DeVilbiss® 5-Liter Compact Oxygen Concentrator Service Manual Danger – no smoking For Product Numbers: 525DS 525KS CAUTION-Federal (U.S.A.) law restricts this device to sale by or on the order of a physician.
T A B LE O F CON T EN T S GENERAL INFORMATION Introduction....................................................................................................................................................................................... 3 Important Safeguards........................................................................................................................................................................ 3 Safety Precautions and General Warnings......................................
GENERAL IN F OR M A T ION Introduction This service manual was designed to provide DeVilbiss Healthcare qualified service technicians and homecare providers with the proper maintenance, service, safety, and repair procedures for the DeVilbiss Oxygen Concentrator. Read and understand all the information contained in this service manual before attempting to operate or perform any maintenance on the concentrator.
UN P ACKING AN D S E T U P Initial Inspection It is suggested that an initial inspection be performed upon receiving the oxygen concentrator. 1. After removing the DeVilbiss Oxygen Concentrator from the carton, examine it for any external damage. If shipping damage has occurred, contact the DeVilbiss Customer Service Department at 1-800-338-1988 (814-443-4881) for specific instructions. Save the carton for possible later return; note the position of the unit and placement of the packing material. 2.
UN P ACKING AN D S E T U P Operating Instructions 1. Remove the power cord completely from the strap. Make sure the power switch is in the “Off” position. 2. 115 Volt Units– Insert the plug into an electrical outlet. The DeVilbiss Oxygen Concentrator uses a two-prong polarized plug and is doubleinsulated to protect against electric shock. 220/240 Volt Units – Ensure it is connected to the unit before inserting plug into an appropriate electrical outlet.
M AIN T ENANCE Alerts: The visible alert located on the front panel reads “Service Required.” The audible alert system is internally powered; no batteries are required. When the indicator lights illuminate or the audible alert sounds, other than during unit start-up, a problem has occurred. • Power Failure (Blinking red “Service Required” light and pulsing audible alert) • Low Flow (Below 0.
M AIN T ENANCE Periodic Homecare Provider Preventative Maintenance Every DeVilbiss Oxygen Concentrator is tested at the factory. To assure continued trouble-free performance, the following preventative maintenance should be performed by the homecare provider during periodic oxygen patient visits. Failure to properly maintain the unit will void the warranty. 1. Check the oxygen concentration with an oxygen analyzer (part #O2ANA)—every two years. a.
T ROU B LE S H OO T ING System Operation The DeVilbiss Oxygen Concentrator uses a pressure swing adsorption system. The air is drawn into the unit through air filters and into a double-head compressor. A pneumatic diagram of the system is shown in Figure 17. The compressed air passes through a rotary valve (Figure 5), which is cycled at a pre-determined rate, and is directed into one of two sieve beds. The sieve beds contain molecular sieve material which is a synthetically-produced inorganic silicate.
T ROU B LE S H OO T ING Simplified Troubleshooting The key to simple troubleshooting is to recognize which type of problem exists and select the most effective approach to solving the problem. The different types of problems and the approaches for solutions are as follows: Type I—The unit runs but a low pressure and flow or high pressure condition exists. NOTE– Low pressure or flow are indicated by both a visible and audible alarm.
T ROU B LE S H OO T ING Troubleshooting Chart A Visible Alarm Audible Alarm Compressor Power Light OFF OFF ON ON Other Symptoms Possible Cause Possible Remedy Pulsating air noise Intake filter not in place or defective Compressor intake hose disconnected Check filter and replace if necessary Reconnect hose Excessive noise Loose or defective motor mounts Defective compressor Defective cooling fan Replace motor mounts Replace compressor Replace cooling fan Fluctuating oxygen flow Occluded
T ROU B LE S H OO T ING Troubleshooting Chart B Visible Alarm Audible Alarm Compressor Blinking Other Symptoms Power Light Pulsing OFF OFF Possible Cause Fan off Line cord not properly installed or defective No power at receptacle Oxygen concentrator circuit breaker activated Line cord quick-connect terminal inside unit is disconnected Defective power switch Defective circuit breaker Possible Remedy Insert plug in receptacle or replace line cord.
