VisionAire Series Service Manual Rev G Dec 2012

____________________________________________________________________________________ Expedited Product Warranty Check service is always at your fingertips with AirSep: Type http://www.airsep.com/medical/equipmentproviders.html

OR In the US or Canada, dial 866-873-9277

AirSep® is a registered trademark of AirSep Corporation. • VisionAire™ is a trademark of AirSep Corporation.

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MN138-1 rev G 12/12

Table of Contents Section 1.0 Introduction 1.1

Equipment Provider Responsibility

1

1.2

Important Notice and Symbol Explanations

2

1.3

VisionAire® Product Warranty

5

1.4

Functional Specifications

6

2.1

Description of Operation

7

2.2

Operation Check

7

2.3

Alarm System

7

2.3.1 Start Up 2.3.2 Power Failure Alarm Test 2.3.3 No Flow Alarm Test

8 8 8

2.4

Oxygen Concentration Test and Specification

8

3.1

Instructions

9

3.2

Patient, Provider, and Routine Maintenance

10

3.2.1 Product Filter – No Maintenance Required 3.2.2 Preparing for New Patient Use/Method of Cleaning and Infection Control

10 10

4.1

Components

11

4.2

Cabinet Removal

11

4.2.1 Removing Front Panel 4.2.2 Removing Back Panel

11 11

Section 2.0 Operation Check and Oxygen Concentration Test

Section 3.0 General Instructions

Section 4.0 Main Components

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4.3

Compressor

11

4.3.1 Compressor Replacement 4.3.2 Capacitor Replacement

12 13

Solenoid Valves

13

4.4.1 Valve Manifold Replacement 4.4.2 Solenoid Valve Coil Replacement

13 15

Sieve Beds

15

4.5.1 Sieve Bed Replacement

15

Cabinet Fan

16

4.6.1 Cabinet Fan Replacement

16

Circuit Board

17

4.7.1 Circuit Board Replacement

18

Product Regulator Check and Setting

19

4.8.1 Setting Product regulator for Normal Operation 4.8.2 Product Regulator Lockout 4.8.3 Back Pressure Correction 4.8.4 Product Regulator Cleaning or Rebuilding

19

4.9

Circuit Breaker Replacement

21

4.10

l/0 Power Switch Replacement

21

4.11

Hour Meter Replacement

22

4.12

Flow Meter Replacement

22

4.13

Power Cord Replacement

23

4.14

Oxygen Monitor Circuit Board Replacement

24

4.15

Mixing Tank Replacement

24

4.16

Exhaust Muffler Replacement

24

4.17

Caster Replacement

25

4.18

Roller Base Replacement

26

4.19

Air Outlet Option (if equipped)

26

4.4

4.5

4.6

4.7

4.8

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Section 5.0 Troubleshooting 5.1

Operation Pressure Test

27

5.1.1 High Operating Pressure 5.1.2 Low Operating Pressure

27 27

5.2

General Troubleshooting

28

5.3

Troubleshooting Chart

29

5.4

Tool Kit and Pressure Test Gauge

32

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Appendix Exploded Drawings Wiring Diagram - VisionAire

