Puritan Bennett | Companion T | User manual | COMPANION® 4923 AND

PURITAN
BENNETT.
©1991 PURITAN-BENNETT CORPORATION
COMPANION" 492a
AND
COMPANION" 590
OXYGEN CONCENTRATORS
SERVICE MANUAL
PART NUMBER 492779
Copyright© 1991 by Puritan-Bennett Corporation. All rights reserved. The information contained in this manual
>. is the sole property of Puritan-Bennett Corporation and may not be reproduced without the permission of the
Company.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
PREFACE
This manual provides the information needed to service the Puritan-Bennett Companion 492a and 590 Oxygen
Concentrators. This information is intended for use by technicians or personnel qualified to repair and service
medical equipment. The information is not all-inclusive and may not be applicable to future Companion 492a
and 590 models.
Technicians should direct any questions regarding Companion concentrator service to Puritan-Bennett Oxygen
Concentrator Division: 1-800-248-0890 or 314-739-7070.
The information contained in this document, including performance specifications, are subject to change without
notice.
Puritan-Bennett makes no warranty of any kind with regard to the material in this manual, including but not
limited to the implied warranties of merchantabilities and fitness for a particular purpose.
Puritan-Bennett shall not be liable for errors contained herein or for incidental or consequential damages in
connection with providing this manual or the use of material in this manual.
DEFINITION OF STATEMENTS
Statements in this manual preceded by the following
words are of special significance.
WARNING
Means there is the possibility of injury or death to
yourself or others.
CAUTION
Means there is the possibility of damage to the unit or
other property.
NOTE
Indicates point of particular interest for more efficient
and convenient operation.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 ii
a
SECTION 1.
SECTION 2.
SECTION 3.
SECTION 4.
TITLE
TABLE OF CONTENTS
INTRODUCTION AND GENERAL INFORMATION ...........
1.1 General Product Description .. ........24224 442420
1.1.1 Optional Accessories and Literature . . . . . . . . . ..
1.2 Performance Specifications . . . . . ..............
1.3 Unpacking and Receiving Inspection . . . . . .. ........
1.4 Operating Procedures . . . . . . .. ..............
1.4.1 OperationalCheck . . ..................
1.42 Operating Instructions . . . ...............
1.5 Routine Maintenance . .. .. ..................
1.6 Recommended Tools and Test Equipment ...........
ТНЕОВУ ОР ОРЕВАТЮМ ........................
2.1 Overview of Concentrator Operation . . . ..... . _—. ..e.
2.2 Pneumatic System Components . . . . . ............
2.3 Electrical System Components . . . . . . .. ..........
2.4 Concentrator System Operation . . . . . ............
PERFORMANCE VERIFICATION . . ..................
3.1
3.2
3.3
3.4
Performance Verification . . . . . .. .. ............
3.1.1 Oxygen Concentration . . . . ..............
3.12 Pneumatic ..... 44041 41 41 01 44 140
3.1.3 Electrical . ...... aerea.
3.1.4 Ventilation System . . ...... .. .. e...
315 Flow ...... aa aa
3.1.6 Sound .....2 222141 LL LL LL LL LL 140
Operational Checklist .. ... . .. .. ............
3.21 Low Concentration . . ... ..............
3.22 ConcentratorWontRun . . ...............
3.2.3. Improper Operation . . . ................
Troubleshooting Guide . . . . . . . . ..............
Balancing Orifices . . . . . . . . eee ea
SERVICE AND REPAIR ..... . .. ...............
1.
2.
3.
Cabinet . . . . . aa aaa
Circuit Breaker .. .. 1... 12111101 LL LL LL 11110
Hour Meter . . . . . . . ea aaa eee
1-10
1-14
1-17
2-1
2-2
2-7
2-16
2-20
3-1
3-2
3-2
3-3
3-8
3-8
3-9
3-10
3-10
3-11
3-11
3-11
3-16
Companion 492a/590 Oxygen Concentrators
iii Service Manual 5-15-91
TITLE
SECTION 4. SERVICE AND REPAIR (continued)
4. Audio Alarm . ..... _... 2 eee.
5. Flowmeter Flow Control Valve ............
6. Flowmeter . . . . .. .................
7. Power Switch . . ...................
8. Control Printed Circuit Board _.............
9. Compressor Platform Assembly . .. .........
10. Compressor(492a) . .................
11. Согпргез5ог (590)... . . . .............
12. Capacitor .. .... .................
13. Cooling Fan .. ....................
14. Pressure Switch . . . . . ...............
15. Pressure Regulator . . . ...............
16. Solenoid . . ... .. e... eee.
17. Sieve Canister .. .. .. 2.244441 44122220
18. Pilot Маме... . .... .. .... .........
19. Restrictor Tube Assemblies . . . . . .. .... ...
20. Outlet Gas Filter . . . . . .. .. ...........
21. Shock Mount . . ...................
22. CompressorCup Seals (580) . . .. .........
SECTION 5. TECHNICAL BULLETINS
SECTION 6. OXYGEN CONCENTRATION INDICATOR (OCI)
6.1 General product Description .............
6.2 Theory of Operation .. .... 4444424420
6.3 Performance Verification ...............
6.4 Troubleshooting and Repair .. .. ..........
TABLE OF CONTENTS (Continued)
6.4.1 Troubleshooting ...............
6.42 Вера... ..................
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
PAGE
4-6
4-6
4-7
4-7
4-9
4-11
4-15
4-19
4-20
4-20
4-21
4-24
4-25
4-28
4-30
4-31
4-32
4-32
FIGURE
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
2-1
2-2
2-3
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2-5
2-6
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2-8
2-9
2-10
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2-12
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2-15
2-16
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2-18
2-19
2-20
2-21
3-1
3-2
3-3
3-4
3-5
3-6
4-1
4-2
LIST OF ILLUSTRATIONS
TITLE
Companion 492a Front View . . . .. .... ..
Companion 492a Rear View ...........
Side Panel View . . . . ..............
Oxygen Concentration Testing ..........
Oxygen Outlet Adapters .............
Humidifier Adapter Attachment . . . . . . . . ..
Humidifier Attachment . . . . . . ........
Oxygen Tubing Attachment to Humidifier . . . . .
Oxygen Tubing Attachment to Adapter . . . . . .
Side Panel Compartment Filters . . . . . . . ..
Pneumatic Diagram . . ..............
Electrical Diagram . . . . . ............
Side Panel View . 1... 222112142440
Compressor Inlet Filter .......... ....
Compressor Drawer, Front View .........
Compressor Drawer, Bottom View ........
Pilot Air Filter . . . . . . . ............
Pilot Valve Operation . . .............
Sieve Canisters . . ................
Expansion Chamber and Muffler . . . . . . . ..
Restrictor Tubes . . . . ..............
Product Canister, Regulator, and Vacuum Check Valve
Right Cabinet, Interior View . . . . ........
Control Panel . . .................
CoolingAirFlow . . . ...............
Cooling Fan . . ..................
Filter Compartment . . .. ............
Sieve Canister 1, Concentrating Cycle .. . . .
Balance Cycle . . .. ...............
Sieve Canister 2, Concentrating Cycle . . . . . .
Oxygen Concentration Testing ..........
Pneumatic Test Kit Connection/Testing . . . . . .
Pneumatic Test Kit Connection/Testing . . . . . .
Pressure Switch Testing . . . . ... ......
Outlet Pressure Testing . . . . ..........
Flowmeter Testing . . ..............
Companion 492a/590 Exterior ..........
Left Cabinet Interior . . . . ............
naa aa e ae 1-11
naa aaa ea a 1-12
aaa ae 1-12
ea aa eee 1-13
ae ae . 1-13
aaa en aa 1-16
aa ae a e aaa 2-5
Зе. 2-7
aaa ea e ea 2-3
aa ae 2-9
ae aa aaa 2-11
aaa aa 2-11
aaa ea 2-12
aaa aaa 2-13
aaa e ae 2-13
a a eee 2-15
aaa a 2-15
aan a ea 2-17
ea a ea 2-17
aa ea aaa 2-18
aaa a 2-19
aaa ee 2-20
aaa aa aaa 2-23
aaa ee 2-25
ea a aaa 2-27
aaa aa e a ea 4-35
Век, 4-39
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
FIGURE
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
6-1
6-2
6-3
LIST OF ILLUSTRATIONS (continued)
TITLE PAGE
Right Cabinet Interior . . . . . . . . .. . . .............. 4-43
Compressor Platform Assembly . . . . . . . .............. 4-47
Companion 492a Compressor . . . . . . ................ 4-49
Companion 590 Compressor . . . . . .. .............. 4-51
Compressor Cylinder-Head Screw Torque Sequence . . ........ 4-53
Companion 590 Compressor Retaining Plate indexing . . . . . . . .. 4-54
Pressure Regulator . . . . . . . re... eee e ae 4-55
Pilot Valve .... 1.222224 1 4 44 4 4 44 ea ea e ee 4-56
492a Front Panel with OCI . ...... . 2.2... ...—.———— 6-2
OCI Circuit Board Installed ......... . 2... 6-3
OCI System .... 2.240244 44 4 4444 4 4 4 4 14e 144 6-8
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
vi
LIST OF TABLES
TABLE TITLE PAGE
1-1 Performance Specifications .. .. .... 4244424444 4 44 46 1-4
1-2 Maintenance Schedule ........ 0202444 444 4 4 4 44 4420 1-14
1-3 Recommended Tools and Test Equipment . . . . . . .......... 1-17
3-1 Troubleshooting Guide . . . . . . . . .. ne nooo 3-12
4-1 Service Procedures .. ..... 2.221122 21441144 1 44440 4-3
6-1 Service Procedures .. ..... 2202022144 4 444 4 111120 6-6
Companion 492a/590 Oxygen Concentrators
vii Service Manual 5-15-91
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 viii (blank)
SECTION 1. INTRODUCTION AND GENERAL INFORMATION
This section provides introductory information on the Companion 492a and 590 Oxygen Concentrators,
including optional equipment, performance specifications, preparation for use, operating procedures, routine
maintenance, and recommended tools and test equipment.
1.1 General Product Description
The Companion 492a and 590 Oxygen Concentrators provide supplemental oxygen at high concentrations.
Each concentrator is equipped with a flowmeter calibrated in .25 liter increments with maximum settings of 4
lpm for the 492a and 5 Ipm for the 590.
Boththe 492a and 590 are compact, lightweight units equipped with four wheels anda handle for ease in delivery
to the home and in transport by the patient at home. The unit's height of 25.4 inches (64.5 cm) enables the
operator to reach the controls with ease (Figure 1-1). In addition, the filter compartment on the side of the unit
makes accessible, without disassembly of the unit, the compressor filters, hour meter, battery, and circuit
breaker.
Always observe the WARNING and CAUTION labels affixed to the front and rear panels as follows:
WARNING:
This machine produces oxygen. Keep away from heat
and open flames. Do not smoke near patient or
machine. Do not oil this machine.
CAUTION:
Federal (U.S.A.) law restricts this device to sale by or
on the order of a physician.
CAUTION:
Do not use in the presence of fluids.
CAUTION:
Electrical shock hazard. Do not remove cover. Refer
service to qualified service personnel.
Companion 492a/590 Oxygen Concentrators
1-1 Service Manual 5-15-91
Figure 1-1: Companion 492a Front View Figure 1-2: Companion 492a Rear View
NOTE
With the exception of flowmeter range and cabinet
labeling, the exterior of the Companion 492a and 590
are identical.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-2
r
~~
1.1.1 Optional Accessories and Literature
The following Puritan-Bennett accessories and literature may be used with the Companion 492a and Companion
590.
Literature Part Number
Companion 432a Patient Instruction Manual 492931"
Companion 492a Patient Instruction Manual with O.C.1.** 492778"
Companion 590 Patient Instruction Manual 492932"
Companion 590 Patient Instruction Manual with O.C.1.** 492827*
Companion Concentrator Patient Checklist 799609
Humidifier Adapter lilustration Sheet 799660
Accessory
Adapter, Humidifier (standard) 492922*
Adapter, Humidifier (long) 492392
Tail Piece 492587
Wing Nut 492588
Humidifier, Bubble (disposable) 001083
Oxygen Concentration Indicator (O.C.1.) (installation required)** 492888
Companion Flowsplitter 493219
Companion Flowsplitter Plug 493220
Companion Flowsplitter Nozzles:
5 LPM 493221
‚75 СРМ 493222
1.0 LPM 493223
1.5 LPM 493224
2.0 LPM 493225
2.5 LPM 493226
3.0LPM 493227
3.5LPM 493228
В
Adapter, Humidifier
(Long)
Adapter, Humidifier
(Standard)
Plug
|
i
4
Humidifier, Bubble
(Disposable)
Companion Flow
Nozzle
Tailpiece & Wingnut
*Appropriate part supplied with unit
**Refer to Section 6 for information conceming ОС!
Companion 492a/590 Oxygen Concentrators
1-3 Service Manual 5-15-91
1.2 Performance Specifications
The Companion 492a and 590 physical characteristics, environmental and electrical requirements, and
pneumatic characteristics are listed in Table 1-1. In most cases the information provided in this table applies to
both the 492a and 590. Any differences in characteristics or requirements between the two models are listed
separately.
TABLE 1-1. PERFORMANCE SPECIFICATIONS
PHYSICAL CHARACTERISTICS
PARAMETER
Cabinet size:
Height
Width
Depth
Assembly weight
492a
590
Shipping container size:
Height
Width
Depth
Shipping weight
492a
590
Noise Level
Cabinet construction
POWER switch
Audio alarm
Oxygen Concentration Indicator (O.C.1.)
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
MEASUREMENT/CONDITION
25.4 in. (64.5 cm)
12.5 in. (31.75 cm)
16.5 in. (41.9 cm)
57 Ib. (25.8 kg)
59 Ib. (26.8 kg)
28.5 in. (72.4 cm)
14.6 in. (37.1 cm)
19.5 in. (49.5 cm)
65 Ib. (29.5 kg)
67 Ib. (30.4 kg)
< 50 dBA at 1 meter
Molded case, hinges open for easy service equipped
with carry handle and 4 casters.
Rocker-type standard. When ON, LED illuminates to
indicate AC power. When unit is equipped with optional
Oxygen Concentration Indicator (O.C.l.), Power Switch
is a push-button type. When ON, LED illuminates to
indicate AC power. Refer to section 6 for all information
pertaining to OCI operation.
When POWER switch is ON, sounds to indicate low
pressure, which may be caused by cycle failure, or
power disconnect. Powered by internal source with
battery back-up.
Refer to section 6 for information pertaining to OCI
operation.
ENVIRONMENTAL REQUIREMENTS
PARAMETER
Storage/shipping temperature
Operating temperature
Stabilization time
Operating Altitude*
ELECTRICAL REQUIREMENTS
REQUIREMENT
-40°F to 158°F (-40°C to 70°C)
50°F to 110°F (10°C to 43°C)
20 minutes minimum
Up to 3000 ft. (314 m) above sea level without degrada-
tion of performance.
PARAMETER
Power
492a
590
Consumption
492a
590
Battery
Power Cord"*
Circuit Breaker
492a
590
Control Printed Circuit Board fuse
PNEUMATIC CHARACTERISTICS
REQUIREMENT
Voltage Frequency Operating Current
(nominal)
120 + 10 V AC 60 Hz 2.9 amps
120 + 10 VAC 60 Hz 3.3 amps
350 W average
400 W average
9 V, long-life alkaline
Double-insulated
5 amp, time-delay
6 amp, time-delay
63 mA, 250 VAC
PARAMETER
Flow rate
492a
590
Oxygen concentration*
492a
590
Static delivery pressure
System operating pressure
MEASUREMENT
0 to 4 Ipm with .25 liter increments
0 to 5 Ipm with .25 liter increments
95 + 3% for 1-3 Ibm
92 + 3% at 4 Ibm
95 + 3% for 1-4 ipm
90 + 3% at 5 Ipm
5 + 0.5 psig
Cycles from approximately 14 to 29 psig
“Atmospheric pressure at altitudes of 3000 ft. (914 m) above sea level may decrease oxygen concentration
levels.
**Unit is Canadian Standard Association (CSA) certified as being Double Insulated.
Companion 492a/590 Oxygen Concentrators
1-5 Service Manual 5-15-91
1.3 Unpacking and Receiving Inspection
Unpack and inspect the Companion 492a/590 as follows:
a.
по ео
Examine shipping container for exterior damage. If container is damaged or contents are
suspected of being damaged, contact carrier to request that inspection of damage be made.
Photograph damaged container before concentrator is unpacked. Contact the shipping point
immediately.
Position shipping container so that shipping arrows are pointing up.
NOTE
If staples were used to seal the shipping carton, take care in
opening and removing the staples so that the shipping carton
will not be damaged.
Open shipping carton top flaps and lay carton on its side.
Hold container down with one hand. Grasp handle, and slide concentrator out of container.
Stand upright on casters and remove yellow cap from oxygen outlet.
Compare packing slip attached to container's exterior with shipment received. If any discrepancies
exist, contact Puritan-Bennett immediately.
Thoroughly inspect the exterior of the Companion 492a/590 for damage.
SAVE ALL PACKING MATERIALS AND SHIPPING CONTAINER FOR REUSE.
NOTE
Contact Puritan-Bennett for a returned goods authorization
(RGA) number if it is necessary to return a unit to the factory.
Write the RGA number on the outside of carton before
shipping.
When required, repack the Companion 492a/590 as follows:
~~ ® ao OT
a
Disconnect any fitting or accessory at oxygen outlet.
Replace oxygen outlet cap (yellow).
Ensure that power cord is wrapped around rear holder.
Ensure that side filter compartment door is securely in place.
Place concentrator inside foam-lined shipping container.
Close the two shorter container flaps, then the two longer flaps.
Secure container with packing tape.
CAUTION
Report any problems found during inspection to freight carrier
or contact Puritan-Bennett Oxygen Concentrator Division for
assistance if necessary.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-6
1.4 Operating Procedures
This section provides the operational check and the operating instructions for the Companion 492a/590.
1.4.1 Operational Check
Perform the following steps before initial use of concentrator at patient site.
NOTE
The use of a properly calibrated oxygen analyzer is required.
a. Ensure that the following filters are clean and securely in place. (Figure 1-3)
Item Location
Air inlet filter Side panel
Compressor inlet prefilter Prefilter housing in filter compartment
Compressor inlet bacteria filter Filter compartment
b. Verity that all internal pressure has been vented by tuming the flowmeter knob fully counterclock-
wise. The flowmeter ball should indicate zero flow.
c. Set POWER switch on top panel to ON before connecting power cord to outlet. If audio alarm
does not sound or is weak, replace nine-volt battery in side compartment. Set POWER switch to
OFF.
d. Connect power cord to AC outlet.
NOTE
If concentrator has been exposed totemperatures below 40°F
(14°C), allow it to reach ambient temperature (approximately
30 minutes) before turning on.
e. Set POWER switch to ON and flowmeter to maximum Ipm on scale. The audio alarm will sound
for a maximum of one minute, then cease. If alarm does not sound or continues to sound after
one minute, see section 3, Performance Verification and Troubleshooting.
f. Verify that POWER switch L.E.D. is illuminated. If indicator is not illuminated, see section 3
Performance Verification and Troubleshooting.
g. Note hour meter reading. (Figure 1-3)
Companion 492a/590 Oxygen Concentrators
1-7 Service Manual 5-15-91
AIR INLET
FILTER |
COMPRESSOR INLET
PREFILTER
Figure 1-3: Side Panel View
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
1-8
COMPRESSOR INLET
BACTERIA FILTER
HOURMETER
1.4.1 Operational Check (continued)
NOTE
Allow concentrator to run (stabilize) for approximately 20
minutes before proceeding.
п. Connect calibrated oxygen analyzerto concentrator’'s oxygen outlet as shown in Figure 1-4. Follow
Oxygen Analyzer manufacturers recommendations for proper connection to concentrator.
I After the 20 minute stabilization time, verify that the concentration is 92% + 3% at 4 Ipm for the
492a and 90% + 3% at 5 Ipm for the 590.
j- If the unit is equipped with the optional OCI verify that the green (normal) L.E.D. is illuminated.
