VisionAire 5 ™

Technical Service Manual

MN241-1 Rev B
Table of Contents
Section 1.0
Introduction
1.1 Equipment Provider Responsibility 5
1.2 Important Notice and Symbol Explanations 6

1.3 Classification 8
1.4 Functional Specifications 13
Section 2.0
Operation Check and Oxygen Concentration Test
2.1 Description of Operation 14
2.2 Operation Check 14
2.3 Safety and Alarm Features and Alarm Test Procedures 15
2.3.1 Compressor Motor 15
2.3.2 General Malfunction 15
2.3.3 Oxygen Monitor 15
2.3.4 Power Failure 15
2.3.5 Product Filter 15
2.4 Start Up 16

2.5 Power Failure Alarm Test 16

2.6 General Malfunction Alarm Test 16

2.7 Low O2 Alarm Test 16

2.8 Oxygen Concentration Test and Specifications 17

Section 3.0
General Instructions
3.1 Instructions 18
3.2 Patient, Provider, and Routine Maintenance 19
3.2.1 Product Filter – No Maintenance Required 19
3.2.2 Preparing for New Patient Use/Method 19
of Cleaning and Infection Control

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Section 4.0
Main Components
4.1 Components 20
4.2 Cabinet Removal 20
4.2.1 Removing Front Panel 20
4.2.2 Removing Back Panel 20
4.3 Compressor 20
4.3.1 Compressor Replacement 21
4.3.2 Capacitor Replacement 22

4.4 Solenoid Valves 22

4.4.1 Valve Manifold Replacement 22
4.4.2 Solenoid Valve Coil Replacement 24
4.5 Sieve Beds 24
4.5.1 Sieve Bed Replacement 24
4.6 Cabinet Fan 25
4.6.1 Cabinet Fan Replacement 25
4.7 Circuit Board 26
4.7.1 Circuit Board Replacement 26
4.8 Product Regulator Check and Setting 27
4.8.1 Setting Product regulator for Normal 27
Operation
4.8.2 Product Regulator Lockout 28
4.8.3 Back Pressure Correction 28
4.8.4 Product Regulator Cleaning or Rebuilding 29
4.9 Circuit Breaker Replacement 29
4.10 l/0 Power Switch Replacement 30
4.11 Hour Meter Replacement 30
4.12 Flow Meter Replacement 31
4.13 Power Cord Replacement 32
4.14 Oxygen Monitor Circuit Board Replacement 33
4.15 Mixing Tank Replacement 33
4.16 Exhaust Muffler Replacement 34
4.17 Caster Replacement 35
4.18 Roller Base Replacement 35

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Section 5.0
Troubleshooting
5.1 Operating Pressure Test 36

5.1.1 High Operating Pressure 36

5.1.2 Low Operating Pressure 36
5.2 General Troubleshooting 37

5.3 Troubleshooting Chart 38

5.4 Tool Kit and Pressure test Gauge 41

Section 6.0
EMC Testing
6.1 EMC Testing Tables 42

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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 CAIRE 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 life-
supporting 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.

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 CAIRE’s
VisionAire Oxygen Concentrators. These symbols are referenced from the appropriate
International Electro-technical Commission (IEC) standards:

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1.3 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 BF 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:
Drip-proof equipment – IP21
Protection against ingress of solid foreign objects greater than 12.5 mm diameter.
Equipment provided with an enclosure preventing 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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WARNING: PREGNANT OR NURSING
WOMEN SHOULD NOT USE ACCESSORIES
RECOMMENDED IN THIS MANUAL, THEY
MAY CONTAIN PHTHALTES.

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1.4 Functional Specifications
Oxygen Concentration: 1-5 liters per minute at 90% +5.5/-5%
(Based on 70°F [21°C] at sea level)
Accuracy: ± 10% of indicated flow setting, or ± 200 ml, whichever is greater.*
Outlet Pressure: 9 PSIG Max
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%): 220-240 VAC, 50 Hz, 1.5 amps, 290 watts
220 VAC, 60 Hz, 1.5 amps, 290 watts

Power Consumption: 290 Watts

Electrical Shock Class II, Type BF

Protection:
Operating Environment* 5° C to 40° C (41° F to 104° F )

Storage Environment -25° C - 70° C (-13°F - 158°F)

Humidity: 15 – 95% (relative humidity non-condensing)

Altitude: -1250 to 10,000 ft (-381 to 3048 m) (tested to 700 – 1060 hPa)

Sound Pressure Level: 45 dB(A) (1 to 5 LPM)

Sound Power Level: 51.29 dB(A)

*Based on an atmospheric pressure ranged of 700hPa to 1060 hPa at (70° F)
The expected service life of the equipment is a minimum of five years.

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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

CAIRE 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.

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 yellow 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.

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2.3 Safety and Alarm Features and Alarm Test Procedures
2.3.1 Compressor Motor
A pressure relief valve is fitted to the compressor outlet and is calibrated to 280 kPa (40 PSIG).
Thermal safety is ensured by a thermostat situated in the stator winding of the compressor
(135°C / 275 °F).