A

Wiring Diagram – VisionAire 2, VisionAire 3

B

Valve Wire Harness – WH105-1

C

Main Assembly

D

Center Section Assembly

E

Compressor Enclosure Assembly

F

Compressor Assembly

G

Valve Manifold Assembly

H

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1.0 Introduction 1.1 Equipment Provider Responsibility All Equipment Providers of the VisionAire™ Oxygen Concentrator must assume responsibilities for handling, operational check-out, patient instruction, and oxygen concentration checks. These responsibilities are outlined below and throughout this manual. As an Equipment Provider, you must do all of the following: § Inspect the condition of each VisionAire unit immediately upon delivery to your business location. Note any sign of damage on the delivery receipt, and report it directly to both the freight company and AirSep Corporation immediately. § Check the operation of each VisionAire unit before delivery to a patient. Confirm the oxygen concentration level is within specifications as referred to in Section 2.4. (Test the power disconnect alarm as described in Section 2.3 of this manual.) § Deliver VisionAire units only to patients authorized by a licensed health care provider or physician’s prescription. The VisionAire oxygen concentrator must not be used as a lifesupporting device. A backup supply of oxygen must be available. § Instruct patients how to use VisionAire in conjunction with the Patient Manual. § Instruct patients to notify their licensed health care provider/physician if they experience any signs of discomfort. § Be available to provide service to each patient at any time. § Establish and implement a protocol to check oxygen concentration. § Refer to the VisionAire Product Warranty if parts replacement is required within warranty period. This unit is not a life-support device. Geriatric, pediatric, or any other patient unable to communicate discomfort while using this oxygen concentrator may require additional monitoring. Patients with hearing and/or sight impairments may need assistance with monitoring the alarms. This device supplies high-concentration oxygen that promotes rapid burning. Do not allow smoking or open flames within the same room of (1) this device, or (2) any oxygen-carrying accessory. Failure to observe this warning can result in severe fire, property damage, and/or cause physical injury or death.

Use no oil, grease, or petroleum-based or other flammable products on or near nasal end of cannula or on the VisionAire unit. Oxygen accelerates the combustion of flammable substances.

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1.2 Important Notice and Symbol Explanations As you read the manual, pay special attention to the WARNING, CAUTION, and NOTE messages. They identify safety guidelines or other important information as follows: Describes a hazard or unsafe practice that can result in severe bodily injury or death. Describes a hazard or unsafe practice that can result in minor bodily injury or property damage. Provides information important enough to emphasize or repeat.

Symbols/Abbreviations Symbols are frequently used on equipment in preference to words with the intention of lessening any possibility of misunderstanding caused by language differences. Symbols can also permit easier comprehension of a concept within a restricted space. The following table is a list of symbols and definitions that may be used with AirSep’s VisionAire Oxygen Concentrators. These symbols are referenced from the appropriate International Electro-technical Commission (IEC) standards:

Symbol

Description

Symbol

ON (power switch on)

Description OFF (power switch off)

No smoking

Do not disassemble

Type B equipment

Consult instructions for use

Warning – Describes a hazard or unsafe practice that if not avoided can result in severe bodily injury, death or property damage

Class II Device

Caution – Describes a hazard or unsafe practice that if not avoided can result in minor bodily injury or property damage

Complies with the 93/42/EEC directive drawn up by the approved organization No. 0459

Note – Provides information important enough to emphasize or repeat

Safety agency for CAN/CSA C22.2 No. 601.1 M90 for medical electrical equipment

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Symbol

Description

Symbol

Consult the accompanying documents

Description

Keep unit and accessories dry Proper disposal of waste of electrical and electronic equipment required

Use no oil or grease

Oxygen outlet connection to the cannula Caution: Federal law (USA) restricts this for sale or rental by or on the order of a physician or licensed health care provider. Fragile – handle with care

Do not expose to open flames

Keep in the vertical position

Oxygen concentration warning LED

See Instructions

Method disposing of waste: All waste from the VisionAire (patient circuit, etc.) must be disposed of using appropriate methods. Method for disposing of the device: In order to preserve the environment, the concentrator must only be disposed of using the appropriate methods. Conformity with EN 60-601 (§ 6.8.2 b): “The manufacturer, assembler, installer or importer is not considered to be responsible themselves for the consequences on the safety, reliability and characteristics of a device unless: - The assembly, fitting, extensions, adjustments, modifications or repairs have been performed by persons authorized by the party in question. - The electrical installation of the corresponding premises complies with IEC regulations. - The device is used in accordance with the instructions for use.” If the replacement parts used for the periodic servicing by an approved technician do not comply with the manufacturer’s specifications, the latter is absolved from all responsibility in the event of an accident. Do not open the device while in operation: risk of electrical shock. This device complies with the requirements of the 93/42/EEC European directive but its operation may be affected by other devices being used close by, such as diathermy and high frequency electro-surgical equipment, defibrillators, short wave therapy equipment, mobile telephones, CB and other portable devices, microwave ovens, induction plates or even remote control toys and more generally electromagnetic interferences which exceed the levels specified by the EN 60601-1-2 standard.

