DeVilbiss 535D Oxygen Concentrator - Service Manual

DeVilbiss iFill® Personal Oxygen Station
Service Manual
Danger – no smoking
Model 535D
Model 535I
CAUTION-Federal (U.S.A.) law restricts this device to sale by or on the order of a physician.
Downloaded from www.Manualslib.com manuals search engine

TA B L E O F C O N T E N T S
GENERAL INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IEC Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Dangers and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UNPACKING AND SETUP
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Patient Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Indicator Light Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE
Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Patient Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Periodic Homecare Provider Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Between Patient Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Aids
Normal Operation & Problem Solving Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Do First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting Chart A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting Chart B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMPONENT TESTING, REPAIR, AND REPLACEMENT
Proper Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cover Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Circuit Breaker (535D) / Fuse (535I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Final Bacteria Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Four-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Long-Life Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oxygen Sensing Device (OSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Intensifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PCB (Printed Circuit Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Supply PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rotary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sieve Beds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FIGURES, DIAGRAMS, AND VIEWS
Figure Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exterior Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-26
Interior Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-39
Pneumatic and Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
ORDERING INFORMATION AND PARTS LIST
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Parts Return and Ordering Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Specifications
DeVilbiss iFill Personal Oxygen Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
iFill Oxygen Cylinder Typical Fill Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LT-1929 2
G E N E R A L I N F O R M AT I O N
Introduction
This service manual was designed to provide DeVilbiss Healthcare qualified service technicians and homecare providers with the
proper maintenance, service, safety, and repair procedures for the DeVilbiss iFill Personal Oxygen Station.
Read and understand all the information contained in this service manual before attempting to operate or perform any maintenance
on the oxygen station.
iFill is a stand-alone oxygen cylinder filling station that produces highly concentrated oxygen for therapeutic applications. Because
of the stand-alone feature, iFill can be used in conjunction with any concentrator.
NOTE– DeVilbiss reserves the right to alter or change the design of the DeVilbiss iFill Personal Oxygen Station series. Hence, slight
differences in construction or components may exist between the unit in hand and what is described in this manual.
IEC SYMBOLS
Attention, consult instruction guide Type BF applied part
AC current Double Insulated
Electric Shock Hazard. Do Not Open Danger-No Smoking
This device contains electrical and/or electronic equipment that must be recycled per EU Directive 2012/19/EU-Waste
Electrical & Electronic Equipment
Important Safeguards
When using electrical products, especially when children are present, basic safety precautions should always be followed. Read all
instructions before using. Important information is highlighted by these terms:
DANGER Urgent safety information for hazards that will cause serious injury or death.
WARNING Important safety information for hazards that might cause serious injury.
CAUTION Information for preventing damage to the product.
NOTE Information to which you should pay special attention.
Important safeguards are indicated throughout this service manual; pay special attention to all safety information.
READ ALL INSTRUCTIONS BEFORE SERVICING.

General Dangers & Warnings
In order to ensure the safe installation, assembly, and operation of the personal oxygen station, these instructions must be followed:
DANGER-NO SMOKING
•D
ANGER-Electric Shock Hazard. If service is required, it should be done by a DeVilbiss Healthcare provider or authorized
service center.
•D
ANGER-Fire Hazard. Do not lubricate. Do not allow grease or oil from your hands or other source to come into contact with
the regulator or cylinder valve connection. These solutions may be flammable and cause injury.
•D
ANGER-Keep the personal oxygen station at least 5 feet (1.6 m) from hot, sparking objects or naked sources of flame.
Position your unit at least 6 inches (16 cm) from walls, draperies, or any other object that might prevent the proper flow of
air in and out of your oxygen station. The oxygen station should be located so as to avoid pollutants or fumes.
•D
ANGER-Oxygen causes rapid burning. Do not smoke while your personal oxygen station is operating, or when you are
near a person utilizing oxygen therapy. Keep the oxygen station at least 5 feet (1.6 m) from hot, sparking objects or naked
sources of flame.
•D
ANGER-Do not lay the cannula down while the cylinder is delivering oxygen. High concentrations of oxygen can cause
rapid burning.
3 LT-1929
G E N E R A L I N F O R M AT I O N
warning
•D
o not install, assemble, or operate this equipment without first reading and understanding the instruction guide and the
oxygen cylinder instruction guide and warning label. If you are unable to understand the warnings, cautions, and
instructions, contact DeVilbiss before attempting to install or use this equipment - otherwise, injury or damage may occur.
•T
he use of this device is limited to an oxygen patient. Cylinders must be used only by an oxygen patient and are not to be
distributed to any other individual for any purpose.
• Do not use parts, accessories, or adapters other than those authorized by DeVilbiss Healthcare.
•N
EVER block the air openings of the product or place it on a soft surface, such as a bed or couch, where the air opening
may be blocked. Keep the openings free from lint, hair and the like.
• If the oxygen station has a damaged cord or plug, if it is not working properly, if it has been dropped or damaged, or if it
has been submersed in water, do not use. A qualified technician should examine and perform repairs as needed.
• If any leakage of the oxygen cylinder is detected, do not attempt to use the cylinder. Turn the rotary selector on the
regulator to “OFF.” If leakage persists, place the cylinder outdoors. Contact DeVilbiss concerning questions pertaining to
servicing or replacing cylinder.
•T
he personal oxygen station is equipped with a High Pressure Relief Valve to ensure the user’s safety. When activated, this
safety feature will make an extremely loud noise. If this noise occurs, turn the unit off and refer to Troubleshooting section
of this manual.
•C
hildren should always be supervised around the personal oxygen station. Failure to do so may result in damage to the unit
or personal injury.
• Improper use of the power cord and plugs can cause a burn, fire, or other electric shock hazards. Do not use the unit if the
power cord is damaged.
WARNING - Handling Warnings

•B
efore moving or repositioning the personal oxygen station, always disconnect the AC power cord. Failure to do so may
result in damage to the unit or personal injury.
•U
se extreme care when handling and filling an oxygen cylinder. Full oxygen cylinders are under pressure and can become a
projectile if dropped or mishandled.
• Never transport the oxygen station with a cylinder connected to it. Injury or damage can occur.
WARNING - Storage and Handling

•D
o not place oxygen cylinders in unventilated spaces such as car trunks. Excessive heat can make the relief valve suddenly
and quickly discharge the cylinder contents, possibly making it a projectile and greatly increasing the oxygen level in
unventilated spaces.
•D
o not leave oxygen cylinders in the cabs of vehicles without ventilation. If a cylinder leaks, a spark could start a fire
causing serious injury or death.
• Remove cylinders from the vehicle when the destination is reached.
• Be sure to secure cylinders from movement during transport.
WARNING - service Warnings

•D
isconnect the power cord from the wall outlet before attempting repairs on the unit. Extra care should be taken if it is
necessary to operate the unit with the cover removed.
• Do
not use oils, greases, or any petroleum-based solvents/cleaners on or near the unit. Use only materials that are
compatible with oxygen.
• Electric
Shock Hazard. When replacing the capacitor, do not touch the terminals or allow metal objects to come in contact
with the terminals on the capacitor. The capacitor may hold a charge for several days after the unit is turned off. The
capacitor is located next to the cooling fan.
CAUTIONS & NOTES

CAUTION– F
ederal law restricts this device to sale by or on the order of a physician.
NOTE– Do not connect to an electrical outlet controlled by a wall switch. No other appliances should be plugged into the wall outlet.
NOTE– The plug on the 535D DeVilbiss iFill Personal Oxygen Station has one blade wider than the other. To reduce the risk of
electric shock, this plug is intended to fit in a wall outlet only one way. Do not attempt to defeat this safety feature.
NOTE– DeVilbiss recommends leaving a full cylinder of oxygen with the patient AFTER setting up the personal oxygen station.
LT-1929 4
U N PA C K I N G A N D S E T U P
Initial Inspection CAUTION–When transporting the DeVilbiss iFill Personal