2.3.2 General Malfunction

If any of the conditions listed below occurs, the general malfunction light ( ) will illuminate
and an audible intermittent alarm will activate. See Figure 1. This includes:
• Obstruction of the flow of oxygen such as a pinch or kink in the delivery cannula, triggered by
high product tank pressure
• High device product tank pressure condition of greater than 33 PSIG (+/-1)
• Low device product tank pressure condition of less than 5 PSIG (+/-1)
• High device temperature of greater than 135°C (275 °F), triggered by low product tank pressure
if the thermal switch located within the compressor trips (shutting down the compressor)

2.3.3 Oxygen Monitor

The oxygen monitor detects any drop in concentration below 82%. If this occurs, the low
oxygen concentration warning light ( ) will illuminate. If the low O2 condition persists, an
audible intermittent alarm will activate. See Figure 1.

2.3.4 Power Failure

In the event the unit is operating, and a loss of power occurs, the power warning light ( )
will illuminate, and an audible intermittent alarm will activate. See Figure 1.

Figure 1
Device warning label and alarm display.

2.3.5 Product Filter

≥ 10 μm filter

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2.4 Start Up
Each time the VisionAire unit is turned on, an alarm should sound.

2.5 Power Failure Alarm Test

1. Disconnect the unit from external power.
2. Set the on/off switch to the “on” position.
3. Verify that the power loss alarm LED illuminates on the front panel and audible
alarm activates.

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.

2.6 General Malfunction Alarm Test

1. Disconnect the unit from external power.
2. Disconnect the compressor.
3. Connect unit to power and turn it on.
4. Verify that the general malfunction alarm LED illuminates on the front panel and
audible alarm activates after the warm-up period.
5. Turn off the unit and disconnect it from power.
6. Reconnect compressor.
7. Connect unit to power and turn it on.
8. Verify the alarm ceases once the compressor is re-connected.

2.7 Low O2 Alarm Test

1. Prior to performing this test procedure, ensure the unit has been turned off for at least
1 hour.
2. Disconnect the unit from external power.
3. Remove zip tie from inlet side of O2 monitor assembly.
4. Disconnect inlet tubing from O2 monitor assembly.
5. Connect unit to power and turn it on to the highest flow setting.
6. Verify that O2 monitor LED illuminates and audible alarm activates after warm-up
period.
7. Turn off the unit and disconnect it from power.
8. Reconnect tubing and re-install zip tie on the O2 monitor.
9. Connect unit to power and turn it on to the highest flow setting.
10. Verify the alarm ceases once the tube is re-attached.

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2.8 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. If a humidifier bottle is used, disconnect it.
2. Connect a calibrated oxygen concentration analyzer to the oxygen outlet.
3. Verify that the product flow rate delivered by the unit matches the patient’s
prescription and does not exceed the capacity of the unit.
4. 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.
5. 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.

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3.0 General Instructions
3.1 Instructions
It is important that patients thoroughly understand how to operate the CAIRE 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

CAIRE 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 CAIRE’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.

Under normal conditions, the sound pressure level should be approximately 45 dB(A), and the
sound power level should be approximately 51 dB(A) should be.

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. 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, and
alongside the back of capacitor to avoid possible damage when front cover is
installed.
5. 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.
6. Before installing compressor cover, assure compressor wires are not in contact
with compressor.
7. Leak test output tubing connection of compressor.
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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 Power Sw from circuit
board.
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
attached to coils for easier installation.

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 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.
a. Care must be taken not to pinch any wires or tubing between the
compressor enclosure and center section before final installation.
b. The wire harness for both the left feed valve and the equalization valve,
along with the wire harness for the right feed valve, must be routed
outside of the valve manifold assembly before connecting to valve coils.

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 c. The AC I/0 power switch wire harness and the pressure tubing to the
circuit board sensor must be routed to the outside of the manifold
assembly and along the back of the capacitor before installation.
7. When reinstalling fittings to top of the sieve beds, ensure wires and tubing on
both sides are located inside of these connections.
8. Be sure to reconnect wire connections labeled LED and Sensor to circuit board.
9. When reattaching tubing to exhaust muffler, be sure to secure with tie-wrap.
10. Install the compressor assembly by following the compressor assembly
installation procedure outlined under section 4.3.1.
4.4.2 Solenoid Valve Coil Replacement
An ohmmeter can be a useful tool in determining the condition of a valve coil. When
using an ohmmeter, each valve coil should be between 713 – 837ohms.
To replace a solenoid valve coil, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and unplug the power cord.
2. Remove back panel.
3. Carefully remove valve retaining clip from coil to be replaced.
4. Disconnect both wire connectors from solenoid valve, lift coil off of valve stem.
5. Install new coil on valve stem, reinstall coil retaining clip, and reconnect both
wire connectors to coil.
6. Valve coil retainer clips must be installed correctly so that the open ends are
pointing downward on top of valve coil.

4.5 Sieve Beds

The VisionAire unit utilizes two sieve beds each containing molecular sieve. The unique
property of molecular sieve enables it to physically attract nitrogen when air passes through this
material, thus producing high concentrated oxygen.
While one sieve bed produces high-concentration oxygen, the other is purged of the nitrogen it
adsorbed (collected) while it concentrates oxygen. Each adsorber (sieve bed) produces oxygen
and delivers it to the mixing tank.

4.5.1 Sieve Bed Replacement

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.
Leaks can be so small in air loss that oxygen concentration is not affected
immediately. The sieve material can become contaminated gradually.
Careful leak testing is important as the sieve material can become
contaminated gradually with very small leaks.

If replacement is necessary, you must replace both sieve beds at the same
time.

