECTION OVERVIEW 1 SYSTEM SETUP 1 THEORY OF OPERATION SECTION OVERVIEW 1 H600 605 M600 605 ENHANCED M600 605 CONCENTRATOR PNEUMATIC OPERATION 1 H600 605 M600 605 ENHANCED M600 605 CONCENTRATOR ELECTRICAL OPERATION 2 M10600 M10605 ENHANCED...

Page 7: ...RFORATED CANOPY REPLACEMENT 31 COMPRESSOR COVER REPLACEMENT 32 MAIN POWER WIRING HARNESS REPLACEMENT 33 MOTOR START RUN CAPACITOR 36 PRESSURE RELIEF VALVE REPLACEMENT 37 COMPRESSOR ASSEMBLY REPLACEMENT 38 IN LINE MUFFLER REPLACEMENT 41 HOUR METER REPLACEMENT 43 VALVE SOLENOID REPLACEMENT 45 PRESSURE REGULATOR REPLACEMENT 47 SIEVE CANISTER ASSEMBLY REPLACEMENT 48 BLOW DOWN MUFFLER REPLACEMENT 50 PO...

Page 8: ...REPAIR REPLACEMENT SECTION OVERVIEW 1 OVERLAY REPLACEMENT 2 CASTER REPLACEMENT 3 BASE CABINET PAN REPLACEMENT 4 REAR CABINET REPLACEMENT 5 FLOW METER REPLACEMENT 7 DISS OUTLET FITTING REPLACEMENT 9 POWER SWITCH REPLACEMENT 11 MAIN PCB FUSE REPLACEMENT 14 MAIN PCB REPLACEMENT 15 OPI WIRING HARNESS REPLACEMENT MODEL M10605 ONLY 17 OPI BOARD REPLACEMENT MODEL M10605 ONLY 18 POWER SWITCH WIRING HARNES...

Page 9: ...MAIN PCB REPLACEMENT 14 OPI PCB REPLACEMENT MODEL 605 ONLY 17 OPI WIRING HARNESS REPLACEMENT MODEL 605 ONLY 19 FRONT CABINET REPLACEMENT 20 COOLING FAN REPLACEMENT 22 MAIN PCB TO COOLING FAN WIRING REPLACEMENT 23 PERFORATED CANOPY REPLACEMENT 24 COMPRESSOR COVER REPLACEMENT 25 MOTOR START RUN CAPACITOR REPLACEMENT 27 COMPRESSOR ASSEMBLY REPLACEMENT 28 MAIN PCB TO COMPRESSOR WIRING REPLACEMENT 31 T...

Page 10: ...LENNIUM SYSTEM FINAL TEST 6 MODEL 605 TEST DATA SHEET 8 MODEL 600 TEST DATA SHEET 9 M10600 M10605 ENHANCED M10600 M10605 TESTING SYSTEM VERIFICATION PROCEDURES 1 MILLENNIUM SYSTEM FINAL TEST 5 MODEL M10605 TEST DATA SHEET 7 MODEL M10600 TEST DATA SHEET 8 TOOLS TEST EQUIPMENT SERVICE TOOLS SUPPLIES 1 ACCEPTABLE TEST EQUIPMENT 2 SCHEMATICS SCHEMATICS STATEMENT 1 ...

Page 11: ...1041909 REV 00 PAGE 6 TABLE OF CONTENTS MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 12: ...essure swing adsorption process TYPES OF CONCENTRATORS MILLENNIUM H600 H605 CONCENTRATORS The Millennium H600 605 Concentrators are equipped with a green cabinet and a fluted Base Cabinet MILLENNIUM M600 M605 M10600 M10605 CONCENTRATORS The Millennium M600 M605 M10600 M10605 Concentrators comes equipped with a grey cabinet a black Base Cabinet and the Hour Meter is located in the Base Cabinet MILL...

Page 13: ...rience servicing oxygen concentrators SERVICE TRAINING Respironics offers service training for the Millennium Concentrators Training includes complete disassembly of the device troubleshooting subassemblies and components and performance testing For more information contact the Service Marketing department at E mail service operations respironics com Phone 724 755 8220 Fax 724 755 8230 SERVICE TEC...

Page 14: ...rcumstances oxygen therapy can be hazardous any user should seek medical advice prior to using this device Where the prescribing physician has determined that an interruption in the supply of oxygen for any reason may have serious consequences to the user an alternate source of oxygen should be available for immediate use Keep the unit away from heat and or open flame as oxygen greatly accelerates...

Page 15: ...id leak detector be careful not to allow it to contact electrical parts Make sure connections of fittings tubing and hoses are secure Be cautious when using thread sealants because they can cause extensive damage to the internal parts of the unit if allowed within tubing or fittings Device operation above or outside of the Voltage LPM Temperature Humidity and or Altitude values specified in the ma...

Page 16: ...IONS FEATURES PAGE 1 1041848 REV 00 MILLENNIUM SERVICE TECHNICAL INFORMATION SPECIFICATIONS FEATURES SECTION OVERVIEW This section identifies the specifications and features of the Millennium Oxygen Concentrator ...

Page 17: ...Concentrator 88 4 5 lpm Oxygen Outlet Pressure No Flow 6 0 1 0 psig Regulated Pressure 5 lpm 5 5 0 25 psig Operating Pressure 70 186 kPa Operating Temperature 55 90 F 13 32 C Storage transport Temperature 30 160 F 34 71 C Storage transport Humidity Operating Humidity Up to 95 non condensing Storage Transport Atmospheric Pressure 790 525 mm Hg Altitude Up to 7 545 ft Up to 2300 m Sound Pressure Lev...

Page 18: ...l LED with intermittent audible alarm and red LED No oxygen flow Oxygen percentage indicator model 605 70 O2 85 M600 605 Enhanced M600 605 Concentrators have a yellow LED with intermittent audible alarm and red LED No oxygen flow Oxygen percentage indicator model 605 70 O2 82 POWER INDICATION Visual green LED next to Power Switch OXYGEN PERCENTAGE INDICATOR MODEL 605 H605 Concentrators Warnings Co...

Page 19: ...ygen Outlet Pressure No Flow 6 0 1 0 psig Regulated Pressure 10 lpm 5 5 0 25 psig Operating Pressure 10 30 psig Operating Temperature 55 90 F 15 32 C Storage transport Temperature 30 160 F 34 71 C Storage Transport Operating Humidity Up to 95 non condensing Storage Transport Atmospheric Pressure 790 525 mm Hg Altitude Up to 1 368 ft Up to 417 m Verify flow and purity at higher altitudes Sound Pres...

Page 20: ... failure and High and low pressure Oxygen percentage indicator M10605 O2 70 ALERT CONDITIONS Concentrators have a have a yellow visual LED with intermittent audible alarm and red LED No oxygen flow Oxygen percentage indicator M10605 70 O2 82 POWER INDICATION Visual green LED below to Power Switch OXYGEN PERCENTAGE INDICATOR MODEL 605 Warnings Conditions Blinking yellow LED after unit is turned on ...

Page 21: ... light the green ON light and the Oxygen percentage Model 605 and M10605 Only HOUR METER ENHANCED M600 605 ENHANCED M10600 M10605 MODEL ONLY Indicates cumulative hours of unit operation REAR AND SIDE CABINET FEATURES SERIAL PLATE Lists model and serial numbers requirements and specifications HOUR METER H600 605 M600 605 M10600 M10605 Indicates cumulative hours of unit operation PRE INLET FILTER Fi...

Page 22: ... units only Model 605 solid green LED with no alarm sound Low Oxygen Alert Condition with Red LED Solid yellow LED with intermittent every 2 seconds audible alarm Alarm Condition Solid red LED and continuous audible Start up Test Light all LED s and sound audible alarm for 2 seconds after power on Warm up Condition OPI units only Model 605 blinking yellow LED with no alarm sound ...

Page 23: ...1041848 REV 00 PAGE 8 SPECIFICATIONS FEATURES MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 24: ...5 Turn on the unit by moving the Power Switch to the ON I position and verify the following all LED s illuminate and audible alarm sounds for two seconds the unit starts running and the green power LED remains illuminated 6 Adjust the Flow Meter to max 5 or 10 lpm depending on the concentrator Turning the Flow Meter clockwise decreases the flow and turning it counter clockwise increases the flow 7...

Page 25: ...1041812 REV 00 PAGE 2 SYSTEM SETUP MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally blank ...

Page 26: ...ceived at Valve Solenoid 8a closing the input and allowing compressed air to continue through sieve bed 9a for 6 25 seconds absorbing the Nitrogen and allowing the Oxygen to flow through check valve 10a and into the product tank 11 At 5 liters of flow approximately 1 3 of the Oxygen is deposited into the product tank and 2 3 is passed through orifice 12 in to sieve bed 9b to purge the Nitrogen fro...

Page 27: ...C power is supplied to the Compressor motor Hour Meter cooling fan and the main circuit board The main circuit board consists of a linear power supply pressure sensor software driven microprocessor green yellow and red LED s and audible alarm The 9 volt battery provides a power source to operate the audible alarm and the red LED alarm light in the event of an AC power failure FIGURE B H600 605 M60...

Page 28: ... to continue through sieve bed 9a for 6 25 seconds absorbing the Nitrogen and allowing the Oxygen to flow through check valve 10a and into the product tank 11 At 5 liters of flow approximately 1 3 of the Oxygen is deposited into the product tank and 2 3 is passed through orifice 12 in to sieve bed 9b to purge the Nitrogen from the sieve bed which exits through the exhaust port of the Valve Solenoi...

Page 29: ... supplied to the Compressor motor Hour Meter cooling fan and the main circuit board The main circuit board consists of a linear power supply pressure sensor software driven microprocessor green yellow and red LED s and audible alarm The 9 volt battery provides a power source to operate the audible alarm and the red LED alarm light in the event of an AC power failure FIGURE D M10600 M10605 ENHANCED...

Page 30: ...pecting and cleaning the Inlet Filter DEALER ANNUAL MAINTENANCE Annual maintenance shall be performed by the Home Care Dealer or at a Respironics service facility Annual maintenance includes the following Checking the condition of the Filters change if necessary Cleaning the cabinet Verifying the oxygen concentration with a calibrated oxygen analyzer This procedure must be performed once a year or...

Page 31: ...onditions and the environment where the unit is used Some signs of poor Compressor performance are low oxygen readings low pressure readings and increased noise level Compressor maintenance shall be performed at intervals commensurate with hospital or home care provider guidelines Compressor Maintenance includes the following A CLEANING THE AIR INLET FILTER 1 Remove the Air Inlet Filter from the s...

Page 32: ...3 Remove the Pre inlet Filter from the Inlet filter FIGURE C FILTER LOCATIONS 4 Wash the foam Pre inlet Filter with a mild detergent and tap water Allow it to air dry completely 5 Inspect the Inlet filter and replace if necessary 6 Place the assembled filters on the filter cover While firmly pressing down on the filter assembly turn the filter assembly clock wise to assure of a tight fit between t...

Page 33: ...ed oxygen is delivered to the patient Check and replace this filter as necessary Procedure 1 Remove the Rear Cabinet CAUTION Do not allow any liquid to enter the unit PART NUMBER H621 Included in Kit Tools Required Micro disk Filter x6 Wire Ties x2 Phillips Screwdriver No 2 Medium w long shaft Diagonals wire cutters WARNING Electrical shock hazard Disconnect the electrical supply before attempting...

Page 34: ... the wire ties that secure the pressure tubing to the Micro disk filter 4 Remove the pressure tubing from the inlet and outlet ports of the Micro disk filter 5 Slide the pressure tubing onto the inlet and outlet ports of the new Micro disk filter 6 Using the wire ties provided secure the pressure tubing to the new Micro disk filter 7 Use the diagonals to cut off the excess from the wire ties ...

Page 35: ... ear x3 Hose 3 8 ID Braided Millennium Screwdriver RI p n H646 Flat blade screwdriver medium T 15 T 20 T 25 Torx bits Included with Millennium screwdriver Torque wrench 30 in lbs RI p n 1033057 One Ear Clamp Pliers RI p n H645 NOTE Respironics requires that all components of the Compressor maintenance kit be used to ensure that the Compressor will function properly after Compressor maintenance has...

Page 36: ...e Front Cabinet Refer to the proper Repair Replacement section for detailed instruc tions 3 Remove the Compressor Cover Perforated Canopy Refer to the proper Repair Replacement section for detailed instructions 4 Remove the four screws securing the filter cover using a T 20 or 7 64 Torx bit FIGURE E SCREW LOCATION 5 Remove and replace the felt filter inside the filter cover FIGURE F FELT FILTER ...

Page 37: ...ERVICE TECHNICAL INFORMATION 6 Remove and replace the O ring on the bottom side of the filter body FIGURE G O RING LOCATION 7 Remove the four screws securing the Compressor head using a T 25 or 1 8 Torx bit FIGURE H COMPRESSOR HEAD SCREW LOCATIONS ...

Page 38: ...NICAL INFORMATION 8 Remove the valve plate and cylinder sleeve FIGURE I REMOVING THE VALVE PLATE AND CYLINDER SLEEVE 9 Separate the cylinder sleeve from the valve plate and discard the sleeve and O ring FIGURE J SEPARATING THE CYLINDER SLEEVE AND VALVE PLATE ...

Page 39: ... K FLAPPER VALVE REMOVAL 11 Remove and replace the gasket on the valve plate 12 Using a T 20 torx bit remove and discard the four screws the piston cup the retainer plate and the cork gasket from the connecting rod assembly NOTE The Valve flappers are located under the keeper strips NOTE A heat gun may be used to loosen the loctite on the screws Valve Keeper Strips Valve Gasket ...

Page 40: ...ERVICE TECHNICAL INFORMATION FIGURE L LOCATION OF THE PISTON CUP RETAINER SCREWS 13 Place the new cork gasket on the connecting rod assembly making sure the cork fits around the pins on the connecting rod assembly FIGURE M INSTALLING THE CORK GASKET ...

Page 41: ...rews provided secure the retainer to the connecting rod assembly and torque screws to 30 in lbs FIGURE N INSTALLING THE PISTON CUP RETAINER 15 Set the new sleeve in place with the O ring away from the piston Slide the sleeve down over the piston cup using your fingers to guide the sleeve without damaging the piston cup FIGURE O INSTALLING THE CYLINDER SLEEVE ...

Page 42: ... the valve plate onto the cylinder sleeve making sure not to pinch the O ring on the cylinder sleeve The valve plate must be positioned properly to ensure proper alignment with the Com pressor head Place the valve gasket in the groove of the valve plate FIGURE Q VALVE GASKET ALIGNMENT HOLES Alignment Holes Valve Gasket ...

Page 43: ... onto the valve plate Using a T 25 Torx bit and a torque wrench tighten the Compressor head bolts to 30 in lbs FIGURE R COMPRESSOR HEAD IN PLACE 18 Place the new Felt filter and the O ring on the Intake filter body 19 Connect the In line Muffler to the bottom of the Compressor head and secure with a clamp ...

Page 44: ...alve Keeper x4 Valve x4 Valve Screw x4 Dynamic Backer x2 Millennium Screwdriver w bits RI p n H646 Cutting Pliers Heat Gun acceptable ranges 200 F thru 900 F 3 8 Drive Hex Bit Holder RI p n 1040446 1 4 Drive Hex bit holder RI p n 1033058 Torque Wrench 18in lbs RI p n 1018495 Torque Wrench 55 in lbs RI p n 1018490 Torque Wrench 100 in lbs RI p n 1024064 Torque Wrench 125 in lbs RI p n 1024062 1 8 A...

Page 45: ...nch 100 in lbs RI p n 1024064 Torque Wrench 125 in lbs RI p n 1024062 1 8 Allen wrench or Hex bit 5 32 Allen Wrench or Hex bit T 25 and T 27 Torx bit Vice Socket wrench Soft cloth One Ear Clamp Pliers RI p n H645 M600 605 230V Enhanced M600 M605 230V NOTE Respironics requires that all components of the Compressor maintenance kit be used to ensure that the Compressor will function properly after Co...