If oxygen concentration is not as specified, see section 3.3, Troubleshooting.
K. Ensure that air flow is emitted through cooling air exhaust vents at base of concentrator (side
opposite air inlet filter).
Perform routine maintenance as outlined in Table 1-2. If concentrator is operated in a dusty environment, the
recommended frequency of routine maintenance should be increased.
Figure 1-4: Oxygen Concentration Testing
Companion 492a/590 Oxygen Concentrators
1-9 Service Manual 5-15-91
1.4.2 Operating Instructions
NOTE
For additional operating instructions, refer to the appropriate
Patient Instruction Manual listed in subsection 1.1.1, Optional
Accessories and Literature.
Perform the following steps:
a. Ensure that air inlet filter (Figure 1-3) is clean.
b. Position concentrator near appropriate AC outlet so that power cord can be connected without
using extension cord.
WARNING
Oxygen greatly accelerates combustion. Keep concentrator
at least five feet (1.5 m) away from sources of heat, smokers,
open flames, or electrical equipment that may spark or
become heated during operation. Oil and grease are highly
flammable. Do not allow contact with concentrator.
CAUTION
Keep air inlet filter and cooling air exhaust vents at least six
inches (15.2 cm) away from walls or draperies. Obstacles
next to unit impede room air from entering concentrator.
c. Set flowmeter control knob to setting prescribed by physician. Do not change setting unless
ordered by physician.
NOTE
Refer to 1.1.1., Optional Equipment, for Puritan-Bennett part
numbers of accessories used in steps d and e.
d. If humidified oxygen has been prescribed by physician, proceed as follows:
1)
2)
3)
4)
5)
Remove humidifier adapter (Figure 1-5) from side panel filter compartment.
Connect humidifier adapter to a properly filled bubble humidifier (Figure 1-6).
Attach the humidifier and adapter to the oxygen outlet spout at unit's front (Figure 1-7).
Connect oxygen tubing to humidifier outlet (Figure 1-8).
Proceed to step f.
e. If humidified oxygen has not been prescribed by physician, proceed as follows:
1)
2)
3)
Place wing nut on tail piece to form tubing adapter (Figure 1-5).
Connect tubing adapter to oxygen outlet at unit's front.
Connect oxygen tubing to tubing adapter (Figure 1-9).
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-10
‘a 1.4.2 Operating Instructions (continued)
f. Connect power cord to AC outlet.
NOTE
If concentrator has been exposed to temperatures below 40°F
(14°C), allow it to reach ambient temperature (approximately
30 minutes) before turning on.
g. Set POWER switch to ON. The audio alarm will sound for a maximum of on minute, then cease.
NOTE
Allow concentrator to run (stabilize) for approximately 20
minutes before using.
NOTE
If concentrator is accidently tipped over, impact of hitting floor
may activate the Printed Circuit Board relay and the audio
alarm may sound. Return concentrator to upright position. Set
POWER switch to OFF, and after five seconds back to ON.
Alarm may sound for a maximum of one minute, then cease.
\ HUMIDIFIER ADAPTER
у Figure 1-5: Oxygen Outlet Adapters
Companion 492a/590 Oxygen Concentrators
1-11 Service Manual 5-15-91
Figure 1-6: Humidifier Adapter Attachment
Figure 1-7: Humidifier Attachment
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-12
Figure 1-9: Oxygen Tubing Attachment To Adapter
Companion 492a/530 Oxygen Concentrators
1-13 Service Manual 5-15-91
1.5 Routine Maintenance
Perform routine maintenance as outlined in Table 1-2. If the concentrator is operated in a dusty environment,
the frequency of maintenance should be increased.
TABLE 1-2 MAINTENANCE SCHEDULE
EBEQUENCY НЕМ ACTION
1. Daily Humidifier bottle Refer to the appropriate manufacturer's operating
P/N 001083 manual.
2. Daily Air inlet filter a. Remove from side panel (Figure 1-3).
P/N 492672
b. Vacuum or wash with mild detergent and water.
Rinse and air dry.
d. Return to side panel.
O
3. Monthly" Compressor inlet a. Remove filter compartment door of concentrator
prefilter (Figure 1-3).
P/N 492193
b. Pull up on inlet prefilter housing to disconnect
from bacteria filter. (Figure 1-9)
C. Remove both compressor inlet prefilters from
the prefilter housing (Figure 1-9) and exchange
the top filter for a new one.
NOTE
The bottom inlet prefilter should also be
replaced if dirty.
d. Reposition the inlet prefilters in the prefilter
housing so that the new filter is on the bottom
and the filter previously on the bottom is now on
top.
e. Reconnect inlet prefilter housing to bacteria filter
by pushing down.
4. Every Six (6) Compressor inlet a. Remove filter compartment door of concentrator
months bacteria filter (Figure 1-3).
P/N 492190
b. Pull up on bacteria filter to disconnect from
connector.
c. Separate prefilter housing from compressor inlet
bacteria filter (Figure 1-9).
d. Replace bacteria filter.
e. Insert prefilter housing onto bacteria filter.
f. Reconnect filter assembly to filter connector,
and reinstall compartment door.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-14
TABLE 1-2 MAINTENANCE SCHEDULE
FREQUENCY
5. Every 1 Year
6. Every 15000 Hrs.
7. As needed
8. As needed
9. As needed
ITEM
Alarm battery
P/N 492297
Outlet gas filter
P/N 492141
Cabinet exterior
Oxygen connect-
ing tubing and
cannula
Cabinet interior
ACTION
a. Remove filter compartment door of concentrator
(Figure 1-3).
b. Unplug connector from battery.
с. Remove and discard battery.
d. Install new battery and connect plug to battery
terminals.
e. Reinstall filter compartment door.
Refer to outlet gas filter service procedure Section 4.
WARNING
To prevent a possibility of electrical shock
to the operator or damage to the con-
centrator, disconnect power cord before
cleaning.
Wipe with damp cloth or sponge and mild house hold
cleaner.
Clean or replace.
a. Open concentrator cabinet. Refer to the cabinet
service procedure in Section 4.
CAUTION
Ensure that the compressed air supply
used to clean the cabinet interior is clean
and oil-free.
b. Blow or vacuum any dust which may have
accumulated inside the concentrator.
Leave air inlet and exhaust vents un-
obstructed.
С. Close concentrator cabinet.
“For those units with OCI installed, change the compressor inlet prefilter every 3 months or as necessary.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
| — INLET PREFILTERS
INLET PREFILTER
HOUSING
INLET BACTERIA
FILTER
Figure 1-10: Side Panel Compartment Filters
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-16
1.6 Recommended Tools and Test Equipment
Standard test equipment tools, and materials used to test and service the Companion 492a/590 are listed below.
If equipment other than specified is used, the substitute must be equal to or better than that listed.
TABLE 1-3. RECOMMENDED TOOLS AND TEST EQUIPMENT
TEST EQUIPMENT
DESCRIPTION
Digital Multimeter
Oxygen Analyzer
Test Flowmeter
Stopwatch
Pneumatic Test Kit
SPECIAL TOOLS
Kit, Pop-Rivet Gun
Pliers, Truarc (for internal retaining
ring with 1/8-inch hole)
Wrench, Torque
#0 Phillips screwdriver
#2 Phillips screwdriver
(min. shaft length of 7 in. recommended)
#2 Magnetic Phillips screwdriver
SERVICE MATERIALS
MODEL/PART
MANUFACTURER NUMBER
John Fluke Co 8000A
Seattle, WA
Hudson 6400, cell 5500
Sierra Instruments 820 Top Trak
Local Supplier NA
Puritan-Bennett P/N 492381
Jensen Tools, Inc Y 339B750
Waldes Kohinoor, Inc
0309 (90” tip)
Alcohol, Isopropyl
Loctite
Swabs, Cotton
Pipe Cement
Leak Detector
Cabinet Touch-Up Paint (4 0z)
Torque Controls TS-30
Local Supplier NA
Local Supplier NA
Local Supplier NA
Local Supplier NA
Loctite Corp 242,680,262
Hardwood Products, Inc 806
Flouramics Inc. LOX 8
Puritan-Bennett Corp 775272
Puritan-Bennett Corp 492648
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 1-18 (blank)
SECTION 2. THEORY OF OPERATION
This section details the operational theory for the Companion 492a/590 Oxygen Concentrators. It includes an
overview of the operation, the pneumatic system and components, the electrical system and components, the
pressure-swing process, and the safety features.
NOTE
Numeric values found in this section are nominal values used
for descriptive purposes only. Due to atmospheric pressure
changes, compressor strength and other factors, pressure
characteristics may vary.
Companion 492a/590 Oxygen Concentrator
2-1 Service Manual 5-15-91
2.1 OVERVIEW OF CONCENTRATOR OPERATION
The Companion Oxygen Concentrators use the pressure swing method of concentrating oxygen from room air.
In this method, compressed air is alternately applied to two canisters containing molecular sieve material which
adsorbs (attracts) nitrogen from the air and allows oxygen and trace gases to pass through.
Molecular sieves belong to a class of compounds known as zeolites. Zeolites are highly porous adsorbents both
naturally occurring and synthetically produced. Within each granule of man-made zeolite exists a system of
precisely arrayed cavities and pores. These are uniform in size and molecular dimension so that molecules are
either readily adsorbed or completely excluded.
In an oxygen concentrator, nitrogen-selective zeolite (molecular sieve material) is used to adsorb nitrogen
molecules in a pressurized tank. It is by physical force (pressure) that this molecular sieve traps nitrogen and
yet allows other gases to flow through the sieve bed. Nitrogen molecules are then desorbed (released) by
venting the sieve bed to the atmosphere thereby reducing the pressure and the adsorptive force.
High oxygen concentration and long sieve bed life is accomplished by the proper use of pressure swing cycles
and efficient purging. However, molecular sieve has a strong affinity for water and will displace any other
molecule in favor of H20. When this happens, nitrogen-selective zeolite loses its affinity for nitrogen and can
be considered to be contaminated. During normal operation though, room humidity does not affect the sieve's
ability to adsorb nitrogen. A thin layer of sieve at the top of the bed is used as a desiccant to wick humidity from
the supply gas preventing further contamination during a concentrating cycle. This moisture is atomized back
into the atmosphere during the exhaust phase. Regeneration of the sieve bed is then completed by purging the
exhausting tank with concentrated, humidity free oxygen.
The pneumatic system (Figure 2-1), under the control of the electrical system, produces a source of compressed
supply air, switches supply air between two molecular sieve canisters, regulates internal pressures, and controls
the final output flow rate of oxygen. The components of this system are the compressor and capacitor, heat
exchanger, four canisters, three solenoid valves, five pilot valves, two restrictors, pressure switch, regulator,
two check valves, flowmeter, expansion chamber, muffler, and four filters.
The electrical system (Figure 2-2) provides the controlling and monitoring functions for the concentrator and
distributes the electrical power required for operation. In addition to the compressor and solenoids mentioned
above, the components of this system are an electronic printed circuit board (PCB), power switch, audio alarm,
hour meter, nine-volt battery, circuit breaker, cooling fan, and an Oxygen Concentration Indicator (OCI) system
(optional).
Following is a description of each of the components that make up the two concentrator systems.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-2
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D 24 VDC, RETUAN(-)
E 9 VDE, SUPPLY(+)
F 9 VDE, RETUAN(-)
+ (GS 9/12 VDC, RETURN(.)
( H 9/12 VDC, RETUAN(-)
* Supply is 12 VDC when concentrator is
connected to AC power. In case of
power failure, supply reverts to 9 VOC
supplied by the battery.
Figure 2-2: Electrical Diagram
Companion 492a/590 Oxygen Concentrator
2-5 (2-6 blank) Service Manual 5-15-91
2.2 PNEUMATIC SYSTEM COMPONENTS
Air Inlet Fil
The air inlet filter (Figure 2-3) is a gross particle filter made of a reusable foam material. It filters large particulate
material from air drawn into the concentrator cabinet by the action of the cooling fan. It is secured to the right
hand side of the cabinet with velcro strips and may be easily cleaned for servicing. (See Table 1-2 Maintenance
Schedule).
nl filter
The compressor inlet prefilter (Figure 2-3 & 2-4) consists of two felt elements that filter particulate matter and
smoke from room air drawn into the compressor. Approximately 60 to 70 liters of air are drawn through the filters
each minute. The felt filter elements are individually replaceable. (See Table 1-2 Maintenance Schedule).
Inl ria Filter
The compressor inlet bacteria filter (Figure 2-3 & 2-4) consists of a bacteria grade element in a sealed housing
that filters bacteria and particulate matter greater than .2 microns in diameter from room air drawn into the
compressor. (See Table 1-2 Maintenance Schedule).
Both the inlet prefilter and bacteria filter are located in the filter compartment accessible from the outside of the
right hand side of the cabinet. The combination of the inlet prefilter and the bacteria filter enables the compressor
to provide clean air to the molecular sieves canisters.
nlet Sil
The inlet silencer (Figure 2-6) is a hollow chamber molded into the compressor platform. The inlet silencer
muffles the sound of the air being pulled into the compressor's inlet.
_- COMPRESSOR INLET
PREFILTER
AIR INLET
FILTER
COMPRESSOR INLET
BACTERIA FILTER
Figure 2-3: Side Panel View
Companion 492a/590 Oxygen Concentrator
2-7 Service Manual 5-15-91
Г
|_— INLET PREFILTERS
INLET PREFILTER
HOUSING
INLET BACTERIA
FILTER
Figure 2-4: Compressor Inlet Filters
2.2 PNEUMATIC SYSTEM COMPONENTS (continued)
Compressor
The compressor (Figure 2-5) is a piston motor-compressor with dual cooling fans and an open chassis design.
The two fans draw cooling air in from each end of the compressor and exhaust it out the center to provide equal
cooling of the bearings as well as the motor. An automatic thermal cut-out switch in the motor interrupts electrical
power to the compressor if it overheats.
The function of the compressor is to compress filtered air to an average system working pressure of 18 PSI.
This compressed air is routed to the molecular sieve canisters which require air under pressure to produce
oxygen. Compressor maintenance can be reduced by proper ventilation and filtering.
Capacitor
The capacitor (Figure 2-6) is an electrical storage device used to help start the compressor motor and improve
compressor performance during operation.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-8
HEAT
EXCHANGER
COMPRESSOR
Figure 2-5: Compressor Drawer, Front View
INLET
SILENCER
CAPACITOR
Figure 2-6: Compressor Drawer, Bottom View
Companion 492a/590 Oxygen Concentrator
2-9 Service Manual 5-15-91
22 PNEUMATIC SYSTEM COMPONENTS (continued)
Heat Exchanger
The heat exchanger (Figure 2-5) is a loop of aluminum tubing that routes the compressor outlet gas to the
reservoir canister. The heat exchanger is located in the path of the compressor cooling air flow and is designed
to dissipate heat through the walls of the tube. This component and the four aluminum canisters (product, sieve
(2), and reservoir) create a "heat sink” to allow warm compressed gas to cool by dissipation during the
concentrator's operation.
В ir Canis!
The reservoir canister (Figure 2-10) is a hollow aluminum tank, approximately 2.3 liters in volume, that stores
air from the compressor under pressure. The reservoir canister acts as a pneumatic pulsation dampener to
moderate the pressure pulses generated by the two compressor pistons. The reservoir canister then supplies
the large volume of air required to charge the sieve canister. This source of compressed air is also used to
pressurize the five pilot valves under the control of the three solenoids. In addition, this canister plays a major
role in the heat dissipation process.
Pilot Air Fil
The pilot air filter (Figure 2-7) is a small sintered-brass element in a sealed plastic housing that filters particulate
matter as small as 25 microns in diameter from the pilot line air coming from the reservoir canister. This filtering
action prevents contaminants from accumulating and occluding the small passages in the pilot tubing and
solenoid valves. Normally, this filter should not need to be serviced.
Solenoid Valves
Three miniature 24 VDC solenoid valves (Figure 2-8) are used to control the pressurization of the pilot valves.
By system design, if one sieve bed is open to supply air, then the opposite sieve bed is open to exhaust.
Therefore, if solenoid valve 1 is activated, pilot pressure is applied to supply pilot valve 1 and exhaust pilot vaive
2. If solenoid valve 2 is activated, pilot pressure is applied to supply pilot valve 2 and exhaust pilot valve 1.
Finally, if solenoid valve 3 is activated, pilot pressure is applied to the balance pilot valve.
Pilot Valves
Five air piloted, diaphragm-poppet valves (Figure 2-8) are used to route gas flow into and out of the two sieve
canisters. When pilot pressure is applied to the valve's pilot port, the poppet assembly (a brass stem with two
rubber diaphragms at each end) is forced down, allowing gas to flow through the valve. When pilot pressure is
removed, pressure against the unbalanced area of the bottom diaphragm moves the poppet assembly against
its seat to stop flow through.the valve (Figure 2-9). A spring, used only in the two exhaust pilot valves, keeps
the valve closed when the concentrator is turned off to prevent contamination of the molecular sieve material.
When a supply pilot valve is actuated, compressed air from the reservoir canister is admitted to a sieve canister
to begin the oxygen concentration process. Simultaneously, the corresponding exhaust pilot valve is actuated
and adsorbed nitrogen from a sieve canister is exhausted through the valve and into the expansion chamber
and muffler and to atmosphere. When the balance pilot valve is activated, the sieve canisters are pneumatically
connected to allow the oxygen layer at the bottom of one sieve bed to flow to the opposite bed. This pre-charge
of oxygen gas increases the pressure in a bed before it begins its concentrating cycle for greater efficiency in
the nitrogen adsorption process.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-10
PILOT AIR
FILTER
Figure 2-7: Pilot Air Filter
EXHAUST PILOT
VALVE 1
EXHAUST PILOT
VALVE 2
SOLENOID 1
SOLENOID 2
SUPPLY PILOT
VALVE 2
SUPPLY PILOT
VALVE 1
SOLENOID 3
1 |
BALANCE PILOT
yd IM AR
Figure 2-8: Solenoid and Pilot Valves
Companion 492a/590 Oxygen Concentrator
2-11 Service Manual 5-15-91
UNACTUATED ACTUATED
E Pilot Pressure (77) sieve Gas
* Spring used in Exhaust Pilot Valves only.
Figure 2-9: Pilot Valve Operation
2.2 PNEUMATIC SYSTEM COMPONENTS (continued)
¡ev nister
The two sieve canisters (Figure 2-10) are aluminum tanks that contain granular molecular sieve material, a
nitrogen selective zeolite that strips nitrogen from air by an adsorption process while allowing oxygen and trace
gases to pass through the sieve.
Nitrogen adsorption occurs when the sieve canister is pressurized from approximately 14 to 20 PSI with
compressed room air. A sieve canister that is saturated with adsorbed nitrogen is regenerated (desorbed) by
venting the sieve canister pressure to atmospheric pressure. Some of the product oxygen is supplied as a purge
gas to increase the efficiency of regenerating the sieve by removing any residual nitrogen molecules remaining
in the canister. This oxygen readily combines with the nitrogen and is flushed from the canister by the purge
pressure.
The sieve canisters must be kept sealed from the atmosphere to prevent contamination of the molecular sieve
material by migration of moisture (humidity) into the canister. Because of sieve material's high affinity for water,
moisture drawn into the sieve canister without proper purging action will render the sieve useless for future
nitrogen adsorption.
Expansion Chamber and Muffler
The expansion chamber/muffler assembly (Figure 2-11) consists of a paper filter element and a plastic
foam-lined chamber that is connected to the exhaust tube coming from the exhaust pilot valves. The assembly
effectively muffles the sound of gas exhausting to atmosphere when the sieve canisters are depressurized
(desorbed) during the regeneration (exhaust) cycle.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-12
PRODUCT
CANISTER
SIEVE
CANISTER 1
RESERVOIR
CANISTER
SIEVE
CANISTER 2
Figure 2-10: Sieve Canisters
EXPANSION ———————
CHAMBER Barri 4 Dh) Ar
MUFFLER
Figure 2-11: Expansion Chamber & Muffler
Companion 492a/590 Oxygen Concentrator
2-13 Service Manual 5-15-91
2.2 PNEUMATIC SYSTEM COMPONENTS (continued)
Restrictor Tube Assemblies
Two restrictor tubes (Figure 2-12) are located just above the balance pilot valve between the tubing coming
from the outlets of the sieve canisters and the product tank. Each restrictor tube assembly contains an orifice
drilled to a specific size and a number recorded on the tube for size identification. This number represents the
liter flow of a gas through the orifice at a standard pressure.