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 Sieve Bed Removal
To remove sieve beds, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and unplug the power cord.
2. Remove back panel.
3. Remove the fitting on the top of each sieve bed.
4. While keeping the four large sieve bed tie-wraps in place, gently pull upwards on
the top tie-wrap and remove each bed.
5. Lift each sieve bed from bottom tie-wrap and disconnect product tubing located at
bottom of each bed connection.
Sieve Bed Installation
To install the sieve beds, follow the sieve bed removal procedure in reverse order.
All tubing connections must be tightened properly to eliminate leaks. (Do not over
tighten fittings.)
To check for leaks, take the following steps:
1. Plug unit in and set the unit’s I/0 switch to the ‘I’ position.
2. Allow unit to run for three minutes.
3. Apply soapy water solution around tubing connections on both sieve beds, and
check for leaks.

4.6 Cabinet Fan

The cabinet fan pulls ambient air into the VisionAire unit. As this air is drawn in, the air cools
internal components (including the compressor) and exits out the bottom of the unit.

4.6.1 Cabinet Fan Replacement

Periodic adjustment of the compressor enclosure may be necessary

during this process.

Cabinet Fan Removal

To replace the cabinet fan, 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. 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.)
4. From the front of the unit, disconnect small tubing from the in-line adaptor
leading to the sensor located on the circuit board.
5. Disconnect the wire connectors labeled AC Power and PowerSw from circuit
board. Disconnect wire connectors labeled LED and Sensor.
6. 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.
7. Locate cooling fan at the back of the compressor enclosure. Review of both the
cooling fan and its wire connection positions should be made prior to fan removal
to allow easier and proper installation of new fan.
8. Remove fan and foam strip from the fan recess area and disconnect wires at
proper locations.
25
 Cabinet Fan Installation
To install the cabinet fan, follow the steps below:

It is very important to install the cabinet fan correctly. Reference

to arrow indicating airflow direction must be made. Improper
installation of cabinet fan may result in unit to overheat and
shutdown.

1. Locate arrow on fan indicating airflow direction. The arrow for airflow must be
pointing towards the compressor when properly installed.
2. Install wire connections onto new fan. Depending on the replacement fan version
being installed, wire connections on fan should be positioned either in the top left
or lower right positions when properly installed.
3. Replace foam strip around housing of new fan. Opening of foam should be
positioned at the upper right corner of fan when installed, and wires from fan
connections routed through same opening of foam at this location.
4. Position both foam strip and cabinet fan into fan recess area located at the back of
the compressor enclosure. When properly installed, both foam strip and fan must
be flush with the edge of fan recess area.
5. Return compressor compartment to the original position, being careful not to
pinch any tubing or wires between compressor enclosure and center section of
unit.
6. After removing tape from the top of each sieve bed, reconnect and tighten
fittings. (Small tubing from the bottom sieve beds and the unit’s power cord
should be located inside and underneath the tubing connected to sieve beds.
7. Reconnect and secure tubing to equalization valve using tie-wraps.
8. Reconnect wire connectors to main circuit board labeled AC Power and
PowerSw. LED, and Sensor.
9. Reattach small tubing to the in-line adaptor leading to the sensor located on the
circuit board, secure with tie wrap.
10. Leak test tubing connections and assure fan is rotating properly.

4.7 Circuit Board

The solid-state printed circuit board controls the timing operation of the five solenoid valves, the
alarm system functions, and regulates the voltage to ensure efficient and optimal performance.

The Printed Circuit Boards (PCBs) contain components that are sensitive to
electrostatic discharge (ESD) and can damage the board if not handled properly.
As when handling any ESD-sensitive PCB, observe standard ESD safety
procedures.

4.7.1 Circuit Board Replacement

Circuit Board Removal
To remove the circuit board, 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. In viewing unit from the back, remove fittings from top of both sieve beds. (This
step will allow easier access to circuit board when the compressor enclosure is
moved). Temporarily seal sieve bed openings with tape to prevent the sieve
material from being exposed to the moisture in room air.
26
 4. In viewing unit from the front, locate circuit board and cut tie-wrap securing
tubing to the transducer on circuit board. Carefully remove tubing from circuit
board sensor.

Care must be taken when removing and installing tubing to circuit

board sensor to prevent damaging sensor.

5. Gently slide entire compressor enclosure towards you to allow access to wire
connections located at the back of the circuit board. (Do not pull out enclosure
too far as damage may occur to certain components within concentrator).
6. Locate and remove the 2-pin wire harness labeled ‘Compressor’ on circuit board.
7. In a clockwise manner, remove remaining wire harnesses from circuit board.
These are wire harnesses labeled: AC Power, Buzzer, PowerSw, Fan, LED, and
the 6-pin wire harness located at the back of the circuit board labeled ‘Valves’.
8. Using a Phillips-head screwdriver, remove screws securing circuit board in place.
Circuit Board Installation
To install the circuit board, follow the steps below:
1. Located at the back of the circuit board, reconnect wire harness to connection
labeled Valves on circuit board.
2. Care should be taken when reconnecting any wire harness to assure they are
installed properly.
3. Perform the remaining steps listed in the circuit board removal procedure in
reverse order.
4. Replace compressor enclosure to its original position and reconnect fittings to the
top of each sieve bed, being careful not to over tighten.
5. Install tubing to the top barb of transducer located on the circuit board. Secure
with tie-wrap.
6. Leak test fitting connections of sieve beds.