Page 46: ...nopy Refer to the proper Repair Replacement section for detailed instructions 4 Disconnect the exhaust tubing Capacitor wires and input power wiring from the Compressor assembly 5 Using a 1 8 Allen wrench or 1 8 Hex bit remove the four Compressor mounts FIGURE S COMPRESSOR MOUNTS 2 OF 4 SHOWN 6 Lift the Compressor assembly out of the Millennium Base 7 Before disassembly mark the outside corners on...

Page 47: ... flapper screw from the Compressor head side of the valve plate Take note of the cut outs on the flapper The new flapper must be placed in the same fashion during assembly Dis card the old flapper keeper restraint and gasket 11 Clean the plate with a soft cloth Install the new flapper Place the new restraint on top of the flap per The keeper should be placed on top of the restraint so the word UP ...

Page 48: ...lapper cutouts before disassembly Discard the flapper keeper and O ring 15 Clean the plate with a clean cloth 16 Install the new flapper Place the keeper on top of the flapper so that the word UP is visible Tighten the screw to 18 in lbs Install the new O ring 17 Perform this procedure on the second valve plate and set aside the valve plates 18 Remove and discard both cylinder sleeves FIGURE X REM...

Page 49: ...s a reference to ensure proper fan orientation FIGURE Y PROPER FAN ORIENTATION 20 Pull upwards from the center of the fan It may be necessary to rock the fan back and forth while pulling upwards to remove it from the shaft CAUTION Do not attempt to pull up on the outside edges of the fan blades ...

Page 50: ...e 5 32 Allen wrench or hex bit through the access hole and loosen the set screw 1 4 turn Rotate the eccentric to top dead center 180 and slide the connecting rod eccentric assembly off of the shaft FIGURE Z REMOVING THE ECCENTRIC 22 Wrap the neck of the connecting rod assembly with a cloth and secure the assembly in a vice being cautious not to clamp down on the eccentric and or bearings FIGURE AA...

Page 51: ...HE SCREW NOTE Considerable care must be taken while removing the piston cup retainer screw The screw has been tightened to 100 in lbs with Loctite on the threads and may become stripped if not removed properly CAUTION During this procedure parts will become hot Do not touch any parts with your bare hands Use pliers to handle the parts until they have cooled ...

Page 52: ...lace a new piston cup on the back of the cup retainer plate Note the locations of the alignment pin on the back of the plate and the alignment hole on the piston head FIGURE AD REPLACE PISTON CUP 26 Press the plate into the cylinder sleeve being careful not to crimp the piston cup Once the plate is seated on top of the piston rotate the plate until the plate pin seats into the piston alignment hol...

Page 53: ...side face down The marks that were made before disassembly must be aligned Check the valve gaskets for proper alignment 31 Place the Compressor head on top of the plates so that the marks align in the corners Install the head screws and tighten the screws to 55 in lbs 32 Place the Compressor on the mounts in the Base Cabinet Make sure the springs are seated properly 33 Align the holes of the Compr...

Page 54: ...In line Muffler Record at each check Clean and replace as needed Check and perform maintenance as recommended 9V BATTERY 2 OXYGEN CONCENTRATION 2 OPI MOTOR START RUN CAPACITOR Check and replace as needed Check Level Check lights at start up Check and replace as recommended NOTE 1 Patients should be instructed to position the unit so that proper ventilation for the unit is maintained and to clean t...

Page 55: ...1041813 REV 00 PAGE 26 MAINTENANCE MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 56: ...in the tubing Reconnect the tubing Reposition the tubing Replace the tubing Audible and visual alarm Pressure relief valve activating Fuse Fails Open fuse on Main PCB Verify the audible and visual alarm due to battery Replace the fuse Fluctuations in oxygen pressure Fluctuations in flow ball Pressure regulator failure Component failure Verify the flow from regulator is correct Preform Oxygen Outle...

Page 57: ...iring harness is connected to the Main PCB Replace the 9 volt battery Connect the wiring harness Connect the wiring harness Connect the wiring harness Replace the Main PCB LED failure Models 600 and 605 Red LED inoperable Green LED inoperable Yellow LED inoperable No power to LEDs Verify the Power Cord is plugged in Verify the battery voltage is greater than 5 volts Verify that all wiring harnesse...

Page 58: ...ectrical continuity Replace the Main PCB Replace the Main PCB Start up alarms inoperable Piezoelectric speaker failure No audible alarm Verify the wiring harnesses are connected Verify the solder joints are not faulty on the Main PCB Verify there are no component failures on the Main PCB Reconnect the wiring harnesses Replace the Main PCB Replace the OPI PCB Replace the Main PCB No audible or visu...

Page 59: ...ss is connected at the Main PCB and valve Reposition the tubing Replace the damaged tubing Reconnect wire harness Replace the pressure relief valve Low oxygen output Oxygen percentage indicator alarm Model 605 Sieve bed contaminated Low or no oxygen production Verify the oxygen output with an oxygen analyzer Verify the Compressor is working properly Replace the Sieve Canister Rebuild or replace th...

Page 60: ...nnect the wiring harnesses Rebuild the Compressor Replace the Compressor Low pressure alarm Sieve Canister leaking Reduced or no oxygen production Verify there are no loose screws on the Sieve Canister Assembly Verify there are no blown gaskets on the Sieve Canister Assembly Tighten the hardware Replace the Sieve Canister Cooling fan failure Warm cabinet temperature Thermal switch open Verify the ...

Page 61: ...complete the cycle Verify both wiring harnesses to the solenoid are attached Verify both wiring harnesses have continuity Verify there are no faulty solder joints on the Main PCB Verify there are no component failures on the Main PCB Reconnect the wiring harnesses Replace wire harnesses main power Replace the Main PCB Replace the Main PCB Inaccurate oxygen readings Oxygen percentage indicator OPI ...

Page 62: ...rify that all filters are clean Verify that the thermal switch is closing after cooling Reposition the concentrator to an open area Replace all dirty filters Replace the thermal switch Loss of power Low pressure alarm Compressor thermal switch failure Compressor winding temperature allowed to exceed 293 5 F 145 5 C Verify that thermal switch is closing after cooling VerifyCompressor is functioning...

Page 63: ...1041814 REV 00 PAGE 8 TROUBLESHOOTING MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 64: ...ironics for any service that involves sieve material disposal Even with the unit disconnected from the electrical supply the Capacitor may still hold an electrical charge strong enough to cause serious bodily injury DO NOT touch the Capacitor terminals simultaneously until the Capacitor has been completely discharged Discharge the Capacitor by shorting the two posts with an insulated screw driver ...

Page 65: ...lay off of the cabinet 2 Clean any remaining residue from the mounting area To install the Overlay 1 Remove the protective backing from the Overlay 2 Carefully align the Overlay with the mounting area Set the Overlay in place and using a circular motion firmly rub the Overlay until it is securely attached to the cabinet FIGURE A OVERLAY LOCATIONS Control Overlay Instruction Overlay ...

Page 66: ...in place firmly push the Caster into its receptacle until completely seated 3 If more than one Caster is being replaced repeat the procedure for each Caster being replaced 4 Carefully return the unit to the upright position NOTE It may be necessary to insert a medium flat blade screwdriver between the Caster and the molded base to pry the Caster from its receptacle Once the Caster has been partial...

Page 67: ...ENT To remove the Base Cabinet Pan 1 Place the unit on a protected work surface and carefully lay the unit over its Rear Cabinet 2 Remove the six Phillips screws securing the Base Cabinet pan to the Base Cabinet FIGURE C SCREW LOCATIONS 3 Grasp the back edge of the Base Cabinet pan and remove it from the Base Cabinet ...

Page 68: ...net pan so the cut out in the foam insulation aligns with the Blow Down Muf fler FIGURE D LOCATION OF BLOW DOWN MUFFLER AND FOAM CUTOUT 2 Align the Base Cabinet pan with the Base Cabinet and set it into place 3 Insert and gently tighten the six Phillips screws provided to secure the Base Cabinet pan to the Base Cabinet Foam Cutout Blow Down Muffler ...

Page 69: ...crewdriver remove the six screws that secure the Rear Cabinet to the Front Cab inet FIGURE E REAR CABINET SCREW LOCATIONS 2 Grasp the Rear Cabinet firmly then slide it toward the back of the unit until it is clear of the guide slot on the Base Cabinet Once clear of the guide slot the Rear Cabinet can be lifted away from the unit FIGURE F REMOVING THE REAR CABINET ...

Page 70: ...old the Front Cabinet in place while sliding the Rear Cabinet onto the Base Cabinet FIGURE G PROPER ALIGNMENT OF GUIDE SLOTS AND RIDGES 3 Using a Phillips screwdriver install and secure the six mounting screws securing the Rear Cabinet to the Front Cabinet NOTE The Base Cabinet has a guide slot to ensure proper alignment of the Rear and Front Cabinets The Rear and Front Cabinets MUST be properly a...

Page 71: ...net 2 Working from inside the Front Cabinet cut the cable ties then remove the pressure tubing from both fittings on the Flow Meter by pulling the tubing from each fitting FIGURE H REMOVAL OF PRESSURE TUBING FROM FLOW METER NOTE The pressure tubing connected to the top fitting on the Flow Meter is connected to the Bacteria Filter The pressure tubing connected to the bottom fitting is connected to ...

Page 72: ...ENT PAGE 9 1041895 REV 00 MILLENNIUM SERVICE TECHNICAL INFORMATION FIGURE I PRESSURE TUBING CONNECTIONS 3 While holding the Flow Meter in place remove the two speed nuts from the threaded fittings on the back of the Flow Meter ...

Page 73: ...er with the holes in the Front Cabi net 2 While holding the Flow Meter in place install the support speed nuts to secure the Flow Meter to the Front Cabinet Hand tighten the speed nuts 3 Connect the pressure tubing to the fittings on the Flow Meter then secure the tubing with the cable ties provided 4 Turn on the unit and check the flow tube connections for leaks 5 If no leaks are detected Turn of...

Page 74: ...ement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Cut the cable tie then remove the pressure tubing connected to the DISS outlet fitting by pulling it off the fitting FIGURE K REMOVING PRESSURE TUBING FROM DISS FITTING 4 While holding the DISS outlet fitting in place use an 11 16 wrench to loosen the nylon jam nut securing the DISS outlet fitting FIGURE L RE...

Page 75: ...g 1 Align the DISS outlet fitting with the opening in the Front Cabinet Insert the DISS outlet fitting into the opening 2 While holding the DISS outlet fitting in place install the new lock washer and nylon jam nut on the DISS outlet fitting Use an 11 16 wrench to carefully tighten the nylon jam nut 3 Connect the pressure tubing to the DISS outlet fitting Secure the tubing to the fitting with the ...

Page 76: ...rward until it is clear from the Base Cabinet 2 Looking at the back of the Power Switch from inside the Front Cabinet note the position and col ors of the wires connected to the terminals on the Power Switch FIGURE N VIEW OF POWER SWITCH FROM INSIDE THE FRONT CABINET ASSEMBLY CAUTION Except for the two red wires that are interchangeable the wires must be connected to the Power Switch as shown Fail...

Page 77: ...hes push the Power Switch out of the Front Cabinet assembly FIGURE P REMOVING THE POWER SWITCH FROM THE FRONT CABINET ASSEMBLY To install the Power Switch 1 Orient the Power Switch so that the single terminal is at the top Align the Power Switch with the opening in the Front Cabinet assembly Press the Power Switch into the Front Cabinet assembly until all four latches on the Power Switch lock in p...

Page 78: ...efer to the Rear Cabinet Replacement Section Slide the Front Cabi net forward until it is clear from the Base Cabinet 2 Using a fuse extractor remove the fuse from its receptacle on the Main PCB To install the Main PCB Fuse 1 Align the fuse with its receptacle on the Main PCB 2 Carefully press the fuse into its receptacle until completely seated FIGURE Q FUSE LOCATION Fuse ...

Page 79: ...odel 605 units Only Remove the OPI wiring harness connector from the J3 location on the Main PCB assembly by pulling the connector directly up from the J3 receptacle 5 Depress the locking tab then remove the Power Switch wiring harness connector from the J2 location on the Main PCB by pulling the connector directly up from the J2 receptacle 6 Using a Phillips screwdriver remove the four screws sec...

Page 80: ...he J2 receptacle on the Main PCB assembly Carefully press the connector onto the receptacle until completely seated 4 For Model 605 units Only Align the connector on the short OPI wiring harness with the J3 recep tacle on the Main PCB assembly Carefully press the connector onto the receptacle until com pletely seated 5 Align the connector on the main power wiring harness with the J1 receptacle on ...

Page 81: ...ess connector from the J7 location on the OPI board by pulling the connector directly up from the J7 receptacle FIGURE T OPI WIRING HARNESS To install the OPI Wiring Harness 1 Align the connector on the OPI board wiring harness with the J7 receptacle on the OPI board Carefully press the connector onto the receptacle until completely seated 2 Align the connector on the OPI wiring harness with the J...

Page 82: ...pulling the connector directly up from the J7 receptacle 3 While holding the oxygen sensor remove the pressure tubing from the sensor by carefully prying the tubing off both oxygen sensor fittings 4 Using a Phillips screwdriver remove the four screws securing the OPI board to the Front Cabinet FIGURE U CONNECTIONS AND MOUNTING SCREW LOCATIONS NOTE The pressure tubing from the Flow Meter is connect...

Page 83: ...ed to secure the OPI board to the Front Cabinet 3 While holding the oxygen sensor install the pressure tubing on the oxygen sensor by carefully pushing the tubing onto the oxygen sensor fittings 4 Align the connector on the OPI wiring harness with the J7 receptacle on the OPI board Carefully press the connector onto the receptacle until completely seated NOTE Once the unit is reassembled verify th...

Page 84: ...et Refer to the Rear Cabinet Replacement Section Slide the Front Cabi net forward until it is clear from the Base Cabinet 2 While firmly pushing the locking tabs inward separate the Power Switch wiring harness from the Main Power Wiring Harness FIGURE W LOCATION OF THE CONNECTOR 3 Remove the female connector from the J2 location on Main PCB FIGURE X MAIN PCB J2 AND POWER SWITCH LOCATIONS Connector...

Page 85: ... Switch Wiring Harness 1 Either feed the Power Switch wiring harness through the original screw down cable ties or if new screw down cable ties are available loosely install four cable ties grouping the Power Switch wir ing harness the O2 solenoid battery wiring harness and the clear and yellow pressure tubing together 2 Install the connectors onto the proper terminals of the Power Switch Ensure t...

Page 86: ...MATION 3 Install the female connector onto the J2 location on the Main PCB 4 Position the screw down cable ties at their mounting posts then secure each using the original screws Tighten the screw down cable ties 5 Connect the Power Switch wiring harness to the main power wiring harness ...

Page 87: ...Front Cabi net forward until it is clear from the Base Cabinet 2 Remove the battery connector from the battery 3 Remove the two connectors from the Valve Solenoid Assembly FIGURE Z VALVE SOLENOID CONNECTIONS 4 Remove the yellow pressure tubing from the top of the Sieve Canister 5 Remove the pressure tubing from the pressure regulator assembly 6 Remove the two red wires connected to the Power Switc...

Page 88: ...he screws that secure the screw down cable ties to the Front Cabinet 9 Either feed the O2 solenoid battery wiring harness through the screw down cable ties or if new screw down cable ties are available cut the cable ties and remove the O2 solenoid battery wiring harness 10 Note the location at which the battery wires exit the large convoluted tubing Cut the cable ties and remove the O2 solenoid ba...

Page 89: ...ouping the O2 solenoid battery wiring harness Power Switch wiring harness along with the clear and yellow pressure tub ing together 3 Install the O2 solenoid battery wiring harness connector onto the J1 location on the Main PCB 4 Install the two red wires from the O2 solenoid battery wiring harness to the Power Switch 5 Position the screw down cable ties at their mounting posts then secure each us...