T ROU B LE S H OO T ING Troubleshooting Chart E Visible Alarm Audible Alarm Compressor Power Light ON ON ON ON Other Symptoms Possible Cause Possible Remedy Fluctuating or no flow System pressure below 9 psi (62.1 kPa) due to: 1. Leak in system 1. Check for leaks in all hoses and fittings 2.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T Proper Repair Procedures The DeVilbiss Oxygen Concentrator is designed for ease of service. To aid service personnel, a Service Kit (part #444-501) is available which contains the necessary gauges, tools, and testing instruments to properly service the oxygen concentrator. On parts that are sold separately, the part number is indicated in parenthesis.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T Cabinet Removal NOTE– A defective check valve may cause a rapid drop in accumulator To remove front and back cabinets (Fig. 3): NOTE– A defective compressor will be indicated by slowly rising pressure below the minimum value. 1. Ensure the unit is unplugged from the wall outlet. 2. Using a screwdriver, remove the six screws that hold the back cabinet to the internal structure and the bib. pressure.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T Compressor If the filters are not occluded and no leaks are found, the compressor must then be removed and repaired or replaced. The DeVilbiss Oxygen Concentrator uses a double-head, oil-free compressor. The compressor is secured to the base with four motor mounts. To remove the compressor: 1. Make sure the unit is unplugged from the wall outlet. 2.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T To replace the final check valve (Figure 10): 8. Place valve plates on the compressor so that heads of reed valve screws are aligned with the indentation in top of pistons. 9. Install the compressor heads so that the holes in the heads are aligned with the holes in the compressor housing. 10. Secure compressor heads with the screws. 1. Make sure the unit is unplugged from the wall outlet. 2.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T Molecular Sieve Beds NOTE– Loosening or removing the compressor mounting plate may The two molecular sieve beds alternately remove the nitrogen from the air passing through them and provide the patient with a constant supply of oxygen. 4. Note wire colors and socket locations before removing wires. 5. Using a pair of duckbill pliers, squeeze the power cord strain relief and pull it out of the base of the unit. 6.
CO M P ONEN T T E S T ING , RE P AIR , AN D RE P LACE M EN T To replace the pressure regulator (Figure 9): beds in order to observe unit cycling and bed pressures. Refer to the section on Normal Operating Sequence. 3. If it is determined that the valve did not shift properly or the bed pressures are uneven, continue testing with step 4. 4.
F IGURE S , D IAGRA M S , AN D VIE W S Figures, diagrams, and views index Exterior Views Figure 1 Front Figure 2 Rear Figure 3 Side Interior Views - The following figures show the exterior of the DeVilbiss 5-Liter Compact Concentrators. The following figures show the interior of the DeVilbiss 5-Liter Compact Concentrators.
F IGURE S , D IAGRA M S , AN D VIE W S Figure 1 - Exterior Front View OSD Indicator Lights Service Required Light (Red) Power Light (Green) Serial Number Label Power Switch Flow Meter Knob Light Panel Flow Meter Oxygen Outlet Port Circuit Breaker Bib Front Cover Caster Base LT-2023 20
F IGURE S , D IAGRA M S , AN D VIE W S Figure 2 - Exterior Rear View Cabinet Screws Caution/ Warning Label Filter Door Air Filter Communication Port Cover Electrical Rating Label Rear Cover Cabinet Screws Base Power Cord Strain Relief (115V Units) 21 IEC Connector (220V/240V Units) LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 3 - Exterior Side View Front Cover Rear Cover Cabinet Screw power Cord Strap Power Cord Caster exhaust Grill LT-2023 22
F IGURE S , D IAGRA M S , AN D VIE W S Figure 4 - Front with Cover Removed Bib Service Required Light (Red) Serial Number Label Light Panel OSD Indicator Lights Power Light (Green) 23 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 5 - Interior, Front View PC Board Pressure Regulator Accumulator Tank Right Sieve Bed Left Sieve Bed Sieve Bed Cable Ties Check Valve Rotary Valve LT-2023 24
F IGURE S , D IAGRA M S , AN D VIE W S Figure 6 - Interior, Front Lower View 1/8” ID Hose Fixed Orifice Check Valves Bib Mounting Slot Sieve Bed Cable Tie Rotary Valve Rotary Valve Wire Harness Ladder Clamp Plastic Hose Clamp 25 1/2” ID Silicone Hose LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 7 - Interior, Front Upper View Accumulator Tank PC Board Communication Harness 1/8” ID Hose Circuit Breaker & Power Switch Wires Main Wire Harness LT-2023 26