While supply air is entering one sieve bed, the restrictor creates back pressure in this canister and thus
determines the rate at which room air can flow through the sieve bed. Meanwhile, the opposite restrictor acts
as a metering device allowing a small amount of product gas (oxygen) to pass through this orifice and into the
bottom of the exhausting sieve bed for purge. Thus, increasing or decreasing the orifice size will alter the balance
of pressure within the sieve beds.
This regulation of pressure allows a filling canister to pressurize properly for maximum nitrogen adsorption. The
product tank pressure is maintained by the "checking" action of the restrictor tube of the exhausting tank while
still permitting a sufficient amount of product oxygen to pass through this orifice and into the exhausting canister
for efficient purge of any residual nitrogen gas.
Product Canister
The product canister (Figure 2-10) is a hollow aluminum tank, approximately one liter volume, that stores product
gas (oxygen) from the sieve canisters under pressure. The product canister functions as a reservoir of oxygen
to ensure a smooth, steady outlet flow as the unit cycles back and forth between the sieve canisters. It is also
responsible for providing sufficient pressure to permit some product oxygen to be used as purge gas through
the restrictors. The amount of purge oxygen then is directly dependent upon the product tank pressure. In turn
the product tank pressure is affected by both the size of the restrictors and the flowmeter setting.
Pressure Switch
The electro-pneumatic, normally closed pressure switch (Figure 2-13) is mounted on the product canister and
senses the pressure of the product gas (oxygen) in the product canister. Normal product canister pressure
keeps the switch contacts open. If the product canister pressure drops below the pressure switch threshold
setting of 4.0 PSI, the switch contacts close and the audio alarm will sound.
Pressure Regulator
The adjustable pressure regulator (Figure 2-13) reduces a nominal oxygen pressure in the product canister to
a constant 5 PSI outlet pressure. The concentrator flowmeter requires a constant 5 PSI source pressure to
accurately control the flow of oxygen through the flowmeter and to the patient.
Vacuum Check Valve
The vacuum check valve (Figure 2-13), located on the output side of the regulator, functions as a siphon break
when the concentrator cools down after being shut off. The valve prevents a vacuum, created when gas in the
product canister cools after the concentrator is shut off, from drawing water in a humidifier bottle into the
flowmeter. When the concentrator is operating, the checking action of the valve prevents output flow from
bleeding to atmosphere.
-Line Ch lv
The in-line check valve (Figure 2-14) is installed in the outlet gas tubing between the pressure regulator and
outlet gas bacteria filter. The purpose of the check valve is to ensure room air does not migrate back into the
sieve canisters through the gas outlet circuit when the concentrator is turned OFF. The check valve is installed
in the outlet gas tubing with the black connector toward the outlet of the concentrator.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-14
Figure 2-12: Restrictor Tubes
Figure 2-13: Product Canister, Regulator and
Vacuum Check Valve
Companion 492a/590 Oxygen Concentrator
2-15 Service Manual 5-15-91
22 PNEUMATIC SYSTEM COMPONENTS (continued)
Qutlet Gas Filter
The outlet gas filter (Figure 2-14) consists of a bacteria-grade element in a sealed housing that filters particulate
matter greater than 0.3 microns in diameter from the oxygen flowing to the flowmeter and eventually to the
patient. This filter provides clean, bacteria-free oxygen to the patient. (See Table 1-2 Maintenance Schedule).
Elowmeter
The flowmeter (Figure 2-15) is a back-pressure compensated gas measuring device which controls the amount
of product oxygen dispensed to the patient. It consists of a tapered hollow tube inscribed with flow markings, a
needle valve, an adjusting knob, an indicator ball, and an inlet and outlet port. With the concentrator operating,
the ball will move up in the tube indicating the amount of oxygen delivered to the patient.
2.3 ELECTRICAL SYSTEM COMPONENTS
Power Switch
The power switch (Figure 2-15) is a double-pole single-throw rocker type with a bezel mounted green L.E.D.
indicator. When the switch is in the ON position, one set of contacts routes 24.6 VDC to the coil of a relay
mounted on the control printed circuit board. This relay activates the compressor, cooling fan, hour meter, and
printed circuit board timing circuits. The second set of power switch contacts routes DC current from the circuit
board to the pressure switch and audio alarm. This DC current is provided at 12 volts while the concentrator is
running and drops to 9 volts, provided by the nine-volt battery, in case of a power failure. (NOTE: If the power
switch is set to ON, the audio alarm will sound when the pressure switch contacts close, regardless of whether
the concentrator is plugged in or not).
Concentrators equipped with the optional Oxygen Concentration Indicator (OCI) incorporate a push button type
power switch. Refer to section 6 for details.
С | Printed Circuit Board
The control printed circuit board (PCB) (Figure 2-14) contains the electronic logic for controlling the operation
of the concentrator. The PCB contains a step-down transformer and a full-wave bridge rectifier that converts
AC voltage to 24 VDC for PCB use and for powering the solenoids. A 63 milli-ampere 250 VAC fuse protects
the PCB components in the event of an over-current condition. The circuitry includes a timing generator and a
detector circuit.
The timing generator produces pulses that are used by the alternate/dwell circuit and the pre-charge time circuit.
The alternate/dwell circuit uses the timing pulses to activate solenoid valve 1 and solenoid valve 2 alternately
for approximately eight seconds each. A dwell period, approximately 0.8 seconds occurring between the
activation of the solenoids valves 1 and 2 enables the balance time circuit to activate solenoid valve 3 for the
balance cycle.
The detector circuit activates a relay if an open condition is detected in a solenoid’s electrical circuit caused,
for example, by a disconnected wire or an open solenoid coil. The relay, when activated, removes power from
the compressor, cooling fan, and solenoids. The detector circuit thus prevents the concentrator from operating
with an electrical failure of the solenoid circuit that could contaminate the molecular sieve material and thereby
destroy its nitrogen-adsorbing properties.
Since complementary metal-oxide semiconductor (CMOS) integrated circuits are present on the PCB, care
must be used when handling the board to prevent static discharge from possibly damaging board components.
Always handle PCBs by their edges only and store them in a static-proof bag.
Companion 4392a/590 Oxygen Concentrator
Service Manual 5-15-91 2-16
CONTROL PRINTED
CIRCUIT BOARD
IN-LINE
CHECK VALVE
FLOWMETER
—— OUTLET
GAS FILTER
_ E |
Figure 2-14: Right Cabinet, Interior View
eo — 8 SWITCH
Figure 2-15: Control Panel
Companion 492a/590 Oxygen Concentrator
2-17 Service Manual 5-15-91
2.3 ELECTRICAL SYSTEM COMPONENTS (continued)
Cooling Fan
Cooling-air flow through the concentrator (Figure 2-16) is provided by a fan (Figure 2-17) located beneath the
compressor. The fan draws in cooling air through the air inlet filter located on the upper right hand side of the
cabinet. The cooling air travels down across the concentrator's four canisters and the compressor and is
exhausted out the bottom left side of the cabinet. Both the intake air filter and exhaust vents of the cabinet must
be free of obstructions for the cooling system to function properly.
ia (439 Ss |
— D RY J
К
J'@ (Gé
Figure 2-16: Cooling Air Flow
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-18
COOLING
FAN
Figure 2-17: Cooling Fan
2.3 ELECTRICAL SYSTEM COMPONENTS (continued)
Hour Meter
The digital hour meter (Figure 2-18) located in the filter compartment, indicates total concentrator running time.
The meter records up to 99,999.99 hours before resetting to zero.
ircui ker
The AC electrical system is protected from short circuits and power surges by a five-ampere (for Companion
492a) or a six-ampere (for Companion 590) resettable push-button circuit breaker (Figure 2-18) located in the
filter compartment.
Audio Alarm
The audio alarm (Figure 2-18) consists of an electronic module powered by either the control printed circuit
board or the nine-volt battery. When the POWER switch is in the ON position, and the pressure switch contacts
are closed, the alarm sounds. If the concentrator is operating on AC, the audio alarm is powered by 12 VDC
from the circuit board. In the event of an AC power failure, the audible alarm will be powered by the nine-volt
battery.
Battery
A nine-volt long-life alkaline battery (Figure 2-18) located in the side panel filter compartment, provides back-up
power to the audio alarm. See Table 1-2. Maintenance Schedule.
X n Concentration Indicator
(See Section 6)
Companion 492a/590 Oxygen Concentrator
2-19 Service Manual 5-15-91
BATTERY
— CIRCUIT
BREAKER
AUDIO
ALARM HOURMETER
Figure 2-18: Filter Compartment
2.4 CONCENTRATOR SYSTEM OPERATION
The Companion 492a/590 concentrates oxygen from room air by a process known as pressure-swing
adsorption. This cyclic process involves two molecular sieve canisters which are alternately pressurized to
approximately 20 PSI with room air and then vented to atmospheric pressure. The nitrogen-selective zeolite in
the molecular sieve canisters adsorbs nitrogen from air under pressure and, in turn, desorbs (releases) nitrogen
when the canister is vented to atmospheric pressure. The process is further enhanced by the incorporation of
a pressure-balance cycle and by the use of product gas (oxygen) as purge gas to increase the efficiency of
regenerating the sieve.
A complete system cycle of approximately 17.6 seconds in duration consists of two 8-second concentrating
cycles and two 0.8-second balance cycles. Gas flow through the Companion 492a/590 pneumatic system is
shown in Figures 2-19 through 2-21.
| in
Discussion of the complete system cycle may begin with sieve canister 1 concentrating oxygen (Figure 2-19).
The compressor pressurizes the reservoir canister, the supply air tubing, and the pilot air tubing with filtered
room air. At the appropriate time, the electronic timing circuit on the PCB sends a 24 VDC signal to energize
solenoid valve 1 for approximately eight seconds. Then, pilot gas under pressure flows through the solenoid
and is applied to the pilot ports of supply pilot valve 1 and exhaust pilot valve 2, simultaneously opening each
pilot valve.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 2-20
2.4 CONCENTRATOR SYSTEM OPERATION (continued)
Supply air from the reservoir canister passes through open supply pilot valve 1 and into sieve canister 1 where
first, water vapor is attracted and held in the top of the canister, then nitrogen is adsorbed and oxygen-rich gas
flows to the product canister metered by restrictor 1. Next, some oxygen-rich gas passes through restrictor 2
and into sieve canister 2 once the pressure in this canister has exhausted to atmosphere through exhaust pilot
valve 2. This purge oxygen migrates up into sieve canister 2 to increase the efficiency of regenerating the
molecular sieve by removing any trace nitrogen in the canister.
Oxygen in the product canister, at a pressure higher than that required at the flowmeter, is reduced and
maintained at 5 PSI by the pressure regulator. Oxygen then passes through the outlet gas filter, the flowmeter,
and finally the oxygen outlet.
Balance Cycle 1
After sieve canister 1 has been concentrating for approximately eight seconds, the electronic timing circuit on
the PCB simultaneously de-energizes solenoid valve 1 and energizes solenoid valve 3 for approximately 0.8
seconds (Figure 2-20). When solenoid valve 1 is de-energized, the pilot pressure source for supply pilot valve
1 and exhaust pilot valve 2 is cut off and the piloting pressure for the valves is vented to atmosphere through
the normally open port of solenoid valve 1. Pressure against the unbalanced area of the bottom diaphragm
closes supply pilot vaive 1. An internal spring closes exhaust pilot valve 2. Now solenoid valve 3 is energized
and pilot air pressure is applied to the pilot port of the balance pilot valve to open the valve.
With the balance pilot valve open and the remaining pilot valves closed, oxygen-rich gas at system pressure
from sieve canister 1 is routed directly to sieve canister 2 to increase pressure in this canister in preparation for
its concentrating cycle.
The placement of restrictor 1 and restrictor 2 downstream of the balance pilot valve ports allows gas from sieve
canister 1 under pressure to flow into and pressurize sieve canister 2 during the balance cycle with minimal
effect on gas in the product canister. This increase of pressure in sieve canister 2 during the balance cycle helps
ensure immediate oxygen flow from this canister at the beginning of its concentrating cycle.
Sieve Canister 2 C ina Cyl
At the end of balance cycle 1, the electronic timing circuit on the PCB simultaneously de-energizes solenoid
valve 3 and energizes solenoid valve 2 for approximately eight seconds (Figure 2-21). When solenoid valve 3
is de-energized, the pilot pressure source for the balance pilot valve is cut off, and the piloting pressure for this
valve is vented to atmosphere through the normally open port of solenoid valve 3. Pressure against the
unbalanced area of the bottom diaphragm closes the balance pilot valve. When solenoid valve 2 is energized,
pilot air pressure is applied to the pilot ports of supply pilot valve 2 and exhaust pilot valve 1 and simultaneously
opens each pilot valve.
Supply air passes through open supply pilot valve 2 and into sieve canister 2 where water vapor is trapped and
nitrogen is adsorbed while oxygen-rich gas flows to the product canister through restrictor 2. Meanwhile, gas
is allowed to exhaust out of sieve canister 1 through open exhaust pilot valve 1 and to atmosphere. This exhaust
gas drives any water vapor from the top of the sieve bed back into the room. (Maintaining this desiccant layer
through proper valving action is critical to long sieve bed life). Then, some oxygen-rich gas also passes through
restrictor 1 and into sieve canister 1 once the pressure in sieve canister 1 has exhausted to the atmosphere
through exhaust pilot valve 1. This purge oxygen migrates up into sieve canister 1 to increase the efficiency of
regenerating the molecular sieve. This cycle duplicates the process of the first concentrating cycle and ensures
constant flow of oxygen to the product canister.
Balan le 2
After sieve canister 2 has been concentrating for approximately eight seconds, the electronic timing circuit on
the PCB simultaneously de-energizes solenoid valve 2 and energizes solenoid valve 3 for approximately 0.8
seconds (Figure 2-20). This cycle then allows the pressure between the two sieve canisters to pre-charge sieve
canister 1 in preparation for its concentrating cycle.
Upon completion of balance cycle 2, the complete system cycle begins again.
Companion 482a/590 Oxygen Concentrator
2-21 Service Manual 5-15-91
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Companion 492a/590 Oxygen Concentrator
2-23 (2-24 blank) Service Manual 5-15-91
a
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Companion 492a/590 Oxygen Concentrator
26 blank) Service Manual 5-15-91
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Companion 492a/590 Oxygen Concentrator
2-27 (2-28 blank) Service Manual 5-15-91
2.5 SAFETY FEATURES
The Companion 492a/590 has an audio alarm, a solenoid valve shut-down feature, and an optional Oxygen
Concentrator Indicator to alert the patient and protect the concentrator in the event of improper operation. The
audio alarm will sound due to inadequate system pressure caused by AC power loss, dity compressor inlet
filters, or leaks/restrictions in the internal pneumatics. When inadequate system pressure is sensed, an
electro-pneumatic pressure switch, mounted on the product canister, activates the aduio alarm. И system
pressure drops below 4.0 PSI, the pressure switch contacts close to activate the audio alarm.
The solenoid shut-down feature consists of a detector circuit on the PCB that monitors the solenoid's electrical
circuits. If an open condition is detected, caused by a disconnected wire or an open solenoid coil, the detector
circuit activates a relay which removes power from the compressor, cooling fan, and the solenoids. This feature
protects the molecular sieve material from contamination in the event of a solenoid electrical problem. The relay
is reset by first correcting the problem and then setting the POWER switch OFF, wait five seconds - then back
ON.
NOTE
Residual pressure in the reservoir canister may prevent the
compressor from starting for up to 20 seconds.
For units equipped with the optional Oxygen Concentration Indicator (OCI) refer to section 6 for details regarding
additional safety features.
Companion 492a/590 Oxygen Concentrator
2-29 Service Manual 5-15-91
SECTION 3. PERFORMANCE VERIFICATION AND TROUBLESHOOTING
It may be necessary to service or verify performance of either the Companion 492a or 590 Oxygen Concentrator.
This section is designed to assist the user in identifying a problem or in checking out the concentrator before
application. There are three conditions where this section may be helpful:
a) To determine the reason for an operational failure.
b) To check overall system operation after the repair or replacement of a component (or system).
c) To verify the concentrator is operating within specification.
For condition a, refer to subsection 3.2; Operational Checklist for help in troubleshooting and problem analysis.
Forconditions b and ¢, subsection 3.1; Performance Verifications will provide checkout procedures for individual
systems and key components. Also, refer to any checkout procedures found in Section 4; Service And Repair
and Section 1; General Information, pages 1-7 through 1-13.
Companion 492a/590 Oxygen Concentrators
3-1 Service Manual 5-15-91
3.1 Performance Verification
This subsection is divided into six performance areas: 1) oxygen concentration, 2) pneumatic, 3) electrical, 4)
cooling, 5) flow, and 6) sound. Although each may be considered a separate system or function for testing, they
all must perform in harmony to achieve the concentrator's end result - high oxygen purity delivered at a
continuous pre-determined flow rate. Should the concentrator fail to pass any performance tests, refer to
subsection 3.2; Operational Checklist, subsection 3.3; Troubleshooting and/or Section 4; Service and Repair,
as needed.
WARNING
The concentrator is electrically powered. To prevent serious injury or death, observe
standard safety procedures when testing the concentrator. The compressor and other
internal components are not grounded. To prevent serious electrical shock, do not touch
metal components when operating the concentrator with cabinet enclosure opened.
Before testing, ensure the following :
a) Airinlet filter, inlet prefilters, inlet bacteria filter, and 9 volt battery are installed (Figure 2-3).
b) Power cord and plug is not damaged or frayed
c) Humidifier bottle and any other delivery apparatus is removed from concentrator outlet.
3.1.1 Oxygen Concentration
Oxygen concentration levels may be checked whenever it is necessary to know that the concentrator is
producing correct oxygen purity. Due to system design, this area of performance verification may be considered
to be the most crucial. Generally, if the concentrator is producing oxygen at or above the minimum specification
at the maximum flow rate, there should be a high confidence level that the other systems are operating properly.
(If your concentrator is equipped with the optional OCI, refer to Section 6 for all information related to this
system).
A) Oxygen Test (Figure 3-1)
1)
2)
3)
With the concentrator plugged in, turn power switch to ON. Set flowmeter to maximum
flowrate (4 LPM or 5 LPM) and allow unit to run for 20 minutes in an open environment.
The flowmeter ball should be occasionally checked and adjusted to ensure that it is
bisected by the line corresponding to the selected flowrate.
Using a properly calibrated oxygen analyzer, follow the manufacturer's recommendations
for how to sample the oxygen outflow of an oxygen concentrator. (Generally, it is
necessary to allow the oxygen to flow across the sampling device of the analyzer. Do not
allow the oxygen to back pressure against the sampling device).
Record the oxygen concentration and compare to the performance specifications in Table
1-1 page 1-5. Should the concentration be below anticipated levels, check the following:
a) Air inlet, inlet prefilters, and inlet bacteria filters are clean.
b) Flowmeter setting is correct (see subsection 3.1.5 Flow).
c) Analyzer accuracy - not calibrated, battery weak, or inadequate oxygen to sampling
device.
If still out of specification, refer to subsection 3.2.1 Low Concentration.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-2
3.1.2 Pneumatic
Figure 3-1: Oxygen Concentration Testing
Because oxygen concentrators are principally pneumatic devices, verifying the pressure specifications in the
Companion concentrator is valuable information in analyzing performance. To do this, the Companion
Pneumatic Test Kit P/N 492381 should be used for all tests in this sub-section.
A) Leak Test
If a concentrator has a leak in a system, it may cause loss of oxygen concentration or possibly
sieve contamination. It is important to leak test the unit before proceeding to pressure tests.