Page 90: ...t Section 9 Remove the OPI board Refer to the OPI Board Replacement Model H605 Only Section To install the Front Cabinet 1 Remove the protective backing from the control Overlay Carefully aligning the Overlay apply it to the Front Cabinet 2 Position the Front Cabinet face down on a protected work surface that will not damage the Front Cabinet 3 Install the OPI Board Refer to the OPI Board Replacem...

Page 91: ...41895 REV 00 PAGE 28 H600 H605 REPAIR REPLACEMENT MILLENNIUM SERVICE TECHNICAL INFORMATION 12 Install the Rear Cabinet Refer to the Rear Cabinet Replacement Section FIGURE AB REAR CABINET SCREW LOCATIONS ...

Page 92: ...l it is clear from the Base Cabinet 3 Remove the two wires from the terminals located on the side of the cooling fan 4 Using a small thin shaft Phillips screwdriver remove the four screws securing the cooling fan to the Compressor Cover FIGURE AC WIRE AND SCREW LOCATIONS 5 While holding the Compressor Cover in place lift the fan up and away from the Compressor Cover FIGURE AD REMOVING FAN FROM COM...

Page 93: ...t then tighten the four screws to secure the fan to the Compressor Cover 3 Connect the fan wires to the terminals on the side of the cooling fan NOTE The fan must be installed so the terminals are oriented towards the front and center of the unit NOTE Ensure that the convoluted tubing covering the fan wires is still properly seated in the wire holder built into the front of the Compressor ...

Page 94: ...rd on the bottom of each side of the Perforated Canopy until the locating posts are clear of the holes in the Compressor Cover FIGURE AE RELEASING CANOPY FROM COMPRESSOR COVER 5 Lift the Perforated Canopy up and away from the Compressor Cover To install the Perforated Canopy 1 While exerting slight inwards pressure on the sides of the Perforated Canopy align the locating posts with the holes in th...

Page 95: ...nto the front of the Compressor Cover 6 Remove the 9 volt battery 7 Lift the Compressor Cover housing straight up and then away from the Base Cabinet FIGURE AF REMOVING THE COMPRESSOR COVER PICTURE SHOWN WITH FAN INSTALLED To install the Compressor Cover 1 Position the Compressor Cover so the built in wire holder is facing the front of the unit 2 Align the round hole in the top of the Compressor C...

Page 96: ...fer to the Perforated Canopy Replacement Section 4 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section WARNING Make sure the AC power is disconnected NOTE The main power wiring harness as been revised to use a 149 F 65 C thermal switch The new revision wiring harness uses a BLUE shrink tubing over the revised thermal switch If the wiring harness in the device being servic...

Page 97: ... TO THE POWER SWITCH WIRING HARNESS 6 Note the position of the Power Cord wires in the main power harness female connector Using an amp terminal retractor remove the Power Cord wire from the connector 7 Note the routing of the main power wiring harness and the location of the cable ties securing the harness to the Base Cabinet Cut the cable ties 8 Remove the two connectors from the Hour Meter NOTE...

Page 98: ...in power wiring harness onto the male connector on the Compressor wires 2 Install the two Hour Meter wires onto the Hour Meter 3 Route the main power wiring harness along the inside of the Base Cabinet Secure the main power wiring harness to the Base Cabinet using three cable ties 4 Install the Power Cord wire connectors in their original position in the main power harness female connector 5 Insta...

Page 99: ...RE AJ CAPACITOR LOCATION 4 Using insulated needle nose pliers carefully remove the female connectors on the Capacitor wires from the two Capacitor terminals 5 After the Capacitor is discharged lift the Capacitor up and out of the molded base To install the Motor Start Run Capacitor 1 Slide the Capacitor into position between the foam insulation and the Compressor assembly standoff 2 Connect the Ca...

Page 100: ...ch or deep well socket turn the pressure relief valve counter clockwise to remove it from the Compressor head FIGURE AK REMOVING THE PRESSURE RELIEF VALVE To install the Pressure Relief Valve 1 Apply an appropriate sealer to the threads of the pressure relief valve 2 Using a 9 16 box end wrench or deep well socket install the pressure relief valve into the Com pressor head Do not over tighten the ...

Page 101: ...he main power cabinet wiring harness by depressing the locking tabs and separating the connectors FIGURE AL DISCONNECTING THE COMPRESSOR ASSEMBLY WIRING HARNESS AND LOCATION OF THE ONE EARED CLAMP 5 Disconnect the wires from the Capacitor terminals 6 Using a crimping clamp tool or diagonals cut the one eared clamp securing the pressure tubing to the outlet port of the Compressor assembly Remove th...

Page 102: ... rubber bumpers securing the Compressor assembly to the standoffs FIGURE AM LOCATION OF THE SHOULDER SCREWS AND RUBBER BUMPERS 8 Lift the Compressor assembly up from the standoffs and helical springs FIGURE AN REMOVING THE COMPRESSOR ASSEMBLY NOTE If the optional Compressor mount kit is being used remove the four helical springs from the Compressor assembly standoffs ...

Page 103: ...8 hex key wrench or socket install and tighten the four screws and rubber bumpers that secure the Compressor assembly to the standoffs 5 Slide the supplied one eared clamp onto the pressure tubing Align the tubing with the Compres sor assembly outlet port Slide the tubing onto the ports 6 Slide the one eared clamp into position on the pressure tubing Using a crimping clamp tool or diagonals firmly...

Page 104: ...ward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Using a crimping clamp tool or diagonals cut the two one eared clamps between the Compressor head and In line Muffler 5 Straighten the pressure hose to gain access to the bottom on the In line Muffler Cut the one eared clamp then remove the pressure hose FIGURE AO LOCATION...

Page 105: ... tubing to the outlet port of the In line Muffler 3 Attach the 1 3 4 pressure hose to the inlet port of the In line Muffler Slide a new one eared clamp onto the supplied 2 pressure tubing 4 Using a crimping tool or diagonals firmly pinch the one eared clamp to securely fasten the pres sure tubing to the inlet port of the In line Muffler 5 Slide a one eared clamp over the 1 3 4 pressure hose 6 Alig...

Page 106: ...n 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Using your fingers or needle nose pliers remove the wires from the terminals on the back of the Hour Meter 5 Spread the tabs on the locking frame out from the Hour Meter FIGURE AQ REMOVING THE HOUR METER WIRES NOTE The Hour Meter wires are in...

Page 107: ... Cabinet FIGURE AR REMOVING THE HOUR METER To install the Hour Meter 1 Align then insert the Hour Meter into its receptacle in the Base Cabinet 2 While holding the Hour Meter in place install the locking frame over the Hour Meter from inside of the Base Cabinet Press it onto the Hour Meter until it snaps in place 3 Install the Hour Meter wires on the terminals on the back of the Hour Meter ...

Page 108: ...ear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the two wire connectors from the Valve Solenoid Assembly 4 Using a 7 64 hex key wrench or socket remove the five screws and flat washers securing the Valve Solenoid to the top of the Sieve Canister Assembly FIGURE AS LOCATION OF THE SCREWS SECURING THE VALVE SOLENOID ASSEMBLY ...

Page 109: ... Sieve Canister Assembly 2 Using the five screws and flat washers provided secure the Valve Solenoid Assembly to the Sieve Canister Assembly The screws should be torqued sufficiently in order to prevent leaks but care should be taken not to crush the shoulder of the valve 3 Reconnect the two wire connectors to the Valve Solenoid Assembly 4 Connect the unit to a power source and turn on the device ...

Page 110: ...AU REMOVING THE PRESSURE REGULATOR To install the Pressure Regulator 1 Apply a layer of Teflon thread tape to the threads of the pressure regulator 2 Align the pressure regulator with the pressure regulator port in the Sieve Canister Assembly Screw the pressure regulator into the Sieve Canister Assembly until strong resistance is felt and the pressure regulator outlet port is oriented in the corre...

Page 111: ...e Valve Solenoid Assembly Refer to the Valve Solenoid Replacement Section 5 Remove the pressure regulator Refer to the Pressure Regulator Replacement Section 6 Using a phillips screwdriver remove the four screws securing the Sieve Canister Assembly to the Base Cabinet 7 Using a crimping clamp tool or diagonals cut the one eared clamp securing the 12 pressure tub ing to the inlet port of the Sieve ...

Page 112: ...Replacement Section 4 Set the Sieve Canister Assembly in place in the Base Cabinet 5 Slide the one eared clamp provided onto the 12 pressure tubing 6 Install the 12 pressure tubing provided on the inlet port of the Sieve Canister 7 Using a crimping clamp tool or diagonals pinch the one eared clamp securing the pressure tub ing to the inlet port of the Sieve Canister Assembly 8 Using a phillips scr...

Page 113: ...id Assembly Refer to the Valve Solenoid Replacement Section 5 Remove the pressure regulator Refer to the Pressure Regulator Replacement Section 6 Note the orientation of the Blow Down Muffler in relation to the Sieve Canister Assembly 7 Using channel locks turn the Blow Down Muffler counter clockwise until it is free of the sieve canister assembly FIGURE AX REMOVING THE BLOW DOWN MUFFLER NOTE If c...

Page 114: ...mp securing the pressure tub ing to the inlet port of the Sieve Canister Assembly 6 Using the 5 16 Nut Driver insert then tighten the four screws that secure the Sieve Canister Assembly to the molded base 7 Install the Valve Solenoid on the top of the Sieve Canister 8 Install the wire connectors on the terminals of the valve solenoid 9 Connect the yellow pressure tubing to the brass fitting on the...

Page 115: ...harness connector from its receptacle on the Power Switch wir ing harness Note the orientation of both the black and white Power Cord wires in the main power wiring harness connector 5 Using an Amp terminal retractor tool remove the female connectors of both the black and white Power Cord wires from the main power wiring harness connector FIGURE AY REMOVING THE POWER CORD WIRES FROM THE MAIN POWER...

Page 116: ...grommet with the cutout in the Base Cabinet Press the grom met into the Base Cabinet until completely seated Using an Amp terminal retractor tool remove the female connectors of both the black and white Power Cord wires from the main power wiring harness connector 6 Plug the main power wiring harness connector into its receptacle on the Power Switch wiring har ness 7 Install the Compressor Cover R...

Page 117: ...r Refer to the In line Muffler Replacement Section 6 Remove Hour Meter Refer to the Hour Meter Replacement Section 7 Remove Sieve Canister Assembly Refer to the Sieve Canister Assembly Replacement Section 8 Remove Power Cord Refer to the Power Cord Replacement Section 9 Remove Base Cabinet and bottom pan To Install the Base Cabinet 1 All components have now been removed from the original Base Cabi...

Page 118: ...pironics for any service that involves sieve material disposal Even with the unit disconnected from the electrical supply the Capacitor may still hold an electrical charge strong enough to cause serious bodily injury DO NOT touch the Capacitor terminals simultaneously until the Capacitor has been completely discharged Discharge the Capacitor by shorting the two posts with an insulated screw driver...

Page 119: ...ount of isoprppyl alcohol applies to a cleaning cloth to remove any adhesive resi due from the cabinet To install the Overlay 1 Remove the protective backing from the Overlay 2 Carefully align the Overlay with the applicable mounting area Set the Overlay in place and using a circular motion firmly rub the Overlay until it is securely attached to the cabinet FIGURE A OVERLAY LOCATIONS Control Overl...

Page 120: ...it in place firmly push the Caster into its receptacle until completely seated 3 If more than one Caster is being replaced repeat the procedure for each Caster being replaced 4 Carefully return the unit to the upright position NOTE It may be necessary to insert a medium flat blade screwdriver between the Caster and the molded base to pry the Caster from its receptacle Once the Caster has been part...

Page 121: ...abinet FIGURE C BASE CABINET PAN SCREW LOCATION 3 Grasp the back edge of the Base Cabinet pan and remove it from the Base Cabinet To install the Base Cabinet Pan 1 Position the Base Cabinet pan so the cut out in the foam insulation aligns with the Blow Down Muf fler FIGURE D BLOW DOWN MUFFLER AND FOAM CUTOUT 2 Align the Base Cabinet pan with the Base Cabinet and set it into place 3 Insert and gent...

Page 122: ...sing a Phillips screwdriver remove the six screws that secure the Rear Cabinet to the Front Cab inet FIGURE E FRONT CABINET SCREW LOCATIONS 2 Grasp the Rear Cabinet firmly then slide it toward the back of the unit until it is clear of the guide slot on the Base Cabinet Once clear of the guide slot the Rear Cabinet can be lifted away from the unit ...

Page 123: ...ectly aligned hold the Front Cabinet in place while sliding the Rear Cabinet onto the Base Cabinet 3 Using a Phillips screwdriver install and secure the six mounting screws securing the Rear Cabinet to the Front Cabinet 4 Torque the six screws to 15 1 inch lbs NOTE The Base Cabinet has a guide slot to ensure proper alignment of the rear and Front Cabinets The rear and Front Cabinets MUST be proper...

Page 124: ...aight out from the Front Cabinet To install the Flow Meter 1 Align the threaded fittings on the back of the supplied Flow Meter with the holes in the Front Cabi net 2 While holding the Flow Meter in place install the support speed nuts to secure the Flow Meter to the Front Cabinet Hand tighten the speed nuts 3 Connect the pressure tubing to the fittings on the Flow Meter then secure the tubing wit...

Page 125: ...While holding the DISS outlet fitting in place use an 11 16 wrench to loosen the nylon jam nut securing the DISS outlet fitting 5 Remove the DISS outlet fitting from the Front Cabinet FIGURE I REMOVING THE DISS FITTING To install the DISS Outlet Fitting 1 Align the DISS outlet fitting with the opening in the Front Cabinet Insert the DISS outlet fitting into the opening 2 While holding the DISS out...

Page 126: ...abinet note the position and col ors of the wires connected to the terminals on the Power Switch FIGURE J CORRECT CONNECTION OF THE WIRES TO THE POWER SWITCH 4 Using needle nose pliers remove the wires from the Power Switch terminals Using your fingers or a small flat blade screwdriver depress the latches on each corner of the Power Switch CAUTION Except for the two red wires that are interchangea...

Page 127: ...ER SWITCH To install the Power Switch 1 Orient the Power Switch so that the single terminal is at the top Align the Power Switch with the opening in the Front Cabinet assembly Press the Power Switch into the Front Cabinet assembly until all four latches on the Power Switch lock in place 2 Install the wires onto the terminals of the Power Switch Ensure that they are installed in their orig inal pos...

Page 128: ... Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Using a fuse extractor remove the fuse from its receptacle on the Main PCB FIGURE L FUSE LOCATION To install the Fuse 1 Align the fuse with its receptacle on the Main PCB 2 Carefully press the fuse into its receptacle until completely seated ...

Page 129: ...odel 605 units Only Remove the OPI wiring harness connector from the J3 location on the Main PCB assembly by pulling the connector directly up from the J3 receptacle 6 Depress the locking tab then remove the Power Switch wiring harness connector from the J2 location on the Main PCB by pulling the connector directly up from the J2 receptacle 7 Using a Phillips screwdriver remove the four screws sec...

Page 130: ...he J2 receptacle on the Main PCB assembly Carefully press the connector onto the receptacle until completely seated 4 For Model 605 units Only Align the connector on the short OPI wiring harness with the J3 recep tacle on the Main PCB assembly Carefully press the connector onto the receptacle until com pletely seated 5 Align the connector on the main power wiring harness with the J1 receptacle on ...

Page 131: ...ess connector from the J7 location on the OPI board by pulling the connector directly up from the J7 receptacle FIGURE O OPI WIRING HARNESS To install the OPI Wiring Harness 1 Align the connector on the OPI board wiring harness with the J7 receptacle on the OPI board Carefully press the connector onto the receptacle until completely seated 2 Align the connector on the OPI wiring harness with the J...