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Classification Type of protection against electric shock: Class II Protection from electric shock is achieved by DOUBLE INSULATION. Protective earthing or reliance upon installation conditions is not required. Degree of protection against electric shock: Type B Equipment providing a particular degree of protection against electric shock, particularly regarding: 1) allowable leakage current; 2) Reliability of protective earth connection (if present). Not intended for direct cardiac application. Degree of protection against harmful ingress of water: Equipment provided with an enclosure preventing entry of such an amount of falling liquid as might interfere with the satisfactory and safe operation of the equipment. Method of cleaning and infection control allowed: Please refer to the General Instructions section in the VisionAire Service Manual. Degree of safety of application in the presence of flammable anesthetic gases: Equipment not suitable for such application. Mode of operation: Continuous duty.

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1.3 VisionAire Product Warranty AirSep Corporation warrants the VisionAire Oxygen Concentrator to be free from defect in parts and workmanship for one, three, or five years (as may be specified on the original invoice provided) from the date of delivery to the original purchaser, under normal use and operation. AirSep Corporation’s obligations under this warranty are limited to the repair or replacement of any such item of equipment (or part thereof) shown to be defective or, at AirSep Corporation’s option, to refunding the purchase price of any such defective item of equipment. Each item of equipment for which a warranty claim is asserted shall, at the request of AirSep Corporation, be returned on a prepaid basis with proof of purchase date to the AirSep factory at the expense of the purchaser. The purchaser will be responsible for freight charges. Replacement parts shall be warranted as stated above for the unexpired portion of the original one, three, or five year parts warranty. This warranty does not extend to any item or part subjected to misuse, accident, improper application, or which has been repaired or altered outside of the AirSep Corporation Factory without the express prior written authorization of AirSep Corporation. THE FOREGOING WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, IN FACT OR IN LAW, INCLUDING WITHOUT LIMITATION THE WARRANTY OF MERCHANTABILITY OR THE WARRANTY OF FITNESS FOR PARTICULAR PURPOSE. IT IS EXPRESSLY UNDERSTOOD THAT PURCHASER’S SOLE AND EXCLUSIVE REMEDY FOR DEFECT IN PARTS IS LIMITED TO ENFORCEMENT OF AIRSEP CORPORATION’S OBLIGATION AS SET FORTH ABOVE, AND AIRSEP CORPORATION SHALL NOT BE LIABLE TO PURCHASER OR OTHERS FOR LOSS OF USE OF THE EQUIPMENT OR FOR OTHER SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.

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1.4 Functional Specifications Oxygen Concentration:

1-5 liters per minute at 90% +5.5/-3% 1-3 liters per minute at 90% +5.5/-3% (VisionAire 3) ⅛-2 liters per minute at 90% +5.5/-3% (VisionAire 2) (Based on 70°F [21°C] at sea level)

Accuracy:

± 10% of indicated flow setting, or ± 200 ml, whichever is greater.

Response Time:

Allow 5 minutes to attain maximum oxygen concentration.

Positioning:

Operate the unit in an upright position, maintaining at least 12 inches (30.5cm) of open space on all sides for ventilation.

Dimensions:

20.8 in. high, 14.1 in. wide, 11.5 in. deep (52.8 cm high, 35.8 cm wide, 29.2 cm deep)

Weight:

30 lb; shipping weight – 37 lb (13.6 kg; shipping weight – 16.7 kg)

Electrical (+/- 10%): 115VAC, 60 Hz, 3 amps, 290 watts 115VAC, 60 Hz, 3 amps, 190 watts (VisionAire 3) 115VAC, 60 Hz, 3 amps, 200 watts (VisionAire 2) 220-240 VAC, 50 Hz, 1.5 amps, 290 watts 220 VAC, 60 Hz, 1.5 amps, 290 watts 230 VAC, 50 Hz, 1.5 amps, 180 watts (VisionAire 2) 230 VAC, 50 Hz, 1.5 amps, 175 watts (VisionAire 3)

Alarms:

Power Failure Low Oxygen Concentration (with optional Oxygen Monitor) Low Pressure High Pressure High Temperature No Flow

Electrical Shock Protection:

Class II, Type B

Operating Temperature Range:

41 to 105°F (5 to 40°C)

Storage Temperature Range:

-4 to 140°F (-20 to 60°C)