Oxygen Station, be careful not to bump the unit or the
It is suggested that an initial inspection be performed upon connectors into obstacles. Otherwise damage to the oxygen
receiving the iFill personal oxygen station. station may occur.
1. After removing the oxygen station from the carton, examine
There are three (3) methods to safely transport the DeVilbiss
it for any external damage. If shipping damage has
iFill Personal Oxygen Station:
occurred, contact the DeVilbiss Customer Service
Department at 1-800-338-1988 or 1-814-443-4881 for 1. Pull or push the unit on its casters using the front handle.
specific instructions. Save the carton for possible later Travel in a line oriented front to back to avoid tipping. Stop
return; note the position of the unit and placement of the the unit to change direction.
packing material. 2. Carry the unit using the front and rear handles
2. Check to make sure both of the cabinet air filters are in simultaneously.
place. 3. Carry the unit using the front handle and the recess located
3. Plug the unit into an electrical outlet. The audible alert will under the rear of the base.
sound momentarily and the indicator panel lights will flash DeVilbiss iFill Oxygen Station Operation
on and then off. The standby light will remain on indicating
the unit is ready for use.
Checklist
4. Attach an empty iFill cylinder to the oxygen station (be sure NOTE– Each time the Oxygen Station is used to fill a cylinder,
rotary selector is "Off." complete the following steps:
5. Push the start/stop switch on the control panel to start the 1. Check the Hydrostatic Test Date.
unit. After a few minutes, the iFill unit will begin filling the NOTE– All US DOT marked iFill cylinders must undergo
cylinder. requalification testing every 5 years. Cylinders that are pi “π”
6. Allow the filling process to continue for at least 20 minutes. marked, which is the official stamp mark required by the
Transportable Pressure Equipment Directive (TPED) certifying
7. Turn the unit off and remove the cylinder.
that the gas cylinder conforms to RID/ADR for use throughout the
8. Use an analyzer to check the oxygen concentration from
European Union, will require recertification within 10 years as
the cylinder. It should be 93% +/- 3%.
defined per Annex B of DIN EN 1802:2002.
NOTE– If cylinder has a PulseDose® regulator attached, turn Recertification testing of cylinders must be done by a certified
knob to the continuous flow setting to check concentration level. testing facility.
Cylinders having a continuous flow regulator attached should be
NOTE– Do not fill oxygen cylinders that have not been tested in
adjusted to 2 LPM to test concentration percentage.
the past five (5) years or ten (10) years, whichever is applicable.
NOTE– If the unit fails to operate properly or if it is damaged,
2. Perform the prefill inspection on the cylinder by following
contact the DeVilbiss Customer Service Department at 1-800-
iFill Oxygen Cylinder External Examination below.
338-1988 or 1-814-443-4881; International 49-621-178-98-230
for information. WARNING
ONLY use cylinders that have the DeVilbiss iFill Personal
Patient Setup Oxygen Station fill connection.
NOTE– Before operating the DeVilbiss iFill Personal Oxygen All cylinders must be inspected before attempting to fill -
Station for the first time, locate the device where desired. otherwise injury or damage may occur.
Choosing A Location iFill Oxygen Cylinder External Examination
WARNING 1. Examine the outside of the cylinder for the following
conditions, and replace the cylinder if they exist:
The personal oxygen station should be at least six (6) inches
a. Dents or dings
away from walls, draperies, or furniture to ensure sufficient
b. Arc Burns
airflow.
c. Oil or Grease
Avoid placing the oxygen station next to heaters, radiators,
d. Any other signs of damage that might cause a cylinder
or hot air registers. It should be kept at least 5 feet (1.6m)
to be unacceptable or unsafe for use.
away from hot, sparking objects or naked sources of flame.
2. Examine the cylinder for evidence of fire or thermal
Do not use in a closet. damage. Evidence includes charring or blistering of the
Do not use in an area where the air may be contaminated paint or other protective coating or heat sensitive indicator.
with carbon monoxide as this may shorten the life of the unit If fire or thermal damage is found, replace the cylinder.
(i.e. near running gasoline engine, furnace, or heater). 3. Inspect the oxygen fill connector for the following:
Transporting iFill Oxygen Station a. Debris, oil or grease
b. Noticeable signs of damage
WARNING c. Signs of corrosion inside the valve
NEVER transport the Personal Oxygen Station with a d. Signs of excessive heat or fire damage
cylinder connected to or stored on it, otherwise injury or Do not use oxygen cylinder if any of the above are found.
damage can occur.
5 LT-1929
U N PA C K I N G A N D S E T U P
Operating Instructions oxygen station. Otherwise, severe injury and/or damage may
occur.
Connecting The iFill Oxygen Cylinder To The DeVilbiss iFill
Personal Oxygen Station Use extreme care when handling and filling an oxygen
cylinder. Full oxygen cylinders are under pressure and can
danger become a projectile if dropped or mishandled.
Fire Hazard. Do not lubricate. Do not allow grease or oil from NOTE– Refer to the General Dangers & Warnings and the
your hands or other source to come into contact with the Handling Warnings in this manual.
regulator or cylinder valve connection. These solutions may
1. Remove the full oxygen cylinder by pushing down on the fill
be flammable and cause injury.
port collar located under the cylinder nipple connector while
WARNING using your other hand to steady the cylinder.
Do not modify ANY connections on the personal oxygen 2. Lift up on the cylinder to remove from the oxygen fill
station. NEVER use tools of any kind to connect/disconnect connector. The green Standby light will turn on after a short
the cylinder and the oxygen station. Severe injury and/or delay.
damage may occur. 3. Oxygen will escape from the fill connector for a short time
Do not drop oxygen cylinders. Use two (2) hands when after the cylinder has been removed. This may be
handling/transporting oxygen cylinders. Otherwise, injury or accompanied by a “pop” with a rush of air. This is normal.
damage may occur. 4. Perform one (1) of the following steps:
NOTE– Refer to the General Dangers & Warnings and the a. If desired, fill another oxygen cylinder. Refer to the
Handling Warnings in this manual. DeVilbiss iFill Personal Oxygen Station Operation
1. Plug the power cord into the wall outlet. Checklist.
2. Set the rotary selector on the cylinder to “OFF.” b. Place the oxygen fill connector cover onto the fill
3. Remove the oxygen fill connector cover from the fill connector.
connector. NOTE– The oxygen fill connector cover should always be used
4. Position the cylinder over the cradle while aligning the whenever cylinders are not being filled.
nipple connector on the oxygen cylinder with the fill
connector. Press until cylinder “clicks” into place. NOTE–
Setting The iFill Oxygen Cylinder Rotary
When using the smaller M4 or M6 size cylinders, it is Selector To The Prescribed Setting
necessary to place the oxygen fill connector cover/cylinder 1. Attach the nasal cannula to the cannula fitting of the iFill
adapter in the cradle to help support the cylinder. When oxygen cylinder. NOTE– If it is an international cylinder,
using the larger ML6, C, D, or E cylinders, the oxygen fill open the cylinder valve first.
connector cover/cylinder adapter is not necessary and can 2. Turn the rotary selector to the L/min. setting prescribed by
be allowed to hang over the side. your physician.
Filling The iFill Oxygen Cylinder WARNING
NOTE– Do not use cylinder while filling. Changing the L/min. setting on the rotary selector will affect
NOTE– Refer to the General Dangers & Warnings and the the dose of oxygen delivered, DO NOT readjust the L/min.
Handling Warnings in this manual. setting unless directed by your physician.
1. Make sure the personal oxygen station is plugged in. 3. To turn the flow of oxygen off, turn the rotary selector
2. Make sure the cylinder is securely connected to the oxygen counterclockwise to the “OFF” position.
station. Refer to Connecting The iFill Oxygen Cylinder To
The DeVilbiss iFill Personal Oxygen Station. Indicator Light Explanation
3. Push the start/stop switch on the control panel. Indicator
4. The following sequence of events should occur: Light Color Oxygen Station Status Effect
a. The FILLING (green) light will illuminate while the None Oxygen station is None
cylinder is filling (refer to iFill Oxygen Cylinder Fill unplugged.
Times).
Standby Oxygen station is ready to Cylinder filling
b. The FULL (green) light will illuminate when the cylinder
(green) begin filling cylinders. not started
is full. Proceed to Removing the iFill Oxygen Cylinder.
Filling Oxygen station is on and Cylinder is filling
NOTE– If the Service (RED) light and audible alert are on,
(green) cylinder is filling.
proceed to Troubleshooting in this service manual.
Full (green) Cylinder is full. Remove
Removing The iFill Oxygen Cylinder cylinder
WARNING Service (red) Oxygen station is on but Service is
Do not modify any connections on the personal oxygen and Audible cylinder is not filling due required.
station. Never lubricate the connections. Never use tools of Alert to internal failure.
any kind to connect/disconnect the oxygen cylinder and the
LT-1929 6
MAINTENANCE
Alert System
The DeVilbiss iFill Personal Oxygen Station alert system will
detect unit component failure. This system is comprised of both
visible and audible alerts which signal the patient if a
malfunction should occur.
The visible alert located on the top indicator light panel reads
“Service.” When the red indicator light illuminates and the
audible alert sounds a problem has occurred and service is
required. Refer to the Troubleshooting section of this manual.
Routine Patient Maintenance