4.8 Product Regulator Check and Setting

The product regulator enables you to set the maximum flow of oxygen output by the VisionAire
unit. To check for proper adjustment of the regulator, take the following steps:
1. Set the I/0 power switch to the “I” position.
2. Allow the unit to run for five minutes.
3. Turn the flow meter adjustment knob counterclockwise until it stops (wide open).
4. The flow meter ball should be set to ½ liter above the maximum flow rate. If not,
the product regulator needs to be reset.
4.8.1 Setting Product Regulator for Normal Operation
Use the following procedure to reset the product regulator:
1. Disconnect the humidifier bottle, if used, and the tubing from oxygen outlet.
2. Plug in the unit.
3. Set the unit’s I/0 power switch to the “I” position, and allow unit to run five
minutes to build up pressure.
4. Turn the flow meter adjustment knob counterclockwise until it stops (wide open).

27
 5. Remove the back panel of unit.
6. Pull outward on the regulator knob to unlock it.
7. Turn the regulator knob (clockwise to increase) until flow meter ball is set to ½
liter above the maximum flow rate.
8. Push in the regulator knob to lock it.
9. Reconnect the back panel.

4.8.2 Product Regulator Lockout

Take the following steps to limit the maximum flow of the oxygen concentrator:

It may be desirable to provide one additional liter or oxygen flow above

the prescribed level of concentration in using the lockout feature

1. Plug in the unit.

2. Set the unit’s I/0 power switch to the “I” position, and allow the unit to run five
minutes to build up pressure.
3. If used, connect the humidifier bottle, oxygen tubing, and cannula to the oxygen
outlet.
4. Remove the back panel of unit.
5. Turn the flow meter adjustment knob counterclockwise until it stops (wide open).
6. Pull outward on the regulator knob to unlock it.
7. Turn the regulator knob counterclockwise to decrease the setting until the flow
meter registers the maximum flow desired.
8. Push in the regulator knob to lock the setting.
9. Reconnect the back panel.

When the lockout adjustment is no longer required, follow the normal

regulator setting procedure as described in Section 4.8.1.

4.8.3 Back Pressure Correction at Maximum Flow Rate

In some cases, additional lengths of oxygen tubing with a humidifier bottle can increase
back pressure and limit oxygen flow below the maximum flow setting.
To achieve full maximum flow setting, use the following procedure:
1. Plug in the unit.
2. Set the unit’s I/0 power switch to the “I” position, and allow the unit to run five
minutes to build up pressure.
3. Connect the humidifier bottle, oxygen tubing, and cannula to the oxygen outlet.
4. Turn the flowmeter adjustment knob counterclockwise until the ball reaches the stop
at the top of the flow meter (wide open).
5. Remove the back panel of unit.
6. Pull outward on the regulator knob to unlock it.
7. Turn the regulator knob clockwise until flow meter ball is set ½ liter above the
maximum flow rate.
8. Push in the regulator knob to lock the setting.

28
 9. Turn the flowmeter adjustment knob clockwise until the flowmeter indicates
maximum flowrate.
10. Reconnect back panel.

When this back pressure correction is no longer required, follow the

normal regulator setting procedure as described in Section 4.8.1.

4.8.4 Product Regulator Cleaning or Rebuilding

Clean or rebuild the product regulator if the flow meter ball fluctuates more than ¼ liter
or if the regulator cannot be adjusted for lockout.
1. Set the unit’s I/0 switch to the “0” position and unplug the power cord.
2. Remove the back panel.
3. Use large pliers to unscrew the bonnet of the product regulator, which contains a
large spring.

Adjust the product regulator fully counterclockwise to unload the spring.

This makes disassembly and reassembly easier.

4. Remove the diaphragm. (Clean or replace it.)

5. Using a Phillips-head screwdriver, unscrew the diaphragm stem guide located in
the center of the regulator body to gain access to the seat.
6. Remove the seat. Be careful not to lose the spring located behind the seat.
7. Clean or replace the seat.
8. With the spring behind the seat, screw the diaphragm stem guide back into the
body of the regulator. (Do not over tighten.)
9. Install a clean or replacement diaphragm.
10. Put the large spring and slip ring into the bonnet, and screw the bonnet onto the
regulator body.
11. Reset the product regulator as described in Section 4.8.1.

4.9 Circuit Breaker Replacement

Circuit Breaker Removal
To remove the circuit breaker, 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 and locate circuit breaker.
3. To gain access to the underside of the circuit breaker, remove screw securing the
right mounting plate assembly to the center section using a Phillips-head
screwdriver.
4. Lift assembly out from unit and disconnect wires from circuit breaker.
5. Remove the securing ring holding the circuit breaker to the mounting plate.
Circuit Breaker Installation
Follow the removal procedure for the circuit breaker in reverse order to install the new
circuit breaker. Wire connections on circuit breaker can be made to either terminal.