Humidity:

15 – 95% (non-condensing)

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2.0 Operational Check and Oxygen Concentration Test 2.1 Description of Operation Air is drawn into the VisionAire Oxygen Concentrator. For overall, sound efficiency, before air enters the compressor, it passes through the unit’s intake muffler. Pressurized air then exits the compressor and moves to the valve manifold. The valve manifold incorporates the use of five two-way solenoid valves which control the flow of air and oxygen in and out of the molecular sieve beds. The unique property of molecular sieve enables it to physically attract (adsorb) nitrogen when air passes through this material, thus producing high concentration oxygen. There are two sieve beds: while one produces high concentration oxygen, the other is purged of the nitrogen it adsorbed (collected) during this pressure swing adsorption (PSA) cycle. Each adsorber produces oxygen and delivers it to the product tank. Oxygen exits the product tank through a pressure regulator, flow control valve, flow meter, and finally exits the unit. The VisionAire unit delivers up to 95.5% oxygen at the prescribed flow rate.

2.2 Operation Check AirSep tests every VisionAire Oxygen Concentrator thoroughly after manufacture. You must perform the following test to ensure that no damage occurred in shipping or handling. Do not use extension cords with this unit or connect too many plugs into the same electrical outlet. The use of extension cords could adversely affect the performance of the device. Too many plugs into one outlet can result in an overload to the electrical panel causing the breaker/fuse to activate or fire if the breaker or fuse fails to operate.

2.3

1.

Open and inspect all cartons (that contain units) upon delivery. Unpack the unit and remove it from the carton. Inspect the unit itself for damage. If the exterior of a unit’s carton is damaged, or the unit itself is damaged, note it on the freight bill signed by the driver.

2.

Plug in the power cord of the unit, and set the I/0 power switch to the “I” position. Check to see that the following occurs: a. A continuous alarm sounds for approximately four seconds. See the troubleshooting chart in Section 5.0 of this manual if the unit’s alarm does anything other than sound for four seconds. b. The compressor runs and flow is indicated in flow meter. c. OPTIONAL: The Oxygen Monitor’s amber light will remain on for four minutes upon startup regardless of unit’s concentration. After four minutes, the light will go out if the concentration level has reached minimum concentration requirements. d. Perform an oxygen concentration test, as described in Section 2.4.

Alarm System The VisionAire Oxygen Concentrator is equipped with an alarm system, which sounds an intermittent alarm when a power failure or other alarm condition occurs. The intermittent alarm sounds are displayed in the following table:

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VisionAire Intermittent Alarm Indicators Condition Audible Alarm

No Power One beep

Low O2 Two beeps

Low Pressure Three beeps

High Pressure Four beeps

High Temperature Five beeps

No Flow Six beeps

If the high pressure alarm is activated, the compressor and valves will shut down, and the audible four–beep alarm will continue. This alarm remains on until you set the I/0 power switch to the “0” position. Refer to Section 5.0 for alarm identifications, and a list of probable alarm causes.

2.3.1 Start Up Each time the VisionAire unit is turned on, an alarm should sound for approximately four seconds.

2.3.2 Power Failure Alarm Test To test the power failure alarm, disconnect the unit from power, set the l/0 power switch to the “I” position. This should activate the audible one-beep alarm. If the unit has not been used for an extended period of time, it needs to operate for several minutes to recharge the power failure alarm.

2.3.3 No Flow Alarm Test To test the no flow alarm, place thumb over oxygen outlet to completely block flow for approximately 10-15 seconds. The flow meter ball should drop to zero and the 6-beep alarm should be activated. (Note: not all units were originally manufactured with a no flow alarm. Units equipped with main circuit boards prior to rev. R will not have this feature.)

2.4 Oxygen Concentration Test and Specification To ensure that the unit’s output of oxygen is within specification, you must perform a test of the oxygen concentration. Test the unit upon delivery to a patient and at periodic intervals. Equipment Providers need to establish and implement a protocol to check oxygen concentration. 1. 2. 3. 4.

5.