Cabinet air filters: clean weekly; wash in warm soapy
A.
water and rinse thoroughly. Allow filters to air dry before
reinstallation.
WARNING
Do not apply liquid directly to the cabinet. Do not utilize any
petroleum-based solvents or cleaning agents.
Do not apply lubricants to fittings.
Exterior cabinet: clean by using a damp cloth or sponge
B.
with a mild household cleaner and wipe it dry. Only if
necessary, wipe the coupler with a clean, dry, lint-free cloth.
Cylinders: clean the cylinders periodically by wiping with a
C.
dry, lint-free cloth. Do not clean with a solvent based
cleaning solution. Avoid getting fluids or debris such as
sand or dirt inside the oxygen cylinder and/or oxygen
connector.
Periodic Homecare Provider

Preventative Maintenance
A. Change extended life intake filter within 8,760 hours.
B. Check oxygen concentration of a system-filled cylinder with
an oxygen analyzer every two years. Refer to steps 4 - 8
listed under Initial Inspection.
C. Check audible alert and indicator lights every two years.
D. Change final bacteria filter within 17,520 hours.
NOTE– This PM Schedule reflects:
• 1,000 hour usage equal to one year based on M6 size
cylinder use
• A normal, clean operating environment
The homecare provider is responsible for:
• Determining the condition of the iFill operating environment
• Determining a preventative maintenance interval frequency
(not to exceed the schedule stated above) which takes into
consideration the specific operating environment.
Between Patient Maintenance

A. Clean or replace the cabinet air filters.
B. Clean the station cabinet and cylinders.
C. Check the oxygen concentration of the system. Refer to
steps 4 - 8 listed under Initial Inspection.
7 LT-1929
TROUBLESHOOTING
Product Description psi. It enters the 1st stage cylinder through an inlet check valve
and is pressurized to approximately 200 to 500 psi. This
The DeVilbiss iFill Personal Oxygen Station uses a dual- pressure will vary based on what part of the filling cycle it is on.
pressure head compressor to simultaneously power a pressure The oxygen then passes through the outlet check valve and is
swing adsorption oxygen generation system and a pneumatic transferred through the inter-stage tube to the 2nd stage
pressure intensifier. It is designed to provide supplemental cylinder. It enters the 2nd stage through another inlet check
oxygen to fill portable cylinders for ambulatory use. valve where it is pressurized further. The 2nd stage pressure
Oxygen cylinders are attached to the iFill unit with a coupler will also vary according to the filling cycle. Oxygen passes
and cylinder nipple set. The application-specific coupler helps through the 2nd stage outlet check valve and enters the
to insure that other cylinders cannot inadvertently be portable cylinder attached to the fill connector.
connected to the iFill system. The cylinder pressure will continue to increase until it reaches
The iFill station is designed to fill various sizes of portable approximately 2000 psi. When the cylinder is filled, the iFill
oxygen cylinders. Cylinders are available with an integrated station will automatically turn off and the indicator panel light
oxygen conserving device or continuous flow regulator will show full.
mounted on top. A pneumatic diagram of the system is shown in Figure 21.
An onboard Oxygen Sensing Device (DeVilbiss OSD®)
monitors the oxygen concentration level to insure that it TROUBLESHOOTING AIDS
remains within specification (93% ± 3%).
Normal Unit Operation & Problem Solving
System Operation Tips:
IMPORTANT: You must understand the following Normal
The iFill’s dual-pressure head compressor draws in room air
Operation before attempting to troubleshoot the 535 iFill.
through air filters to power the oxygen generation system and
1. When the unit is plugged in, all control panel lights
the pressure intensifier. The output of one of the compressor
illuminate briefly and the audible alert sounds a short
heads is routed to a rotary valve. The valve directs the flow of
beep. The standby light remains on.
compressed air to a pair of sieve beds in the unit in a timed
sequence that is controlled by a PC board. As air passes 2. After attaching a cylinder to the quick connect coupler and
through the beds, nitrogen is separated from the air stream pressing the start button, the standby light goes out and
which results in higher concentrations of oxygen exiting the the filling light comes on.
bed. As one bed is being pressurized, the other bed is 3. The fan, rotary valve, and four-way valve operate
depressurized allowing the nitrogen to be discharged from the continuously for 10 seconds, but the compressor remains
unit through an exhaust muffler connected to the rotary valve. off.
Oxygen from the pressurized bed is directed through a check 4. After 10 seconds the compressor comes on and the
valve to an accumulator tank. oxygen generating system and intensifier begin to operate.
During this time the three-way valve routes all oxygen from
When the iFill Personal Oxygen Station is first turned on to
the accumulator tank to the main PC board’s Oxygen
begin filling a cylinder, the three-way valve is held energized
Sensing Device (OSD) at a flow of 2.5 to 3 LPM.
routing all oxygen from the accumulator tank through the final
5. When the OSD senses 91% oxygen, normally within 3 to 4
bacteria filter to the Oxygen Sensing Device (OSD) until the
minutes, the three-way valve routes all oxygen from the
required purity is achieved (approximately 4 minutes). This
accumulator tank to the intensifier, which begins filling the
period when the unit is running but not filling a cylinder is
cylinder.
referred to as the warm up mode. Once the oxygen purity is
NOTE–Throughout the normal filling cycle, the three-way
reached, the three-way valve deenergizes routing all oxygen
valve will cycle every 24 seconds to send a small sample
from the accumulator tank and final bacteria filter to the inlet of
of gas to the OSD to verify a minimum purity of 90%. If the
the intensifier. The intensifier accepts the low pressure oxygen
OSD senses less that 90% purity, the unit reenters the
and boosts the pressure of the gas to approximately 2000 PSI
warm up mode.
for filling portable oxygen cylinders.
6. When the cylinder is filled to approximately 2,000 PSIG,
This is done by using the second compressor head to supply the unit stops and the full light illuminates. The fan
compressed air to drive the two-stage intensifier. The continues to run for several minutes to cool down the unit;
intensifier’s main body or power cylinder houses the drive then stops and completes the fill cycle.
piston which in turn “drives” the pistons that are located in the
1st and 2nd stage respectively. The flow of the compressed air Equipment:
to the intensifier is controlled with a four-way valve. After being • pare Light Control Panel: Plugs into the main PC board
S
used to compress the oxygen, the exhaust air from the power allowing full access to the unit when the covers are
cylinder is routed back to the intake of the compressor to help removed.
reduce the overall energy consumption of the filling station. • Spare Parts: Installed to verify faulty components
Oxygen is supplied to the intensifier at a pressure of 30 to 45 • Flow Test Fixture: Connect to the three-way valve top
metal fitting to assist in isolating problems.
LT-1929 8
TROUBLESHOOTING
• Small Magnet: Placed on the intensifier center drive