1
2.
Open the cabinet of the Concentrator. (See service procedure step 1, Section 4).
Inspect all hoses, connections, and fittings in the pneumatic system. Check for tightness,
Kinks, wear, or damage to parts. Correct any deficiencies.
Plug concentrator's power cord into AC outlet, turn power switch ON and allow unit to run
for several minutes.
Use a leak detector to carefully spray all connections in the concentrator and observe them
for a bubbling action indicating a leak. Start with the compressor and work through all of the
canisters and valves to the outlet. (The outlet side of each exhaust pilot valve does not need
to be leak tight). If a leak is detected, correct by tightening, resealing with pipe cement, or
repairing the connection.
WARNING
Use caution with leak detector. Do not allow to contact electrical connectors or com-
ponents. Electrical shock or damage to the concentrator may occur.
Companion 492a/590 Oxygen Concentrators
3-3 Service Manual 5-15-91
3.1.2 Pneumatic (continued)
B) Pressure Tests
There are three pressure tests to perform on the Companion concentrator. Do the following steps
to check out the reservoir canister pressure (which indicates sieve canister filling pressure),
product canister pressure and outlet gas pressure. Because the pressure in a concentrator can
vary with altitude, barometric changes and compressor performance, a range of acceptable
pressures are shown for the following tests. With experience you should be able to identify a
normal range for your testing location and concentrators.
1.
2.
Turn concentrator off after completing the leak test described in step A.
Locate 1/4" ID tubing connected betweenthe brass tee, above the restrictor tube assemblies,
and the product tank.
Remove clamp and product tank tubing from tee fitting. Tee in 1/4" ID tubing from pneumatic
test kit (Figure 3-2).
Locate and disconnect the small pilot air tubing leading to the brass nipple on the balance
solenoid valve. Tee in the 1/16" ID tubing from the pneumatic test kit (Figure 3-3).
Set the selector switch on test kit to RSVR (to the left), and turn the concentrator's power
switch ON. Set the flowmeter to the maximum LPM indicated on its scale and allow the unit
to run for several minutes. (NOTE: If needle on gauge reaches 30 PSI, turn unit OFF and
see subsection 3.3; Troubleshooting Guide.
Verify pressure in reservoir canister slowly increases, from 14 + 1.5 PSI (drop point) to 20
+ 2.0 PSI (fill) and then rapidly climbs to 27 + 2.0 PSI (kick). After the kick, the pressure
should fall back to the drop point and repeat. Record all three pressures on two consecutive
cycles. Record only the drop point pressures to the tenth of a PSI, (i.e. 14.2).
Verify the balance (the difference of pressure) at the drop point on two consecutive cycles
is not greater than 0.4 PSI. (i.e. 14.2 and 14.4 PSIG). Refer to subsection 3.4; Balancing
Orifices, if difference is greater than .4 PSIG.
Set selector switch on test kit to PROD (to the right). Verify the product canister pressure is
between 6.5 to 11.0 PSI (Figure 3-2). Although there is not a "balance" of pressure in the
product tank, the pressure on two consecutive cycles should not vary by more than 4.0 PSI.
NOTE
If either of the above tests yield unsatisfactory results, perform Balancing orifices
procedures in subsection 3.4.
10.
11.
12.
With thumb and forefinger, crimp the short 1/4" ID tube above the brass restrictor tube tee.
(Figure 3-4) to restrict the flow of gas to the test kit gauge and product canister.
Gradually reduce gauge pressure until the pressure switch in the product canister activates
the audio alarm. Verify the alarm sounds at 4.0 PSI + 0.2 PSI. Refer to Section 4; Service
And Repair, step 14 if set incorrectly.
Set the concentrator's power switch to OFF and disconnect test kit tubing. Reconnect 1/4"
ID tubing from product tank to restrictor tube assembly brass tee and secure with new clamp.
Reconnect 1/16" 1D tubing to brass nipple at base of balance solenoid valve.
Connect tailpiece (P/N 492587) and wingnut (P/N 492588) outlet adapters to outlet of
concentrator. Connect 1/4" ID tubing of test kit to adapter and verify the test gauge selector
switch is set to PROD (right).
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-4
~ 3.1.2 Pneumatic (continued)
13. Set the concentrator’s power switch to ON, turn flowmeter to 1 lpm, and let run for several
minutes.
14. Place thumb over open end of large tee from test kit (Figure 3-5).
15. Verify concentrator outlet static pressure is 5 + 0.5 PSI. Refer to Section 4, step 15, if out of
tolerance.
16. Disconnect the 1/4" ID tubing and outlet adapters.
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Figure 3-2: Pneumatic Test Kit Connection/Testing
Companion 492a/590 Oxygen Concentrators
3-5 Service Manual 5-15-91
Figure 3-3: Pneumatic Test Kit Connection/Testing
Figure 3-4: Pressure Switch Testing
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-6
paria rate emi
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Figure 3-5: Outlet Pressure Testing
3.1.3 Electrical
The electrical systems provide the controlling and monitoring functions for the oxygen concentrator. The
” following tests and observations should be made to verify performance of these components.
A)
B)
Physical Observation
With the unit unplugged, open the Companion cabinet and inspect all wires, connectors and
terminals for tightness, wear or fraying. Inspect power cord and plug. Repair or replace as
necessary.
Low Pressure Alarm
1. With the unit unplugged, turn flowmeter control knob counterclockwise to drain any residual
pressure from product canister.
Remove 9V battery from its holder in the filter compartment.
Use a multimeter tester to check battery voltage. Replace if less than 8.0 volts.
Connect concentrator's power cord to an appropriate AC outlet and turn power switch to
ON.
Verify audio alarm activates. Turn the concentrator's power switch OFF.
Install 9V battery into holder. Disconnect power cord from AC power source. Turn the
concentrator's power switch to ON.
/. Verify audio alarm activates. Turn the concentrator's power switch OFF.
NOTE
When the Companion concentrator is connected to an AC power source, the audio alarm
is powered from a 12V signal from the Control PCB. The 9V battery powers the audio
alarm only during a loss of power or Control PCB failure.
Companion 492a/590 Oxygen Concentrators
3-7 Service Manual 5-15-91
3.1.3 Electrical (continued)
C) Control Printed Circuit Board
1.
2.
м о с ео
Open cabinet
Turn flowmeter control knob counterclockwise approximately one revolution and drain any
residual pressure from the product canister.
With concentrator plugged in, turn the power switch ON.
Verify audio alarm sounds until pressure builds in the product canister.
Verify that the front panel POWER indicator is illuminated.
Verify the cooling fan and the compressor operate.
Verify the solenoids cycle by listening for a slight puff of air followed by the exhaust of a
sieve canister approximately every eight (8) seconds.
3.1.4 Ventilation (Cooling) System
3.1.5 Flow
Remove, inspect, and clean if necessary the air inlet filter. Reinstall the filter.
Open cabinet. Inspect air vents at bottom of left half of Companion cabinet. Clean and
remove any blockage at vents.
Connect concentrator's power cord to AC outlet and set the power switch to ON. Observe
the cooling fan and verify its operation.
Close cabinet and verify there is a strong push of air coming from the vents at the bottom
left of concentrator.
Connect concentrator power cord to AC and set power switch to ON. Allow unit to run a
minimum of 5 minutes.
Verify outlet static pressure is 5 + 0.5 PSI. (See subsection 3.1.2 B, Steps 12 through 15).
Connect the test flowmeter (Sierra Top-Trak model 820 mass flowmeter) to the concentrator
as shown in Figure 3-6.
With the line bisecting the flowmeter ball, verify the flow is + 5% of full scale at each setting.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-8
3.1.6 Sound
Figure 3-6: Flowmeter Testing
Occasionally, it may be necessary to determine if a concentrator is operating above the minimum acceptable
decibel levels. To achieve an accurate measurement requires duplicating the same environmental conditions
under which the factory tests are conducted. This may prove to be expensive and difficult. As an alternative,
there are comparison tests and observations that may resolve concerns about the noise level of a Companion
concentrator.
If an unusually loud noise is heard, generally it is detectable by attempting to locate the source of the sound.
Open the concentrator cabinet and inspect for the following:
1.
a son
Inlet bacteria filter properly seated in filter compartment.
Compressor inlet hoses properly connected.
Shock mounts for tears allowing compressor to drop. Loose compressor bolts.
Heat exchanger rubbing.
Internal tubing disconnected. Check especially exhaust hose at exhaust pilot valves and
expansion chamber.
Noisy compressor or cooling fan. Disconnect one terminal from cooling fan during operation
to segregate. Reconnect when done.
NOTE
To resolve problem, adjust, repair, or replace as needed. Referto Section 4 for appropriate
component.
Companion 492a/590 Oxygen Concentrators
3-9 Service Manual 5-15-91
3.1.6 Sound (continued)
If a Companion concentrator is reported "noisy", it may be helpful to compare it to several other Companion
units. The sound level (as measured in decibels) is a weighted average of many frequencies. Some users may
be more sensitive to certain frequency ranges and, therefore, perceive more sound. Comparison of one unit to
another may be valuable in determining excessive noise reported on a concentrator.
3.2 Operational Checklist
If a Companion concentrator requires servicing, this section will be helpful in determining the source of the
problem. Used in conjunction with the Troubleshooting Guide, (subsection 3.3), this checklist will provide the
technician with a logical approach to discovering any equipment malfunctions. There are three categories of
concentrator failures 1) Low concentration (subsection 3.2.1), 2) Unit won't run (subsection 3.2.2), or 3) Unit
operates improperly (subsection 3.2.3). Refer to the category that best suits your concentrator's problem and
follow the checklist to reveal the symptoms that describe the problem. Next, refer to the Troubleshooting Guide
by matching your unit's symptoms to those listed to suggest a component or system most suspect. Follow the
suggested corrective action to test and/or resolve the problem. (Refer to section 6 for Troubleshooting the OCI
system).
3.2.1 Low Concentration
1. Verify oxygen analyzer is calibrated and working properly. Check manufacturer's operating
instructions for proper use and maintenance.
2. Measure concentration at maximum setting on flowmeter scale to determine if unit is
producing the minimum specified level of oxygen after 20 minutes. (Refer to Table 1-1).
3. Inspect and clean all filters.
Open cabinet. Visually inspect all hoses, tubes, and fittings for looseness or kinks.
With concentrator running, use a leak detector to spray all pneumatic fittings and observe
for a bubbling action which indicates a leak. All fittings with the exception of those coming
from the pilot exhaust valves through to the muffler must be air tight. Repair by tightening
or removing and resealing the fitting with an approved pipe cement. (Refer to subsection
3.1.2 A).
NOTE
It is critical that all leaks be eliminated from the concentrator before proceeding.
6. Connect the Pneumatic Test Kit to the concentrator (Refer to subsection 3.1.2 B; Pressure
tests). Turn the unit on and allow to cycle several minutes.
/. With the selector switch set to RSVR observe the pressures in the reservoir canister. Read
subsection 3.1.2 B, steps 5 through 7 and compare results with the expected pressures.
8. Ifthe readings are not normal, refer to the Troubleshooting Guide. (i.e. low, high, imbalance
or erratic pressure). Refer to symptom with appropriate description for the observed
behavior.
9. Turn selector switch to PROD and repeat observations for product tank. Compare pressures
to specifications in subsection 3.1.2 B, step 8 and use Troubleshooting Guide appropriately.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-10
nr
3.2.2 Concentrator Won't Run
1. Verify unit is plugged into proper AC power source. Set power switch to ON position.
2. Green front panel power indicator should illuminate. Audio alarm should activate (open
flowmeter and drain product canister first). If circuit breaker pops out refer to Troubleshooting
Guide.
3. Test for fan operation by placing hand over vents at bottom left side of cabinet.
With concentrator unplugged, inspect all wiring and connections for looseness or discon-
nects.
5. Open cabinet and observe compressor and cooling fan. If compressor and cooling fan start
to operate and both immediately stop, see Section 4, step 16 for solenoid testing.
6. If cooling fan runs and compressor runs momentarily and then stops, remove the small pilot
air tube from the balance solenoid valve to vent pressure from the reservoir canister.
Reconnect the pilot air hose and attempt to restart the concentrator.
3.2.3 Improper Operation
1. Noise beyond normal operation is usually detectable by careful observation with cabinet
open.
2. A pneumatic leak, especially on the intake tubes and fittings of the compressor may cause
excessive noise. Compressor vibration may cause component rubbing which may be
another source of noise.
3. Refer to subsection 3.1.6 for discussion on sound.
4. Reported erratic behavior or intermittent shutdown should be tested and observed where
possible. Refer to subsection 3.2.2 if appropriate.
3.3 Troubleshooting Guide
This section is designed for easy reference to determine the problem with a Companion concentrator. Generally,
it is necessary to do some investigation to discover what symptoms the concentrator is exhibiting. Subsection
3.2 Operational Checklist should be consulted before proceeding with troubleshooting in order to get a clear
understanding of all of the symptoms a concentrator problem may have. Then match the descriptions in the
"Symptom" column that describes the unit's problem as accurately as possible. Next, look at the "Probable
Cause” column which will detail several possible reasons (most likely to least likely to occur) to explain the
observed behavior of the concentrator. Finally, column three "Corrective Action” suggests possible solutions,
tests and/or repairs to resolve a suspected probable cause. This guide is not all-inclusive but it is intended to
serve as an outline for solving operational problems.
WARNING
Some of the following procedures require AC power be applied when testing. To prevent
the possibility of serious electrical shock, connect grounding wire to metal components
and follow standard safety procedures.
Companion 492a/590 Oxygen Concentrators
3-11 Service Manual 5-15-91
SYMPTOM
TABLE 3-1
PROBABLE CAUSE
CORRECTIVE ACTION
1. No audio alarm when
power switch turned
ON and AC power
connected to con-
centrator.
AC power disconnected
AC power connected,
battery removed.
a. Residual pressure in product
tank
b. Loose electrical connection
С. Defective audio alarm
d. Defective pressure switch
e. Defective power switch
f. Defective battery
g. Control PCB fuse
h. Defective control PCB
Open flowmeter knob to reduce
product tank pressure below 4.0 psi.
Inspect all electrical connections,
especially pressure switch, power
switch, audio alarm, and Control PCB
at J2 for good connection.
Remove wires from audio alarm
terminals. Using wire jumpers and
observing both the battery and alarm
polarity, connect the 9V battery directly
to the alarm terminals. If audio alarm
does not activate, replace alarm per
the appropriate procedure in Section 4.
Remove wires from pressure switch
terminals. Using a wire jumper,
connect both wires together. If unit
alarms, replace pressure switch per
the appropriate procedure in Section 4.
Test power switch by jumping white
and black wires connected to terminals
4 and 5. If alarm sounds replace switch
per appropriate service procedure in
Section 4.
Test with multimeter set on DC. If less
than 8.0 volts, replace battery.
Test and replace per appropriate
service procedure in Section 4.
Replace per appropriate procedure in
Section 4.
2. Continuous alarm/
power switch on/
pilot lamp not lit/unit
not operating.
a. No power to unit
b. No power at AC outlet
с. Circuit breaker activated or
defective
d. Control PCB fuse
e. Defective control PCB
f. Loose electrical connection
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
3-12
Connect power cord to AC outlet.
Inspect household circuit breaker or
fuse.
Reset circuit breaker. If circuit breaker
activates, disconnect concentrator
from AC power and inspect internal
wiring for short circuits. Inspect for
locked compressor, shorted capacitor,
or faulty circuit breaker.
Test and replace per appropriate
service procedure in Section 4.
Replace per appropriate service
procedure in Section 4.
Inspect AC power cord, circuit breaker,
power switch and Control PCB forgood
connections.
SYMPTOM
TABLE 3-1
PROBABLE CAUSE
CORRECTIVE ACTION
g. Defective power switch
Test power switch by jumping blue and
brown wires connected to terminals 1
and 2. If unit starts, replace switch per
appropriate service procedure in
Section 4.
Continuous alarm/
power switch and
pilot lamp ON/ com-
pressor and cooling
fan not running.
a. Disconnected wire to one of
the three solenoids
b. Defective solenoid valve
Loose electrical connection
Defective PCB
e. Defective cooling fan causing
compressor thermal cutoff
switch activated after
concentrator has been
operating
Reconnect. Set power switch off, then
on.
Test and replace per appropriate
service procedure in Section 4.
Inspect internal wiring
Replace per appropriate service
procedures in Section 4.
Test for 120 VAC at fan terminal wires.
Replace per appropriate service
procedure in Section 4.
Continuous alarm/
power switch and
pilot lamp ON/ com-
pressor runs for a
period of time, then
stops/ cooling fan
still operating.
a. Compressor over-heated due
to restricted cabinet
cooling-air flow
b. Defective compressor internal
thermal switch
Check that unit is operating in an open
environment and the air inlet is
unobstructed. See also subsection
3.1.4. Allow compressor to cool and
retest.
Replace compressor per appropriate
service procedure in Section 4.
Continuous alarm/
power switch and
pilot lamp ON/ com-
pressor won't start/
cooling fan operates.
a. Residual pressure in reservoir
canister
b. Capacitor (may cause circuit
breaker to actuate)
Loose electrical connection
Faulty compressor
Wait 10-15 seconds for valves to cycle
and relieve pressure.
Check wire terminals at capacitor.
Replace capacitor per appropriate
service procedure in Section 4.
Inspect internal wiring.
Replace compressor per appropriate
service procedure in Section 4.
Concentrator runs - No
power switch light
a. Loose wires to L.E.D.
b. Plugto L.E.D. reversed
c. Faulty L.E.D.
Check wires to power switch L.E.D.
If the plug to the L.E.D. is reversed, the
L.E.D. will not illuminate. Refer to
Section 4, step 7h ACTION and NOTE
statements.
Replace lamp.
Companion 492a/530 Oxygen Concentrators
3-13
Service Manual 5-15-91
SYMPTOM
TABLE 3-1
PROBABLE CAUSE
CORRECTIVE ACTION
7. Low reservoir pressure/
compressor and cool-
ing fan running/ low
concentrations/ con-
centrator may alarm.
a. Compressor inlet prefilters or
bacteria filter dirty
b. Leak
c. Diaphragm leak in supply,
exhaust, or balance pilot
valves
d. Defective solenoid valve
e. Weak or worn compressor
f. Outlet pressure too high
Replace dirty filters.
Leak test entire pneumatic system, per
subsection 3.1.2 A.
Inspect all 5 pilot air valves per
appropriate service procedure in
Section 4. Replace as necessary.
If air leaks through pilot valve exhaust
port and pilot valve has been inspected
with no problems found, replace
solenoid per appropriate service
procedure in Section 4.
Replace entire compressor or replace
piston cup seals per appropriate
service procedure in Section 4.
Test per subsection 3.1.2 B steps 12
through 15. If incorrect reset regulator
per Section 4, step 15.
8. High reservoir canister
pressure/ low con-
centrations/ unit may
alarm.
a. Stuck diaphragm in pilot air
valve
b. Contaminated sieve beds
Inspect solid diaphragms in the supply
and exhaust pilot valves per
appropriate service procedure in
Section 4.
Replace per appropriate service
procedure in Section 4.
9. Imbalance in drop point
pressure/ low con-
centration/ unit may
alarm.
a. Leaks
b. Faulty diaphragm in pilot air
valve
с. Restrictor tube assembly
blocked
d. Mismatched restrictor tube
assembly
Companion 492a/530 Oxygen Concentrators
Service Manual 5-15-91
3-14
Leak test per subsection 3.1.2 A.
Check especially bottoms of sieve
beds, and supply and balance pilot
valve fittings. Repair as necessary.
Remove test and replace, if necessary
per appropriate service procedure in
Section 4.
Remove compression nuts from
restrictor tube assemblies and inspect
orifice for blockage.
Drop point differences greater than 0.4
PSI between cycles. See subsection
3.4; Balancing Orifices.
rr
TABLE 3-1
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
10. Low or erratic product a. Leaks Leak test per subsection 3.1.2 A.
canister pressure/ Check especially from restrictor tubes
low concentrations/ to flowmeter. Repair as necessary.
unit may alarm.
b. Regulator dirty, out of adjust-
ment or defective
c. Faulty diaphragm in balance
pilot valve
d. Stuck supply or exhaust pilot
valve solid diaphragm
e. Incorrectly sized restrictors
Disassemble, clean, reassemble, and
test per appropriate service procedure
in Section 4. Replace if necessary.