29
4.10 I/0 Power Switch Replacement
I/0 Power Switch Removal
To remove the I/0 power switch, 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 and locate the I/0 power switch.
3. To gain access to the underside of the switch, remove screw securing the right
mounting plate assembly to the center section using a Phillips-head screwdriver.
4. Lift assembly out from unit and disconnect wires from switch.
5. To allow easier access to the I/0 power switch, remove the circuit breaker from
mounting plate, leaving wires connected. (Refer to circuit breaker removal
procedure 4.9.1).
6. With circuit breaker removed, use large adjustable pliers to unlock the top and
bottom securing tabs of power switch while pushing power switch through front
of mounting plate at the same time.
I/0 Power Switch Installation
Follow the removal procedure for the I/0 power switch in reverse order to install a new
power switch.
1. Be sure to reinstall the new switch properly by having the ‘0’ on the switch
located on the bottom when finished.
2. Wire connections on the left side of switch should be from circuit breaker and
hour meter wires. Wire connections on the right side of switch from the circuit
board wires. (The smaller size wires are from the circuit board.)
3. Same side wire connections of power switch can be made to either terminal.

4.11 Hour Meter Replacement

This is a dual timer hour meter.

To toggle between the two display screens - press the pinhole reset
switch once to display “TMR1” mode.
To reset the timer display – confirm that “TMR1” is displayed in the
upper left corner. Press and hold the pinhole reset switch for 3 seconds
until 0.0 is displayed.

Hour Meter Removal

To remove the hour meter, 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 hour meter.
3. To gain access to the underside of the hour meter, remove screw securing the
right mounting plate assembly to the center section using a Phillips-head
screwdriver.
4. Lift assembly out from unit and disconnect wires from hour meter.
5. While pressing in the securing tabs located in each corner of hour meter, push
hour meter through the front of the mounting plate. (It may be easier to perform
this step to one side of the hour meter at a time.)

30
 Hour Meter Installation
To install a new hour meter, follow the steps below:
1. Follow the removal procedure for the hour meter in reverse order.
2. Be sure to reinstall the new hour meter properly by having the ‘hourglass’ icon
located on the bottom when finished.
3. The top two hour meter wire connections should be from the white wire from
power cord and the white wire from the circuit board harness.
4. The lower two hour meter wire connections should be from the black wire from
the I/0 power switch and the black wire from the circuit board harness.
5. Connections for the same color wires can be made to either terminal.

4.12 Flow meter Replacement

Care must be taken when removing and installing the flowmeter on
units equipped with an O2 monitoring systems to prevent damaging
circuit board sensor. The tubing assembly from the top of the flow
meter is connected to sensor.

Flowmeter Removal
To remove the flow meter, 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 and locate flow meter.
3. To gain access to the underside of the flow meter, remove screw securing the left
mounting plate assembly to the center section using a Phillips-head screwdriver.
4. Carefully lift assembly out from unit.
5. Cut only the top tie-wraps on each tubing connection of flow meter and
disconnect tubing from flow meter.
6. Remove flow meter nuts securing flow meter to the mounting plate, remove flow
meter.

Flowmeter Installation
1. To install a new flow meter, follow the flow meter removal procedure in reverse
order. Leak test the tubing connections.
2. Assure flow meter reads ½ liter above the maximum flow rate when fully opened.
(Refer to section 4.8 Product Regulator Check and Setting for proper adjustment as
needed).
3. To avoid the possibility of activating no flow alarm, set flow meter to desired liter
flow prior to turning unit off.

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4.13 Power Cord Replacement

Power Cord Removal

To remove the power cord, 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. Using a Phillips-head screwdriver, remove screw securing the right mounting
plate assembly from the center section.
4. Carefully pull out assembly and disconnect the power cord wire connections from
the hour meter (white) and circuit breaker (black).
5. From the back of unit, completely pull power cord out of holder and unwrap the
power cord wires from the ferrite bead (ring). Please note configuration of wires
around the ferrite ring at this time. Do not dispose ring.
6. Using large adjustable pliers, remove power cord strain relief from base of unit by
pressing in the top and bottom of the strain relief while pulling out towards you at
the same time.

Power Cord Installation

To install a new power cord, follow the steps below.
1. Place both new power cord and old power cord together (side-by-side) to
determine location to install strain relief on new power cord.
2. Route both wire ends of new power cord into entry location on the base of unit
and pull power cord through hole to the pre-determined location to install strain
relief to new power cord.
3. Install strain relief onto power cord and secure power cord to base.
4. Locate ferrite ring and insert both wire leads from new power cord into the center
of ferrite ring so that the outside insulation of power cord is flush with the inside
rim of ferrite ring.
5. Continue to wrap both power cord wires around and through the center of ferrite
ring 6 times. (The last few times will require wires to be inserted individually
one at a time into center of ferrite ring.)
6. Insert power cord into holding clamps located to the right of the left sieve bed,
and route the power cord to the inside of the top left sieve bed tubing connection.
7. Reconnect the white wire from power cord to the hour meter and the black wire
from power cord to the circuit breaker.
8. Reinstall right mounting plate assembly to center section using a Phillips-head
screwdriver.
9. When properly installed, ferrite ring should be located in the recessed area behind
the right mounting plate assembly.
10. Reinstall both covers and turn unit on to confirm operation.

32
4.14 Oxygen Monitor Circuit Board Replacement
Oxygen Monitor Circuit Board Removal
To remove the circuit board, follow the steps below:

Care must be taken when removing and installing tubing to circuit board
sensor to prevent damaging sensor.

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. When viewing unit from the back, locate oxygen monitor circuit board and
remove the tie-wraps at tubing connections.
4. Carefully remove tubing from circuit board sensor.
5. Disconnect wire harness from circuit board.
6. Using Phillips-head screwdriver remove screws securing circuit board to center
section. Remove circuit board.
Oxygen Monitor Circuit Board Installation
To install a new circuit board, follow the removal procedure in reverse order.