NOTE–After completing any repairs, ensure hour meter on
section to visually indicate intensifier operation. the right cover is connected to the DC wire harness and the
NOTE–The intensifier’s piston travels up and down to control panel ribbon connector is connected to the main PC
within ¾” of the top and bottom of the drive section. If the board prior to installing the left cover.
piston (magnet) stops or takes longer than 9 seconds to
travel one way, the unit will shut off and alarm. Performance Test:
NOTE–Always remove the magnet after troubleshooting Before returning to service, the iFill Station should be tested to
and repair. ensure it is operating properly. This can be done by filling a
• Stopwatch or watch with a second hand cylinder and then testing the oxygen concentration from the
cylinder. Refer to steps 4-8 listed under Initial Inspection. It is
Do First: recommend that the cylinder be filled completely before testing
• Visually inspect unit for physical damage concentration level. This will allow for verification of fill time for
• Secure any loose wire and tubing connections the repaired iFill station.
NOTE–The tubing from the three-way valve must be
connected to the top port of the OSD or random shut
down occurs that is difficult to troubleshoot.
• Warm up the unit and duplicate the problem twice.
NOTE–A cold unit, or one that has just been plugged in,
will alarm and react differently which may make
troubleshooting more difficult.
Knowledge:
• Become familiar with the names and locations for all
components
• If the oxygen purity does not come up to specification
(91%) during a continuous 11 minute run in warm up, the
unit will shut off and alarm.
• After the first 70 seconds from startup, if the flow to the
OSD is below 1.5 lpm, the unit will shut off and alarm.
• If the intensifier has a leak or the oxygen concentrator
portion of the unit is not performing correctly, the unit may
constantly transition in and out of the warm up mode
causing extended fill times.
NOTE–Occasionally the unit will go back into warm up
mode for a short period during the early portion of a
cylinder filling cycle. This is most common when filling an
empty cylinder.
o To troubleshoot, use a flow test fixture that allows a
maximum flow of 3 lpm. Remove the tubing from the
top metal fitting of the three-way valve and install the
tubing from the flow test fixture in its place.
o If the unit no longer transitions in/out of warm up,
either the tubing to the intensifier is leaking or the
intensifier itself is faulty.
NOTE–The three-way valve will make a clicking sound
every 24 seconds indicating the unit is in its normal fill
cycle. This clicking sound will not be heard during the
warm up mode.
o If the unit continues to transition in/out of warm up, the
concentrator portion is not performing correctly. Check
for leaks, faulty sieve beds, faulty rotary valve, etc.
• If the unit is running and not constantly transitioning in and
out of warm up mode, but does not fill a cylinder, the
problem is the intensifier. Ensure that there are no system
leaks and that the cylinder and regulator or conserver is
not leaking.
9 LT-1929
TROUBLESHOOTING
Troubleshooting Chart A
Problems During Initial Start Up
(From start up thru approximately 4 minutes run time.)
Symptom
(initial through 4 minutes) Possible Cause Remedy
(#1) No control panel lights or audible 1. C
ircuit breaker tripped or faulty in 535D or 1. R
eset or replace circuit breaker/replace
alarm when unit first plugged in. fuse blown in 535I. fuse.
2. No AC power at receptacle. 2. C
heck power source or use different
receptacle.
3. A
C wire harness not connected to main PC 3. Connect AC wire harness.
board.
4. L
ight panel ribbon cable loose or not 4. R
econnect ribbon cable to main PC
connected to the main PC board. board.
5. Defective DC power supply board. 5. Replace DC power supply board.
6. Defective light panel. 6. Replace light panel.
7. Defective main PC board. 7. R eplace main PC board.
(#2) W
hen start button is pressed: 1. N
o cylinder present or not snapped onto 1. F
ully snap cylinder onto coupler.
- standby light stays on. coupler.
- nothing happens. 2. C
oupler switch not connected to main PC 2. C
onnect coupler switch.
board.
3. Defective light panel start switch. 3. Replace light panel.
4. Defective main PC board. 4. Replace main PC board.
5. Defective intensifier coupler switch. 5. Replace intensifier.
(#3) W
hen start button is pressed: 1. D
C wire harness disconnected at main PC 1. R
econnect DC wire harness at main
- light panel standby light goes off board. PC board.
and full light comes on instantly. 2. Faulty main PC board. 2. Replace main PC board.
- nothing happens.
3. Faulty DC wire harness. 3. Replace DC wire harness.
(#4) When start button is pressed: 1.F
an wires not connected to main PC board. 1. Connect fan wires.
- the standby light goes off and 2.Faulty fan wires or connector. 2. Repair or replace fan.
filling light comes on. 3.Faulty fan. 3. Replace fan.
- fan does not run. 4.Faulty main PC board. 4. Replace main PC board.
(#5) When start button is pressed: 1.D
C wire harness not connected to rotary 1. Connect DC wire harness.
- the standby light goes off and valve hall effect board.
filling light comes on. 2. Faulty main PC board. 2. Replace main PC board.
- the fan runs. 3. Faulty rotary valve. 3. Replace rotary valve.
- the rotary and four-way valves are
cycling.
- unit alarms after approximately
4 seconds.
(#6) When start button is pressed: 1. D
C wire not connected to rotary valve 1. Connect DC wire harness.
- the standby light goes off and motor.
- the fan runs. 3. Faulty rotary valve. 3. Replace rotary valve.
- the rotary valve is not cycling, the
four-way is.
- unit alarms after approximately 4
seconds.
(#7) When start button is pressed: 1. F
our-way valve connector is not connected 1. Connect valve to DC wire harness.
- the standby light goes off and to DC wire harness.
- the fan runs. 3. Faulty four-way valve. 3. Replace four-way valve.
- the rotary valve is cycling, the
4. Faulty DC wire harness. 4. Replace wire harness.
four-way is not.
- after 10 seconds the compressor
does not run.
- the intensifier is not cycling
- after 20 seconds the unit stops
and alarms.
LT-1929 10
TROUBLESHOOTING
Symptom
(initial through 4 minutes) Possible Cause Remedy
(#8) When start button is pressed: 1. C
ompressor not connected to AC wire 1. Connect AC wire harness.
- the standby light goes off and harness.
filling light comes on. 2. Capacitor wire not connected. 2. Connect AC wire harness.
- the fan runs. 3. Faulty capacitor. 3. Replace capacitor.
- the rotary and four-way valves are
4. Faulty main PC board. 4. Replace main PC board.
cycling.
- after 10 seconds the compressor 5. Faulty compressor. 5. Replace compressor.
does not run. 6. Faulty AC wire harness. 6. Replace AC wire harness.
and alarms.
(#9) When start button is pressed: 1. F
aulty compressor. (Verify faulty 1. Replace compressor.
- the standby light goes off and compressor by using duck bill pliers to pinch
filling light comes on. the tubing closed that comes from the
- the fan runs. compressor just below the small DC power
- the rotary and four-way valves are supply board. If the compressor PR valve
cycling. does not pop off immediately, replace the
- after 10 seconds the compressor compressor)
runs. 2. Faulty four-way valve. 2. Replace four-way valve.
- the intensifier is not cycling.
3. Faulty intensifier. 3. Replace intensifier.
and alarms.
(#10) When start button is pressed: 1. T hree-way valve not connected at main PC 1. Connect three-way valve wire harness.
- the standby light goes off and board.
filling light comes on. 2. S ystem air leak (compressor tubing, sieve 2. Repair connection or leak.
- the fan runs. beds, accumulator tank, bacteria filter, etc.).
- the rotary and four-way valves 3. Tubing not connected between the 3-way 3. Connect tubing to top OSD fitting.
are cycling. valve and the top fitting of the OSD.
- after 10 seconds the
4. Faulty three-way valve or occluded orifice in 4. Replace three-way valve.
compressor starts.
- the intensifier is cycling. valve.
- after 70 seconds the unit stops 5. Faulty main PC board. 5. Replace main PC board.
and alarms.
(#11) W hen start button is pressed: 1. Intensifier hall effect board wires not 1. C
onnect DC wire harness to intensifier
- the standby light goes off and connected. hall effect board.
- the fan runs. 3. Faulty DC wire harness. 3. Replace DC wire harness.
- the rotary and four-way valves
are cycling. 4. Faulty intensifier. 4. Replace intensifier.
- after 10 seconds the
compressor starts.
- compressor is struggling, PR
valve may pop off.
- intensifier does not cycle.
- after 18-20 seconds the unit
stops and alarms.
(#12) When start button is pressed: 1. T
ubing from three-way valve to OSD faulty 1. Install muffler in tubing between clamp
- the standby light goes off and (does not have small white muffler inside). and valve.
- the fan runs.
- the rotary and four-way valves
are cycling.
- after 10 seconds the compressor
starts.
- unit stops and alarms just after
compressor starts.
NOTE–After completing any repairs, ensure Hour Meter on the right cover is connected to the DC wire harness and the Control Panel
ribbon connector is connected to the main PC Board prior to installing the left cover. Also ensure magnet has been removed if used to
troubleshoot.
NOTE–Before returning to service, the iFill Station should undergo a Performance Test to ensure it is operating properly (refer to page 9).
11 LT-1929
TROUBLESHOOTING
Troubleshooting Chart B
Problems during fill cycle
(After unit running longer than approximately 4 minutes run time.)
Symptom
(during fill - after 4 minutes) Possible Cause Remedy
(A) The unit runs for 11 minutes after 1. S
ystem air leak (compressor tubing, sieve 1. Repair or replace as necessary.
start up then shuts off and alarms. beds, accumulator tank, bacteria filter, etc.).
-N ote that if the OSD does not see 2. Faulty OSD on main PC board. 2. Replace main PC board.
91% oxygen after 11 consecutive 3. Faulty sieve beds. 3. Replace sieve beds.
minutes the unit shuts off and 4. Faulty rotary valve. 4. Replace rotary valve.
alarms. 5. Faulty compressor (low output flow). 5. Replace compressor.
- (If unit is in warm up mode the
three-way click sound will not be
heard every 24 seconds)
(B) The unit shuts off and alarms prior 1. S
ystem air leak (compressor or four-way 1. Repair or replace as necessary.
to filling a cylinder to 2,000 PSIG. valve tubing connections)
-V erify unit did not go back into 2. Faulty four-way valve (internal leakage) 2. Replace four-way valve.
warm up mode for 11 consecutive 3. F
aulty compressor (verify faulty compressor 3. Replace compressor.
minutes per (A) above. by using duck bill pliers to pinch the tubing
- The intensifier drive piston travels closed that comes from the compressor just
slowly and or does not travel fully below the small DC power supply board. If
as verified visually with magnet. the compressor PR valve does not pop off
- (Similar to start up immediately, replace the compressor)
Troubleshooting A, #9 but this 4. Faulty intensifier. 4. Replace intensifier.
usually occurs during cylinder
filling at higher pressures)
(C) The unit shuts off and alarms prior 1. D
C wire harness not properly connected to 1. R
econnect DC wire harness to
to filling a cylinder to 2,000 PSIG. Intensifier hall effect board. intensifier hall effect board.
- The intensifier drive piston travels 2. Faulty or intermittent four-way valve. 2. Replace four-way valve.
to the end and sits there until unit 3. Faulty main PC board. 3. Replace main PC board.
alarms. (See Troubleshooting A,
#7) 4. Faulty DC wire harness. 4. Replace DC wire harness.
5. Faulty intensifier. 5. Replace intensifier.
(D) The unit runs for an extended 1. S
ystem air leak (compressor tubing, sieve 1. R
epair or replace as necessary.
period of time and does not fill a beds, accumulator tank, bacteria filter, etc.).
cylinder or complete a normal fill 2. Faulty sieve beds. 2. R
eplace sieve beds.
cycle. The unit does not alarm. 3. Faulty rotary valve. 3. Replace rotary valve.
-V
erify unit does not constantly go 4. Faulty compressor (low output flow). 4. Replace compressor.
in and out of warm up mode for 5. Faulty intensifier. 5. Replace intensifier.
several minutes at a time, but not
for 11 consecutive minutes as in
(A) above.
NOTE–After completing any repairs, ensure Hour Meter on the right cover is connected to the DC wire harness and the Control
Panel ribbon connector is connected to the main PC Board prior to installing the left cover. Also ensure magnet has been removed if
used to troubleshoot.
NOTE–Before returning to service, the iFill Station should undergo a Performance Test to ensure it is operating properly (refer to
page 9).
LT-1929 12
C O M P O N E N T T E S T I N G , R E PA I R , A N D R E P L A C E M E N T
Proper Repair Procedures To replace covers (Figures 18):