Remove, test and replace, if necessary
per appropriate service procedure in
Section 4.
First disassemble and inspect the
supply pilot valve diaphragms and then
the exhaust pilot valve diaphragms.
Refer to the appropriate service
procedure in Section 4.
Change restrictors per subsection 3.4,
Balancing Orifices.
11. Unit alarms/ cycles/ Defective pressure switch or set- Test or replace per appropriate service
oxygen flows and ting out of adjustment procedure in Section 4.
concentration within
specifications/ pres-
sures normal.
12. Low or no oxygen flow a. Flowmeter knob turned oft Set flow to desired level.
or pressure/ unit
operating/ no alarm.
b. Kinked or obstructed tubing Inspect internal tubing from product
canister to flowmeter.
c. Regulator out of adjustment or Test per subsection 3.1.2 B, steps 12
defective through 15. Replace per appropriate
service procedure in Section 4.
Unit Alarm d. Disconnected tubing Inspect internal tubing and connections
from compressor to flowmeter.
13. Noise. a. Component rubbing Inspect per subsection 3.1.6; steps 3
(Pulsating air)
(Grinding sound)
b. Tubing disconnected
C. Compressor
d. Compressor or cooling fan
through 6.
Inspect per subsection 3.1.6; steps 1
through 5.
Piston seal torn or worn out. Replace
per appropriate service procedure in
Section 4.
Inspect per subsection 3.1.6, step 6.
Replace as needed per Section 4.
Companion 492a/590 Oxygen Concentrators
3-15
Service Manual 5-15-91
3.4 Balancing orifices
Restrictor tube assemblies each contain an orifice drilled to a specific size. A number is assigned to each tube
that represents the liter flow of gas through the orifice at a standard pressure. It may be necessary to change
restrictor tubes in a Companion Concentrator for one of the following reasons:
A) During performance verification testing, concentration is out of specification and pneumatic testing
reveals an imbalance in the reservoir canister drop point pressures. (Refer to subsection 3.1.2)
B) The drop point pressures are within specifications, however the concentration at the maximum
flowrate is out of specification.
NOTE
Before performing the following procedure it is necessary to ensure that all leaks have
been eliminated from the concentrator’'s system.
1. Open the concentrator cabinet, connect the pneumatic test kit, and after five minutes of
operation, record the drop, fill, and kick pressures of each sieve cycle as described in
subsection 3.1.2 B, steps 1 through 7.
2. To determine the balance pressure of the sieve beds, compare the drop pressures of two
consecutive pressure cycles. If the pressures differ by more than 0.4 PSI, one or both of the
restrictor tubes may need to be replaced to achieve a pressure balance.
3. Determine which drop pressure value corresponds to which restrictor tube (and consequent-
ly which sieve bed), by operating the concentrator and observing the test gauge. Lay your
finger lightly over the open exhaust port on the end of solenoid valve 2 (refer to Figure 2-8
for solenoid 2 location). With the test gauge connected and the concentrator operating, feel
for a slight puff of air from the exhaust port of solenoid 2. This represents the close of the
solenoid and thus the end of the fill cycle for sieve canister 2. Immediately observe the gauge
and you should note a rapid climb (kick pressure). After this kick pressure the gauge needle
should fall to the next drop point. This drop point is the beginning pressure for the right sieve
canister (sieve canister 1), which corresponds to the right restrictor tube.
4. Inorderto balance (bring the pressures within .4 PSI at the drop point) the orifices, it will be
necessary to change one restrictor tube and install a new one with a larger or smaller orifice.
(A larger rating on the tube will result in more flow and lower sieve bed filling pressure. The
opposite will occur for a smaller orifice number.) Refer to the example below to appropriately
size the restrictors.
EXAMPLE: After five minutes of continuous operation, the drop point pressures are 14.9
PSIG and 14.2 PSIG. The restrictors are rated 8.8 (left) and 8.7 (right). Through
the testing described above, you have determined that the right restrictor is
producing the 14.2 PSIG drop pressure. Preferably, you should bring the lower
drop pressure up to the higher drop pressure of the other sieve canister. Thus,
to bring the 14.2 PSIG drop pressure up, replace the right restrictor tube with
one having less flow (and a smaller rating). Try a restrictor that is .1 or.2
smaller. (Refer to the parts list for Figure 4-2 in Section 4 for part numbers that
correspond to the desired orifice size. In this case, an orifice sized 8.6 or 8.3).
5. By trying different orifice sizes you should be able to accomplish a balance. Although the
actual pressures may change up or down as the concentrator acclimates, the drop point
balance should remain constant.
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91 3-16
r
3.4
Balancing orifices (continued)
6.
7)
Occasionally a drop point balance may exist but the oxygen concentration may not be within
specification. In this case the restrictor tubes may have orifice sizes that are too restrictive
(sieve bed fills too slowly) or too large (sieve bed pressure too low for proper adsorption.)
Increase or decrease the orifice sizes as appropriate by observing the reservoir canister
pressure specifications as a guide.
Whenever restrictor tubes have been changed, operate the concentrator a minimum of 12
hours and recheck both the reservoir canister pressures and the oxygen concentration for
compliance with specifications.
Companion 492a/590 Oxygen Concentrators
3-17 Service Manual 5-15-91
Companion 492a/590 Oxygen Concentrators
Service Manual 5-15-91
3-18 (blank)
‘J
9.
SECTION 4. SERVICE AND REPAIR
This section describes how to service the individual components of the Companion 492a and 590 Oxygen
Concentrators. Included are instructions, where applicable, for removal, disassembly, operational check,
cleaning, adjustment, alignment, reassembly, and installation.
After removing a component, visually inspect for damage or any other indication that the component is defective.
Unless otherwise specified, replace as needed with a new component. Refer to the exploded-view drawings for
replacement part numbers.
For service and repair procedures relating to the optional Oxygen Concentration Indicator (OC!) refer to
section 6.
WARNING
The concentrator is electrically powered. To prevent serious injury or death,
observe standard safety procedures when servicing. Always ensure that
power is removed before servicing concentrator.
CAUTION
After a component has been serviced, the concentrator's overall system
operation must be verified per section 3.3, Performance Verifications, before
the concentrator is used.
CAUTION
Ensure that the compressed-air supply used to clean and dry components is
clean and oil-free.
Companion 492a/590 Oxygen Concentrator
4-1 Service Manual 5-15-91
SECTION 4. SERVICE AND REPAIR (Continued)
Service procedures are provided in Table 4-1 as follows:
as
«= ll
- CO
N ГО [0 = 05005 05 +5 ША a +
NN + OMONYSO UN © N
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
Component
Cabinet
Circuit Breaker
Hour Meter
Audio Alarm
Flowmeter Flow Control Valve
Flowmeter
Power Switch
Control Printed Circuit Board
Compressor Platform Assembly
Compressor (492a)
Compressor (590)
Capacitor
Cooling Fan
Pressure Switch
Pressure Regulator
Solenoid Valve
Sieve Canister
Pilot valve
Restrictor Tube Assemblies
Outlet Gas Filter
Shock Mount
Compressor Cup Seals (590)
4-2
TABLE 4-1. SERVICE PROCEDURES
(Refer to the appropriate figure(s) for numbers shown in bold print.)
COMPONENT ITEM
1. Cabinet
(Figure 4-1)
OPENING a. Companion 492a/590
b. Airinlet filter 14
C. Screw 16
d. Screw 15
e. Cabinet
CLOSING f. Cabinet side panels
(Figure 4-3)
4-3
ACTION
Remove humidifier, (if installed), from
oxygen outlet connector.
WARNING
Electrical shock hazard. Verify AC
power is removed before opening
concentrator cabinet.
Remove from right side panel.
Using a #2 phillips screwdriver, remove
from cabinet side panel.
Using a #2 phillips screwdriver with a shatt
at least seven inches long, loosen screw
15. The cabinet's left and right case hal-
ves Will separate as screw is loosened.
NOTE
An O-ring is installed over screw
item 15 on interior of cabinet and is
intended to hold screw in place
during reassembly of cabinet's case
halves. Removal of screw from right
case half is not necessary.
Pull left and right side panels away from
one another to open cabinet. The cabinet
will hinge in rear of concentrator. Do not
open cabinet more than approximately a
90 degree angle.
CAUTION
The concentrator will not be stable
setting on its casters if left and right
side panels are opened more than
approximately 90 degrees.
Ensure that cabinet screw 37 and o-ring
41 are installed in right side panel.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ACTION
Cabinet side panels Close right and left side panels to within
approximately two inches of each other.
Insert screw 18 through right side panel.
Push screw in far enough so that it ex-
tends through right side panel tube 22 and
into left side panel tube 50 (Figure 4-2).
Cabinet side panel Tighten screw 37 first and then screw 18.
screws 18 and 37
(Figure 4-3)
Air inlet filter Reinstall on right side panel.
2. Circuit Breaker 19
(Figure 4-3)
REMOVAL Cabinet Perform OPENING procedure.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
PCB harness Remove three wire harness connectors
connectors from Control PCB 44.
Tube Remove from tube clamp 24.
Inlet air duct cover 46 Remove five screws 45, and air duct cover
46, from right case interior. Control PCB
does not need to be removed from cover.
Circuit breaker Disconnect two terminal wires.
terminals
Filter compartment door Remove.
16
Hex nut 10 Remove from circuit breaker (Figure 4-1).
Circuit breaker Remove from cabinet interior.
INSTALLATION Replacement circuit Install knurled nut, item 6, (Figure 4-1)
(Figure 4-1) breaker onto circuit breaker's threaded shaft so
Replacement circuit
breaker
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-4
that approximately 1/4 inch of threads are
exposed.
Install in right side panel so that circuit
breaker number is in a vertical and
readable position. Secure circuit breaker
with hex nut in interior of filter compart-
ment.
7
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM ACTION
К. Circuit breaker Using needle-nose pliers and old circuit
terminals breaker as a guide, carefully bend each
terminal at approximately a 45 degree
angle toward cabinet hinge. Reconnect
wires to terminals. The circuit breaker is
not polarity sensitive, either wire may be
connected to either terminal.
|. Air inlet duct cover, Reverse removal procedures and
tube and Control reinstall.
PCB wire harness
connectors
m. Cabinet Perform CLOSING procedures.
3. Hour Meter 21
(Figure 4-3)
REMOVAL a. Cabinet Perform OPENING procedure.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
b. PCB harness Remove three wire harness connectors
connectors from Control PCB 44.
Tube Remove from tube clamp 24.
Air inlet duct cover 46 Remove five screws 45 and cover 46 from
right case interior. Control PCB does not
need to be removed from cover.
e. Hour meter terminals Disconnect two terminal wires.
f. Filter compartment door Remove.
16
g. Rivets (Figure 4-1) Remove two rivets 13 securing hour meter
with 1/8 inch drill.
h. Hour meter Remove from filter compartment interior.
INSTALLATION i. Replacement hour Insert into mounting hole from filter com-
meter
partment so that last digits (red numerals)
are toward bottom of concentrator.
Secure to cabinet with two 1/8 inch pop-
rivets.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
1
+
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
ITEM
Hour meter terminals
ACTION
Using needle-nose pliers and old hour-
meter as a guide, carefully bend each
terminal at approximately a 45 degree and
toward cabinet hinge. Reconnect wires to
terminals. The hour meter is not polarity
sensitive, either wire may be connected to
either terminal.
k. Air inlet duct cover, Reverse removal procedures and
tube and Control reinstall.
PCB wire harness
connectors
|. Cabinet Perform CLOSING procedures.
4. Audio Alarm 25
(Figure 4-3)
REMOVAL a. Cabinet Perform OPENING procedure.
b. Audio alarm terminals Disconnect two terminal wires.
c. Air inlet filter 17 Remove.
d. Retaining ring 11 Remove from filter compartment.
(Figure 4-1)
e. Audio alarm Remove from cabinet interior.
INSTALLATION f. Replacement audio Insert into mounting hole from right
alarm cabinet interior.
g. Retaining ring Attach to replacement audio alarm from
filter compartment.
h. Audio alarm terminals Reconnect red wire to positive terminal
Cabinet
and black wire to negative terminal.
Perform CLOSING procedures.
5. Flowmeter Flow
Control Valve 2
(Figure 4-3)
REMOVAL
Flowmeter knob 1
Flow control valve
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-6
Remove by pulling away from flowmeter.
Remove from flowmeter body with 1/2
socket wrench.
CAUTION
To prevent flowmeter damage, the
flow control valve must be set to a
fully counterclockwise position
before reassembly.
”
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
Replacement fiow
control valve
ACTION
Install into flowmeter body and carefully
tighten with 1/2 inch socket wrench.
d. Flowmeter knob Align with flat on flow control valve shaft
and install.
6. Flowmeter 3
(Figure 4-3)
REMOVAL Cabinet Perform OPENING procedure.
Oxygen Tubes 12, 10 Disconnect two tubes from flowmeter inlet
and outlet connectors.
c. Two flowmeter Remove from flowmeter's threaded con-
brackets 8 and nuts nectors.
9
d. Cabinet control panel Remove flowmeter.
INSTALLATION e. Replacement flowmeter Install in mounting hole with control knob
at top of concentrator.
f. Flowmeter brackets Install on replacement flowmeter.
and nuts
g. Oxygen tubes Reconnect tubing to inlet and outlet flow-
meter connectors. Refer to Section 2,
(Figure 2-1) for tubing orientation.
h. Cabinet Perform CLOSING procedures.
7. Power Switch 5
(Figure 4-3)
NOTE
For units equipped with optional
O.C.I refer to section 6 for Power
Switch service procedures.
REMOVAL a. Cabinet Perform OPENING procedure.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
b. PowerL.E.D. 4 Using a needle-nose pliers, unplug the
Power switch terminals
Power switch body
connector from the Power L.E.D.'s leads.
Disconnect four terminal wires.
Locate four retaining tabs at each corner.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM
e. Fourretaining tabs
ACTION
Press inward with flat-blade screwdriver,
one after the other, while pushing switch
through control panel toward outside of
cabinet.
NOTE
The Power L.E.D. is mounted in a
removable bezel. The bezel and
L.E.D. are supplied with replace-
ment power switch. Verify correct
orientation of bezel before installa-
tion. Power L.E.D. should be posi-
tioned above switch closest to
terminals #2 and #5.
Position so that power L.E.D. is towards
top of concentrator.Press into mounting
hole from outside of control panel until
retaining tabs catch.
Connect four terminal wires. Referto Sec-
tion 2, (Figure 2-2) for wire orientation.
Connect to wire harness connector. The
longer L.E.D. lead must connect to posi-
tion 2 (black wire) on wire connector.
Refer to Section 2, (Figure 2-2) for con-
nector orientation.
NOTE
The Power L.E.D. is a polarity sen-
sitive device. Improper connection
of wire harness connector will not
damage L.E.D., but will prevent il-
lumination when power is applied.
Verify proper operation of the Power
L.E.D. after installation. If the L.E.D.
does not illuminate, remove the con-
nector, rotate it 180 degrees,
reinstall the connector, and retest.
Perform CLOSING procedure.
INSTALLATION
f. Replacement power
switch
g. Power switch terminals
h. Power L.E.D. leads
i. Cabinet
8. Control Printed a. Cabinet
Circuit Board 44
(Figure 4-3)
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-81 4-8
Perform OPENING procedure.
p TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM ACTION
CAUTION
The control printed circuit board
contains complementary metal-
oxide semiconductor (CMOS) in-
tegrated circuits (IC's) which are
static-sensitive devices. To prevent
IC damage, observe standard safety
procedures as follows:
* Wear grounding wrist strap.
* Work on grounded conductive
mat.
« Handle PCB by edges only.
* Store PCB in conductive plas-
tic bag.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
/ FUSE TESTING b. Fuse 69 Remove from fuse holder on Control PCB.
Verify resistance of approximately 15
ohms using digital multimeter. Reinstall in
fuse holder.
REMOVAL C. PCB harness Remove three wire harness connectors
connectors from Control PCB 44.
d. Control PCB Remove five screws 43 from control PCB.
Separate Control PCB from cover.
INSTALLATION e. Replacement Control Install into cabinet and secure with five
PCB SCrews.
f. ~~ Three wire harness Reverse removal procedures and
connectors reinstall.
g. Cabinet Perform CLOSING procedure.
9. Compressor Platform
Assembly 49
(Figure 4-3)
REMOVAL a. Cabinet Perform OPENING procedure.
Companion 492a/590 Oxygen Concentrator
4-9 Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
DISASSEMBLY
(Figure 4-4)
REASSEMBLY
Compressor wire
harness connector
25 (Figure 4-4)
Compressor platform
assembly
Inlet tube and clamp 35
Two screws 14 and
two clamps 15 and
21
Capacitor 17 terminals
Strap 6 and grommet
16
Cooling fan 22
terminals
Two screws 33, washer
28, and locknuts 29
Heat exchanger 30
Compressor
Compressor platform
assembly
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-10
ACTION
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
Disconnect and remove compressor wire
harness connector and grommet 26 (Fig-
ure 4-4) from air dam 62 (Figure 4-3).
Using a magnetic tip #2 phillips
screwdriver, remove two screws 50. Dis-
connect inlet tube 26 from platform con-
nector while sliding platform assembly out
of cabinet.
Remove from compressor and platform
connectors.
Remove from platform assembly.
WARNING
To prevent serious electrical shock,
discharge capacitor by shorting ter-
minals with insulated - handle
screwdriver.
Disconnect two terminal wires.
Cut strap and pull each capacitor wire,
one at a time through the grommet.
Disconnect two terminal wires.
Use a 5/64-inch 90° Allen wrench and a
5/16-inch socket to remove from com-
pressor. Two clamps 27 do not need to be
removed from the heat exchanger.
Unscrew brass nut 31 and remove heat
exchanger 30 from compressor.
Support compressor with one hand and
remove four cap screws 12 with 7/16-inch
socket wrench. Separate compressor
from platform.
Reverse DISASSEMBLY procedure.
~~ TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM ACTION
NOTE
Apply a small amount of Loctite 242
to threads of four compressor
mounting bolts 12 before reassemb-
ly.
INSTALLATION m. Compressor platform Reverse REMOVAL procedure. Do not
assembly over-tighten two screws 50.
10. Compressor (492a)
REMOVAL a. Compressor platform Perform REMOVAL and DISASSEMBLY
assembly procedures steps 9a through 9k.
DISASSEMBLY b. Twelve cylinder head Remove from cylinder heads 26, 9.
(Figure 4-5) screws 1
C. Cylinder heads and Remove both cylinder heads, along with
valve plates connector tubes 2, and both valve plates
4.
d. Piston sleeves Remove both sleeves 6.
г, HOUSING e. Four-blade fan 19 Pry away from motor shaft 15 with
WELL A flatblade screwdriver.
f. Connecting rod screw 8 Turn motor shaft until screw is visible
through lower access port on wire-har-
ness side of housing.
g. Connecting rod screw Loosen several turns with 5/32-inch allen
wrench.
п. Set screw 17 Turn eccentric 18 until screw is visible
through upper access port.
|. Set screw Loosen only 1/4-turn with 1/8-inch allen
wrench.
В Piston 7 Slip piston connecting rod off of bearing
16, and slide entire eccentric bearing as-
sembly 20 off shaft.
NOTE
Bearing is bonded to connecting rod
with Loctite. If necessary, insert
screwdriver blade into slit at rod bot-
tom, and turn to break rod loose from
bearing.
ge k. Piston Grasp at top inside housing well, and slip
connecting rod off shaft.
Companion 492a/590 Oxygen Concentrator
4-11 Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
HOUSING
WELL B
CLEANING
REASSEMBLY
—
Connecting rod
Five-blade fan 11,
eccentric bearing
assembly, and
piston
Cylinder head interiors
and housing wells
Valve plates
Eccentric bearing
assemblies
Compressor body
New connecting rod
Screw
Piston
Piston
Bearing
Bearing
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-12
ACTION
Move to one side of shaft, and then lift
while moving back into housing above
shaft. Remove through top of housing.