F IGURE S , D IAGRA M S , AN D VIE W S Figure 8 - PC Board Valve Wire Harness Connector Hour Meter Connector Communication Harness Connector OSD Alert Capacitor for Power Fail Alert Fuse 27 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 9 - Interior, Top View PC Board Intake Bacteria Filter Hour Meter Pressure Regulator 1/8” ID Hose Accumulator Tank Test Point Fitting Sieve Bed Test Point Sieve Bed Test Point Right Sieve Bed Left Sieve Bed LT-2023 28
F IGURE S , D IAGRA M S , AN D VIE W S Figure 10 - Interior, Behind Bib Plastic Elbow Final Bacteria Filter Power Switch 1/8” ID Hose Flow Meter Final Check Valve Circuit Breaker Light Panel Ribbon Connector Switch Detail *Red Wire *Red Wire Brown Wire (or 2 Black Wires) 2 Black Wires (or 1 Brown Wire) * Either red wire can be connected to either left hand terminal of the switch 29 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 11 - Interior Rear View Bib Screws Pressure Regulator Accumulator Tank Intake Bacteria Filter Communication Port Compressor Filter Intake Silencer Compressor Compressor Connector Strain Relief Power Cord (115V Units) LT-2023 30
F IGURE S , D IAGRA M S , AN D VIE W S Figure 12 - Interior, Rear Lower View Grommet Intake Silencer Ladder Clamps 1/2” ID Braided Hose Pressure Relief Valve Exhaust Fitting Compressor Housing 1/2” ID Silicone Hose Compressor Wire Harness Compressor Connector Motor Mount 31 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 13 - Compressor Housing - Rear View Exhaust Muffler Ladder Clamp Compressor Housing 1/2” ID Silicone Hose Thermostat (220/240 Volt Units) Rear View of Rotary Valve Compressor Connector LT-2023 32
F IGURE S , D IAGRA M S , AN D VIE W S Figure 14 - Interior, Base View Cooling Fan Guard Compressor Mounting Supports Cooling Fan Fan Mounting Screw Power Cord Connector Compressor Connector Cooling Fan Wires Capacitor Wires 33 Capacitor LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 15 - GSE Compressor Intake Fitting Head Screw Pressure Relief Valve Exhaust Fitting Motor Mount Electrical Connector LT-2023 34
F IGURE S , D IAGRA M S , AN D VIE W S Figure 15A - GSE Compressor With Head Removed Spacer Cup Seal Rod (beneath cup retainer) Sleeve Rod Screw Cup Retainer Valve Plate O-Ring Retainer Reed Valve or Flapper Screw Sleeve PR Valve Exhaust Fitting Compressor Head Intake Fitting Head Gasket Connecting Tubes 35 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S Figure 16 - Rotary Valve Stepper Motor Left Sieve Bed Fitting Right Sieve Bed Fitting Valve Wire Harness Front View Pressure Exhaust Fitting Pressure Intake Fitting Rear View LT-2023 36
F IGURE S , D IAGRA M S , AN D VIE W S 525DS & 525KS Figure 17 - Pneumatic Diagram 37 LT-2023
F IGURE S , D IAGRA M S , AN D VIE W S For 220V/240V Units LT-2023 38 (220V/240V Units) (115V Units) Figure 18 - Wiring Diagram
W ARRAN T Y IN F OR M A T ION DeVilbiss 525DS Compact Oxygen Concentrator Limited Warranty DeVilbiss Healthcare warrants the DeVilbiss 525DS Compact Oxygen Concentrators under the conditions and limitations stated below. DeVilbiss warrants this equipment to be free from defects in workmanship and materials for five (5) years from date of factory shipment to the original purchaser, (typically the healthcare provider).
OR D ERING IN F OR M A T ION AN D P AR T S LI S T Ordering Information When ordering components, instruction guides, or service manuals the following must be provided: • Unit Catalog Number • Unit Serial Number • Part Number • Quantity Required DeVilbiss Compact Concentrator 5 Liter Series Instruction Guide: • A-525 525DS English, Spanish, French • SE-525 525DS & 525KS English, Spanish, French, German, Italian, Dutch, Portuguese DeVilbiss Compact Concentrator 5 Liter Series Service Manual: • LT-
OR D ERING IN F OR M A T ION AN D P AR T S LI S T Accessories Bubble Humidifier HUM16 Cannula CAN00 Cannula w/2.1m (7 ft) tubing CAN70 Casters, Locking 525DS-603 Fitting, Straight Hum.
OR D ERING IN F OR M A T ION AN D P AR T S LI S T Components (continued) 525DS 525KS 444-582 444-582 Standard Flow Meter 505DZ-607 505DZ-607 Low Output Flow Meter 515LF-607 515LF-607 Foam Kit 525D-600 525D-600 Fuse (For PC Board) 515ADZ-627 515AKZ-610 1/8” ID (Blue) (4’ Lg) 444-554 444-554 1/4” ID (Blue) (4’ Lg) 444-525 444-525 1/2” ID (Braided) (4’ Lg) 444-549 444-549 1/2” ID (Silicone) (2’ Lg) 505DZ-634 505DZ-634 Plastic (1/4” ID Hose) 444-524 444-524 Plastic (1/2” ID Hoses
sp e c i f i c a t i o n s Catalog Number DEVILBISS 5-LITER COMPACT Concentrator 525Ds Delivery Rate (Lower delivery rates available for low flow applications) 525KS 1 to 5 LPM Maximum Recommended Flow 5 LPM Outlet Pressure 8.5 psig (58.6 kPa) Electrical Rating 115V~, 60 Hz, 3.3 Amp 220-230 V~, 50 Hz, 1.55 Amp 230 V~, 60 Hz, 1.
DeVilbiss Healthcare 100 DeVilbiss Drive Somerset, Pennsylvania 15501 USA 814-443-4881 Sunrise Medical Canada, Inc. 237 Romina Drive, Unit 3 Concord, Ontario L4K 4V3 CANADA 905-660-2459 Sunrise Medical Ltd.