1. Replace right cover first by setting cover on station base.
This section contains the proper procedures for testing,
repairing and replacement of various components in the 2. Reconnect the indicator panel ribbon cable into the top of
DeVilbiss iFill Personal Oxygen Station. The oxygen generating the main PC board.
system components of the iFill station are very similar to ones 3. Secure the two screws in the bottom of the right cover.
in a concentrator; therefore some of the same tools can be 4. Reconnect the hour meter electrical connector.
used. 5. Replace left cover on the station.
A service kit (part# 444-501) is available which contains 6. Secure the five screws that hold the left cover to the
gauges, tools and test instruments to aid personnel in properly structure (three on top and two at bottom).
servicing the iFill station. In addition, an oxygen analyzer (part# 7. Replace cradle.
R217P62 or R218P12) is needed to periodically check the 8. Secure cradle with 1/4 turn fasteners.
oxygen concentrations from an iFill cylinder.
NOTE– Be sure to read all of the steps involved before Capacitor
beginning any of the procedures in this manual. The capacitor enables the compressor to start and run by
NOTE– After repairing or replacing a component, turn the iFill supplying voltage to the windings of the compressor motor. A
station on run a Performance Test to ensure it is operating defective capacitor may prevent the compressor from starting
properly (refer to page 9). or cause it to run slower. The capacitor is located on the
NOTE– When testing for leaks use a certified leak detection Plexiglas mounting platform above the compressor by the
solution such as SWAGELOK, Snoop® or equivalent. Do not cooling fan.
use solutions containing ethylene glycol. WARNing
CAUTION– Do not apply leak test solution to any part of the Electric Shock Hazard. When replacing the capacitor, do not
rotary valve or PC board assembly. touch the terminals or allow metal objects to come in
CAUTION– Use only DeVilbiss Healthcare replacement parts contact with the terminals on the capacitor. The capacitor
and accessories. may hold a charge for several days after the unit is turned
off.
WARNing
When servicing the DeVilbiss iFill station, be absolutely
To replace the capacitor (Figure 12):
certain that the correct tools are used and that parts are free 1. Ensure the iFill station is unplugged from the wall outlet.
of oil and grease or any material not compatible with 2. Remove the left and right covers from the iFill station.
oxygen. 3. Use needle-nose pliers to disconnect the two wires from
Electric shock hazard. The covers should only be removed capacitor terminals.
by a qualified DeVilbiss Healthcare homecare provider. 4. Cut the plastic cable ties holding the capacitor in place and
Disconnect the power cord from the wall outlet before remove capacitor.
attempting repairs on the unit. Extra care should be taken if 5. Reconnect wires to new capacitor.
it is necessary to operate the unit with the covers removed. 6. Install the new capacitor and secure with new cable ties.
7. Replace covers. NOTE–Be sure to reattach indicator panel
Cover Removal and Replacement ribbon connector and hour meter electrical connector (refer
to Cover Removal and Replacement in this manual).
To remove left cover (Figures 1 & 3):
1. Ensure the iFill station is unplugged from the wall outlet. Check Valves
2. Use a flat screwdriver to loosen the 1/4 turn fasteners that
secure the cylinder cradle to the top of the unit. Remove The check valves are located between the outlet of each sieve
cradle. bed and the accumulator tank. During operation they alternately
open and close allowing oxygen to pass through to the
3. Use a Torx screwdriver with a size T-25 bit (or flat
accumulator tank.
screwdriver) to remove the five screws that hold the left
cover to the internal superstructure (three on top and two To replace check valves (Figure 10):
at bottom). 1. Ensure the iFill station is unplugged from the wall outlet.
4. Lift and remove cover from unit. 2. Remove the left and right covers from the iFill station.
To remove right cover (Figures 2, 3, &18): 3. Remove the tubing from both ends of the check valve.
1. Remove left cover first. 4. Reattach tubing to the ends of the new check valve.
2. Carefully disconnect indicator panel ribbon cable from top NOTE– Make sure the outlet end of the check valve is
of main PC board. pointing toward the accumulator tank.
3. Disconnect hour meter electrical connector. 5. Replace covers. NOTE–Be sure to reattach indicator panel
4. Remove the two screws from the bottom of right cover and ribbon connector and hour meter electrical connector (refer
then remove cover from unit. to Cover Removal and Replacement in this manual).
13 LT-1929
Circuit Breaker (535D)/Fuse (535I) 8. Turn the compressor upside down so that it is resting on the
heads.
The circuit breaker or fuse is located in the lower rear of the unit.
9. Remove the four compressor motor mount hex nuts and
The circuit breaker fuse will activate should a major fault condition
mounting plate.
occur within the unit.
10. Unscrew the studded motor mounts from the compressor
To replace circuit breaker (Figure 4A): feet by hand.
1. Ensure the iFill station is unplugged from the wall outlet. 11. Inspect the motor mounts and replace if damaged.
2. Remove the left and right covers from the iFill station. 12. Install motor mounts on replacement compressor and
3. Remove compressor and mounting plate. reattach the mounting plate using the four hex nuts.
4. Disconnect wires from circuit breaker terminals. 13. Position compressor and mounting plate in base and secure
5. Use a pair of duckbill pliers to squeeze the plastic locking with two screws at the back of the plate.
tabs on the side of the circuit breaker while pushing it out of 14. Reinstall support brackets and secure with screws at the top
the hole in the base of the unit. and bottom.
6. Install the new circuit breaker by pushing it through the hole 15. Reattach the tubing to the four compressor fittings and
until it locks into place. secure with ladder clamps.
7. Reconnect wires to terminals. 16. Reconnect the compressor electrical connector.
8. Replace compressor and mounting plate. 17. Replace covers. NOTE–Be sure to reattach indicator panel
9. Replace covers. NOTE–Be sure to reattach indicator panel ribbon connector and hour meter electrical connector (refer
ribbon connector and hour meter electrical connector (refer to Cover Removal and Replacement in this manual).
to Cover Removal and Replacement in this manual). To rebuild compressor:
To replace fuse (Figure 4B): The top end of the compressor may be rebuilt using Compressor
1. Ensure the iFill station is unplugged from the wall outlet. Service Kit part number 515ADZ-643. Follow the steps below to
2. Use a small screwdriver to remove the fuse drawer located rebuild the compressor:
in the IEC connector. 1. Remove compressor from base of iFill station. Refer to
3. Remove the defective fuse and replace with a new fuse Compressor Replacement instructions above for removal.
4. Replace the fuse drawer into the IEC connector. To inspect and/or replace internal compo-
nents:
Compressor
1. Remove the eight screws that hold the compressor heads in
A DeVilbiss GSE dual-pressure head compressor is used to place. NOTE–When removing the heads, be sure to keep
power the oxygen generating element of the iFill station. It is each head and its components with the correct compressor
located in the base of the unit beneath the Plexiglas platform and side.
secured to a mounting plate with four silicone motor mounts. 2. Check for proper placement of or damage to the gaskets on
NOTE– An internal thermo-protective device will activate and shut the bottom of the compressor heads. Replace if damaged.
the compressor off if it overheats. It will take several minutes to 3. Remove reed valve plates. A reed valve is located on each
reset before the compressor can be restarted. side of the valve plate.
NOTE– A pressure relief (PR) valve is attached to each of the 4. The compressor reed valves should be flush with the valve
pressure heads to prevent high pressure build-up in the system plate. If the valve is broken or not flush with the valve plate
should a component malfunction occur. or foreign matter is detected inside the head, clean or
replace the compressor reed valves.
To replace the compressor (Figure 13):
1. Ensure the iFill station is unplugged from the wall outlet. To replace the compressor reed valves:
2. Remove the left and right covers from the iFill station. a. Remove the screw holding the compressor reed valves
3. Disconnect the compressor electrical connector. in position on the valve plate and discard the used reed
valves.
4. Loosen the ladder clamps and remove the tubing from all
four compressor fittings (two intake fittings and two exhaust b. Position the new reed valves so that they are centered
fittings). and completely cover the holes in the valve plate.
5. Use a Torx screwdriver with a size T-25 bit (or flat c. Place the metal retainer on the reed valves and secure
screwdriver) to remove the two screws from the back of the with the reed valve screw.
compressor mounting plate. 5. Check for proper placement of or damage to the rubber
6. Remove the two mounting plate support brackets by o-ring on the bottom of the valve plate. Replace if damaged.
loosening the screws (four total) from the top and bottom of 6. Remove piston sleeves by pulling upward and inspect cup
each bracket. NOTE–The top of the support brackets is seal on pistons. Replace if badly worn or damaged.
secured to the underside of the Plexiglas mounting platform
To replace cup seal:
and the bottom attaches to the compressor mounting plate.
a. Remove rod screw from top of piston.
7. Carefully lift the compressor and mounting plate out of the
b. Remove the cup retainer plate.
iFill base.
LT-1929 14
c. Discard defective cup seal. filter pointing down and secure with cable tie.
d. Place new cup seal into position. 6. Replace covers. NOTE–Be sure to reattach indicator panel
e. Replace cup retainer plate. ribbon connector and hour meter electrical connector (refer
f. Secure with screws. to Cover Removal and Replacement in this manual).
7. Reposition sleeve on piston. NOTE– In some cases, it may
be easier to position sleeve on piston before installing a new Four-Way Valve
cup seal and retainer plate. The four-way valve is mounted on the side of the intensifier and
8. Place valve plates on the compressor so that heads of reed interconnects the intensifier with the compressor. During
valve screws are aligned with the indentation in top of operation, the four-way valve controls air flow by directing
pistons. compressed air to the intensifier and routing the exhaust air
9. Install the compressor heads so that the holes in the heads back to the compressor.
are aligned with the holes in the compressor housing.
To replace the four-way valve (Figure 15):
10. Secure compressor heads with the screws.
1. Ensure the iFill station is unplugged from the wall outlet.
Cooling Fan 2. Remove the left and right covers from the iFill station.
3. Disconnect the four-way valve electrical connector.
The cooling fan provides a constant air flow to cool the
4. Disconnect the tubing from the fittings at the bottom of the
compressor. A defective fan may cause the compressor’s
valve. Be sure to note the position of each piece of tubing
internal thermo-protective device to activate and shut the
before removing it from the valve.
compressor off. Should this occur, it will require several minutes
for the thermo-protective device to reset. The fan is located on 5. Use a Torx screwdriver with a size T-27 bit to loosen the
the Plexiglas mounting platform above the compressor. four retaining screws that secure the valve to the intensifier
and then remove valve.
To replace cooling fan (Figure 12): 6. Install the two o-rings onto the new valve.
1. Ensure the iFill station is unplugged from the wall outlet. 7. Install the new four-way valve using the four retaining
2. Remove the left and right covers from the iFill station. screws.
3. Disconnect the fan electrical connector from main PC board. 8. Reconnect the tubing and electrical connector.
4. Use a Torx screwdriver with a size T-15 bit to remove the 9. Replace covers. NOTE–Be sure to reattach indicator panel
four retaining screws that secure the cooling fan to the ribbon connector and hour meter electrical connector (refer
Plexiglas mounting platform. to Cover Removal and Replacement in this manual).