Replace connecting rod screw.
Repeat steps e through | to remove.
WARNING
To prevent personal injury, use face
shield and observe standard safety
procedures when using com-
pressed-air gun.
Blow out or brush away dirt and dust.
Wipe off both sides with clean cloth.
Wipe oft with clean, cloth. Scrape off ex-
cessive Loctite from outside diameter with
knife.
Stand on end, housing well 8 facing up.
CAUTION
Keep Loctite away from all plastic
parts.
Place one drop only of Loctite 242 on
threads, and insert, but do not tighten, into
side hole on connecting rod.
Position above housing well so that con-
necting rod screw head is facing wire-har-
ness side of housing.
Insert into housing, and place connecting
rod over shaft end.
Wipe any grease or oil off outer race.
CAUTION
Do not allow Loctite to seep inside
bearing or on eccentric.
Apply very thin film of Loctite 680 to outer
circumference with small pad.
Pr TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
у
ECCENTRIC-
PISTON
ALIGNMENT
~~
dad.
ab.
ac.
ad.
de.
af.
ag.
ah.
a.
aj.
ak.
al.
Eccentric bearing
assembly
Eccentric bearing
assembly
Eccentric
Connecting rod
Connecting rod screw
Sleeve
Sleeve
Sleeve
Compressor body
Sleeve
Valve plate
Valve plate
Two of the six cylinder
head screws
Motor shaft
Motor shaft
Set screw
4-13
ACTION
Position so that set screw is aligned with
flat on shatt.
Hold piston steady with one hand, and slip
assembly onto shaft, bearingfirst, and into
connecting rod.
Tum until connecting rod screw is visible
through lower access port on wire-har-
ness side of housing.
Center on eccentric bearing assembly so
that bearing face is flush with rod face.
CAUTION
To prevent bearing failure, do not
ovenrtighten connecting rod screw.
Tighten to 15 inch-pounds (1.69 new-
ton/meters) with torque wrench.
Wipe out inner surface. Inspect for
scratches and burrs.
Position above housing well so that
stepped edge is facing out.
Install carefully onto piston, taking care
not to damage seal around piston head.
Set on feet.
Position in center of housing well.
Position over piston, O-ring 5 side down,
so that head of reed valve screw is aligned
with notch on piston head.
Place on housing well to engage stepped
edge of sleeve. Note that six mounting
holes are aligned with those in housing.
Insert into two valve plate holes on
housing’s centerline, and rotate two turns.
Hold valve plate in place over piston, and
spin shaft.
Turn unit eccentric set screw is visible
through upper access port.
tighten to 30 inch-pounds (3.39 new-
ton/meters) with torque wrench. Do not
allow eccentric to move on shaft.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM
am. Valve plate
an. Sleeve
ao. O-ring
ap. Valve plate
aq. Head gasket 3 for
cylinder head B 9
ar. Cylinder head B
as. Twocylinder head
screws
at. Eccentric
au. Compressor body
av. Compressor
aw. Cylinder head screws
ax. Cylinder head screws
ay. Four-blade fan
az. Five-blade fan
INSTALLATION ba. Compressor platform
assembly
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 4-14
ACTION
Remove two cylinder head screws and
then plate.
Hold, and turn eccentric. Ensure that
sleeve is not touching front or back
shoulder of well.
Inspect for cuts and tears. Ensure proper-
ly seated in valve plate groove.
Repeat steps ag and ah.
Inspect for cuts and tears. Ensure proper-
ly seated in cylinder head groove.
Place over valve plate, and place con-
necting rod in the up position.
Insert into holes on housing's center line,
and tighten until snug.
Turn and check for alignment between
piston and valve plate.
Stand on end, housing well A facing up.
Repeat steps r through at with the follow-
ing change:
Connector tubes 2 are inserted between
cylinder head A and B before head A is
connected to housing.
Insert remaining into heads, and tighten
all 12 to 20 inch-pounds (2.27 new-
ton/meters) with torque wrench in se-
quence shown in (Figure 4-7).
Repeat step aw for 30 inch-pounds (3.41
newton/meters).
Press onto housing well A shaft, with flat
in fan hole aligned with flat on shaft and
with spring clamp facing in.
Press onto housing well B shaft, with flat
in fan hole aligned with flat on shaft and
with spring clamp facing in.
CAUTION
Ensure that both fans are securely
in place.
Reverse DISASSEMBLY and REMOVAL
procedures steps 9a through 9k.
m- TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
11.
Compressor (590)
REMOVAL
DISASSEMBLY
(Figure 4-6)
HOUSING
WELL A
Compressor platform
assembly
Eight cylinder head
screws 29
Cylinder heads and
valve plates
Piston sleeves
Fan À 19
Connecting rod screw
16
Connecting rod screw
Set screw 17
Set screw
Piston assembly
Piston assembly
Connecting rod
Piston assembly
4-15
ACTION
Preform REMOVAL and DISASSEMBLY
procedures setup 9a through 9k.
Remove from cylinder heads 28 and 10.
Remove both cylinder heads, along with
connector tubes 1 and both valve plates
3.
Remove both sleeves 5.
Pry away from motor shaft with flat-blade
screwdriver. Label Fan A for correct reas-
sembly.
Turn motor shaft until screw is visible
through lower access port on wire-har-
ness side of housing.
Loosen several turns with 5/32-inch allen
wrench.
Turn eccentric 20 until screw is visible
through upper access port.
Loosen only 1/4-turn with 1/8-inch allen
wrench.
Slip connecting rod 9 off bearing 21, and
slide entire eccentric bearing assembly 18
off shaft 22.
NOTE
Bearing is bonded to connecting rod
with Loctite. If necessary, insert
screwdriver blade into slit at rod bot-
tom, and turn to break rod loose from
bearing.
Grasp at top inside housing well, and slip
connecting rod off shaft.
Move to one side of shaft, and then lift
while moving back into housing above
shaft. Remove through top of housing.
Replace connecting rod screw.
Remove four screws 6 on each piston to
separate retainer plate 7, cup seal 8, and
connecting rod 9.
Companion 432a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
HOUSING
WELL B
CLEANING
REASSEMBLY
B fan 12, eccentric
bearing assembly,
and piston
Cylinder head interiors
and housing wells
Valve plates & piston
assembly
components
Eccentric bearing
assemblies
Compressor body
Piston assembly
Piston assembly
Piston assembly
Piston assembly
New connection rod
screw
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-16
ACTION
Repeat steps e through m to remove.
WARNING
To prevent personal injury, use face
shield and observe standard safety
procedures when using com-
pressed-air gun.
Blow out or brush away dirt and dust.
CAUTION
Use care not to damage intake and
exhaust reed valves 23 on valve
plates.
Wipe off with clean cloth.
Wipe off with clean cloth. Scrape off ex-
cessive Loctite from outside diameter with
knife.
Stand on end, housing well B facing up.
Install cup seal on stepped edge of
retainer plate. Cupped side of cup seal
should face retainer plate.
Install the cup seal and retainer plate on
the connecting rod. Rotate the retaining
plate to position the index mark and
beveled edges as shown in Figure 4-8.
Place one drop of Loctite 242 on threads
of the four screws. Install the screws and
torque to 20-inch pounds (2.27 new-
ton/meters).
Repeat steps s through u for the second
piston assembly.
CAUTION
Keep Loctite away from all plastic
parts.
Place one drop of Loctite 242 on threads,
and insert, but do not tighten, into side
hole on connecting rod.
pP TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
>
ECCENTRIC-
PISTON
ALIGNMENT
Y a
ITEM
X.
aa.
ab.
ac.
ad.
de.
af.
ag.
ah.
a.
aj.
Piston
Piston
Bearing
Bearing
Eccentric bearing
assembly
Eccentric bearing
assembly
Eccentric
Connecting rod
Connecting rod screw
Sleeve
Sleeve
Compressor body
Sleeve
4-17
ACTION
Position above housing well so that con-
necting rod screw head is facing wire-har-
ness side of housing.
Insert into housing, and place connecting
rod over shaft end.
Wipe any grease or oil off outer edge of
bearing.
CAUTION
Do not allow Loctite to seep inside
bearing or onto eccentric.
Apply very thin film of Loctite 680 to outer
circumference with small pad.
Position so that set screw is aligned with
flat on shaft.
Hold piston steady with one hand and slip
assembly onto shaft, bearing first, and into
connecting rod.
Turn until connecting rod screw is visible
through lower access port on wire-har-
ness side of housing.
Center on eccentric bearing assembly so
that bearing face is tlush with rod face.
CAUTION
To prevent bearing failure, do not
overtighten connecting rod screw.
Tighten to 15 inch-pounds (1.69 new-
ton/meters) with torque wrench.
Wipe out inner surface. Inspect for
scratches and burrs.
Install carefully onto piston, taking care
not to damage cup seal.
Set on feet.
Position in center of housing well.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
ak.
al.
am.
an.
do.
ap.
aq.
dar.
as.
at.
au.
av.
aw.
ax.
ay.
az.
ITEM
Valve plate
Valve plate
Four cylinder head
screws
Motor shaft
Motor shaft
Set screw
Valve plate
Sleeve
O-ring 6
Valve plate
Head gasket 4 for
cylinder head B
Cylinder head B
Four cylinder head
screws
Eccentric
Compressor body
Compressor
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
ACTION
Position over piston, O-ring side down, so
that headof reed valve screw 26 is aligned
with notch on piston head and the reed
valve on the top of the valve plate is
positioned nearest to the harness side of
the compressor.
Place on housing well to engage edge of
sleeve. Note that four mounting holes are
aligned with those in housing.
Insert into four valve plate holes and
rotate two turns.
Hold valve plate in place over piston, and
spin shaft.
Tum until eccentric set screw is visible
through upper access port.
Tighten to 30 inch-pounds (3.39 new-
ton/meters) with torque wrench. Do not
allow eccentric to move on shaft.
Remove four cylinder head screws and
then plate.
Hold sleeve, and turn eccentric. Ensure
that sleeve is not touching front or back
shoulder of well.
Inspect for cuts and tears. Ensure proper-
ly seated in valve plate groove.
Repeat steps ak and al.
Inspect for cuts and tears. Ensure proper-
ly seated in cylinder head groove.
Place over valve plate, and place con-
necting rod in the up position.
Insert into holes on housing's center line,
and tighten until snug.
Turn and ensure piston does not contact
valve plate.
Stand on end, housing well A facing up.
Repeat steps aw thru ax for cylinder head
A side of compressor with the following
change:
Connector tubes 1 are inserted between
cylinder head A and B before head A is
connected to housing.
7 TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
INSTALLATION
ITEM
ba.
bb.
be.
Cylinder head screws
Cylinder head screws
Fan A
Fan B
Compressor platform
assembly
ACTION
Tighten all to 20 inch-pounds (2.27 new-
ton/meters) with torque wrench in a
crisscross pattern.
Repeat step ba for 30 inch-pounds (3.41
newton/meters).
Press onto housing well A shaft, with flat
in fan hole aligned with flat on shaft and
with spring clamp facing in.
Press onto housing well B shaft, with flat
in fan hole aligned with flat on shaft and
with spring clamp facing in.
CAUTION
Ensure that both fans are securely
in place.
Reverse DISASSEMBLY and REMOVAL
procedures.
12. Capacitor 17
rr (Figure 4-4)
REMOVAL
INSTALLATION
Cabinet
Compressor platform
assembly
Capacitor 17 terminals
Two straps 18
Replacement capacitor
Capacitor terminals
4-19
Perform OPENING procedure.
Perform REMOVAL procedure, step 9
a through c.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator. Discharge
capacitor by shoring terminals with
insulated - handle screwdriver.
Disconnect two terminal wires.
Cut straps and remove capacitor from
compressor platform.
Attach to underside of platform assembly
with two new straps 18.
Reconnect two terminal wires.
NOTE
The capacitor is not a polarity sensi-
tive component. Either wire may be
connected to either terminal.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
Compressor platform
assembly
Cabinet
ACTION
Perform INSTALLATION procedure.
Perform CLOSING procedure.
13. Cooling Fan 22
(Figure 4-4)
REMOVAL
INSTALLATION
Cabinet
Cooling fan 22
terminals
Two screws 4
Cooling fan
Replacement cooling
fan
Two screws
Cooling fan terminals
Perform OPENING procedure.
WARNING
Electrical shock hazard. Verify AC
power has been removed before
servicing concentrator.
Disconnect two terminal wires.
Remove from compressor platform as-
sembly.
Remove by sliding fan toward front of
compressor platform assembly. The rear
of the cooling fan is retained by clips which
are molded into the platform.
Position the fan with the flow arrow point-
ing down and blades up as shown in Fig-
ure 4-4 and slide the rear of the fan into
the two clips on the compressor platform.
Install into compressor platform assembly
and tighten.
Reconnect the two terminal wires.
Cooling fan Verify correct operation per subsection
3.1.4.
NOTE
The cooling fan is not a polarity sen-
sitive component. Either wire may
be connected to either terminal.
Cabinet Perform CLOSING procedure.
14. Pressure Switch 37
(Figure 4-2)
REMOVAL Cabinet Perform OPENING procedure.
Pressure switch Disconnect two terminal wires.
terminals
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-20
rr
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM
Pressure switch
ACTION
Using a 7/16-inch open end wrench, un-
screw from product canister 34.
INSTALLATION d. Replacement pressure Apply a small amount of pipe cement to
switch pressure switch thread. Distribute the ce-
ment around the entire fitting. Do not allow
cement to enter interior of pressure
switch.
e. Replacement pressure Install into product canister and tighten
switch with wrench. Do not overtighten. Position
the switch so that the terminals are toward
the top of the concentrator.
f. Pressure switch Reconnect two terminal wires.
terminals
SETTING g. Pressure switch The pressure switch is factory preset. To
verify current setting perform subsection
3.1.2 B steps 2, 3, 8,9 and 10. If incorrect,
turn adjustment screw on face of switch
with small screwdriver and retest. If switch
will not hold a setting, replace.
NOTE
The pressure switch is not a polarity
sensitive component. Either wire
may be connectedto either terminal.
h. Cabinet Perform CLOSING procedures.
15. Pressure Regulator
41 (Figure 4-2)
REMOVAL Cabinet Perform OPENING procedure.
Vacuum check valve Disconnect from pressure regulator con-
38 and tubing 40 nector.
c. Oxygen tubing 44 Disconnect from pressure regulator con-
nector.
d. Pressure regulator 41 Turn counterclockwise at fitting assembly
and fitting
assembly 39
4-21
39 until reguiator and fitting are removed
from product canister 34.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
DISASSEMBLY
(Figure 4-9)
CLEANING
REASSEMBLY
Regulator body 10
Regulator body
Regulator body
Regulator body
Bonnet assembly 2
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-22
ACTION
NOTE
DISASSEMBLY procedure is
provided for regulator cleaning pur-
poses only. Internal regulator repair
parts are not available. A faulty
regulators must be replaced as a
complete assembly.
Hold firmly in one hand and unscrew
bonnet assembly 2.
CAUTION
To prevent damage to regulator
plastic seat 6, remove seat carefully
from body with 3/8-inch wide flat
blade screwdriver.
NOTE
During disassembly, removal of fit-
ting assembly 11 from regulator
body 10 is not necessary.
Remove remaining internal parts per Fig-
ure 4-9.
WARNING
To prevent personal injury, use face
shield and observe standard safety
procedures when using com-
pressed-air gun.
Apply isopropy! alcohol with cotton swab
to cavities. Blow dry with compressed-air
gun.
CAUTION
To prevent damage to regulator
plastic seat, install seat carefully into
body and hand tighten with 3/8-inch
wide blade screwdriver.
Replace internal parts per Figure 4-9.
Screw onto regulator body. Do not over-
tighten.
Да
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
INSTALLATION
(Figure 4-9)
TESTING
ADJUSTMENT
(Figure 4-9)
Pressure regulator
Oxygen tubing 44
(Figure 4-2)
Vacuum check valve 38
and tube 40
m. AC power cord
n.
0.
p.
q.
Г.
Front control panel
Concentrator flowmeter
Test pressure gauge
Test pressure gauge
Bonnet assembly 2
4-23
ACTION
NOTE
If a replacement regulator is to be
installed, reuse the fitting assembly
11 from the faulty regulator. Apply a
small amount of pipe cement to re-
placement regulator and fitting as-
sembly threads. Distributed the
cement around the entire fitting. Do
not allow cement to enter interior of
regulator. Do not overtighten.
Install into the product canister. Use care
not to cross thread. Position the regulator
as shown in Figure 4-2.
Connect to pressure regulator.
Connect to pressure regulator.
WARNING
The following procedure requires
AC power be applied to con-
centrator. Metal components are not
grounded. To prevent possibility of
serious electrical shock, connect
grounding wire to metal components
before applying power to unit.
Connect to AC outlet.
Push power switch to ON position.
Adjust flow to 1 1рт. If installing a new
regulator, it is necessary to turn the
regulator adjustment knob several turns
clockwise to achieve an outlet pressure.
NOTE
Allow concentrator to run (stabilize)
for approximately 20 minutes before
proceeding.
Connect to oxygen outlet spout 28 or 32
Figure 4-3. Perform subsection 3.1.2 B
steps 12 through 15.
Verify pressure reading of 5.0 + 0.5 psig.
Cut and remove strap 1. Push lock ring 14
up against adjustment knob 15.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
s. Adjustment knob 15
t. Locking ring 14
u. Concentrator
v. Cabinet
ACTION
NOTE
To prevent pressure trapping be-
tween the pressure regulator and
test pressure gauge, make adjust-
ments to the regulator in small incre-
ments and vent a small amount of
oxygen at the pressure gauge be-
tween each adjustment.
Adjust for test pressure gauge reading of
5.0 + 0.5 psig.
Pull down to lock, and install a new strap.
Set the power switch to OFF, unplug the
AC power cord, and disconnect the test
pressure gauge.
Perform CLOSING procedure.
16. Solenoid 20, 24
(Figure 4-2)
TESTING
(Electrical)
TESTING
(Pneumatic)
a. Cabinet
b. Solenoid terminals
C. Solenoid terminals
d. Solenoid terminals
e. AC power cord
f. Front control panel
g. Solenoid valve
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-24
Perform OPENING procedure.
Disconnect two terminal wires.
Using digital multimeter, verify resistance
is approximately 850 ohms.
Apply 24 V dc using external power supp-
ly. Verify faint clicking sound inside
solenoid when 24 V dc is applied.
WARNING
The following procedure requires
AC power be applied to the con-
centrator. Metal components are not
grounded. To prevent possibility of
serious electrical shock, connect
ground wire to metal components
before applying power to the unit.
Connect to AC outlet.
Push power switch to ON position.
Verify solenoid is correctly activating pilot
valve by presence of appropriate supply,
exhaust, or balance gas flows. Perform
subsection 3.1.2 B steps 4 through 6 for
correct cycling.
7
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
REMOVAL
INSTALLATION
ITEM
h.
Solenoid valve
Front control panel
AC power cord
Small pilot tubing C, D,
orE
Solenoid valve
Replacement solenoid
valve
Replacement solenoid
valve
Replacement solenoid
valve terminals
Solenoid Valve
Cabinet
ACTION
Leak test solenoid gasket joints and
threaded connection with conservative
use of liquid leak detector.
Push power switch to OFF position
Remove from AC outlet.
Mark for correct replacement location
then remove from solenoid brass connec-
tors.
Hand loosen and rotate counterclockwise
to remove from pilot valve.
Apply small amount of pipe cement to
threads. Do not allow cement to enter
interior of solenoid.
Install into pilot valve and hand tighten.
Position the solenoid's electrical terminals
as shown in Figure 4-2.
Connect two terminal wires.
NOTE
The solenoid valve is not a polarity
sensitive component. Either wire
may be connectedto either terminal.
Leak test threaded connection with con-
servative use of liquid leak detector solu-
tion.
Perform CLOSING procedure.