Page 132: ...pulling the connector directly up from the J7 receptacle 4 While holding the oxygen sensor remove the pressure tubing from the sensor by carefully prying the tubing off both oxygen sensor fittings 5 Using a Phillips screwdriver remove the four screws securing the OPI board to the Front Cabinet FIGURE P CONNECTIONS AND MOUNTING SCREW LOCATIONS NOTE The pressure tubing from the Flow Meter is connect...

Page 133: ...ed to secure the OPI board to the Front Cabinet 3 While holding the oxygen sensor install the pressure tubing on the oxygen sensor by carefully pushing the tubing onto the oxygen sensor fittings 4 Align the connector on the OPI wiring harness with the J7 receptacle on the OPI board carefully press the connector onto the receptacle until completely seated NOTE Once the unit is reassembled verify th...

Page 134: ...et Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Disconnect the male connector on the Power Switch wiring harness from this female connector on the main power wiring harness FIGURE R LOCATION OF THE CONNECTOR 4 Remove the female connector from the J2 location on the Main PCB FIGURE S MAIN PCB J2 AND POWER SWITCH LOCATIONS ...

Page 135: ...he screws that secure the screw down cables ties to the Front Cabinet 8 Either feed the Power Switch wiring harness through the screw down cable ties or if new screw down cable ties are available cut the cable ties and remove the Power Switch wiring harness CAUTION Except for the two red wires that are interchangeable the wires must be connected to the Power Switch as shown Failure to do so will r...

Page 136: ...the clear and yellow pressure tubing together 2 Install the connectors onto the proper terminals of the Power Switch Ensure that they are installed in their original position FIGURE T POWER SWITCH TERMINAL LOCATIONS 3 Install the female connector onto the J2 location on the Main PCB 4 Position the screw down cable ties at their mounting posts then secure each using the original screws Tighten the ...

Page 137: ... Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the battery connector from the battery 4 Remove the two connectors from the Valve Solenoid Assembly FIGURE U VALVE SOLENOID CONNECTIONS 5 Remove the yellow pressure tubing from the top of the Sieve Canister 6 Remove the pressure tubing from the pressure regulator assembly 7 Remove the two red wires connected to the Power Switc...

Page 138: ...he screws that secure the screw down cable ties to the Front Cabinet 10 Either feed the O2 solenoid battery wiring harness through the screw down cable ties or if new screw down cable ties are available cut the cable ties and remove the O2 solenoid battery wiring harness 11 Note the location at which the battery wires exit the large convoluted tubing Cut the cable ties and remove the O2 solenoid b...

Page 139: ...ew down cable ties are available loosely install four cable ties grouping the O2 solenoid battery wiring harness Power Switch wiring harness along with the clear and yellow pressure tub ing together 3 Install the O2 solenoid battery wiring harness connector onto the J1 location on the OPI board 4 Install the two red wires from the O2 solenoid battery wiring harness to the Power Switch 5 Position t...

Page 140: ...t Section 10 Remove the OPI board Refer to the OPI Board Replacement Model M605 Only Section To install the Front Cabinet 1 Remove the protective backing from the control Overlay Carefully aligning the Overlay apply it to the Front Cabinet 2 Position the Front Cabinet face down on a protected work surface that will not damage the Front Cabinet 3 Install the OPI Board Refer to the OPI Board Replace...

Page 141: ...41896 REV 00 PAGE 24 M600 M605 REPAIR REPLACEMENT MILLENNIUM SERVICE TECHNICAL INFORMATION 12 Install the Rear Cabinet Refer to the Rear Cabinet Replacement Section FIGURE W FRONT CABINET SCREW LOCATIONS ...

Page 142: ... Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the two wires from the terminals located on the side of the cooling fan 4 Using a small thin shaft Phillips screwdriver remove the four screws securing the cooling fan to the Compressor Cover FIGURE X WIRES AND SCREW LOCATIONS NOTE The two wires are interchangeable ...

Page 143: ...the cooling fan with the holes in the Compressor Cover 2 Insert then tighten the four screws to secure the fan to the Compressor Cover 3 Connect the fan wires to the terminals on the side of the cooling fan NOTE The fan must be installed so the terminals are oriented towards the front and center of the unit NOTE Ensure that the convoluted tubing covering the fan wires is still properly seated in t...

Page 144: ...ress inward on the bottom of each side of the Perforated Canopy until the locating posts are clear of the holes in the Compressor Cover FIGURE Z LOCKING POST LOCATION 5 Lift the Perforated Canopy up and away from the Compressor Cover To install the Perforated Canopy 1 While exerting slight inward pressure on the sides of the Perforated Canopy align the locating posts with the holes in the Compress...

Page 145: ...screws securing the cover to the base then proceed to Step 8 8 Lift the Compressor Cover housing straight up and then away from the Base Cabinet FIGURE AA REMOVING THE COMPRESSOR COVER COMPRESSOR COVER SHOWN WITH FAN INSTALLED To install the Compressor Cover 1 Position the Compressor Cover so the built in wire holder is facing the front of the unit 2 Align the round hole in the top of the Compress...

Page 146: ...er to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Disconnect the female connector on the main power wiring harness from the male connector on the Power Switch harness FIGURE AC DISCONNECTING THE MAIN POWER WIRING HARNESS FROM THE POWER SWITCH WIRING H...

Page 147: ...ssor wires FIGURE AD DISCONNECTING THE MAIN POWER WIRING HARNESS FROM THE COMPRESSOR WIRING HARNESS To install the Main Power Wiring Harness 1 Install the female connector of the main power wiring harness onto the male connector on the Compressor wires 2 Install the two Hour Meter wires onto the Hour Meter 3 Route the main power wiring harness along the inside of the Base Cabinet Secure the main p...

Page 148: ...RE AE CAPACITOR LOCATION 4 Using insulated needle nose pliers carefully remove the female connectors on the Capacitor wires from the two Capacitor terminals 5 After the Capacitor is discharged lift the Capacitor up and out of the molded base To install the Motor Start Run Capacitor 1 Slide the Capacitor into position between the foam insulation and the Compressor assembly standoff 2 Connect the Ca...

Page 149: ...from the main power cabinet wiring harness by depressing the locking tabs and separating the connectors FIGURE AF DISCONNECTING THE COMPRESSOR ASSEMBLY WIRING HARNESS AND THE LOCATION OF THE ONE EARED CLAMP 5 Disconnect the wires from the Capacitor terminals 6 Using a crimping clamp tool or diagonals cut the one eared clamp securing the pressure tubing to the outlet port of the Compressor assembly...

Page 150: ...Align the tubing with the Compres sor assembly outlet port Slide the tubing onto the ports 3 Slide the one eared clamp into position on the pressure tubing Using a crimping clamp tool or diagonals firmly pinch the one eared clamp to secure the pressure tubing 4 Confirm that the In line Muffler is not touching the side wall of the Base Cabinet or main power wir ing harness 5 Install the Capacitor w...

Page 151: ...ward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Using a crimping clamp tool or diagonals cut the two one eared clamps between the Compressor head and In line Muffler 5 Straighten the pressure hose to gain access to the bottom on the In line Muffler Cut the one eared clamp then remove the pressure hose FIGURE AH LOCATION...

Page 152: ...es sure tubing to the outlet port of the In line Muffler 3 Attach the 1 3 4 pressure hose to the inlet port of the In line Muffler Slide a new one eared clamp onto pressure tubing 4 Using a crimping tool or diagonals firmly pinch the one eared clamp to securely fasten the pres sure tubing to the inlet port of the In line Muffler 5 Slide a one eared clamp over the 1 3 4 pressure hose 6 Align then s...

Page 153: ...s on the back of the Hour Meter 5 Spread the tabs on the locking frame out from the Hour Meter 6 While holding the tabs spread away from the Hour Meter push it through the openings in the Base Cabinet FIGURE AJ REMOVAL OF THE HOUR METER To install the Hour Meter 1 Align then insert the Hour Meter into its receptacle in the Base Cabinet 2 While holding the Hour Meter in place install the locking fr...

Page 154: ...ear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the two wire connectors from the Valve Solenoid Assembly 4 Using a 7 64 hex key wrench or socket remove the five screws and flat washers securing the Valve Solenoid to the top of the Sieve Canister Assembly FIGURE AK LOCATION OF THE SCREWS SECURING THE VALVE SOLENOID ASSEMBLY ...

Page 155: ...e Sieve Canister Assembly 2 Using the five screws and flat washers provided secure the Valve Solenoid Assembly to the Sieve Canister Assembly The screws should be torqued sufficiently in order to prevent leaks but care should be taken not to crush the shoulder of the valve 3 Reconnect the two wire connectors to the Valve Solenoid Assembly 4 Connect the unit to a power source and turn on the device...

Page 156: ... REMOVAL OF THE PRESSURE REGULATOR To install the Pressure Regulator 1 Apply a layer of Teflon thread tape to the threads of the pressure regulator 2 Align the pressure regulator with the pressure regulator port in the Sieve Canister Assembly Screw the pressure regulator into the Sieve Canister Assembly until strong resistance is felt and the pressure regulator outlet port is oriented in the corre...

Page 157: ...r Assembly to the Base Cabinet 7 Using a crimping clamp tool or diagonals cut the one eared clamp securing the 12 pressure tub ing to the inlet port of the Sieve Canister 8 Remove the 12 pressure tubing from the inlet port of the Sieve Canister FIGURE AN LOCATION OF THE ONE EARED CLAMP AND MOUNTING SCREWS 3 OF 4 SHOWN 9 Lift the Sieve Canister Assembly up and out of the Base Cabinet 10 Remove the ...

Page 158: ...sert then tighten the four screws that secure the Sieve Canister Assembly to the molded base 9 Install the pressure regulator Refer to the Pressure Regulator Replacement Section 10 Install the Valve Solenoid on the top of the Sieve Canister Refer to the Valve Solenoid Replace ment Section 11 Install the wire connectors on the terminals of the valve solenoid 12 Connect the yellow pressure tubing to...

Page 159: ...d Assembly Refer to the Valve Solenoid Replacement Section 5 Remove the pressure regulator Refer to the Pressure Regulator Replacement Section 6 Note the orientation of the blown down muffler in relation to the Sieve Canister Assembly 7 Using channel locks turn the Blow Down Muffler counter clockwise until it is free of the sieve canister assembly FIGURE AO REMOVING THE BLOW DOWN MUFFLER NOTE If c...

Page 160: ...mp securing the pressure tub ing to the inlet port of the Sieve Canister Assembly 6 Using the 5 16 Nut Driver insert then tighten the four screws that secure the Sieve Canister Assembly to the molded base 7 Install the Valve Solenoid on the top of the Sieve Canister 8 Install the wire connectors on the terminals of the valve solenoid 9 Connect the yellow pressure tubing to the brass fitting on the...

Page 161: ...harness connector from its receptacle on the Power Switch wir ing harness Note the orientation of both the black and white Power Cord wires in the main power wiring harness connector 5 Using an Amp terminal retractor tool remove the female connectors of both the black and white Power Cord wires from the main power wiring harness connector FIGURE AP REMOVING THE POWER CORD WIRES FROM THE MAIN POWER...

Page 162: ...grommet with the cutout in the Base Cabinet Press the grom met into the Base Cabinet until completely seated Using an Amp terminal retractor tool remove the female connectors of both the black and white Power Cord wires from the main power wiring harness connector 6 Plug the main power wiring harness connector into its receptacle on the Power Switch wiring har ness 7 Install the Compressor Cover R...

Page 163: ...Refer to the In line Muffler Replacement Section 7 Remove the Hour Meter Refer to the Hour Meter Replacement Section 8 Remove the Sieve Canister Assembly Refer to the Sieve Canister Assembly Replacement Sec tion 9 Remove the Power Cord Refer to the Power Cord Replacement Section 10 Remove the Base Cabinet and bottom pan To install the Base Cabinet 1 All components have now been removed from the or...

Page 164: ...to Respironics for any service that involves sieve material disposal Even with the unit disconnected from the electrical supply the Capacitor may still hold an electrical charge strong enough to cause serious bodily injury DO NOT touch the Capacitor terminals simultaneously until the Capacitor has been completely discharged Discharge the Capacitor by shorting the two posts with an insulated screw ...

Page 165: ...m the cabinet To install the Overlay 1 Remove the protective backing from the Overlay 2 Carefully align the Overlay with the applicable mounting area Set the Overlay in place and using a circular motion firmly rub the Overlay until it is securely attached to the cabinet FIGURE A PROPER INSTALLATION OF FRONT CABINET OVERLAY NOTE When using isopropyl alcohol to clean the mounting area for the contro...

Page 166: ...unit in place firmly push the Caster into its receptacle until completely seated 3 If more than one Caster is being replaced repeat the procedure for each Caster being replaced 4 Carefully return the unit to the upright position NOTE It may be necessary to insert a medium flat blade screwdriver between the Caster and the molded base to pry the Caster from its receptacle Once the Caster has been pa...

Page 167: ...se Cabinet FIGURE C SCREW LOCATIONS 3 Grasp the back edge of the Base Cabinet Pan and remove it from the Base Cabinet To install the Base Cabinet Pan 1 Position the Base Cabinet Pan so the cut out in the foam insulation aligns with the Blow Down Muffler FIGURE D LOCATION OF BLOW DOWN MUFFLER AND FOAM CUTOUT 2 Align the Base Cabinet Pan with the Base Cabinet and set it into place 3 Insert and gentl...

Page 168: ...binet firmly then slide it toward the back of the unit until it is clear of the guide slot on the Base Cabinet Once clear of the guide slot the Rear Cabinet can be lifted away from the unit To install the Rear Cabinet 1 Align the ridges on the Rear Cabinet with the guide slot in the Base Cabinet NOTE The Base Cabinet has a guide slot to ensure proper alignment of the rear and Front Cabinets The re...

Page 169: ...nce the guide slot and ridges are correctly aligned hold the Front Cabinet in place while sliding the Rear Cabinet onto the Base Cabinet FIGURE F ALIGNMENT OF GUIDE SLOT AND RIDGES 3 Using a Phillips screwdriver install and secure the six mounting screws securing the Rear Cabinet to the Front Cabinet ...

Page 170: ...hen remove the pressure tubing from both fittings on the Flow Meter by pulling the tubing from each fitting FIGURE G REMOVE THE PRESSURE TUBING FROM THE FLOW METER 4 While holding the Flow Meter in place remove the two speed nuts from the threaded fittings on the back of the Flow Meter NOTE The pressure tubing connected to the top fitting on the Flow Meter is connected to the bacteria filter The p...

Page 171: ...eter with the holes in the Front Cabi net 2 While holding the Flow Meter in place install the support speed nuts to secure the Flow Meter to the Front Cabinet Hand tighten the speed nuts 3 Connect the pressure tubing to the fittings on the Flow Meter then secure the tubing with the cable ties provided 4 Turn on the unit and check the flow tube connections for leaks 5 If no leaks are detected Turn ...

Page 172: ...net Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Cut the cable tie then remove the pressure tubing connected to the DISS outlet fitting by pulling it off the fitting FIGURE I REMOVE TUBING FROM DISS FITTING 4 While holding the DISS outlet fitting in place use an 11 16 wrench to loosen the nylon jam nut securing the DISS outlet fitting FIGURE J REM...

Page 173: ...lign the DISS outlet fitting with the opening in the Front Cabinet Insert the DISS outlet fitting into the opening 2 While holding the DISS outlet fitting in place install the new lock washer and nylon jam nut on the DISS outlet fitting Use an 11 16 wrench to carefully tighten the nylon jam nut 3 Connect the pressure tubing to the fittings on the DISS outlet fitting Secure the tubing to the fittin...

Page 174: ...forward until it is clear from the Base Cabinet 3 Looking at the back of the Power Switch from inside the Front Cabinet note the position and col ors of the wires connected to the terminals on the Power Switch FIGURE L VIEW OF POWER SWITCH FROM INSIDE THE FRONT CABINET ASSEMBLY CAUTION Except for the two red wires that are interchangeable the wires must be connected to the Power Switch as shown Fa...