If a humidifier bottle is used, disconnect it. Connect a calibrated oxygen concentration analyzer to the oxygen outlet. Verify that the product flow rate delivered by the unit matches the patient’s prescription and does not exceed the capacity of the unit. Set the unit’s l/0 power switch to the “I” position. Allow approximately five minutes for the oxygen concentration to stabilize. Take oxygen concentration readings and verify levels are within specification at the liter flow being tested. Disconnect the oxygen analyzer, and reconnect the humidifier bottle. Do not measure oxygen concentration output after the product stream passes through a humidifier bottle, or erroneous readings will result. 8 MN138-1 rev, G

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3.0 General Instructions 3.1 Instructions It is important that patients thoroughly understand how to operate the AirSep VisionAire unit. This enables proper treatment as prescribed by a qualified, licensed health care provider/physician. If patients experience any discomfort or the unit alarms, they must notify their licensed health care provider/physician immediately. You, as the Equipment Provider, are responsible to see that each patient receives the Patient Manual. Explain each step in the operation of the unit to the patient in reference to this manual. Smoking while using oxygen is the number one cause of fire, injury, and death. You must follow these safety warnings: Do not allow smoking, candles, or open flames within the same room of the device or oxygen-carrying accessories. Smoking while wearing an oxygen cannula may result in facial burns and possibly death. Removing the cannula and placing it on surfaces such as bedding, sofas, or other cushion material will cause a flash fire when exposed to a cigarette, heat source, or flame. If you smoke, you must follow these 3 life-saving steps: turn off the oxygen concentrator, take off the cannula, and leave the room where this device is located.

“No Smoking – Oxygen in Use” signs must be prominently displayed in the home or where the oxygen concentrator is in use. Patient and their caregivers must be informed about the dangers of smoking in the present of, or while using, medical oxygen

This device supplies high-concentration oxygen that promotes rapid burning. Do not allow smoking or open flames within the same room of (1) this device, or (2) any oxygen-carrying accessory. Failure to observe this warning can result in severe fire, property damage, and /or cause physical injury or death. Electrical shock hazard. Disconnect the power cord from the electric outlet before you clean the unit to prevent accidental electrical shock and burn hazard. Only your Equipment Provider or a qualified service technician should remove the covers or service the unit.

Care should be taken to prevent the VisionAire from getting wet or allowing any liquid to enter the unit. This can cause the unit to malfunction or shut down, and cause an increased risk for electrical shock or burns.

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Do not use liquid directly on the unit. Clean the exterior of unit and power cord only with a mild household cleaner applied with a damp cloth or sponge, and then wipe all surfaces dry.

3.2 Patient, Provider, and Routine Maintenance AirSep does not require any preventative or routine maintenance on the VisionAire concentrator. VisionAire’s unique design and technology allows for a virtually maintenance-free oxygen concentrator. You do not need to perform any maintenance as long as the VisionAire unit remains within specifications at the desired flow rate. The VisionAire does not incorporate an external air intake gross particle filter or batteries that require replacement.

3.2.1 Product Filter – No Maintenance Required The product filter is located internally within the unit’s product tank. There is no requirement for replacement. It is designed to last for the life of the concentrator.

3.2.2 Preparing for New Patient Use/Method of Cleaning and Infection Control When you remove the VisionAire from a patient’s home or facility, always dispose of the used cannula and humidifier bottle. Clean the exterior of the VisionAire with soapy water solution or mild household cleaner applied with a damp cloth or sponge to remove any gross debris. Do not use liquid directly on unit, and be careful not to get liquid into the interior of the unit. Next, following same guidelines above, clean the exterior with either a common chemical disinfectant or bleach solution*, wear eye and skin protection. After using the disinfecting solution, wipe entire unit with a cloth or sponge applied with water only, then wipe dry. Make sure unit is completely dry and then retest it before you return it to inventory. *

The manufacturers of sodium hypochlorite products recommend various strengths of a bleach solution for killing bacteria, etc., based on the type of germ to disinfect; however, a generally recommended solution is ¾ cups of household bleach per gallon of water.