17. Sieve Canister
Assembly 33
(Figure 4-2)
REMOVAL
a.
Cabinet
4-25
NOTE
Replacement of sieve canisters is
not a normal maintenance proce-
dure. Sieve canisters should only be
replaced when all other efforts to
achieve factory specified oxygen
levels have been exhausted. Con-
sult your authorized Puritan-Bennett
repair facility before proceeding.
Perform OPENING procedure
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
COMPONENT
TABLE 4-1. SERVICE PROCEDURES (continued)
Two straps 17
Two compression nuts
12 (connected to
plastic elbows on
bottom of sieve
canisters)
Oxygen a and pilot
pressure tubing d
Balance pilot valve 19
(including attached
fitting and
components)
Canister insulation 57
Pilot air filter assembly
6 and 1/16-inch
pilot tubing 10
Six plastic
compression nuts
12, 14 (connected
to elbows and tees
of four pilot valves
7, 25)
Screws 4 and canister
clamps 3
Sieve canister 33
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-26
ACTION
CAUTION
The following service procedure re-
quires removal of fittings or com-
ponents which will expose the sieve
canister’'s internal sieve material to
room air. Care should be taken so
that this material is not exposed to
room air for long periods of time (i.e
overnight). When ever possible plug
open ports and fittings to prevent
sieve contamination. Do not remove
plugs from replacement sieve
canisters until ready to install. Do not
interrupt the installation process
untilcompleted or until all open ports
are plugged.
Cut and remove.
Loosen and disconnect from plastic el-
bows.
Disconnect from center port of brass tee
21 and brass fitting 11 of solenoid valve
20.
Remove from concentrator cabinet and
set aside.
Remove from interior of concentrator.
Remove 1/16-inch pilot air tubing from
both brass connectors 11 of solenoids 24.
Remove 1/16-inch pilot air tubing both
exhaust pilot valves 7.
Loosen and disconnect plastic tubing
from pilot valves elbows and tee.
Remove the two screws and canister
clamp for each sieve canister.
Remove by pulling top of canister away
from cabinet interior and sliding canister
toward top of concentrator.
r-
TABLE 4-1. SERVICE PROCEDURES (continued)
MPONENT
REPLACEMENT
Two brass tees 9
Two plastic elbows 8
Two plastic elbows,
and brass tees
Replacement sieve
canister
Two plastic elbows and
brass tees
4-27
ACTION
NOTE
For this procedure it is not neces-
sary to separate each sieve
canisters solenoid valve, exhaust
pilot valve, and supply pilot valve
from each other. These components
may be removed from each sieve
canister as an assembly thus reduc-
ing the possibility of creating system
leaks.
CAUTION
When removing solenoid and pilot
valves from sieve canister, do not
apply force to solenoid body.
Remove this assembly as described
below.
Remove the solenoid, exhaust pilot, and
supply pilot valves as one assembly from
each sieve canister by turning brass tee
with 1/2-inch open-end wrench in
counterclockwise direction.
Remove elbows connected to bottom of
each sieve canister.
CAUTION
When applying pipe cement, do not
allow cement to enter interior of fit-
ting.
Add a small amount of pipe cement to
threads which were removed from the
sieve canister of brass tee and plastic
elbows. Distribute the cement evenly
around the entire threaded area.
Remove plugs from threaded connectors.
Thread into appropriate port of each sieve
canister. Take care not to cross thread or
over tighten. Position as shown in Figure
4-2.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM
p. Replacement sieve
canisters
q. Concentrator
ACTION
Reverse remainder of removal procedure
performed above. Hand tighten plastic
compression nuts. Refer to Figures 2-1,
2-2, and 4-2, if necessary, for positioning
of components and connection of wires
and tubes.
Perform performance verification proce-
dures in subsection 3.1.1 and 3.1.2.
18. Pilot Valve 7,25,19
(Figure 4-2)
DISASSEMBLY a. Cabinet
b. Solenoid valve 20,24
terminals
(Figure 4-10) с. Snapring1
d. Endcap?
e. Diaphragm (slotted) 4
f. Snapring1
g. Portcap 9
п. Poppet5
i. Support washer 7
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 4-28
Perform OPENING procedure.
CAUTION
If pilot valve remains disassembled
for extended lengths of time, (i.e.
longer than necessary to perform
service), seal valve openings to
prevent contamination of sieve
material.
If disassembly is to be performed on supp-
ly or balance pilot valves, remove terminal
wires and pilot air tubing from solenoid
valve and remove solenoid from pilot
valve. Refer to solenoid valve REMOVAL
and INSTALLATION procedures when
necessary.
Carefully remove from end cap 2 with
snap ring pliers (90-degree tip).
Remove slowly. Then carefully pull out
spring 3 (For exhaust pilot valves only).
Peel edge away from valve body, and pull
off of poppet 5.
Carefully remove from port cap 9.
Pull carefully away from valve body.
Push poppet, with solid diaphragm 8 at-
tached out of pilot valve body 6.
Remove from valve body.
" TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
CLEANING
INSPECTION
REASSEMBLY
>
Y
j- Pilot valve body 6
k. Two diaphragms
|. Two diaphragms
m. Pilot valve body
п. Support washer 7
O. Pilot valve body
p. Slotted diaphragm
4-29
ACTION
WARNING
To prevent personal injury, use face
shield and observe standard safety
procedures when using com-
pressed-air gun.
Apply isopropyl alcohol with cotton swab
to cavities and seating surfaces. Blow dry
with compressed-air gun.
Apply isopropyl alcohol with soft brush.
Blow dry with compressed-air gun.
Hold up to light, stretch, and check for
cuts, holes, and cracks, especially at seat-
ing surfaces. If either is defective, replace
both diaphragms with kit 10.
Inspect for corrosion, cracks, and burrs. If
defective, replace entire component.
CAUTION
To prevent damage to concentrator,
ensure that parts remain clean
during reassembly.
Place into port cap side of body, with
concave end facing inward as shown
below.
SUPPORT
WASHER
CD
° (©)
Place poppet, with solid diaphragm at-
tached, into port cap side, and push in
until diaphragm meets support washer.
Place into end cap side of body with seat-
ing surface facing in.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT ITEM
q. Pilot valve body
r. Pilot valve body
$. Endcap
t. Port cap
u. Solenoid valves
ACTION
Hold poppet steady at port cap side and
at end cap side. Press seating surface
around poppet flange until flange is visible
as shown below.
— d
J J > LA
Ty ZF. ml” FLANGE
O T
Install spring (for only exhaust pilot val-
ves) into cavity of poppet on slotted
diaphragm side of pilot valve.
Install over slotted diaphragm and secure
with snap ring. Ensure that snap ring is
pressed into valve body groove with ring's
sharp edge facing out.
Install over solid diaphragm and secure
with snap ring. Ensure that snap ring is
pressed into valve body groove with ring's
sharp edge facing out.
Apply a small amount of pipe cement to
the threads of the solenoids that were
removed. Evenly distribute the cement
around the entire solenoid fitting without
allowing any cement to enter the interior
of solenoid. Reinstall each solenoid and
reconnect the appropriate terminal wires.
The solenoid is not a polarity sensitive
device. Either wire of the appropriate wire
pair may be connected to either solenoid
terminal.
v. Cabinet Perform CLOSING procedures.
19. Restrictor Tube a. Cabinet Perform OPENING procedure.
Assemblies 13
(Figure 4-2)
Companion 492a/5380 Oxygen Concentrator
Service Manual 5-15-91 4-30
CAUTION
If restrictor tubes are removed for
extended lengths of time, (i.e. longer
than necessary to perform service),
seal open legs of tees connected to
balance pilot valve to prevent con-
tamination of sieve material.
rr TABLE 4-1. SERVICE PROCEDURES (continued)
Oxygen tube a
Plastic compression
nuts 14
Clamp 22
Tubing inserts 15
plastic compression
nuts 14
Tubing inserts, plastic
compression nuts,
and brass tee
Replacement restrictor
tube assemblies
Concentrator
Cabinet
ACTION
Remove from center leg of brass tee 21.
Loosen and remove two plastic compres-
sion nuts which are attached to bottom of
restrictor tubes, from balance pilot valve’s
two plastic tees 16.
Loosen and remove each restrictor tube
from brass tee 21.
Remove two inserts and nuts from restric-
tor tubes.
Connectto replacement restrictor tube as-
semblies.
Reinstall into cabinet. Reconnect and
hand tighten plastic compression nuts.
Reconnect oxygen tubing to center leg of
brass tee.
Perform pneumatic test procedures listed
in subsection 3.1.2 B steps 4 through 7.
Refer to subsection 3.4 if necessary.
Perform CLOSING procedure.
MPONENT
INSTALLATION
20. Outlet Gas Filter 13
(Figure 4-3)
REMOVAL
INSTALLATION
Cabinet
Oxygen tubing 12, 14
Replacement outlet
gas filter
Cabinet
4-31
Perform OPENING procedures.
Cut flush with inlet and outlet of outlet gas
filter. Discard filter.
Install between oxygen tubes 12 and 14.
If flow arrows are present on replacement
filter, point arrow toward oxygen tube
which is connected to the flowmeter inlet.
Filters without arrows may be installed in
either direction.
Perform CLOSING procedures.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
21. Shock Mounts 8
(Figure 4-4)
REMOVAL
DISASSEMBLY
REASSEBMLY
REASSEMBLY
Compressor platform
assembly
Sixteen 1/8" rivets 7
Four shock mounts 8
Four replacement
shock mounts
Rivets
Compressor platform
assembly
ACTION
Perform REMOVAL and DISASSEMBLY
procedures steps 9a through 9i.
Use a 1/8" drill bit to drill out the center of
the rivets. Remove and discard.
Remove shock mounts from compressor
platform and discard.
Place shock mounts on compressor plat-
form with rivet holes of shock mounts
aligned with rivet holes in compressor
platform.
Secure each shock mount to compressor
platform with four 1/8" rivets.
Perform REASSEMBLY and INSTALLA-
TION procedures steps 9m and 9n.
22. Compressor Cup
Seal 8 (Figure 4-6)
REMOVAL
REASSEMBLY
Compressor platform
assembly
Eight cylinder head
screws 31
Cylinder heads and
valve plates 3
Piston sleeves 5
Cup seal 8
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-32
Perform REMOVAL and DISASSEMBLY
procedures setup 9a through 9d.
NOTE
Some compressors may require a
#25 torx head screw driver to
remove the eight cylinder head
screws.
Remove from cylinder heads 30 and 10.
Remove both along with connector tubes
1.
Remove and discard.
Remove four retaining plate screws 6 on
each piston to separate retainer plate 7,
cup seal, and connecting rod 9. Discard
cup seals.
NOTE
An extra connecting rod is required
to fit cup seal and retainer plate into
piston sieeve.
от TABLE 4-1. SERVICE PROCEDURES (continued)
COMPONENT
COMPONENT
~~
INSTALLATION
Y a
ITEM
f.
Piston sleeve
Cup seal
Retainer plate
Retaining plate screw
Piston sleeve
Cup seal assembly
Cup seal assembly
Retaining plate screws
Valve plates, cylinder
heads, connector
tubes
Cylinder head screws
Compressor platform
assembly
4-33
ACTION
Place over top of extra connecting rod and
let drop to the bottom of the rod.
Place new cup seal on extra connecting
rod top. Make sure that the inside
diameter of the cup seal fits over the out-
side diameter of the ridge on the top of the
connecting rod.
Place over the cup seal and connecting
rod. Line up screw holes.
Install two screws hand tight to secure
retainer plate and cup seal to the extra
connecting rod.
Pull up around the cup seal and the
retainer plate to form the cup seal.
With piston sleeve in place over the cup
seal remove the two screws 6 and remove
the complete assembly from the extra
connecting rod.
Place the piston sieeve, cup seal and
retainer plate assembly on the connecting
rod 9 in the compressor.
Place loctite 242 in the four screw holes
of the connecting rod and tighten four
screws to twenty inch pounds.
NOTE
Repeat steps f through m for other
piston.
Reverse REMOVAL procedures.
Install eight screws and tighten to thirty
inch pounds in a criss cross pattern.
Reverse DISASSEMBLY and REMOVAL
procedures 9a through 9d.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-34 (blank)
J
J
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ITEM
a > WE" —
O N ©
9
10
11
12
13
14
15
16
17
18
19
20
COMPANION 492a/590 EXTERIOR PARTS LIST (Figure 4-1)
PART NUMBER
492297
492884
Reference*
492288
492196
492437
Included in item 5
492832
492782
492687
Included in item 5
Included in item 8
492187
492111
492672
492661
492662
492190
492192
492193
492350
DESCRIPTION
Battery, 9V
Battery Cushion
Serial Plate
Warning Label
Circuit Breaker, 492a, 5 AMP
Circuit Breaker, 590, 6 AMP
Knurled Nut
Battery Connector Assembly
Audio Alarm
Velcro Strip (5 Required)
Hex Nut
Locking Ring
Hour Meter (120V)
18" Rivet (2 Required)
Air Inlet Filter
Short Cabinet Screw
Long Cabinet Screw
Inlet Bacteria Filter
Prefilter Housing
Inlet Prefilter ( 2 Required)
Battery Label
"Item shown for descriptive purposes only and is not available for sale as an individual repair part.
Companion 492a/590 Oxygen Concentrator
4-37 Service Manual 5-15-91
(HUE1Q Ob-t} 6E-t
1018J]U32U03 uaBAxO 065/e267 LoILEduiOO
L6-S1-S [ENUEW aIAJaS
зона 19ш9е2 Na :Z-t 840614
ITEM
© ©0 NO OV bh WN =
— ck
- C
ok A
WwW го
Suffix
01
-02
-03
-04
-05
-06
-07
-08
-09
-10
-11
-12
-13
-14
-15
-16
-17
-18
ITEM
14
15
16
17
18
19
20
21
22
23
LEFT CABINET INTERIOR PARTS LIST (Figure 4-2)
PART NUMBER
492967
492665
492664
492717
492287"
492760
492634
492875
492666
493176*
492284
Included in item 8
492133
Restrictor Size
6.5
6.6
6.7
6.8
6.9
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.0
8.1
8.2
PART NUMBER
Included in item 16
492132
492874
492104
492130
492100
492443
432135
492134
492095
нон
DESCRIPTION
Cabinet Assembly, Left (Does not include item 53 & 60)
Grommet
Canister Clamp
Screw
Brass Fitting
Pilot Air Filter Assembly
Exhaust Pilot Valve
Plastic Eibow w/Insert
Brass Tee
146" Tubing
Brass Fitting
Compression Nut
Restrictor Tube Assembly Set (add suffix to part number
for correct size)
Suffix Restrictor Size
-19 8.3
-20 8.4 P C-493930-¢6
-21 8.5 - 905
22 8.6 SA 393 \
-23 8.7
-24 8.8
-25 8.9
-26 9.0
-27 9.1
-28 9.2
-29 9.3
-30 9.4
-31 9.5
-32 9.6
-33 9.7
-34 9.8
-35 9.9
-36 10.0
DESCRIPTION
Compression Nut
Tubing Insert
Plastic Tee w/Insert
Plastic Strap, Large
14" |.D. Plastic Tubing
Balance Pilot Valve
Balance Solenoid Valve
Brass Tee
Clamp
14" 1.D. Plastic Tubing
Companion 492a/590 Oxygen Concentrator
4-41 Service Manual 5-15-91
LEFT CABINET INTERIOR PARTS LIST (Figure 4-2) (continued)
ITEM PART NUMBER
24 492442
25 492100
26 492087
27 492890
28 492862
29 492926
30 492890
31 492556
32 493299
33 492990
492991
34 493300
35 492139
36 493177*
37 492633
38 492050
39 492953
40 Included in item 38
41 492621
42 492114
43 492182
44 493174"
45 493178"
46 492873
47 492171
48 492910
49 492172
50 492663
51 492174
52 492309
53 Refer to Figure 4-3 item 7
54 Included in item 60
55 Included in item 60
56 492801
57 Included in item 60
58 Included in item 60
59 Included in item 60
60 492929
* Tubing Sold in 3 foot lengths.
** Tubing Sold in 4 foot lengths.
DESCRIPTION
Supply Solenoid Valve
Supply Pilot Valve
1/4" 1.D. Plastic Tubing
Clamp
Compressor Exhaust Hose
Sleeve
Clamp
Reservoir Intake Fitting
Reservoir Canister Assembly
Sieve Canister Assembly, 492a (set of 2)
Sieve Canister Assembly, 590 (set of 2)
Product Canister Assembly
Brass Elbow
1/4" 1.D. Tubing
Pressure Switch
Vacuum Check Valve Assembly
Fitting Assembly
Tubing
Pressure Regulator
Exhaust Muffler
Plastic Elbow
316" 1.D. Tubing
34" |.D. Tubing
Large Caster Washer
516" Hex Nut
Bushing
16" Lockwasher
Left Upper Cabinet Tube
Caster
Small Caster Washer
Control Panel Label! (set of two for left and right cabinets)
Cabinet Insulation
Cabinet Insulation
Canister Insulation
Cabinet Insulation
Cabinet Insulation
Cabinet Insulation
Left Cabinet Insulation Kit
***For units manufactured August, 1991 and later order P/N 492284.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-42
(yuejq pr-b) Et-t
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L6-51-5 ¡ENUEW adAIIS
¿OUSlu| ¡UIQ \ubly :E-p 210614
ITEM
Y O ua с
O ©
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
RIGHT CABINET INTERIOR PARTS LIST (Figure 4-3)
PART NUMBER
492596
492595
492072
492558
492828
492823
492807
492623
492810
492597
492210
493174**
492071
493174"
492141
493174"
492802
492647
492672
492662
492196
492437
492671
492187
492656
492682
492987
492782
493175*"
492885
492627
492278
492168
492167
492166
492171
492172
492873
492107
492661
DESCRIPTION
Flowmeter Knob
Flowmeter Valve Assembly
Flowmeter, 492a, 4 Ipm
Flowmeter, 590, 5 Ipm
Green L.E.D.
Power Switch (includes item 4)
Flowmeter Fitting
Label, Control Panel, 492a w/o OCI*
Label, Control Panel, 590 w/o OCI* bc, 21334
Flowmeter Bracket
Flowmeter Nut
Tubing, %16" 1.D.
In-line Check Valve
Tubing, 316" 1.D.
Outlet Gas Filter
Tubing, 316" I.D.
Filter Door Insulation (Also included in item 68)
Filter Compartment Door
Air Inlet Filter
Long Cabinet Screw
Circuit Breaker, 492a, 5 amp
Circuit Breaker, 590, 6 amp
Wire Grommet
Hour Meter, 120VAC
Right Upper Cabinet Tube
Intake Filter Adapter
Small Tube Clamp
Audio Alarm
Tubing, 38" I.D.
Spout Nut
Oxygen Outlet Spout, Plastic
14" x 316" Spout Fitting
Spout Coupling
Spout Washer
Oxygen Outlet Spout, Chrome
¥16" Hex Nut
56" Lock Washer
Large Caster Washer
Cord Clamp
Short Cabinet Screw
Companion 492a/590 Oxygen Concentrator
4-45 Service Manual 5-15-91
ITEM
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
PART NUMBER
492309
492174
492964
492290
492673
492789
492746
492660
492650
492771
492653
Refer to Figure 4-4
492661
Included in item 53
Included in item 53
492870
Included in item 56
Included in item 56
492840
492839"
492868
Included in item 57
Included in item 58
492800
492774
Included in item 68
Included in item 68
Included in item 68
Included in item 68
Included in item 68
492928
492560
492651
492652
492654
492713
492832
RIGHT CABINET INTERIOR PARTS LIST (Figure 4-3) (Continued)
DESCRIPTION
Small Caster Washer
Caster
Cabinet Assembly, Right (Does not include item 7 & 68).