Page 175: ...dle nose pliers remove the wires from the Power Switch terminals Using your fingers or a small flat blade screwdriver depress the latches on each corner of the Power Switch 5 While depressing the latches push the Power Switch out of the Front Cabinet assembly FIGURE N REMOVING THE POWER SWITCH FROM THE FRONT CABINET ASSEMBLY Red Red White Black Yellow Brown Yellow Blue ...

Page 176: ...witch so that the single terminal is at the top Align the Power Switch with the opening in the Front Cabinet assembly Press the Power Switch into the Front Cabinet assembly until all four latches on the Power Switch lock in place 2 Install the wires onto the terminals of the Power Switch Ensure that they are installed in their orig inal position ...

Page 177: ... Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Using a fuse extractor remove the fuse from its receptacle on the Main PCB FIGURE O FUSE LOCATION To install the Main PCB Fuse 1 Align the fuse with its receptacle on the Main PCB 2 Carefully press the fuse into its receptacle until completely seated Fuse ...

Page 178: ... For M10605 Only Remove the OPI wiring harness connector from the J3 location on the Main PCB assembly by pulling the connector directly up from the J3 receptacle 6 Depress the locking tab then remove the Power Switch wiring harness connector from the J2 location on the Main PCB by pulling the connector directly up from the J2 receptacle 7 Using a Phillips screwdriver remove the four screws securi...

Page 179: ... with the J2 receptacle on the Main PCB assembly Carefully press the connector onto the receptacle until completely seated 4 For M10605 Only Align the connector on the short OPI wiring harness with the J3 receptacle on the Main PCB assembly Carefully press the connector onto the receptacle until completely seated 5 Align the connector on the main power wiring harness with the J1 receptacle on the ...

Page 180: ...arness connector from the J7 location on the OPI board by pulling the connector directly up from the J7 receptacle FIGURE R OPI WIRING HARNESS To install the OPI Wiring Harness 1 Align the connector on the OPI board wiring harness with the J7 receptacle on the OPI board Carefully press the connector onto the receptacle until completely seated 2 Align the connector on the OPI wiring harness with th...

Page 181: ...receptacle 4 While holding the oxygen sensor remove the pressure tubing from the sensor by carefully prying the tubing off both oxygen sensor fittings 5 Using a Phillips screwdriver remove the four screws securing the OPI board to the Front Cabinet FIGURE S CONNECTIONS AND SCREW LOCATIONS ON OPI BOARD 6 While holding the wiring harness out of the way remove the OPI board from the Front Cabinet NOT...

Page 182: ...et 3 While holding the oxygen sensor install the pressure tubing on the oxygen sensor by carefully pushing the tubing onto the oxygen sensor fittings 4 Align the connector on the OPI wiring harness with the J7 receptacle on the OPI board carefully press the connector onto the receptacle until completely seated NOTE Once the unit is reassembled verify that there are no O2 leaks Set the Flow Meter t...

Page 183: ...the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Disconnect the male connector on the Power Switch wiring harness from this female connector on the main power wiring harness FIGURE U LOCATION OF THE CONNECTOR 4 Remove the female connector from the J2 location on the power control board Main PCB FIGURE V MAIN PCB J2 AND POWER SWITCH LO...

Page 184: ...Switch Wiring Harness 1 Either feed the Power Switch wiring harness through the original screw down cable ties or if new screw down cable ties are available loosely install four cable ties grouping the Power Switch wir ing harness the O2 solenoid battery wiring harness and yellow pressure tubing together 2 Install the connectors onto the proper terminals of the Power Switch Ensure that they are in...

Page 185: ...emale connector onto the J2 location on the Main PCB 4 Position the screw down cable ties at their mounting posts then secure each using the original screws Tighten the screw down cable ties 5 Connect the male connector on the Power Switch wiring harness from the female connector on the main power wiring harness ...

Page 186: ...move the Rear Cabinet Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the battery connector from the battery 4 Remove the two connectors from the Valve Solenoid Assembly FIGURE X VALVE SOLENOID CONNECTIONS 5 Remove the two red wires connected to the Power Switch NOTE The two red wires are interchangeable ...

Page 187: ...wiring harness into the large convoluted tubing Ensure that the battery wires exit the large convoluted tubing at their original location Secure the convoluted tub ing with four cable ties 2 Either feed the O2 solenoid battery wiring harness through the original screw down cable ties or if new screw down cable ties are available loosely install four cable ties grouping the O2 solenoid battery wiri...

Page 188: ...er to the OPI Board Replacement Model M10605 Only Section To install the Front Cabinet 1 Remove the protective backing from the control Overlay Carefully aligning the Overlay apply it to the Front Cabinet 2 Position the Front Cabinet face down on a protected work surface that will not damage the Front Cabinet 3 Install the OPI Board Refer to the OPI Board Replacement Model M10605 Only Section 4 In...

Page 189: ...all thin shaft Phillips screwdriver remove the four screws securing the cooling fan to the Compressor Cover FIGURE Z LOCATION OF COOLING FAN WIRES AND MOUNTING SCREWS 5 While holding the Compressor Cover in place lift the fan up and away from the Compressor Cover To install the Cooling Fan 1 Align the cooling fan with the holes in the Compressor Cover 2 Insert then tighten the four screws to secur...

Page 190: ... side of the Perforated Canopy until the locating posts are clear of the holes in the Compressor Cover 5 Lift the Perforated Canopy up and away from the Compressor Cover To install the Perforated Canopy 1 While exerting slight inwards pressure on the sides of the Perforated Canopy align the locating posts with the holes in the Compressor Cover 2 Release the pressure then ensure that the locating p...

Page 191: ...ilt into the front of the Compressor Cover 6 Remove the 9 volt battery 7 Lift the Compressor Cover housing straight up and then away from the Base Cabinet To install the Compressor Cover 1 Position the Compressor Cover so the built in wire holder is facing the front of the unit 2 Align the round hole in the top of the Compressor Cover housing with the inlet port of the Com pressor assembly 3 Set t...

Page 192: ...male connector on the Power Switch harness FIGURE AC LOCATION OF THE MAIN POWER WIRING HARNESS 5 Note the position of the Power Cord wires in the main power harness female connector Using an amp terminal retractor remove the Power Cord wire from the connector 6 Note the routing of the main power wiring harness and the location of the cable ties securing the harness to the Base Cabinet Cut the cabl...

Page 193: ... of the Base Cabinet Secure the main power wiring harness to the Base Cabinet using three cable ties 4 Install the Power Cord wire connectors in their original position in the main power harness female connector 5 Install the female connector on the main power wiring harness onto the male connector on the Power Switch wiring harness 6 Connect the red wires to the Hour Meter terminals FIGURE AD LOC...

Page 194: ...insulated needle nose pliers carefully remove the female connectors on the Capacitor wires from the two Capacitor terminals 5 After the Capacitor is discharged lift the Capacitor up and out of the molded base To install the Motor Start Run Capacitor 1 Slide the Capacitor into position between the foam insulation and the Compressor assembly standoff 2 Connect the Capacitor wires to the terminals on...

Page 195: ...he connectors 5 Disconnect the wires from the Capacitor terminals 6 Using a crimping clamp tool or diagonals cut the one eared clamp securing the pressure tubing to the outlet port of the Compressor assembly Remove the pressure tubing from the Compressor assembly outlet port 7 Using a 1 8 hex key wrench or socket remove the four shoulder screws and rubber bumpers securing the Compressor assembly t...

Page 196: ...1 8 hex key wrench or socket install and tighten the four screws and rubber bumpers that secure the Compressor assembly to the standoffs 5 Slide the supplied one eared clamp onto the pressure tubing Align the tubing with the Compres sor assembly outlet port Slide the tubing onto the ports 6 Slide the one eared clamp into position on the pressure tubing Using a crimping clamp tool or diagonals firm...

Page 197: ...two one eared clamps between the Compressor head and In line Muffler FIGURE AG LOCATION OF THE ONE EARED CLAMPS IN LINE MUFFLER SHOWN W O FOAM 5 Straighten the pressure hose to gain access to the bottom on the In line Muffler Cut the one eared clamp then remove the pressure hose 6 Remove the In line Muffler To install the In line Muffler 1 Slide a new one eared clamp onto the existing 12 pressure ...

Page 198: ...he 1 3 4 pressure hose connected to the Sieve Canister Attach the pressure hose to the Out port elbow of the In line Muffler 5 Using a crimping tool or diagonals firmly pinch the one eared clamp to securely fasten the pres sure tubing to the inlet port of the In line Muffler 6 Slide a one eared clamp over the 1 3 4 pressure hose 7 Align then seat the short pressure tubing on the Compressor assembl...

Page 199: ...lacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section FIGURE AI EXTERNAL VIEW OF HOUR METER 4 Using your fingers or needle nose pliers remove the wires from the terminals on the back of the Hour Meter FIGURE AJ INTERNAL VIEW OF HOUR METER NOTE The Hour Meter wires are interchangeabl...

Page 200: ... away from the Hour Meter push it through the openings in the Base Cabinet To install the Hour Meter 1 Align then insert the Hour Meter into its receptacle in the Base Cabinet 2 While holding the Hour Meter in place install the locking frame over the Hour Meter from inside of the Base Cabinet Press it onto the Hour Meter until it snaps in place 3 Install the Hour Meter wires on the terminals on th...

Page 201: ...EW LOCATIONS 5 Lift the Valve Solenoid Assembly up and away from the Sieve Canister Assembly To install the Valve Solenoid Assembly 1 Align the Valve Solenoid Assembly with the holes in the top of the Sieve Canister Assembly 2 Using the five screws and flat washers provided secure the Valve Solenoid Assembly to the Sieve Canister Assembly The screws should be torqued sufficiently in order to preve...

Page 202: ...SURE REGULATOR To install the Pressure Regulator 1 Apply a layer of Teflon thread tape to the threads of the pressure regulator 2 Align the pressure regulator with the pressure regulator port in the Sieve Canister Assembly Screw the pressure regulator into the Sieve Canister Assembly until strong resistance is felt and the pressure regulator outlet port is oriented in the correct position 3 Instal...

Page 203: ...placement Section 11 Remove the brass fitting from the top of the Sieve Canister Assembly To install the Sieve Canister Assembly 1 Install the supplied canister gasket on the bottom of the Sieve Canister Assembly 2 Install the brass fitting in the top of the Sieve Canister Assembly 3 Install the Blow Down Muffler onto the Sieve Canister Assembly Refer to the Blowdown Muffler Replacement Section 4 ...

Page 204: ...tion 6 Note the orientation of the blown down muffler in relation to the Sieve Canister Assembly 7 Using channel locks turn the Blow Down Muffler counter clockwise until it is free of the sieve canister assembly FIGURE AN REMOVING THE BLOW DOWN MUFFLER To install the Blow Down Muffler 1 Align the Blow Down Muffler with the Sieve Canister Assembly s threaded fitting Screw the Blow Down Muffler onto...

Page 205: ...wer Cord wires into the hole in the Base Cabinet 2 Route the Power Cord wires to the main power wiring harness connector 3 Align the female connectors on the end of the black and white Power Cord wires with their recep tacles in the main power wiring harness connector 4 Press each Power Cord wire female connector into the main power wiring harness connector until completely sealed 5 Align the Powe...

Page 206: ...placement Sec tion 6 Remove In line Muffler Refer to In line Muffler Replacement Section 7 Remove Hour Meter Refer to Hour Meter Replacement Section 8 Remove Sieve Canister Assembly Refer to Sieve Canister Replacement Section 9 Remove Power Cord Refer to Power Cord Replacement Section To Install the Base Cabinet 1 All components have now been removed from the original Base Cabinet To begin reassem...

Page 207: ...1041898 REV 01 PAGE 44 M10600 M10605 REPAIR REPLACEMENT MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 208: ...ve Canister Assembly to Respironics for any service that involves sieve material disposal Even with the unit disconnected from the electrical supply the Capacitor may still hold an electrical charge strong enough to cause serious bodily injury DO NOT touch the Capacitor terminals simultaneously until the Capacitor has been completely discharged Discharge the Capacitor by shorting the two posts wit...

Page 209: ... to a cleaning cloth to remove any adhesive resi due from the cabinet To install the Overlay 1 Remove the protective backing from the Overlay 2 Carefully align the Overlay with the applicable mounting area Set the Overlay in place and using a circular motion firmly rub the Overlay until it is securely attached to the cabinet NOTE When using isopropyl alcohol to clean the mounting area for the cont...

Page 210: ...olding the unit in place firmly push the Caster into its receptacle until completely seated 3 If more than one Caster is being replaced repeat the procedure for each Caster being replaced 4 Carefully return the unit to the upright position NOTE It may be necessary to insert a medium flat blade screwdriver between the Caster and the molded base to pry the Caster from its receptacle Once the Caster ...

Page 211: ...abinet pan to the Base Cabinet FIGURE C SCREW LOCATION 3 Grasp the back edge of the Base Cabinet pan and remove it from the Base Cabinet To install the Base Cabinet Pan 1 Position the Base Cabinet pan so the cut out in the foam insulation aligns with the Blow Down Muf fler FIGURE D BLOW DOWN MUFFLER AND FOAM CUTOUT 2 Align the Base Cabinet pan with the Base Cabinet and set it into place 3 Insert a...

Page 212: ...e the filter from side of cabinet 2 Using a Phillips screwdriver remove the six screws that secure the Rear Cabinet to the Front Cab inet FIGURE E FRONT CABINET SCREW LOCATION 3 Grasp the Rear Cabinet firmly then slide it toward the back of the unit until it is clear of the guide slot on the Base Cabinet Once clear of the guide slot the Rear Cabinet can be lifted away from the unit ...

Page 213: ...guide slot and ridges are correctly aligned hold the Front Cabinet in place while sliding the Rear Cabinet onto the Base Cabinet 3 Using a Phillips screwdriver install and secure the six mounting screws securing the Rear Cabinet to the Front Cabinet 4 Torque the six screws to 15 1 inch lbs NOTE The Base Cabinet has a guide slot to ensure proper alignment of the rear and Front Cabinets The rear and...

Page 214: ...oth fittings on the Flow Meter by pulling the tubing from each fitting FIGURE G VIEW OF FLOW METER FROM INSIDE THE FRONT CABINET 4 While holding the Flow Meter in place remove the two speed nuts from the threaded fittings on the back of the Flow Meter 5 Remove the Flow Meter from the Front Cabinet assembly by pulling it straight out from the Front Cabinet NOTE The pressure tubing connected to the ...

Page 215: ...le holding the Flow Meter in place install the support speed nuts to secure the Flow Meter to the Front Cabinet Hand tighten the speed nuts 3 Connect the pressure tubing to the fittings on the Flow Meter then secure the tubing with the cable ties 4 Turn on the unit and check the flow tube connections for leaks 5 If no leaks are detected turn off the unit reassemble and test NOTE The Flow Meter mus...

Page 216: ...ONT CABINET 4 While holding the DISS outlet fitting in place use an 11 16 wrench to loosen the nylon jam nut securing the DISS outlet fitting 5 Remove the DISS outlet fitting from the Front Cabinet FIGURE I DISS FITTING REMOVAL To install the DISS Outlet Fitting 1 Align the DISS outlet fitting with the opening in the Front Cabinet Insert the DISS outlet fitting into the opening 2 While holding the...

Page 217: ...R SWITCH CONNECTIONS 4 Using needle nose pliers remove the wires from the Power Switch terminals Using your fingers or a small flat blade screwdriver depress the latches on each corner of the Power Switch 5 While depressing the latches push the Power Switch out of the Front Cabinet assembly To install the Power Switch 1 Orient the Power Switch so that the single terminal is at the top Align the Po...

Page 218: ...J18 and J19 of the Main PCB 4 Looking at the back of the Power Switch from inside the Front Cabinet note the position and col ors of the wires connected to the terminals on the Power Switch 5 Using needle nose pliers remove the connectors from the Power Switch terminals To install the Main PCB to Power Switch Wiring 1 Install the connectors onto the proper terminals of the Power Switch Ensure that...