5. Remove the defective cooling fan and install the
replacement fan using the four retaining screws. NOTE– Hour Meter
When installing the fan, be sure the air flow directional arrow The hour meter provides the total running hours of the iFill
on the side of the fan is pointing down toward the station. It is mounted in the right side cover behind the air filter.
compressor.
6. Reconnect the electrical connector to the main PC board. To replace the hour meter (Figure 18):
7. Replace covers. NOTE–Be sure to reattach indicator panel 1. Ensure the iFill station is unplugged from the wall outlet.
ribbon connector and hour meter electrical connector (refer 2. Remove the left and right covers from the iFill station.
to Cover Removal and Replacement in this manual). 3. Remove air filter from the right side cover.
4. Compress the four plastic locking tabs on the side of the
Final Bacteria Filter hour meter and push the meter toward the outside of the
The final bacteria filter is used to filter the oxygen as it leaves cover to remove it.
the accumulator tank prior to entering the pressure intensifier. It 5. Install new hour meter by compressing the four locking tabs
is recommended that this filter be changed within 17,520 hours while pushing the meter into the right side cover until it locks
of unit operation. The filter is mounted on the vertical piece of into place.
metal superstructure in the center of the unit near the main PC 6. Replace covers. NOTE–Be sure to reattach indicator panel
board. ribbon connector and hour meter electrical connector (refer
NOTE– On early versions of the iFill station, this filter may be to Cover Removal and Replacement in this manual).
located in the base of the unit below the pressure intensifier.
Long-Life Intake Filter
To replace the final bacteria filter (Figure 12):
The long-life intake filter is under the cylinder cradle.
2. Remove the left and right covers from the iFill station. To replace the long-life intake filter (Figure 5):
3. Disconnect tubing from both ends of filter. 1. Ensure the iFill station is unplugged from the wall outlet.
4. Cut the plastic cable tie holding the filter in place and 2. Use a flat screwdriver to loosen both 1/4 turn fasteners by
remove filter. turning counterclockwise 1/4 turn then remove the cylinder
5. Reconnect tubing to the replacement filter with arrow on cradle.
15 LT-1929
3. Reach into the iFill station and remove the long-life intake room environment only. Tools must be kept oil free. Do not use
filter and discard. lubricants.
4. Insert new long-life intake filter into the intake extension
To replace the pressure intensifier (Figure 8):
tube making sure the filer is centered in the opening.
5. Install the cylinder cradle (with fill connector cover facing
forward) by turning the 1/4 turn fasteners in the clockwise 2. Remove the left and right covers from the iFill station.
direction. 3. Remove the four-way valve from the side of the intensifier.
Refer to valve removal instructions.
Oxygen Sensing Device (OSD) 4. Disconnect wires from terminals on pressure switch.
5. Disconnect cylinder detect switch electrical connector from
The onboard Oxygen Sensing Device (OSD) is mounted on the main PC board.
PC board and is responsible for monitoring the oxygen purity
6. Disconnect the wire harness connector from the small
level being produced by the iFill station. At unit start-up, oxygen
sensor hall effect board that is mounted on the side of the
passes through the OSD and is exhausted; it does not enter the
intensifier body.
intensifier. After approximately four minutes when the oxygen
has reached the proper purity level, the three-way valve shifts 7. Disconnect tubing from the oxygen inlet fitting at the bottom
and will begin to direct the oxygen to the inlet of the pressure of intensifier.
intensifier. During operation, the OSD continues to monitor the 8. Carefully rest the iFill station on its side and remove the hex
oxygen purity. If the concentration level falls below specification nuts that secure the three intensifier mounts to the base of
of 90% (93% ± 3 %) the main PC board causes the three-way the unit. The intensifier can now be removed.
valve to shift and prevent the oxygen from entering the 9. Unscrew the three mounts from the bottom of intensifier
intensifier. and install them on the replacement intensifier.
1. The OSD is part of the Main PC board; refer to instructions 10. Reconnect the tubing to the oxygen inlet fitting at the
on how to replace the PCB (Printed Circuit Board). bottom of the intensifier.
11. Position intensifier with mounts attached into the base of
Power Cord the iFill station and secure with hex nuts.
12. Reconnect all wires and electrical connectors.
To replace the power cord (Figures 4A &14):
13. Reinstall the four-way valve.
- 115 volt units only
NOTE–230 volt units have a detachable power cord. ribbon connector and hour meter electrical connector (refer
1. Ensure the iFill station is unplugged from the wall outlet. to Cover Removal and Replacement in this manual).
2. Remove the left and right covers from the iFill station.
3. Remove compressor and mounting plate. PCB (Printed Circuit Board)
4. Disconnect the power cord electrical connector and then Main PC Board
remove both wires (black & white) from connector housing.
The main printed circuit (PC) board is responsible for monitoring
5. Remove ferrite core from the end of power cord wires.
and controlling the DeVilbiss iFill oxygen station. In addition to
6. Loosen the power cord strain relief and push cord out of the
the controlling circuitry, the audible alert and oxygen sensing
hole in the base of the unit.
device (OSD) are also located on the main PC board. The
7. Insert a new power cord through the hole and secure with board is mounted on the vertical piece of metal superstructure
strain relief. that separates the oxygen generation system components from
8. Reinsert wires into connector housing and reconnect the the pressure intensifier in the center of the unit.
power cord connector to the unit wire harness.
To replace the main board (Figure 12):
9. Reinstall ferrite core.
10. Replace compressor and mounting plate. 1. Ensure the iFill station is unplugged from the wall outlet.
11. Replace covers. NOTE–Be sure to reattach indicator panel 2. Remove the left and right covers from the iFill station.
ribbon connector and hour meter electrical connector (refer 3. Carefully disconnect tubing from the OSD.
to Cover Removal and Replacement in this manual). 4. Disconnect all electrical connections (6 connectors) from
the board.
Pressure Intensifier 5. Use a Torx screwdriver with a size T-10 bit to remove the
two retaining screws that secure the PC board to the metal
The pneumatic pressure intensifier is located in the front part of
superstructure.
the iFill station. The two stage intensifier utilizes a large drive
6. Carefully remove board from the plastic stand-offs.
piston in the power cylinder and smaller pistons in the 1st and
2nd stage cylinders to generate pressure. It receives low 7. Mount new PC board on stand-offs and secure with screws.
pressure oxygen from the accumulator tank and increases it to 8. Reconnect all electrical connectors and OSD tubing.
approximately 2000 PSI. The high pressure is used to fill 9. Replace covers. NOTE–Be sure to reattach indicator panel
portable oxygen cylinders attached to the fill connector. ribbon connector and hour meter electrical connector (refer
CAUTION–The pressure intensifier must be replaced in a clean to Cover Removal and Replacement in this manual).
LT-1929 16
CAUTION–Do not apply any force or flex the PC Board when ribbon connector and hour meter electrical connector (refer
connecting or disconnecting electronic or pneumatic to Cover Removal and Replacement in this manual).
components. Damage to the electronic assembly is possible.
DC Power Supply PC Board
Sieve Beds
The sieve beds are located in the front of the unit behind the
The DC power supply PC board supplies DC voltage to operate
pressure intensifier. They are alternately pressurized by the
the main PC board. It is located on the Plexiglas mounting
rotary valve and remove the nitrogen from the compressed air
platform above the compressor.
passing through them. The resulting high concentration of
To replace the power supply board (Figure 12): oxygen is supplied to the pressure intensifier.
1. Ensure the iFill station is unplugged from the wall outlet. NOTE–Sieve beds should be ordered and changed in pairs.
To replace the sieve beds (Figure 11):
3. Disconnect the two electrical connectors from the board.
4. Carefully remove board from the plastic stand-offs.
5. Install replacement board by pushing it down onto stand-offs
until it locks into place. 3. Remove the pressure intensifier first. Refer to Intensifier
Removal instructions. NOTE–The four-way valve does not
6. Reconnect the electrical connectors.
have to be removed from the intensifier when replacing the
7. Replace covers. NOTE–Be sure to reattach indicator panel sieve beds; however, the electrical connector and tubing still
ribbon connector and hour meter electrical connector (refer need to be disconnected from the four-way valve.
4. Disconnect the tubing from the top and bottom of each sieve
CAUTION–Do not apply any force or flex the PC Board when bed.
connecting or disconnecting electronic or pneumatic 5. Cut the plastic cable ties holding the sieve beds in place
components. Damage to the electronic assembly is possible. and remove the beds.
6. Install new beds and secure with new plastic cable ties.
Rotary Valve
7. Reconnect the tubing to the beds.
The rotary valve is located at the bottom of the unit between the 8. Reinstall the pressure intensifier.
sieve beds. It alternately distributes compressed air to the sieve 9. Replace covers. NOTE–Be sure to reattach indicator panel
beds in a timed sequence. While one bed is being pressurized, ribbon connector and hour meter electrical connector (refer
the other bed is being exhausted through the valve. Exhaust to Cover Removal and Replacement in this manual).
gases go through the valve exhaust port and exit through the
CAUTION-Do not use regenerated sieve material.
exhaust muffler.
To replace the rotary valve (Figures 15 & 17): Three-Way Valve
1. Ensure the iFill station is unplugged from the wall outlet. The three-way valve is mounted on the vertical piece of metal
2. Remove the left and right covers from the iFill station. superstructure in the center of the unit next to the main PC
3. Remove the pressure intensifier first. Refer to Intensifier board. It is responsible for directing oxygen from the
Removal instructions. NOTE–The four-way valve does not accumulator tank to the inlet of the pressure intensifier as well
have to be removed from the intensifier when replacing the as to the oxygen sensing device (OSD). At unit start-up, the
rotary valve; however, the electrical connector and tubing valve prevents oxygen from entering the intensifier. After
still need to be disconnected from the four-way valve. approximately four minutes when the oxygen has reached the
4. Cut cable tie holding rotary valve wire harness and proper purity level, the three-way valve will begin to direct the
disconnect harness from the valve. oxygen to the inlet of the pressure intensifier.
5. Loosen speedy clamps and remove tubing from both sides
of valve.
To replace the three-way valve (Figure 12):
6. Loosen ladder clamp and remove tubing from the
compressor exhaust fitting that is located closest to the PR 2. Remove the left and right covers from the iFill station.
valve on compressor. 3. Disconnect the three-way valve electrical connector from the
7. Pull rotary valve forward slightly and then loosen ladder PC board.
clamps and remove tubing from the two fittings on the 4. Disconnect the three pieces of tubing from the valve.
backside of valve. 5. Use a Torx screwdriver with a size T-10 bit to remove the
8. Reattach tubing to the same two fittings on the new rotary two retaining screws that secure the three-way valve to the
valve. metal superstructure and remove valve.
9. Reattach tubing to the compressor exhaust fitting. 6. Install the replacement valve using the retaining screws.
10. Reattach tubing to fittings on both sides of valve. 7. Reconnect the three pieces of tubing and electrical
11. Reconnect valve wire harness and secure with cable tie. connector.
12. Reinstall the pressure intensifier. 8. Replace covers. NOTE–Be sure to reattach indicator panel
ribbon connector and hour meter electrical connector (refer
17 LT-1929
Figures, diagrams, and views index