O-Ring
Cord Wrap Screws
Control PCB Screws
Control PCB, 120VAC VW /осл A 297)
Screw
Inlet Air Duct Cover
Cord Retainer
Cord Wrap
Compressor Module Assembly
Screw
Connector
Connector
Power Cord Assembly
Connector
Connector
High Voltage Wire Harness
Power Switch Wire Harness
Low Voltage Wire Harness
Connector
Connector
Air Dam Insulation
Air Dam
Insulation, Top Middle
Insulation, Top Back
Insulation, Top Front
Insulation, Middle
Insulation, Exhaust Tunnel
Right Cabinet Insulation Kit
Control PCB Fuse (63 MA)
Handle Cap
Handle
Dowel Pins
Large Tube Clamp
Battery Connector Assembly
* If unit is equipped with OCI Refer to Section 6 for appropriate part number.
** Tubing sold in 4 foot lengths. -
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-46
ITEM PART NUMBER
49296]
1 Refer to Figure 4-5 or 4-6
2 492043
3 493175*
4 492108
5 492770
6 492044
8 49 ETC
9 492965
10 492078
11 492079
12 493289
13 492799
14 492789
15 492107
16 492671
17 492989
18 492104
19 Included in item 1
20 Included in item 1
21 492773
22 4921093
23 Included in item 1
24 Included in item 1
25 Included in item 1
26 Included in item 1
27 492942
28 492946
29 492944
30 492966
31 Included in item 31
32 Included in item 31
33 492943
34 49204?
35 492822
* Tubing sold in four foot lengths.
in this figure.
PER
Se Feur 49393 1 (A
sera 493930 =)
LouEf
COMPRESSOR PLATFORM PARTS LIST
DESCRIPTION
Compressor Assembly
Intake Fitting
Tube, 36" 1.D.
Fan Screw
Tyrap Mount
Plastic Strap, Small
15" Rivet
Shock Mount
Platform Assembly (includes items 7 & 8)
Cup Washer
Lock Washer
Compressor Mounting Bolt
Insulation
Screw
Clamp
Wire Grommet
Capacitor, 120 VAC
Plastic Strap, large
Connector
Wire Harness
Clamp
Cooling Fan, 120 VAC
Connector
Wire Harness
Connector & Wire Harness
Grommet
Clamp
Flat Washer
Locknul
Heat Exchanger Assembly (includes items 31 & 32)
Brass Nut
Ferrule
Allenhead Screw
Exhaust Fitting Assembly (includes items 31 & 32)
Clamp
[> An additional set of items 27, 28, 29 and 33 are installed on the rear of the compressor bul are го! =
Figure 4-4: Compressor Platform Assembly
Companion 492a/590 Oxygen Concentr:
4-47 (4-48 blank) Service Manual 5-1£
O
HOUSING WELL B
HOUSING WELL A
Figure 4-5: Companion 492a Compressor
Companion 492a/590 Oxygen Concentrator
4-49 Service Manual 5-15-91
492a COMPRESSOR PARTS LIST (Figure 4-5)
ITEM PART NUMBER DESCRIPTION
— 492956 492a Compressor Assembly, 120VAC, NEW
(includes items 1 through 26)
— 492957 492a Compressor Assembly, 120VAC, REMANUFACTURED
(includes items 1 thorugh 26)
1 492027 Cylinder Head Screw
2 492028 Connector Tubes (2) with O-Rings (4)
3 492031 Head Gasket
4 492032 Valve Plate
5 492033 Valve Plate O-Ring
6 Included in item 21 Sleeve
7 Included in item 21 Piston/Rod Assembiy
8 492036 Connecting Rod Screw
9 492030 Cylinder Head B
10 492592 Cylinder Head Plug
11 492038 Five-Blade Fan
12 Reference” Cooling Fan Wires/Connector
13 Reference” Compressor Wires/Connectors
14 Reference* Capacitor Wires/Connectors
15 Reference* Motor Shaft
16 Included in item 21 Bearing
17 492039 Set Screw
18 Included in item 21 Eccentric
19 492040 Four-Blade Fan
20 492041 Eccentric Bearing Assembly (includes items 16, 17 & 18)
21 492954 Piston & Sleeve Assembly (includes items 6 & 7)
22 492465 Reed Valve
23 492963 Reed Valve Restraint
24 492563 Reed Valve Keeper Strip
25 492962 Reed Valve Plate Screw
26 492029 Cylinder Head A
* Item shown for descriptive purposes only and is not available for sale as an individual repair part.
Items 22, 24 and 25 are also used on the underside of each valve plate, item 4. The reed valve restraint,
item 23 is not used in this location.
Companion 492a/530 Oxygen Concentrator
Service Manual 5-15-91 4-50
HOUSING WELL
@
(2)
(20)
©
Figure 4-6: Companion 590 Compressor
A
Companion 492a/590 Oxygen Concentrator
4-51 Service Manual 5-15-91
ITEM
(соч ол во о
NY N ГО ГО № ГО ГО NY NOY = À eh À AP eh eh mh ed aA
O ©0 < OO Oh bb WN = OO © 00 < С) Oh bh Ww ГО — ©
PART NUMBER
492959
492961
492482
492481
492480
492479
492478
492477
492476
492475
493125**
492471
492592
492038
Reference*
Reference"
Reference"
492036
492039
493340"*
492470
Included in item 18
Included in item 18
Reference"
492465
492963
492563
492962
492592
492472
492027
590 COMPRESSOR PARTS LIST (Figure 4-6)
DESCRIPTION
590 Compressor Assembly, 120 VAC, NEW
(includes items 1 through 29)
590 Compressor Assembly, 120 VAC, REMANUFACTURED
(includes items 1 through 29)
Connector Tubes (2) and O-Rings (4)
Head Gasket
Valve Plate
Valve Plate O-Ring
Sleeve
Retaining Plate Screw x
Retaining Plate <=
Cup Seal —> (5 rst C-2942"10 -CO 35
Connecting Rod
Cylinder Head B
Cylinder Head Plug
Fan B
Cooling Fan Wires/Connectors
Compressor Wire Harness
Capacitor Wires/Connectors
Connecting Rod Screw
Set Screw
Eccentric Bearing Assembly (includes items 17, 20 & 21)
Fan À
Eccentric
Bearing
Motor Shaft
Reed Valve
Reed Valve Restraint
Reed Valve Keeper Strip
Reed Valve Screw
Cylinder Head Plug
Cylinder Head A
Cylinder Head Screw
* Item shown for descriptive purposes only and is not available for sale as an individual repair part.
** For concentrators whose last 6 digits are 009055 or lower order part number 492474 for item 9 and item
18 should be part number 492473.
Items 23, 25 and 26 are also used on the underside of each valve plate item 3. The reed valve restraint,
item 24 is not used in this location.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-52
Figure 4-7: Compressor Cylinder-Head Screw Torque Sequence
Companion 492a/590 Oxygen Concentrator
4-53 Service Manual 5-15-91
Figure 4-8: Companion 530 Compressor Retaining Plate Indexing
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 4-54
PRESSURE REGULATOR PARTS LIST
ITEM PART NUMBER
492621
492044
Reference"
Reference”
Reference”
Reference*
Reference”
Reference”
Reference*
Reference”
Reference”
492953
Included in item 13
492050
Reference"
Reference"
oO — ©) ло А © го —
dl = A À CO
RR © Го — ©
*
DESCRIPTION
Pressure Regulator, Complete (items 2 through 10)
Plastic Strap
Bonnet Assembly
Spring
Plastic Washer
Diaphragm
Plastic Seat
Black Seal
Poppet
Spring
Regulator Body
Fitting Assembly
Tube
Vacuum Check Valve Assembly
Lock Ring
Adjustment Knob
Item shown for descriptive purposes only and is not availalbe for sale as an individual repair part.
Figure 4-9: Pressure Regulator
Companion 492a/590 Oxygen Concentrator
4-55 Service Manual 5-15-91
ITEM
= DO OO NO Сл po WN =
*
PART NUMBER
492634
492100
492052
Reference*
492935
Included in item 10
492936
Reference”
492055
Included in item 10
Reference*
492952
PILOT VALVE PARTS LIST
DESCRIPTION
Exhaust Pilot Valve
Supply or Balance Pilot Valve
Snap Ring
End Cap
Spring (used only in exhaust pilot valve)
Diaphragm (slotted)
Poppet
Valve Body
Support Washer
Diaphragm (solid)
Port Cap
Pilot Valve Diaphragm Kit (items 4 & 8)
ltem shown for descriptive purposes only and is not available for sale as an individual repair part.
Figure 4-10: Pilot Valve
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
4-56
SECTION 6. OXYGEN CONCENTRATION INDICATOR (OCI™)
This section provides information required to test, troubleshoot, and repair the optional Oxygen Concentration
Indicator, including additional information in the form of a general product description and theory of operation.
Companion 492a/590 Oxygen Concentrator
6-1 Service Manual 5-15-91
6.1 General Product Description
The Companion 492a and 590 oxygen concentrators may be equipped with an OCI which may be either factory
or field installed. For field installation, a conversion Kit including step by step instructions is available (492888).
Changes to the concentrator with OCI installed consists of a different front control panel and addition of an
internal circuit board ( Figures 6-1 and 6-2 ).
The Oxygen Concentration Indicator (OCI) is a real-time oxygen sampling device utilizing ultrasonic sound wave
technology. An internal sensor is located in-line between the concentrator’s product canister and flowmeter to
analyze the product gas being delivered to the patient. The OCI system will automatically activate after five
minutes of concentrator operation. Upon activation, one of three front panel L.E.D.s will illuminate indicating
that the percentage of oxygen in the concentrator's output gas is within the ranges shown below.
INDICATORS RANGE (+ 3%)
Green Above 85%
Y ellow Between 70 and 85%
Red Below 70%
If the oxygen concentration drops to below 70%, and the red indicator activates, the OCI circuitry will interrupt
power to the concentrator's compressor. A low pressure alarm will activate after the gas in the product canister
is depleted.
NOTE
Concentrators with OCI installed require a minimum of 1/4
lpm flow for the system to function properly.
A
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a LT
Figure 6-1: 492a Front Panel with OCI
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 6-2
fa
ны РО ;
OCI PRINTED
CIRCUIT BOARD
(PCB) O.C.I. FRONT
PANEL PRINTED
CIRCUIT BOARD
(PCB)
OXYGEN ———
TUBES
GAS SAMPLE
CHAMBER
Figure 6-2: OCI Circuit Board Installed
6.2 Theory Of Operation
The OCI makes use of the well known principle that different gases have different characteristics in their abilities
to propagate, or transmit, ultrasonic sound waves. One of the systems components is a gas sample chamber
that samples the concentrator gas in a continuous flow. A sound wave is transmitted over a fixed distance from
one end of the gas sample chamber to the other end of the chamber. This "time-to-fly" is electronically measured
and converted to an electronic signal. The "time-to-fly" is dependent upon the concentrator gas purity, the gas
temperature, and the pressure of the concentrator gas. A temperature sensor is located within the concentrator
gas stream in order to electronically compensate for temperature effects. The concentrator gas in the sample
chamber is maintained at a constant pressure level.
The "time-to-fly" is measured and converted to an electronic signal, external factors are compensated for, and
the resultant output is processed into useful analytical information (the LEDs and shutdown system) through
standard electronic circuitry.
Companion 492a/590 Oxygen Concentrator
6-3 Service Manual 5-15-91
6.3 Performance Verification
Before attempting to verify the performance of the OCI, it is essential that the Companion Concentrator meets
all performance specifications found in Section 1: Introduction and Section 3: Performance Verification and
Troubleshooting. If during this process, the OCI is suspect or prevents further concentrator verification (i.e. unit
shuts oft) open the cabinet, and with the concentrator unplugged, disconnect the OCI by disconnecting the wire
harness header, item 12 from the OCI board at J5 (Figure 6-3). This will disarm the OCI and control panel
indicators but will not affect the concentrator's operation.
a. Allow the concentrator to stabilize by running a minimum of 20 minutes at the maximum flow rate
as indicated on the flowmeter.
b. Attach a properly calibrated oxygen analyzer to the outlet spout (Figure 1-4). Verify the
concentrators’ performance is within specification (see 1.4.1, step i).
c. Verify the green OCI front panel indicator labeled NORMAL is illuminated five minutes after
concentrator start-up.
d. Rotate the flowmeter knob counter-clockwise two turns for 492a or 1 1/4 turns for 590 to increase
the flow and decrease oxygen concentration.
e. Observe the oxygen analyzer. Within several minutes the concentration will drop. When the
analyzer reads approximately 85%, the yellow OCI front panel indicator should illuminate.
f. Allow the concentration to fall until the unit shuts off and the red OCI front panel indicator is
illuminated. The analyzer readout should be approximately 70%.
NOTE
The oxygen analyzer is located several feet downstream from
the concentrator. Therefore, the oxygen analyzer is
measuring the product gas at a different location and point in
time than the OCI. This fact combined with the instantaneous
measurement time of the OCI as compared to the relatively
long measurement time of common analyzers will cause an
apparent disagreement between the OCI and the analyzer
indicators.
g. Within a few minutes the audio alarm should sound. Depress the power switch to OFF.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 6-4
6.4 Troubleshooting and Repair
The OCI installed on a Companion concentrator is a gas monitoring device and does not affect the performance
of the concentrator. Should operation of the OCI be suspect, refer to the following sections.
6.4.1 Troubleshooting
This section is designed for easy reference to determine the problem with a concentrator equipped with OCI.
Refer to the category that matches the symptom(s) you observe. Then refer to the probable cause column which
suggest problems in order of most likely to least likely to occur.
SYMPTOM
1. Concentrator runs
5 minutes then
shuts off
PROBABLE CAUSE CORRECTIVE ACTION
d.
No flow
Flowmeter set too
high
Oxygen below 70%
High outlet pressure
Defective OCI
Set flow at minimum of 1/4 Ipm.
Set flowmeter ball at or below maximum
setting on flowmeter scale.
Troubleshoot concentrator per Section 3.
Check outlet pressure per 3.1.2 steps 12
through 15. Reset if necessary per ap-
propriate service procedure in section 4.
Disconnect wire harness from OCI PCB con-
nector J5. Run unit for 5 minutes at maximum
flow rate. If Oxygen is above 70% replace
OCI board per repair Section 6.4.2.
2. Concentrator runs/
concentration
above 85% / no
green OCI LED.
Concentrator has not
run for 5 minutes
Loose connection
High outlet pressure
Detective OCI
Run unit for more than 5 minutes.
Verify secure wire harness connections be-
tween OC! PCB at J5 and front panel PCB
at J4.
Check outlet pressure per 3.1.2 steps 12
through 15. Reset if necessary per ap-
propriate service procedure in section 4.
Follow steps a through g, subsection 6.3. If
yellow indicator illuminates at step e and the
red indicator illuminates (concentrator shuts
down) at step f or if no indicators illuminate
but concentrator shuts off below 70%, then
the front panel PCB may be defective.
Replace the front panel PCB as described in
repair subsection 6.4.2. If no OCI lights func-
tion, and unit does not shut off below 70%,
then the OCI PCB is most likely defective.
Replace the OCI PCB as described in repair
subsection 6.4.2.
3. Concentrator runs/
concentration
range does not
agree with ОС!
indicators (See
subsection 6.1)
Incorrect outlet
pressure
Defective OCI PCB
board
Check outlet pressure per 3.1.2 steps 12
through 15. Reset if necessary per ap-
propriate service procedure in section 4.
Replace as described in repair subsection
6.4.2.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
6.4.2 Repair
The following section describes how to service the individual components of the Oxygen Concentration Indicator
(OCI) system. Included are instructions for removal and installation for each major component of the OCi system.
After removing a component, visually inspect for damage or any other indication that the component is defective.
Unless otherwise specified, replace as needed with a new component. Refer to Figure 6-3 for replacement part
numbers. Perform subsection 6.3, Performance Verification, after completing service procedures found in Table
6-1.
Service procedures for the OCI system are provided in Table 6-1 as follows.
Step Number Component
1 OCI Printed Circuit Board
2 OCI Front Panel Printed Circuit Board
TABLE 6-1 SERVICE PROCEDURES
(Numbers in bold print correspond to items shown in Figure 6-3)
COMPONENT ITEM ACTION
1. OCI Printed Circuit
Board (PCB) 16
(Figure 6-3) CAUTION
The OC! printed circuit board con-
tains complementary metal-oxide
semiconductor (CMOS) integrated
circuits (IC's) which are static-sensi-
tive devices. To prevent IC damage,
observe standard safety procedures
as follows:
« Wear grounding wrist strap.
. Work on grounded conduc-
tive mat.
« Handle PCB by edges only.
« Store PCB in conductive
plastic bag.
REMOVAL a. Cabinet Perform OPENING procedure located in
Section 4.
b. Harness connector 12 Disconnect from OCI PCB at J5.
с. Oxygen tubes Cut and carefully remove the two oxygen
tubes where they connect to the gas sam-
pling chamber on the OCI PCB (Figure
6-2).
d. Screw 15 Remove six screws which attach OCI
PCB to air inlet duct cover 18.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91 6-6
rr
COMPONENT
INSTALLATION
TABLE 6-1 SERVICE PROCEDURES (continued)
ITEM
Replacement OCI PCB
Cabinet
ACTION
NOTE
The wire hamess connectors are
keyed and may only be installed in
one direction. Match connector con-
figuration to OCI PCB pins before
attempting to reinstall the connector.
Reverse REMOVAL procedure. Install
and tighten six screws in a criss-cross
pattern.
Perform CLOSING procedures located in
Section 4.
2. OCI Front Panel
Printed Circuit
Board (PCB) 8
REMOVAL
INSTALLATION
Cabinet
Oxygen tubes
(not shown)
Two flowmeter brack-
ets 5 and nuts 6
Flowmeter
Two connectors 10,11
Four nylon nuts 9
OCI front panel PCB
Replacement OCI front
panel PCB
Cabinet
Perform OPENING procedure located in
Section 4.
Remove from flowmeter 1 inlet and outlet
connectors.
Remove from flowmeter threaded con-
nectors.
Remove from concentrator.
Remove from OCI front panel PCB at J4
and J3.
Remove using a 5/16-inch socket wrench.
Remove from concentrator cabinet inte-
rior.
NOTE
The wire harness connectors 10 and
11 are keyed and may only be in-
stalled in one direction. Verify cor-
rect location, and match connector
configuration to front panel PCB
pins before attempting to reinstall
the connector.
Reverse REMOVAL procedure. After
hand tightening four nylon nuts, turn each
nut no more than 3/4 of a turn. Verify
correct connection of oxygen tubing to
flowmeter. Refer to Pneumatic Diagram
Figure 2-1 if necessary.
Perform CLOSING procedure located in
Section 4.
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
Figure 6-3: O.C.I. System
Companion 492a/590 Oxygen Concentrator
Service Manual 5-15-91
6-8
OXYGEN CONCENTRATION INDICATOR (OCI) SYSTEM PARTS LIST
ITEM PART NUMBER DESCRIPTION
1 432072 Flowmeter (432a)
492558 Flowmeter (590)
2 492624 OCI Control Panel Label (4924)
492809 OCI Control Panel Label (590)
3 492438 Nylon Screw
4 492964 Right Concentrator Cabinet
5 492597 Flowmeter Bracket
6 492210 Flowmeter Nut
7 432667 Nylon Spacer
8 492745 Front Panel PCB
9 492439 Nylon Nut
10 Reference’ Connector (15 pin)
11 Reference" Connector (14 pin)
12 Reference" Connector (14 pin)
13 492939 Clamp
14 492741 Screw
15 492789 Screw
16 492744 OCI PCB
17 492746 Control PCB
18 492650 Air Inlet Duct Cover
19 Reference" Connector (11 pin)
20 Reference* Connector (15 pin)
21 492837 Wire Harness (Control PCB to Front Panel PCB)
22 492838 Wire Harness (Front Panel PCB to OCI PCB)
23 492946 Washer
J1 Reference’ Control PCB connector (connects to front panel PCB J3)
J2 Reference” Control PCB connector
J3 Reference” Front panel PCB connector (connects to control PCB J1)
J4 Reference” Front panel PCB connector (connects to OCI PCB J5)
J5 Reference* OCI PCB connector (connects to front panel PCB J4)
J6 Reference* Control PCB connector
* Item shown for descriptive purposes only and is not available for sale as an individual repair part.
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