Page 219: ...ry from Compressor Cover 4 Remove the battery connector from the battery 5 Remove the battery wiring harness connectors from terminals J14 and J15 on the Main PCB assembly Refer to Figure L To remove the Main PCB to Battery Wiring 1 Connect the battery wiring harness connectors to terminal J14 and J15 on the Main PCB Refer to Figure L 2 Connect the battery connector to the battery 3 Install the ba...

Page 220: ...the Rear Cabinet Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Using a fuse extractor remove the fuse from its receptacle on the Main PCB FIGURE M FUSE LOCATION To install the Fuse 1 Align the fuse with its receptacle on the Main PCB 2 Carefully press the fuse into its receptacle until completely seated ...

Page 221: ...ain PCB assembly Refer to the block diagram in Figure N 5 Remove the valve solenoid wiring connectors from the terminal locations J8 J9 J11 and J12 on the Main PCB assembly Refer to the block diagram in Figure N 6 Remove the Power Switch wiring connectors from the terminal locations J18 J19 J1 and J4 on the Main PCB assembly Refer to the block diagram in Figure N 7 Remove the Compressor wiring con...

Page 222: ...0 MILLENNIUM SERVICE TECHNICAL INFORMATION 10 Using a Phillips screwdriver remove the four screws securing the Main PCB assembly to the Front Cabinet While holding the wiring harness out of the way remove the Main PCB assembly from the Front Cabinet assembly FIGURE O SCREW LOCATIONS ...

Page 223: ...e N 5 Install the wiring from the Power Switch to the following terminals on the Main PCB assembly white wire J18 black wire J19 white wire J4 and black wire J1 terminals Refer to the block dia gram in Figure N 6 Install the wires from the valve solenoid to the to the following terminals on the Main PCB assem bly black wire J9 red wire J8 black wire J11 and red wire J12 terminals Refer to the bloc...

Page 224: ...p from the J7 receptacle 4 While holding the oxygen sensor remove the pressure tubing from the sensor by carefully prying the tubing off both oxygen sensor fittings 5 Using a Phillips screwdriver remove the four screws securing the OPI board to the Front Cabinet FIGURE P CONNECTION AND MOUNTING SCREW LOCATIONS 6 While holding the wiring harness out of the way remove the OPI board from the Front Ca...

Page 225: ...3 While holding the oxygen sensor install the pressure tubing on the oxygen sensor by carefully pushing the tubing onto the oxygen sensor fittings 4 Align the connector on the OPI wiring harness with the J7 receptacle on the OPI board carefully press the connector onto the receptacle until completely seated NOTE Once the unit is reassembled verify that there are no O2 leaks Set the Flow Meter to 0...

Page 226: ...ull ing the connector directly up from the J3 receptacle 4 Remove the OPI wiring harness connector from the J7 location on the OPI board by pulling the connector directly up from the J7 receptacle FIGURE Q OPI WIRING HARNESS To install the OPI Wiring Harness 1 Align the connector on the OPI board wiring harness with the J7 receptacle on the OPI board Carefully press the connector onto the receptac...

Page 227: ...he Main PCB Replacement Section 10 Remove the OPI board Refer to the OPI PCB Replacement Model 605 Only Section To install the Front Cabinet 1 Position the Front Cabinet face down on a protected work surface that will not damage the Front Cabinet 2 Install the OPI Board Refer to the OPI PCB Replacement Model 605 Only Section 3 Install the Main PCB Refer to the Main PCB Replacement Section 4 Instal...

Page 228: ...600 605 ENHANCED M10600 M10605 REPAIR REPLACEMENT PAGE 21 1041897 REV 00 MILLENNIUM SERVICE TECHNICAL INFORMATION 12 Install the Rear Cabinet Refer to the Rear Cabinet Replacement Section FIGURE R SCREW LOCATIONS ...

Page 229: ...e cooling fan to the Compressor Cover FIGURE S COOLING FAN SCREW AND WIRE LOCATIONS 5 While holding the Compressor Cover in place lift the fan up and away from the Compressor Cover To install the Cooling Fan 1 Align the cooling fan with the holes in the Compressor Cover 2 Insert then tighten the four screws to secure the fan to the Compressor Cover 3 Connect the fan wires to the terminals on the s...

Page 230: ... 3 Remove the connectors on the Main PCB to fan wiring from the terminals on the cooling fan 4 Remove the wire connectors from the terminals J2 and J5 on the Main PCB assembly Refer to Figure T To install the Main PCB to Cooling Fan Wiring 1 Install the connectors of the Main PCB to cooling fan wiring to the J2 and J5 terminals on the Main PCB assembly Ensure that the wires are fully seated on the...

Page 231: ...forated Canopy until the locating posts are clear of the holes in the Compressor Cover FIGURE U LOCKING POST LOCATION 4 Lift the Perforated Canopy up and away from the Compressor Cover To install the Perforated Canopy 1 While exerting slight inwards pressure on the sides of the Perforated Canopy align the locating posts with the holes in the Compressor Cover 2 Release the pressure then ensure that...

Page 232: ...rd until it is clear from the Base Cabinet 3 Remove the filter configuration and Silicone grommet installed in the concentrator FIGURE V FILTERS REMOVED FROM SILICONE GROMMET AND 9 VOLT BATTERY LOCATION 4 Remove the cooling fan Refer to the Cooling Fan Replacement Section 5 Remove the 9 volt battery 6 Remove the Perforated Canopy Refer to the Perforated Canopy Replacement Section 7 Remove the two ...

Page 233: ...Compressor Cover housing with the inlet port of the Com pressor assembly 2 Set the Compressor Cover into place on the Base Cabinet Ensure that the bottom of the Com pressor Cover housing is correctly seated on the Base Cabinet 3 Secure the Compressor Cover to the Base Cabinet with a phillips head screw on each side of the Compressor Cover 4 Install the Perforated Canopy Refer to the Perforated Can...

Page 234: ...anced units proceed to step 5 For M600 M605 Enhanced units proceed to step 6 FIGURE X TERMINALS TO REMOVE FROM CAPACITOR 5 Determine if the Capacitor is screwed into the Base Cabinet If so unscrew the Capacitor from the Base Cabinet 6 After the Capacitor is discharged lift the Capacitor up and out of the molded base To install the Motor Start Run Capacitor 1 Slide the Capacitor into position betwe...

Page 235: ...until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Separate the connection where the brown wire from the Compressor and the white wire from the Main PCA meet Refer to the block diagram in Figure Y 5 Separate the connection where the blue wire from the thermal protection switch and the black wire from the Main PCA meet Refer to ...

Page 236: ...the Compressor assembly Remove the pressure tubing from the Compressor assembly outlet port 8 For M10600 M10605 Enhanced Compressors mounted with 4 rubber bumpers remove the 4 screws and bumpers securing Compressor to Base Cabinet If unit does not have 4 rubber bumpers then proceed to Step 9 9 Lift the Compressor assembly up from the standoffs and helical springs FIGURE Z TOP VIEW OF THE COMPRESSO...

Page 237: ...the ports 4 Slide the one eared clamp into position on the pressure tubing Using a crimping clamp tool or diagonals firmly pinch the one eared clamp to secure the pressure tubing 5 Confirm that the In line Muffler is not touching the side wall of the Base Cabinet 6 Install the Capacitor wire connectors onto the terminals of the Capacitor 7 Push together the brown wire connector from the Compressor...

Page 238: ...to the Compressor Cover Replacement Section 4 Remove the connectors on the Main PCB to Compressor wiring from terminals J6 and J20 Note the orientation of both the black and white wires on the Main PCB assembly Refer to the block diagram in Figure AA 5 Disconnect the black wire from the Main PCB to Compressor wiring from the blue wire coming from the thermal protection switch Refer to the block di...

Page 239: ... wire from the Main PCB to Compressor wire harness to the blue wire coming from the thermal protection switch Ensure that the wire connectors are fully seated Refer to the block diagram in Figure AA 3 Connect the white wire from the Main PCB to Compressor wire harness to terminal J6 on the Main PCB assembly Ensure that the wire connectors are fully seated Refer to the block diagram in Figure AA 4 ...

Page 240: ...g from the Main PCB to Com pressor wire harness Refer to the Block Diagram in Figure AB 5 Disconnect the other side of the thermal protection switch from the blue wire coming from the Compressor assembly Refer to the Block Diagram in Figure AB To Install the Thermal Protection Switch 1 Connect one side of the thermal protection switch to the blue wire coming from the Compressor assembly Refer to t...

Page 241: ...ront Cabinet forward until it is clear from the Base Cabinet 3 Remove the Compressor Cover Refer to the Compressor Cover Replacement Section 4 Using a crimping clamp tool or diagonals cut the two one eared clamps between the Compressor head and In line Muffler 5 Straighten the pressure hose to gain access to the bottom on the In line Muffler Cut the one eared clamp then remove the pressure hose FI...

Page 242: ... fasten the pres sure tubing to the outlet port of the In line Muffler 3 Attach the 1 3 4 pressure hose to the inlet port of the In line Muffler Slide a new one eared clamp onto pressure tubing 4 Using a crimping tool or diagonals firmly pinch the one eared clamp to securely fasten the pres sure tubing to the inlet port of the In line Muffler 5 Slide a one eared clamp over the 1 3 4 pressure hose ...

Page 243: ...inet Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Using your fingers or needle nose pliers remove the wires from terminals J16 and J17 on the Main PCB assembly Refer to the block diagram in Figure AE 4 Starting at one corner carefully peel the Overlay off of the cabinet Refer to Overlay Replacement Section NOTE The Hour M...

Page 244: ...e Hour Meter 1 Install the Hour Meter into the Front Cabinet Hand tighten the two small screws which secure the Hour Meter 2 Connect the wires from the Hour Meter to terminals J16 and J17 on the Main PCB assembly Ensure that the wires are fully seated on the Main PCB assembly Refer to the block diagram in Figure AE 3 If Overlay was not damaged when removed install Overlay onto cabinet If Overlay w...

Page 245: ...ACEMENT FIGURE AG ELECTRONIC BLOCK DIAGRAM To remove the Valve Solenoid 1 Remove the Rear Cabinet Refer to the Rear Cabinet Replacement Section 2 Slide the Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the wire connectors from terminals J8 J9 J11 and J12 on the Main PCB assembly Refer to the block diagram in Figure AG ...

Page 246: ...TION 4 Using a 7 64 hex key wrench or socket remove the five screws and flat washers securing the Valve Solenoid to the top of the Sieve Canister Assembly FIGURE AH SCREW LOCATIONS 5 Lift the Valve Solenoid Assembly and wiring harnesses up and away from the Sieve Canister Assembly FIGURE AI REMOVAL OF THE VALVE SOLENOID ...

Page 247: ...re the Valve Solenoid Assembly to the Sieve Canister Assembly The screws should be torqued sufficiently in order to prevent leaks but care should be taken not to crush the shoulder of the valve 3 Reconnect the wire connectors to terminals J8 J9 J11 and J12 on the Main PCB assembly Refer to the block diagram in Figure AG 4 Connect the unit to a power source and turn on the device Apply snoop leak d...

Page 248: ... Front Cabinet forward until it is clear from the Base Cabinet 3 Remove the pressure tubing from the outlet port on the pressure regulator 4 Note the orientation of the pressure regulator outlet port The new pressure regulator must be installed with the outlet port in the same position FIGURE AJ ORIENTATION OF THE PRESSURE REGULATOR 5 Using a pair of channel locks remove the pressure regulator fro...

Page 249: ...r into the Sieve Canister Assembly until strong resistance is felt and the pressure regulator outlet port is oriented in the correct position 3 Install the pressure tubing on the pressure regulator outlet port 4 Connect the unit to a power source and turn on the unit Apply snoop leak detector to the area where the pressure regulator mounts to the Sieve Canister Assembly and where the O2 tubing con...

Page 250: ...regulator Refer to the Pressure Regulator Replacement Section 6 Using the 5 16 Nut Driver Supplied in RI p n H647 Millennium Tool Kit remove the four screws securing the Sieve Canister Assembly to the Base Cabinet FIGURE AL LOCATION OF MOUNTING SCREWS 3 OF 4 SHOWN 7 Using a crimping clamp tool or diagonals cut the one eared clamp securing the 12 pressure tub ing to the inlet port of the Sieve Cani...

Page 251: ... crimping clamp tool or diagonals pinch the one eared clamp securing the pressure tub ing to the inlet port of the Sieve Canister Assembly 8 Using the 5 16 Nut Driver insert then tighten the four screws that secure the Sieve Canister Assembly to the molded base 9 Install the pressure regulator Refer to the Pressure Regulator Replacement Section 10 Install the Valve Solenoid on the top of the Sieve...

Page 252: ...ssembly Refer to the Valve Solenoid Replacement Section 5 Remove the Pressure Regulator Refer to the Pressure Regulator Replacement Section 6 Remove the Sieve Canister Assembly 7 Note the orientation of the blown down muffler in relation to the Sieve Canister Assembly 8 Using channel locks turn the Blow Down Muffler counter clockwise until it is free of the sieve canister assembly FIGURE AM REMOVI...

Page 253: ...ng the pressure tub ing to the inlet port of the Sieve Canister Assembly 6 Using the 5 16 Nut Driver insert then tighten the four screws that secure the Sieve Canister Assembly to the molded base 7 Install the Valve Solenoid on the top of the Sieve Canister Refer to the Valve Solenoid Replace ment Section 8 Install the wire connectors on the terminals of the valve solenoid 9 Connect the yellow pre...

Page 254: ... the Power Cord To install the Power Cord 1 Insert the Power Cord wires into the hole in the Base Cabinet 2 Route the Power Cord wires up to the Main Power Switch 3 Align the black and white Power Cord wires with their receptacles on the Main Power Switch 4 Align the Power Cord strain relief grommet with the cutout in the Base Cabinet Press the grom met into the Base Cabinet until completely seate...

Page 255: ...ove In line Muffler Refer to the In line Muffler Replacement Section 7 Remove Hour Meter Refer to the Hour Meter Replacement Section 8 Remove Sieve Canister Assembly Refer to the Sieve Canister Assembly Replacement Section 9 Remove Power Cord Refer to the Power Cord Replacement Section 10 Remove Base Cabinet and bottom pan Installing the Base Cabinet 1 All components have now been removed from the...

Page 256: ...he repair kits for the Millennium Oxygen Concentrators For technical assistance or replacement part ordering information contact Respironics Product Support USA and Canada Phone 1 800 345 6443 Fax 1 800 866 0245 Email service respironics com International Phone 1 724 387 4000 Fax 1 800 387 5012 Visit Respironics Home Page on the World Wide Web at www respironics com ...

Page 257: ...t Page 9 Cabinet Hardware Kit Page 9 Cable Tie Screw Down Kit Page 9 Capacitor Kits Page 10 Caster Kits Page 11 Compressor Bracket Kit Page 17 Compressor Cover Perforated Canopy Kits Page 18 Compressor Elbow Fitting Kit Page 13 Compressor Inlet Adaptor Kit Page 13 Compressor Kits Page 12 Compressor Maintenance Kits Page 15 Compressor Mounting Kits Page 16 Compressor Spring Kit Page 18 Cooling Fan ...

Page 258: ...Kit Page 49 Main PCB to Fan Cable Wiring Kit Page 48 Main Power Wiring Harness Kits Page 46 Micro disk Filter Kit Page 24 O2 Solenoid Battery Wiring Harness Kit Page 47 One eared Clamp Kit Page 42 OPI PCB Kit Page 33 OPI Wiring Harness Kit Page 47 OPI O2 Solenoid Battery Wiring Harness Kit Page 47 Overly Kits Page 34 Perforated Canopy Kit Page 37 Power Cord Kit Page 40 Power Cord Retainer Kit Page...

Page 259: ...ister Kits Page 43 Silencer Kits Page 23 Silicone Grommet Kit Page 22 Single Port to Four Port Compressor Conversion Kit Page 13 Solenoid Gasket Kit Page 46 Spare Gasket Seal Kit Page 14 Spare Piston Cup Seal Kit Page 14 Spare Plate Valve Flapper Kit Page 14 Stand Alone Pediatric Flow Meter Kit Page 27 Thermal Protection Switch Kit Page 48 Tubing Kit Page 44 Valve Solenoid Kits Page 45 Warning Ins...