Exterior Views
The following figures show the exterior of the DeVilbiss iFill Personal Oxygen Station.
Figure 1 Left Side.................................................................................................................................................................... 19
Figure 2 Right Side.................................................................................................................................................................. 20
Figure 3 Top............................................................................................................................................................................. 21
Figure 4A Lower Rear (535D).................................................................................................................................................... 22
Figure 4B Lower Rear (535I)..................................................................................................................................................... 23
Figure 5 Top with Cradle Removed......................................................................................................................................... 24
The following figures show the DeVilbiss iFill Personal Oxygen Station and the Cylinders.
Figure 6 Cylinder Attached to Fill Connector........................................................................................................................... 25
Figure 7 iFill Cylinders with PulseDose Conserving Device and Continuous Flow Regulators.............................................. 26
Interior Views
The following figures show the interior of the DeVilbiss iFill Personal Oxygen Station.
Figure 8 Front, Pressure Intensifier......................................................................................................................................... 27
Figure 9 Right Side.................................................................................................................................................................. 28
Figure 10 Top, Check Valves and Orifice.................................................................................................................................. 29
Figure 11 Beds and Accumulator Tank...................................................................................................................................... 30
Figure 12 Rear Top.................................................................................................................................................................... 31
Figure 13 Compressor............................................................................................................................................................... 32
Figure 14 Rear Lower, Exhaust Muffler and Harness (535D)................................................................................................... 33
Figure 15 Four-Way and Rotary Valves.................................................................................................................................... 34
Figure 16 Intensifier (Bottom).................................................................................................................................................... 35
Figure 17 Front Lower with Intensifier Removed...................................................................................................................... 36
Figure 18 Inside Right Cover..................................................................................................................................................... 37
Figure 19 Left Side.................................................................................................................................................................... 38
Figure 20 Rear........................................................................................................................................................................... 39
Diagrams
Figure 21 Pneumatic Diagram................................................................................................................................................... 40
Figure 22 Wiring Diagram.......................................................................................................................................................... 41
LT-1929 18
Figure 1 - Exterior, Left Side View
Fill Connector
Fill Port Collar