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4.0 Main Components 4.1 Components The design of the VisionAire Oxygen Concentrator allows for easy access and removal of most components. This allows you to perform repair and replacement of parts with minimal time and effort. To prevent accidental electric shock or burn, be sure to set the unit’s I/0 power switch to the “0” position and unplug the power cord of the unit from the electrical outlet before you service the VisionAire Oxygen Concentrator. Some internal components, including the compressor may require cooling down before component removal. Care should be taken when removing all components. Before reattaching tubing connections using a tie-wrap, remove 1/8 inch (0.32 cm) from end of tubing to assure a proper seal. Tubing should be cut evenly across width.

4.2 Cabinet Removal 4.2.1 Removing Front Panel To remove the unit’s front panel, locate and unscrew both ¼ turn fasteners located at the top of the unit.

4.2.2 Removing Back Panel To remove the unit’s back panel, locate and unscrew both ¼ turn fasteners located behind the humidifier bottle retaining strap within the humidifier bottle recess area of back panel.

4.3 Compressor The compressor is the “pump” within the oxygen concentrator that pushes the room air into the top of the sieve beds. This allows oxygen to flow out of the bottom of the sieve beds in the VisionAire unit. Two different aspects of the compressor cause concern: the output and the sound level. Output Compressor output refers to how much compressed air the compressor can produce. This depends upon the model of the compressor, stroke length, bore size, and cup seal condition. The cup seals form the seal between the piston and the cylinder wall. As the cup seals wear, the compressor’s output begins to gradually decrease. This reduction in compressor output results in less air for the sieve beds. Therefore, the production of oxygen decreases. Since this drop in oxygen production occurs over a long period of time, preventative maintenance on the compressor is not required. You can continue a patient’s therapy on the VisionAire unit as long as that unit’s oxygen concentration level at the prescribed flow rate is within AirSep’s specifications.

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Sound Level The condition of the compressor’s cup seals, bearings, and other components can result in an increased sound level. If the compressor’s cup seals or bearings wear to the point that they become noisy, the concentrator may become noticeably louder, therefore compressor service or exchange may be required.

4.3.1 Compressor Replacement Some internal components, including the compressor may require cooling down before component removal. Care should be taken when removing all components. Compressor Assembly Removal To remove the compressor assembly, follow the steps below: 1. Set the unit’s I/0 switch to the “0” position and unplug the power cord. 2. Remove the front panel of unit. 3. Remove screws securing the compressor cover to the compressor enclosure, and remove cover to access compressor assembly. 4. Locate the 2-pin wire connection labeled ‘compressor’ on circuit board, and carefully disconnect connector from the circuit board. 5. Disconnect both wire connections from capacitor. 6. Remove the compressor by gently lifting it up and pulling it towards you at the same time. 7. Disconnect output tubing from left side of compressor assembly. Compressor Assembly Installation To install compressor assembly, follow the steps below: 1. Locate new compressor assembly. 2. Attach output tubing to compressor. Turn tubing ¼ turn in counter-clockwise direction and hold in that position while tightening fitting. If this is not done, the compressor will lean forward and contact the enclosure cover. 3. Assure compressor assembly is installed correctly. All four compressor springs must be installed on to their corresponding spring guides located on the bottom of the compressor compartment. 4. The end of the temperature probe must be located within the compressor compartment and positioned behind the compressor wires before installing the compressor cover. 5. Care should be taken when reconnecting wire connections to the circuit board and capacitor. Both sets of wires from compressor must be routed properly through the loop on tie wrap mount located inside of the compressor compartment, up through the small recessed area of compressor compartment in front of temperature probe, and alongside the back of capacitor to avoid possible damage when front cover is installed. 6. Compressor wires must be allowed to freely move within tie wrap loop. Care must be taken to assure compressor wires are not pulled by loop of tie wrap mount when properly installed. If new tie wrap is needed, it is important to engage only the first few notches of the tie wrap. 7. Before installing compressor cover, assure compressor wires are not in contact with compressor. 8. Leak test output tubing connection of compressor. 12 MN138-1 rev, G

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4.3.2 Capacitor Replacement The capacitor starts the compressor. If the compressor cannot start, the capacitor may be defective and require replacement. To replace the capacitor, follow the steps below: 1. Set the unit’s I/0 switch to the “0” position and unplug the power cord. 2. Remove front panel and locate capacitor. 3. Gently slide entire compressor enclosure towards you to allow easier access to the capacitor. (Do not pull out enclosure too far as damage may occur to certain components within concentrator). 4. Carefully disconnect both wire connections from the capacitor, slide capacitor out from tie-wrap. 5. To install new capacitor, slide capacitor into the tie-wrap holding it in place, and connect both wire connections to capacitor. Tie-wrap should be centered on capacitor when properly installed. 6. Return compressor enclosure to its original position, reinstall front cover.