4.15 Mixing Tank Replacement

Mixing Tank Removal and Installation

To replace the mixing tank, 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. When viewing unit from the back, locate mixing tank and cut tie-wraps securing the
mixing tank to the center section. (Do not remove tie-wraps at this time.)
4. Disconnect tubing connections from the mixing tank before removing it.
5. After review of correct installation is made, remove the tie-wraps which held the
mixing tank in place. Install new tie-wraps to secure mixing tank to center section.
Do not tighten tie-wraps at this time.
6. Reconnect tubing to mixing tank, secure tubing with tie-wraps.
7. Position mixing tank into place and tighten tie-wraps to secure.

Before final installation, care must be taken when installing new

tie-wraps and the mixing tank to avoid pinching any tubing or
wires. Inspection for this should be thoroughly made before
final installation.

33
4.16 Exhaust Muffler Replacement
Exhaust Muffler Removal and Installation
To replace the exhaust muffler, follow the steps below:
1. Follow steps 1-7 in the Compressor Assembly Removal procedure outlined under
section 4.3.1.
2. Locate exhaust muffler assembly in back of compressor enclosure, cut tie-wrap
securing it in place.
3. Remove tie-wrap from tubing connection, disconnect tubing.
4. Unscrew the top half (exhaust muffler) from exhaust muffler body.
5. Install new exhaust muffler to the muffler body, being careful not to over tighten to
prevent damaging threads of exhaust muffler.
6. Remove back panel.
7. To install tie-wrap for new muffler assembly, the compressor enclosure is required
to be pulled out toward the front of unit. To allow greater access, remove tubing
connections at the equalization valve, and disconnect the fittings from both sieve
beds. (Temporarily seal sieve bed openings with tape to prevent the sieve material
from being exposed to the moisture in room air.)
8. From the front of the unit, gently slide entire compressor enclosure towards you.
(Do not pull out enclosure too far as damage may occur to certain components
within concentrator.)
9. Starting from inside the compressor compartment, install new tie-wrap though the
bottom opening located in the recessed area where the exhaust muffler assembly
will be installed. (Hint: it may be easier if the end of the tie-wrap is formed into a
‘hook’ shape before this step.)
10. Route tie-wrap up the back of the compressor compartment and into the top
opening of the compressor enclosure. When finished, both ends of tie-wrap
should be located inside the compressor enclosure.
11. Reattach tubing to exhaust muffler assembly securing with tie-wrap.
12. Place muffler assembly into recessed area, securing with installed tie-wrap.
13. Return compressor compartment to the original position, being careful not to
pinch any tubing or wires between compressor enclosure and center section of
unit.
14. Reinstall compressor assembly following the Compressor Assembly Installation
procedure outlined under section 4.3.1.
15. Reconnect and tighten fittings to top of sieve beds. Bottom sieve bed tubing and
the unit’s power cord should be located inside these tubing connections.
16. Reconnect and secure tubing to equalization valve using tie-wraps.
17. Leak test tubing connections on sieve beds and equalization valve.

34
4.17 Caster Replacement
Caster Removal
To replace a caster, it is necessary to remove the base of unit from the center section. To
do this, 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 compressor cover from the compressor enclosure to access front screws
securing center section to base.
4. Using a Phillips-head screwdriver, remove the screws in the front and back of
unit securing the base of unit to the center section.
5. Gently position the entire concentrator on its back and separate the base from the
center section. (Power cord is still attached to base.)
6. From the underside of base, secure caster nut (located just above the wheel of
caster) using a 1/2-inch combination wrench.
7. While securing the nut, remove the top nut of caster using a 9/16-inch
combination wrench.

Caster Installation
To install a caster, follow the removal steps in reverse order.
1. Larger washer should be installed onto caster before inserting into underside of
base.

4.18 Roller Base Replacement

Roller base removal and Installation
To replace the base on the VisionAire concentrator, please 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. Follow Power Cord Removal procedure outlined under section 4.13.
4. Remove compressor cover from the compressor enclosure to access front screws
securing center section to base.
5. Using a Phillips-head screwdriver, remove the screws in the front and back of unit
securing the base of unit to the center section.
6. Gently position the entire concentrator on its back and separate the base from the center
section.
7. Follow Caster Replacement procedure outlined under section 4.17 to remove casters
and install onto new base.
8. Install center section onto new base making sure the power cord location on the base is
located at the back of the unit. Secure base to center section with screws using a
Phillips-head screwdriver.
9. Follow Power Cord Installation procedure outlined under section 4.13. (Note: location
of strain relief on power cord is already determined.)
10. Using a Phillips-head screwdriver, reinstall compressor cover to compressor enclosure.

35
5.0 Troubleshooting
5.1 Operating Pressure Test
Testing the operating pressure is a useful diagnostic tool when a concentrator has low oxygen
concentration and requires servicing. Units functioning normally do not require operating tests.
Use the following procedure to test the operating pressure of the unit:
1. Set the unit’s I/0 power switch to the “0” position, and unplug the power cord.
2. Remove the front panel of unit.
3. Locate the pressure test port location (black tube located on the top right side between the
compressor enclosure and center section). Using a pressure test adapter (CAIRE p/n: KI257-
2), connect the pressure gauge to the test port.
4. Plug in the power cord, and set the unit’s I/0 power switch to the “I” position.
5. Set the flowmeter to the maximum flow rate for the unit and allow it to run five minutes.
6. Observe the maximum and minimum readings on the pressure test gauge.
The maximum reading should not exceed: 30 PSIG (207 kPa)
The minimum reading should not be less than: 8 PSIG (55 kPa)

When you turn the unit on, the system pressure always registers higher than
normal for the first few minutes of operation.