Page 260: ...Concentrators 130 0009 00 9 volt Alarm Battery AC INLET KIT Concentrator Model Kit Included in Kit All 230V Models except M600 50 and M605 50 192 0008 00 AC Inlet POWER CORD RETAINER KIT Concentrator Model Kit Included in Kit H600 H605 230V Concentrators M600 M605 230V Concentrators except models M600 50 and M605 50 260 0523 00 Power Cord Retainer ...

Page 261: ...ERVICE TECHNICAL INFORMATION 230V AC INLET FUSE KIT Concentrator Model Kit Included in Kit All 230V Concentrators 1006513 Fuse 4 0 A SLO BLO x10 230V FUSE HOLDER KIT Concentrator Model Kit Included in Kit All 230V Concentrators 1007742 Fuse Holder ...

Page 262: ...40 MM Plasti KW x4 Fuse Holder Kit s 1006494 1017602 ONly H600 H605 230V 1006494 M600 M605 1015584 M600 M605 230V except M600 50 M605 50 1017601 M600 50 M605 50 1017602 M600 M605 120V M10600 M10605 1018250 Enhanced M600 M605 120V 1023800 Enhanced M10600 M10605 1023801 Enhanced M600 10 Enhanced M600 16 Enhanced M600 20 Enhanced M600 30 Enhanced M600 40 Enhanced M605 10 Enhanced M605 16 Enhanced M60...

Page 263: ...Head Phillips Screws x6 BLOW DOWN MUFFLER KITS Concentrator Model Kit Included in Kit All Millennium Concentrators 1006704 Blow Down Muffler Assembly 3 8 Nylon Fitting M600 M605 Concentrators Enhanced M600 605 Concentrators M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 260 0805 10 Blow Down Muffler Only H600 605 230V Concentrators 260 0805 20 Blow Down Muffler Only ...

Page 264: ...y with Blower CABLE TIE SCREW DOWN KIT Concentrator Model Kit Included in Kit All Millennium Concentrators H641 Cable Ties x10 CABINET HARDWARE KIT Concentrator Model Kit Included in Kit M600 M605 Concentrators Enhanced M600 M605 Concentrators M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1015605 Screw 10 32 x 0 75 Phillips Head Black x20 Screw 10 32 x 0 5 Phillips Head Black x1...

Page 265: ...t H600 H605 Concentrators M600 M605 120V Concentrators Enhanced M600 M605 120V Concentrators H180 1502 25 Capacitor 15 uf metal can only All Millennium M10600 M10605 Concentrators 1014671 Capacitor 25 uf metal can All M600 605 230V Concentrators Enhanced M600 605 230V Concentrators 1017607 Capacitor 15 uf 370 Volt metal can Foam ...

Page 266: ... TECHNICAL INFORMATION CASTER KITS Concentrator Model Kit Included in Kit All Millennium Concentrators H624 Caster x4 push in stem All Millennium Concentrators 1026632 Caster x1 push in stem All Millennium Concentrators H649 Caster w Brake x2 push in stem ...

Page 267: ...amp M10600 M10605 1017773 Enhanced M600 M605 120V 1023216 Enhanced M10600 M10605 1023219 M600 M605 230V except M605 70 1015613 M605 70 1015614 H600 H605 230V H612 Enhanced M600 10 Enhanced M600 16 Enhanced M600 20 Enhanced M600 30 Enhanced M600 40 Enhanced M600 50 Enhanced M605 10 Enhanced M600 16 Enhanced M600 20 Enhanced M600 30 Enhanced M600 40 Enhanced M600 50 1023217 Enhanced M605 70 1023218 ...

Page 268: ...1 O Ring Cylinder Sleeve X1 Valve Plate Assembly x1 Head Pressure Relief Valve x1 Cylinder Head x1 Screw Head x4 Decal Respironics Logo x1 One eared Clamp x1 COMPRESSOR INLET ADAPTOR KIT Concentrator Model Kit Included in Kit M10600 M10605 Concentrators M600 M605 230V Concentrators 1031501 Pipe Nipple 1 4 x 1 1 2 Compressor Inlet Adapter COMPRESSOR ELBOW FITTING KIT Concentrator Model Kit Included...

Page 269: ...ncentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 1034057 O Ring Square Cut Gasket SPARE PLATE VALVE FLAPPER KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 1027185 Retainer Screws x2 Keepers x2 Flapper valves x2 H600 H605 Concentrators M600 605 Concentrat...

Page 270: ...e Valve Flapper exhaust valve Flapper intake Cylinder Sleeve O ring sleeve O ring intake filter cover Gasket intake Felt Filter Screw 6 32 x 3 16 valve Screw 10 24 x 625 retainer In line Muffler molded fittings Clamp One eared Clamp Hose 3 8 ID Braided x 1 3 4 All 230V Millennium Concentrators 1015569 Piston Cup x2 Cup Retainer Screw x2 Valve Keeper x4 Head Screws x8 Head Gasket x2 Valve Restraint...

Page 271: ...sket x2 Cup Retainer Screw x2 Valve Restraint x2 Cylinder Sleeve x2 O ring Sleeve x2 Valve Keeper x4 Valve x4 Valve Screw x4 Instruction Sheet Dynamic Backer x4 COMPRESSOR MOUNTING KITS Concentrator Model Kit Included in Kit H600 H605 120V Concentrators M10600 M10605 Concentrators H616 Spring helical x4 Compressor Bumper x4 10 24 x 1 00 hex solder screw x4 COMPRESSOR MAINTENANCE KITS ...

Page 272: ... 16 LG x4 Spring Gold Helical Compression x2 Spring Black Helical Compression x2 Washer 8 SAE Type A Plain x4 Instruction Sheet COMPRESSOR BRACKET KIT Concentrator Model Kit Included in Kit M10600 M10605 Enhanced M10600 M10605 Concentrators M600 M605 230V Concentrators 1018492 Mounting Brackets x2 8 x 1 2 Taptite T 20 Torx Pan Head screws x4 Compressor Spring Retainer x4 COMPRESSOR MOUNTING KITS ...

Page 273: ...in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605Concentrators Serial Number Cutoff M600 600000023921 M605 605000010395 M600 10 600100001125 M600 16 600160001002 M600 30 600300001020 M600 40 600400001201 M600 50 600500001035 M605 10 605100002563 M605 16 605160001658 M605 20 605200001384 M605 40 605400001244 M605 50 605500001949 M605 70 605700001429 M10600 106000001520 M10605 106...

Page 274: ...60001002 M600 20 Not in production as of Dec 31 2003 M600 30 600300001020 M600 40 600400001201 M600 50 600500001035 M605 10 605100002563 M605 16 605160001658 M605 20 605200001384 M605 30 Not in production as of Dec 31 2003 M605 40 605400001244 M605 50 605500001949 M605 70 605700001429 M10600 106000001520 M10605 106051001425 1018700 Compressor Cover Compressor Foam Perforated Canopy Label battery L...

Page 275: ...ng fan H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 360 9100 15 DISS OUTLET FITTING KIT Concentrator Model Kit Included in Kit All Millennium Concentrators H628 DISS outlet fitting 1 2 lock washer 1 2 13 jam nut nylon ELBOW HOSE KIT Concentrator Model Kit Included in Kit All Millennium Concentrators 1006510 Fitting 3 8 hose barb elbow nylon Hose braided 1 ft One...

Page 276: ...05 230V Concentrators 1038485 LONG LIFE FILTER RETROFIT KIT Concentrator Model Kit Included in Kit Enhanced M600 M605 230V Concentrators 1038364 Long Life Filter Compressor Cover Adapter Filter Canopy Enclosure Seal Labels Screws AIR INLET FILTER KITS Concentrator Model Kit Included in Kit All Millennium Concentrators H619 Air Inlet Filter x6 All Millennium Concentrators 1022682 Air Inlet Filter x...

Page 277: ...605 230V Concentrators 1017605 Whisper Cap H600 H605 230V Concentrators 1006511 INLET FILTER KITS Concentrator Model Kit Included in Kit All Millennium Concentrators H620 Inlet Filter x6 All Millennium Concentrators 1022683 Inlet Filter x1 SILICONE GROMMET KIT Concentrator Model Kit Included in Kit All Millennium Concentrators 1015581 Silicone Grommet x10 ...

Page 278: ...605 Concentrators Enhanced M10600 M10605 Concentrators 1017796 Inlet Filter w blue silencer x6 All 230V Concentrators 1015557 Inlet Filter w clear silencer x6 SILENCER KITS Concentrator Model Kit Included in Kit M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1014672 Silencer M10 blue All 230V Concentrators 1018485 Silencer M10 clear x12 ...

Page 279: ...Pre inlet Filter x6 All Millennium Concentrators 1022681 Pre inlet Filter x1 MICRO DISK FILTER KIT Concentrator Model Kit Included in Kit All Millennium Concentrators H621 Micro disk Filter x6 RETAINER INLET FILTER KITS Concentrator Model Kit Included in Kit H600 H605 Concentrators 1007561 Retainer Inlet Filter x10 H600 H605 Concentrators 1006691 Retainer Inlet Filter x1 ...

Page 280: ...ncentrators H654 Retainer Intake Filter x10 FILTER COVER KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 605 Concentrators H652 Filter Cover FELT FILTER KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators H653 Felt Filter x6 ...

Page 281: ... Speed Nuts x2 Cable tie x2 M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1017847 Flow Meter 10 lpm Speed Nuts x2 Cable tie x2 H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators H644 Pediatric Flow Meter 1 lpm Speed Nuts x2 Cable tie x2 H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 528 Locking Flow Meter Speed Nuts...

Page 282: ...rator Model Kit Included in Kit All Millennium Concentrators 1029720 Flowmeter Knob STAND ALONE PEDIATRIC FLOW METER KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators H537 1 Stand alone Pediatric Flow Meter 1 lpm Instruction Sheet ...

Page 283: ...VICE TECHNICAL INFORMATION FOAM KIT Concentrator Model Kit Included in Kit All Millennium Concentrators H623 Front Cabinet foam Rear Cabinet foam Compressor housing foam Base foam assembly Base foam Compressor Base foam hose port Base bottom pan foam ...

Page 284: ...600 120V 1015606 M605 120V 1015607 Enhanced M600 1023212 Enhanced M605 1023213 M10600 M10605 1018248 Enhanced M600 10 Enhanced M600 16 Enhanced M600 20 Enhanced M600 30 Enhanced M600 40 Enhanced M600 50 Enhanced M605 10 Enhanced M605 16 Enhanced M605 20 Enhanced M605 30 Enhanced M605 40 Enhanced M605 50 1023214 Enhanced M10600 M10605 1023236 M605 70 1017598 Enhanced M605 70 1023235 H600 H605 230V ...

Page 285: ...Millennium Concentrators H639 063 A 250 V SLO BLO 5mm x 20mm 2 pack GASKET KITS Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 1007715 Bottom Gasket x2 Foam Pad Instructions One eared clamp H600 H605 Concentrators M600 M605 Concentrators Enhanced M600 M605 Concentrators 1009057 Bottom Gasket x10 Foam Pad X5 Instructions One e...

Page 286: ...NICAL INFORMATION HOUR METER KITS Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605 Concentrators 199 0600 60 Hour Meter Locking frame Enhanced M600 M605 Concentrators Enhanced M10600 M10605 1017578 Hour Meter ...

Page 287: ...centrator Model Kit Included in Kit All 120V Millennium Concentrators H622 In line Muffler molded fittings One eared clamp Hose 3 8 ID braided 1 3 4 All 230V Millennium Concentrators 1018460 In line Muffler molded fittings One eared clamp Hose 3 8 ID braided 1 3 4 lg Hose 3 8 ID braided 10 1 4 lg Foam ...

Page 288: ...ERVICE TECHNICAL INFORMATION OPI PCB KIT Concentrator Model Kit Included in Kit H605 Concentrators M605 Concentrators Enhanced M605 Concentrators M10605 Concentrators Enhanced M10605 Concentrators H633 OPI PCB Screw 6 19 x 31 pan head low torque x4 ...

Page 289: ... Enhanced M605 Concentrators 1020646 Enhanced M605 Control Overlay Enhanced M10600 Concentrators 1020650 Enhanced M10600 Control Overlay Enhanced M10605 Concentrators 1020651 Enhanced M10605 Control Overlay H600 230V Concentrator M600 230V Concentrator H340 0600 10 Model 600 230V Control Overlay H605 230V Concentrator M605 230V Concentrator H340 0605 10 Model 605 230V Control Overlay Enhanced M600...

Page 290: ...L INFORMATION Enhanced M605 10 Concentrator Enhanced M605 16 Concentrator Enhanced M605 20 Concentrator Enhanced M605 30 Concentrator Enhanced M605 40 Concentrator Enhanced M605 50 Concentrator Enhanced M605 70 Concentrator 1020649 M605 Control Overlay OVERLY KITS ...

Page 291: ...5 50 Concentrators M605 70 Concentrators M605 90 Concentrators H320 0650 10 Warning Instruction Label English French German Spanish Italian H600 20 Concentrators H605 20 Concentrators M600 20 Concentrators M605 20 Concentrators H320 0650 20 Warning Instruction Label English Greek Swedish Danish Dutch Finnish H600 30 Concentrators H605 30 Concentrators M600 30 Concentrators M605 30 Concentrators H3...

Page 292: ...Included in Kit All Millennium Concentrators 260 0671 00 Perforated Canopy POWER SWITCH KITS Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605 Concentrators 441 0600 00 Power Switch Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1017563 Power Switch ...

Page 293: ...ICAL INFORMATION PRESSURE REGULATOR KIT Concentrator Model Kit Included in Kit All Millennium Concentrators 365 0001 00 Pressure Regulator PRESSURE RELIEF VALVE KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators 365 0600 10 Pressure Relief Valve ...

Page 294: ... Enhanced M600 120V Concentrators 1023199 Main PCA 6 19 x 31 pan head low torque screw x4 Enhanced M605 120V Concentrators 1023200 Enhanced M10600 Concentrators 1023201 Enhanced M10605 Concentrators 1023202 M605 70 Concentrators 1018463 Enhanced M600 10 Concentrators Enhanced M600 16 Concentrators Enhanced M600 20 Concentrators Enhanced M600 30 Concentrators Enhanced M600 40 Concentrators Enhanced...

Page 295: ...s M600 M605 120V Concentrators M10600 M10605 Concentrators H617 Power Cord Strain Relief REAR ACCESS DOOR KITS Concentrator Model Kit Included in Kit H600 H605 Concentrators 1008750 Rear Access Door w foam M600 M605 Concentrators Enhanced M600 M605 Concentrators M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1015609 Rear Access Door w foam ...

Page 296: ...door w foam Instruction label 10 32 x 1 2 pan head phillips screw x6 Cable tie Replacement Serial Number Plate Clear Overlay x2 Instruction Sheet M600 M605 120V Concentrators Enhanced M600 M605 Concentrators 1015608 M600 M605 230V except Model M605 70 1017599 M605 70 Concentrators 1017600 H600 H605 230V Concentrators 1006498 M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1043691 ...

Page 297: ...9550 Replacement Serial Number Plate Clear Overlay x2 Instruction Sheet H600 H605 230V Concentrators M600 M605 230V Concentrators 1039551 H605 70 Concentrators M605 70 Concentrators 1039552 H600 H605 120V Concentrators M600 M605 120V Concentrators 1039553 ONE EARED CLAMP KIT Concentrator Model Kit Included in Kit All Millennium Concentrators H640 One eared Clamp 10 pack ...

Page 298: ...cabinet bottom One eared clamp M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1017774 H600 H605 230V Concentrators H613 SHIPPING CARTON KITS Concentrator Model Kit Included in Kit M600 M605 Concentrators Enhanced M600 M605 Concentrators M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1019347 Shipping Carton Bottom Insert Top Insert Poly bag H600 H605 Concentrator...