4.4 Solenoid Valves The VisionAire uses five two-way solenoid valves: two feed, two waste, and one equalization. Each valve has an open (energized) and closed (de-energized) position. As the VisionAire operates, two or three valves are always energized. The solenoid valves of the VisionAire unit require no scheduled maintenance.

4.4.1 Valve Manifold Replacement Valve Manifold Removal To remove the valve manifold, follow the steps below: 1. Set the unit’s I/0 switch to the “0” position and unplug the power cord. 2. Remove both front and back panels. 3. Remove the compressor assembly by following the compressor removal procedure outlined under section 4.3.1. 4. Remove tubing attached to the exhaust muffler assembly. Do not remove muffler assembly. 5. Disconnect small tubing from the in-line adaptor leading to the sensor located on the circuit board. 6. Disconnect the wire connectors labeled AC Power and PowerSw from circuit board. (If equipped with an O2 oxygen monitor, also disconnect wire connectors labeled O2 LED and Sensor). 7. From back of unit, disconnect tubing connections at the equalization valve and disconnect fittings from top of both sieve beds. Temporarily seal sieve bed openings with tape to prevent the sieve material from being exposed to the moisture in room air. Prolonged exposure to room air results in contamination and permanent damage to the sieve material.

8. With adjusting compressor enclosure (alternating pulling out top and bottom), gently remove the compressor enclosure from the center section of unit by sliding it out through the front. 9. With the compressor enclosure completely removed, carefully remove all valve retainer clips and coils from each valve stem. Wire connectors can remain 13 MN138-1 rev, G

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attached to coils for easier installation. ( Please refer to the Valve Wire Harness drawings WH105-1 located on page C in the Appendix section of this manual as needed) Care must be taken when removing and installing valve coil retainer clips. 10. Using 1/8-inch Allen wrench, remove mounting bolt securing the manifold to the center section. Remove manifold assembly from compressor enclosure. 11. With the tubing still attached from the exhaust muffler and compressor, remove the fittings and tubing located on the underside of the valve manifold using a 7/16-inch open end wrench. 12. Disconnect fittings and remove the sieve bed feed tubing from manifold using a 9/16-inch open end wrench. 13. Disconnect small tubing from both sides of the valve manifold. Valve Manifold Installation To replace the valve manifold, follow the steps below: To follow this procedure easier, view the manifold from the front when reassembling components to manifold. Equalization valve will be positioned in the front of manifold when viewed this way. 1. Perform the valve manifold removal procedure in reverse order. 2. When installing the fittings from the sieve bed tubing, do not over tighten. 3. Remove original sealant tape from threads on fittings which will be installed to underside of manifold. Apply new sealant tape to fittings before installation. a. Fitting with braided tubing attached (compressor) must be installed to the left underside of manifold. Fitting with tubing attached (exhaust muffler) must be installed to the right underside of manifold. b. Foam pieces should be in place over fittings before installing manifold to compressor enclosure. 4. Valve manifold must be positioned properly before installation. When positioned correctly, the front of the valve manifold will face towards the back of the compressor enclosure, and will rest on the support pins on top of the enclosure. 5. When installing coils onto manifold valve stems, view manifold from the front. a. The front valve stem is the equalization valve and its coil should be installed having the wire terminals positioned on the bottom of the valve stem. The other coils must be installed having their wire terminals located on top of their valve stems. b. The outside (feed) valve coils must be installed so their wire terminals are pointing towards the front of manifold. c. The inside (exhaust) valve coils must be installed so their wire terminals are pointing towards the back of manifold. d. Valve coil retainer clips must be installed correctly so that the open ends are pointing downward on top of valve coil. 6. Periodic adjustment of the compressor enclosure may be required when reinstalling into center section. 14 MN138-1 rev, G

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