5.1.1 High Operating Pressure

Higher than normal operating pressure may indicate any of the following:
• A restrictive exhaust muffler, which does not allow the waste (purge) gas to exit the
system freely. Operate the unit with the exhaust muffler disconnected to see if the
operating pressure returns to normal.
• An improperly operating circuit board or solenoid valve.
Confirm that the circuit board and solenoid valve function properly.
• Contaminated sieve beds.
Change the sieve beds.
5.1.2 Low Operating Pressure
If the oxygen concentration level at the desired liter flow is within CAIRE’s specifications, no
service is required, even if operating pressure is low. If concentration is below specifications at
the desired liter flow rate with low operating pressure, this may indicate any of the following:
• A restriction in the compressor intake path may be limiting the amount of room air
available to the compressor.
Check compressor intake path for obstruction. Clean/remove obstruction and verify
normal operating pressure returns.
• An improperly operating circuit board or solenoid valve.
Confirm that the circuit board and solenoid valve function properly.
• A leak in the unit, which allows system pressure to escape.
Leak test unit.
• A compressor with reduced output. If it is below specifications, replace or repair the
compressor.

36
5.2 General Troubleshooting
Before reviewing the troubleshooting chart, the following steps may be useful to isolate any
malfunctions:
1. Turn on the concentrator. If the unit does not turn on, refer to the troubleshooting chart.
2. Turn the flow meter knob until it is wide open at the highest setting. The ball should be located
½ liter above the maximum flow rate. If the flow meter ball is not located at this setting, adjust the
regulator until the ball is set ½ liter above the maximum flow rate with the flow meter completely
open.
3. Make sure the unit is cycling properly by:
a. observing the flow meter ball is stable (flow meter ball does not move up and down more
than ¼ liter.)
b. checking circuit board if high or low pressure lights are illuminated and audible pressure
alarm is sounding.
4. Place your thumb over outlet of unit. The flowmeter ball should drop to the bottom of the
flowmeter. If the ball does not drop completely to the bottom, there is a leak present between the
top of the flowmeter and the outlet of the unit.
5. If concentrator is not meeting specifications, make sure that the unit is leak-free by testing all tubing
connections and fittings with leak testing solution. Protect circuit board(s) from solution and start
leak test at the compressor, following air flow of unit to oxygen outlet. Repair all leaks by
tightening connections and fittings.
6. If unit is alarming, refer to the Alarm Indicator Chart in Section 2.3 for probable solutions.
7. Set the concentrator at the maximum flow rate and connect an operating pressure test gauge to unit.
Determine pressure parameters by observing high and low pressure points on the gauge. If pressures
are high or low, refer to Section 5.1.
8. Review troubleshooting chart to isolate and repair any other malfunctions.

37
5.3 Troubleshooting Chart

Problem Probable Cause Solution

Unit does not run. • No power to unit. • Check wall outlet for power.
• Unit circuit breaker tripped/faulty • Reset or replace circuit breaker.
I/0 power switch in “I” position.
• Faulty electrical connections. • Check electrical connections.
• Faulty circuit board. • Replace circuit board.
• Faulty I/0 power switch. • Replace I/0 power switch.

Compressor runs with intermittent

alarm. Oxygen concentration at max • Faulty pressure transducer. • Replace circuit board.
flow rate is within specifications.

Compressor runs and shuts down

periodically. Only start up alarm • Faulty oxygen monitor circuit board. • Replace oxygen monitor circuit board.
activates

• Restricted air flow. • Remove obstruction.

Compressor runs and shuts down • Unit overheating due to improper • Locate unit away from heating
periodically with general malfunction location. Compressor thermally cut source, providing adequate
light ( ) and intermittent audible off due to excessive heat. NOTE: It ventilation on all sides.
alarm. will not restart until it cools down. • Do not operate more than one unit
• Faulty cabinet fan. side by side.
• Replace cabinet fan.

Compressor runs with general • Leak • Leak test and repair leak.
malfunction light ( ) and intermittent • Reduced air intake • Check compressor intake path for
audible alarm. • Weak compressor obstruction. Clean/remove
• Faulty circuit board. obstruction.
• Replace compressor.
• Replace circuit board.

Compressor does not start with I/O • Extreme cold start. • Allow unit to reach room
switch in “I” position and general • Faulty electrical connection for temperature.
malfunction light ( ) and intermittent compressor. • Check electrical connections for
alarm • Faulty capacitor. compressor.
• Faulty circuit board. • Replace capacitor.
• Replace circuit board

Unit shuts down periodically with • Restriction in exhaust muffler. • Replace exhaust muffler.
general malfunction light ( ) and • Contaminated sieve beds. • Replace sieve beds.
intermittent audible alarm • Faulty solenoid valve. • Replace solenoid valve manifold.
• Faulty circuit board. • Replace circuit board

38
 Problem Probable Cause Solution
Compressor relief valve activates • Faulty electrical connection at waste • Repair electrical connection.
(popping sound) valve. • Replace valve coil. (Use of an
• Faulty solenoid valve coil. ohmmeter can be helpful to easily
• (Acceptable rating: 713-837 Ohms) determine faulty coil).
• Contaminated sieve beds. • Replace sieve beds.
• Faulty circuit board. • Replace circuit board.
• Faulty relief valve. • Replace relief valve.