Page 299: ...99 Bottom Insert M600 M605 Concentrators Enhanced M600 M605 Concentrators M10600 M10605 Concentrators Enhanced M10600 M10605 Concentrators 1018705 TUBING KIT Concentrator Model Kit Included in Kit All Millennium Concentrators 1024105 Yellow Pressure Tubing Cable Tie w Screw Mount x5 Cable Tie x2 Hose Clamp Self Tightening Tubing 3 16 ID x 5 16 OD Clear PVC Tubing 3 16 ID x 5 16 OD PVC Formed Tubin...

Page 300: ...Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605 Concentrators H625 Valve Solenoid Assembly 6 32 x 1 2 screw nypatch x5 6 washer flat x5 Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1023349 Valve Solenoid Assembly 6 32 x 1 2 screw nypatch x5 6 washer flat x5 ...

Page 301: ...Solenoid Gasket x20 MAIN POWER WIRING HARNESS KITS Concentrator Model Kit Included in Kit H600 H605 120V Concentrators M600 M605 120V Concentrators 610 00620 00 Main Power Wiring Harness M10600 M10605 Concentrators 1014669 Main Power Wiring Harness M600 M605 230V Concentrators 1015562 Main Power Wiring Harness H600 H605 230V Concentrators 610 00640 00 Main Power Wiring Harness ...

Page 302: ...s 610 00600 00 O2 Solenoid Battery Wiring Harness OPI O2 SOLENOID BATTERY WIRING HARNESS KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605 Concentrators 610 00610 00 OPI O2 Solenoid Battery Wiring Harness OPI WIRING HARNESS KIT Concentrator Model Kit Included in Kit H600 H605 Concentrators M600 M605 Concentrators M10600 M10605 Concentrators 61...

Page 303: ...10605 Concentrators 610 00615 00 Power Switch Wiring Harness THERMAL PROTECTION SWITCH KIT Concentrator Model Kit Included in Kit Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1017901 Thermal Protection Switch MAIN PCB TO FAN CABLE WIRING KIT Concentrator Model Kit Included in Kit Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1017560 Main PCB to Fan ...

Page 304: ...rator Model Kit Included in Kit Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1017837 Main PCB to Battery Cable MAIN PCB TO COMPRESSOR CABLE WIRING KIT Concentrator Model Kit Included in Kit Enhanced M600 M605 Concentrators Enhanced M10600 M10605 Concentrators 1024060 Main PCB to Compressor Cable ...

Page 305: ...1041901 REV 00 PAGE 50 REPAIR KITS MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 306: ...he unit by moving the Power Switch to the ON I position and verify the following All LEDs light up and the audible alarm sounds for two seconds The unit starts running The red LED light goes off and the audible alarm stops The yellow LED blinks until the specified oxygen level is reached OPI version Only SYSTEM PRESSURE TEST The system pressure test is used to verify the internal operating pressur...

Page 307: ...atric Flow Meter 3 Connect the pressure gauge from the tool kit to the DISS outlet fitting The flow ball should drop to 0 0 lpm 4 If the oxygen pressure does not fall between 5 0 and 7 0 psig perform steps 5 through 13 If the pressure does fall between 5 0 and 7 0 psig proceed to next test 5 Remove the pressure gauge from the DISS outlet fitting 6 Remove the Front and Rear Cabinets 7 Insert a T fr...

Page 308: ...n the end of the regulator 11 Disconnect the pressure gauge and T fitting 12 Reconnect the clear oxygen tubing to the pressure regulator 13 Install the Front and Rear Cabinets NOTE If the regulated pressure is low turn the wrench clockwise to increase the regulated pressure If the regulated pressure is high turn the wrench counter clockwise to decrease the pressure ...

Page 309: ...the three oxygen readings and then divide by three to find the average oxygen purity 8 Locate the average oxygen purity on the Oxygen Percentage Voltage Verification Char refer to Figure A 9 Compare the voltage reading from the DMM to the voltage listed on the chart for the oxygen purity average that you calculated refer to Figure A 10 The voltage reading from the DMM must fall within the values l...

Page 310: ...L 605 ONLY Oxygen Concentration Percentage Average Average Acceptable Voltage Output VDC 96 3 96 to 3 72 VDC 95 3 92 to 3 68 VDC 94 3 88 to 3 64 VDC 93 3 84 to 3 60 VDC 92 3 80 to 3 56 VDC 91 3 76 to 3 52 VDC 90 3 72 to 3 48 VDC 89 3 68 to 3 44 VDC 88 3 64 to 3 40 VDC 87 3 60 to 3 36 VDC 86 3 56 to 3 32 VDC 85 3 52 to 3 28 VDC 82 3 40 to 3 16 VDC ...

Page 311: ...und within 60 seconds Record the results 6 With the pressure gauge still connected and held in a vertical position measure the oxygen outlet pressure The oxygen outlet pressure should be within 5 0 7 0 psig If the oxygen outlet pressure needs adjusted refer to the Oxygen Outlet Regulated Pressure Test Section Record the results 7 Connect the black ground lead from the DMM to pin 19 and the red pos...

Page 312: ...cted to the DISS outlet measure and record the oxygen concentration Set the Flow Meter to two 2 lpm except for units equipped with a Pediatric Flow Meter set to 0 1 lpm Measure and record the oxygen concentra tion 9 Reinstall the Front and Rear Cabinets 10 In ink sign and date the Testing Data Sheet after all tests have been completed If the unit has failed any of the tests performed the unit must...

Page 313: ..._______ Step 5 No Flow Alarms 60 sec PASS FAIL Step 6 Oxygen Outlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING Step 7 Oxygen Alalyzer Reading 1ST CYCLE 2ND CYCLE 3RD CYCLE Average O2 Purity 3 cycles DMM Voltage Reading PASS FAIL Step 8 Flow Meter Oxygen Concentration M605 H605 120V 88 5 lpm 92 0 5 to 4 lpm H605 230V 87 4 lpm 92 0 5 to 3 lpm M605 Enhanced M605 230V 94 2 0 5 to 4 lpm 92 4 5 lpm al...

Page 314: ...________ Step 3 VAC __________ Hz __________ Step 4 Hour Meter __________ Step 5 No Flow Alarms 60 sec PASS FAIL Step 6 Oxygen Putlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING NOTE Step 7 is not required for this Model Step 8 Flow Meter Oxygen Concentration H600 M600 120V 88 5 lpm 92 0 5 to 4 lpm H600 230V 87 4 lpm 92 0 5 to 3 lpm M600 Ehanced M600 230V 94 2 0 5 to 4 lpm 92 4 5 lpm 2 lpm 5 lpm ...

Page 315: ... 3 VAC __________ Hz __________ Step 4 Hour Meter __________ NOTE Step 5 is not required for this Model The Alarm will not sound with the 1 Liter Pediatric Flowmeter installed Step 6 Oxygen Outlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING Step 7 Oxygen Alalyzer Reading 1ST CYCLE 2ND CYCLE 3RD CYCLE Average O2 Purity 3 cycles DMM Voltage Reading PASS FAIL Step 8 Flow Meter Oxygen Concentration H...

Page 316: ... Step 2 Serial Number __________ Step 3 VAC __________ Hz __________ Step 4 Hour Meter __________ NOTE Step 5 is not required for this Model The Alarm will not sound with the 1 Liter Pediatric Flowmeter installed Step 6 Oxygen Outlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING NOTE Step 7 is not required for this Model Step 8 Flow Meter Oxygen Concentration H600 M600 Enhanced M600 120V 92 0 1 lpm...

Page 317: ...1041903 REV 00 PAGE 12 TESTING MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 318: ...AND START UP TEST 1 Connect the Power Cord to a power source 2 Turn on the unit by moving the Power Switch to the ON I position and verify the following All LEDs light up and the audible alarm sounds for two seconds The unit starts running The red LED light goes off and the audible alarm stops The yellow LED blinks until the specified oxygen level is reached OPI version Only SYSTEM PRESSURE TEST T...

Page 319: ...roceed to step 5 5 Remove the pressure gauge from the DISS outlet fitting 6 Remove the Front and Rear Cabinets 7 Insert a T from the tool kit in between the regulator and the clear oxygen tubing and connect the pressure gauge 8 Set the Flow Meter to 10 lpm 9 With the gauge held in a vertical position verify that the regulated pressure is at 5 5 0 25 psig 10 If the regulated pressure needs adjusted...

Page 320: ...ng for each cycle 7 Add the three oxygen readings and then divide by three to find the average oxygen purity 8 Locate the average oxygen purity on the Oxygen Percentage Voltage Verification Chart refer to Figure A 9 Compare the voltage reading from the DMM to the voltage listed on the chart for the oxygen purity average that you calculated refer to Figure A 10 The voltage reading from the DMM must...

Page 321: ...L 605 ONLY Oxygen Concentration Percentage Average Average Acceptable Voltage Output VDC 96 3 96 to 3 72 VDC 95 3 92 to 3 68 VDC 94 3 88 to 3 64 VDC 93 3 84 to 3 60 VDC 92 3 80 to 3 56 VDC 91 3 76 to 3 52 VDC 90 3 72 to 3 48 VDC 89 3 68 to 3 44 VDC 88 3 64 to 3 40 VDC 87 3 60 to 3 36 VDC 86 3 56 to 3 32 VDC 85 3 52 to 3 28 VDC 82 3 40 to 3 16 VDC ...

Page 322: ...thin 60 seconds Record the results 6 With the pressure gauge still connected and held in a vertical position measure the oxygen outlet pressure The oxygen outlet pressure should be within 5 0 7 0 psi If the oxygen outlet pressure needs adjusted refer to the Oxygen Outlet Regulated Pressure Test Section Record the results 7 Connect the black ground lead from the DMM to pin 19 and the red positive l...

Page 323: ...ISS outlet mea sure and record the oxygen concentration Set the Flow Meter to three 3 lpm Measure and record the oxygen concentration 9 Reinstall the Front and Rear Cabinets 10 In ink sign and date the Testing Data Sheet after all tests have been completed If the unit has failed any of the tests performed the unit must be repaired and retested according to this service manual NOTE After completing...

Page 324: ...rial Number __________ Step 3 VAC __________ Hz __________ Step 4 Hour Meter __________ Step 5 No Flow Alarms 60 sec PASS FAIL Step 6 Oxygen Putlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING Step 7 Oxygen Analyzer Reading 1ST CYCLE 2ND CYCLE 3RD CYCLE Average O2 Purity 3 cycles DMM Voltage Reading PASS FAIL Step 8 Flow Meter Oxygen Concentration M10605 Enhanced M10605 120V 92 4 10 lpm 94 2 3 lpm...

Page 325: ...technician performing tests Step 2 Serial Number __________ Step 3 VAC __________ Hz __________ Step 4 Hour Meter __________ Step 5 No Flow Alarms 60 sec PASS FAIL Step 6 Oxygen Outlet Pressure 5 0 7 0 psig PRESSURE GAUGE READING NOTE Step 7 is not required for this Model Step 8 Flow Meter Oxygen Concentration M 10600 Enhanced M10600 120V 92 4 10 lpm 94 2 3 lpm 3 lpm 10 lpm Signature _____________...

Page 326: ...ead Screwdriver large blade 9 16 wrench or deep well socket 11 16 wrench 15 in lbs Torque wrench Respironics p n 1033056 18 in lbs Torque wrench Respironics p n 1018495 30 in lbs Torque wrench Respironics p n 1033057 55 in lbs Torque wrench Respironics p n 1018490 100 in lbs Torque wrench Respironics p n 1024064 125 in lbs Torque wrench Respironics p n 1024062 1 4 Drive Torx Bit Holder Respironics...

Page 327: ...ping clamp tool Millennium Screwdriver w bits Respironics p n H646 Included in H647 Tool Kit Millennium Pressure gauge kit Respironics p n H648 Included in H647 Tool Kit ACCEPTABLE TEST EQUIPMENT DIGITAL MULTIMETER Specification 3 1 2 digit readout Acceptable Options Fluke 87 or better model Any commercially available multimeter that meets the above specifications OXYGEN ANALYZER Specifications Ra...

Page 328: ...which they are intended Patents are pending The schematics are intended to satisfy administrative requirements only They are not intended to be used for component level testing and repair Any changes of components could effect the reliability of the device prohibit lot tracking of electronic components and void warranties Repairs and testing are supported only at the complete board level The schem...

Page 329: ...OUT 4 OUT 24PC15SMTB 30 MT1 1 CONN FAS T ON S P ADE 250 032 J 5 1 CONN FAS T ON S P ADE 250 032 J 20 5V 5V 1uF C 15 10 9 8 LM324 U2 C 4 5V 11 G ND 5 7 6 8 4 2 3 1 T 1A 01uF C3 G ND 01uF C5 1 CONN FAS T ON S PADE 110 020 J16 HOUR MET ER 1 2 3 2N7002 Q9 R 23 3 3M 16 OSC 1 15 OSC 2 4 MCLR 17 R A 0 18 R A 1 1 R A 2 2 R A 3 3 R A 4 13 R B 7 12 R B 6 11 R B 5 10 R B 4 14 VDD 6 R B 0 7 R B 1 8 R B 2 9 R ...

Page 330: ...N7002 Q1 R 10 3 01K CR5 MMBZ5234BL 12V R 14 1 50K 12VB G ND 5V R 20 100K R 19 100K L6 22uH G ND P WR S W MONIT OR 01uF C19 1 IN 3 IN 2 OUT 4 OUT 24PC15SMTB 30 MT1 1 CONN FAS T ON S P ADE 250 032 J 5 1 CONN FAS T ON S P ADE 250 032 J 20 5V 5V 1uF C 15 10 9 8 LM324 U2 C 4 5V 11 G ND 5 7 6 8 4 2 3 1 T 1A 01uF C3 G ND 01uF C5 1 CONN FAS T ON S PADE 110 020 J16 HOUR MET ER 1 2 3 2N7002 Q9 R 23 3 3M 16 ...

Page 331: ... 3 2N7002 Q1 R 10 3 01K CR5 MMBZ5234BL 12V 12VB G ND 5V R 20 100K R 19 100K L6 22uH G ND P WR S W MONIT OR 01uF C19 1 IN 3 IN 2 OUT 4 OUT 24PC15SMTB 30 MT1 1 CONN FAS T ON S P ADE 250 032 J 5 1 CONN FAS T ON S P ADE 250 032 J 20 5V 5V 1uF C 15 10 9 8 LM324 U2 C 4 5V 11 G ND 5 7 6 8 4 2 3 1 T 1A 01uF C3 G ND 01uF C5 1 CONN FAS T ON S PADE 110 020 J16 HOUR MET ER 1 2 3 2N7002 Q9 R 23 3 3M 16 OSC 1 1...

Page 332: ...UT 4 OUT 24PC15SMTB 30 MT1 1 CONN FAS T ON S P ADE 250 032 J 5 1 CONN FAS T ON S P ADE 250 032 J 20 5V 5V 1uF C 15 10 9 8 LM324 U2 C 4 5V 11 G ND 5 7 6 8 4 2 3 1 T 1A 01uF C3 G ND 01uF C5 1 CONN FAS T ON S PADE 110 020 J16 HOUR MET ER 1 2 3 2N7002 Q9 R 23 3 3M 16 OSC 1 15 OSC 2 4 MCLR 17 R A 0 18 R A 1 1 R A 2 2 R A 3 3 R A 4 13 R B 7 12 R B 6 11 R B 5 10 R B 4 14 VDD 6 R B 0 7 R B 1 8 R B 2 9 R B...

Page 333: ...1041904 REV 00 PAGE 6 SCHEMATICS MILLENNIUM SERVICE TECHNICAL INFORMATION This page intentionally left blank ...

Page 334: ...Reorder Number 1041825 1044572 Rev 00 BRM 5 7 2007 ...

Page 335: ...Service Technical Information Millennium Oxygen Concentrators ...

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