Unit alarms with l/0 power switch in “I” • Faulty electrical connection. • Repair electrical connection.
position. Circuit breaker repeatedly • Faulty capacitor. • Replace capacitor.
trips. • Faulty circuit breaker. • Replace circuit breaker.
• Faulty compressor. • Replace compressor.
• Faulty circuit board. • Replace circuit board.

Cabinet fan does not turn. • Faulty electrical connections. • Check electrical connections.
• Faulty cabinet fan. • Replace cabinet fan.

Flowmeter fluctuates • Improperly set or faulty product • Check regulator setting. Repair or
regulator. replace regulator.
• Leak. • Leak test and repair leak.
• Reduced air intake (suction) • Check compressor intake path for
• Faulty flowmeter. obstruction. Remove obstruction.
• Worn compressor. • Replace flowmeter.
• Faulty circuit board. • Replace compressor
• Faulty solenoid valve. • Replace circuit board.
• Replace solenoid valve manifold.

Limited or low flow. • Restriction in humidifier/tubing. • Replace humidifier or tubing.

• Product regulator set too low. • Adjust regulator setting.
• Leak. • Leak test and repair.
• Reduced air intake (suction) • Check compressor intake path for
• Weak compressor obstruction and remove, if needed.
• Faulty circuit board • Check system pressure and rebuild or
• Restriction in mixing tank exchange compressor.
• Faulty solenoid valve. • Replace circuit board.
• Replace mixing tank
• Replace valve manifold.

No flow indicated on flowmeter but • Internal leak. (likely in location from • Leak test and repair. In particular,
general malfunction light ( ) and unit regulator to flow meter) regulator / fittings following air path
intermittent audible alarm DO NOT • Main circuit boards prior to Rev. R to flow meter. Repair leaks.
activate. do not have a ‘no flow’ alarm

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 Problem Probable Cause Solution
Low oxygen concentration. Oxygen • Ambient or unit’s temperature is too • Unit operating above temperature
monitor yellow light ( ) and high. range specifications.
intermittent audible alarm • Leak. • Leak test and repair.
• Reduced air intake (suction) • Blocked air intake or exhaust.
• Restriction in exhaust muffler • Defective cabinet fan.
• Contaminated sieve beds • Check compressor intake path for
• Weak compressor. obstruction. Clean/remove
• Faulty circuit board. obstruction.
• Faulty solenoid valve • Replace or clean exhaust muffler.
• Replace sieve beds.
• Check system pressure, and rebuild
or replace compressor.
• Replace circuit board
• Replace valve manifold.

No flow indicated on flowmeter with • Flowmeter is turned off. • Turn flowmeter knob
general malfunction light ( ) and • Regulator is turned off. counterclockwise to allow flow of
intermittent audible alarm • Cannula tubing blocked or kinked oxygen.
• External restriction at outlet of unit • Unlock regulator knob and turn
• Internal restriction of airflow. clockwise to allow flow of oxygen.
• (Refer to section 4.8 Product
Regulator
• Check and Setting for proper
adjustment).
• Check cannula tubing. Replace if
necessary.
• Reduce/remove attachments from
outlet of unit (humidifier bottle,
tubing, etc).
• Check internal tubing for blockage or
kinks.

Alarm does not sound. • Unit has been turned off for an • Turn on unit and let run for several
extended period of time. minutes to charge alarm capacitor.
• Faulty electrical connection. With unit running, disconnect from
• Faulty buzzer. power source and verify power
• Faulty I/0 power switch. failure alarm (1-beep).
• Faulty circuit board. • Repair electrical connection
• Replace buzzer.
• Replace I/0 power switch.
• Replace circuit board.

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5.4 Tool Kit and Pressure Test Gauge
The tools needed for you to properly service the VisionAire unit are listed below:
Multi-adjustable pliers, small wire cutters, small needle-nose pliers, slotted-head screwdriver, Phillips-
head screwdriver, adjustable wrench, 1/2-inch combination wrench, 7/16-inch combination wrench,
9/16-inch combination wrench, and 1/8-inch Allen wrench.
Pressure test adapter. (CAIRE p/n: KI257-2).

A pressure test gauge (CAIRE p/n: KI036-1) to read operating system pressures on the VisionAire unit
should be kept available at all times.

An ohmmeter/multi-meter is a useful diagnostic tool when troubleshooting electrical components (coil,

etc.).

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6.0 Tool Kit and Pressure Test Gauge
6.1 EMC Testing Tables

Medical equipment needs special precautions regarding EMC and needs to be installed and put
into service according to the EMC information provided in this section.

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 CAIRE Inc.
2200 Airport Industrial Dr., Ste 500
Ball Ground, GA 30107
www.cairemedical.com

Copyright © 2018 CAIRE Inc. CAIRE Inc. reserves the right to discontinue its products, or change the prices, materials,
equipment, quality, descriptions, specifications and/or processes to its products at any time without prior notice and with
no further obligation or consequence. All rights not expressly stated herein are reserved by us, as applicable.

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