Cradle
Rear
Handle Front Handle
Intake Filter
Left Cover
Screw
Base
Caster
19 LT-1929
Figure 2 - Exterior, Right Side View
Fill Connector
Cover
Cradle
Front
Handle
Rear Handle
Hour Meter
Right Cover
Power Cord
Strain Relief
Base
Note-Strain relief and power
cord are 115V unit only.
Caster
LT-1929 20
Figure 3 - Exterior, Top View
Fastener (stud)
Cradle
Fill Connector Cover
Instruction Label Service Required Light (Red)
Standby Light (Green)
Full Light (Green)
Filling Light (Green)
Start/Stop Switch
Fill Connector
Left Cover Right Cover
Front Handle
21 LT-1929
Figure 4A-Exterior, Lower Rear View (535D)
Serial Number
and Electrical
Rating Label
Circuit Breaker
Serial Number
Bar Code Label
Caster
Strain Relief
Power Cord
Note-Strain relief and power
cord are 115V unit only.
Exhaust Grill
LT-1929 22
Figure 4B - Exterior, Lower Rear View (535I)
Serial Number and

Electrical Rating Label
IEC Connector
Fuse Serial Number

Bar Code Label
Caster
Exhaust Grill
23 LT-1929
Figure 5 - Exterior, Top View - Cradle Removed
Fastener
Receptacle
Intake Bacteria
Filter
LT-1929 24
Figure 6 - Exterior, Cylinder Attached to Fill Connector
PulseDose
Conserving
Device
M6
Cylinder
Fill Connector
Fill Port
Cradle Collar
Fill Connector Cover

NOTE-Place cover in cradle
when using M4 or M6 cylinders
only.
25 LT-1929
Figure 7 - Exterior, iFill Cylinders w/Conserving

Device & Continuous Flow Regulator
Rotary
Selector
PulseDose
Conserving
Device
Pressure
Gauge Continuous Flow Regulator
Cannula Fitting
Cannula Fitting (on rear)
Shut Off
Shut Off Valve Valve
Nipple Connector w/
Hydrostatic Test Nipple Connector Cylinder Dust Cap
Date (stamped on w/Cylinder Dust
cylinders) Cap
NOTE-Contact your
homecare provider or the
cylinder manufacturer for
details.
Rotary
Selector
PulseDose
Conserving
Device
Pressure
Gauge Continuous Flow Regulator
Cannula Fitting (on rear)
Cannula Fitting
Nipple Connector w/Cylinder
Dust Cap (not shown)
Nipple
Connector
Hydrostatic Test w/Cylinder
Date (stamped on Dust Cap
cylinders) (not shown)
NOTE-Contact your
homecare provider or the
cylinder manufacturer for
details.
LT-1929 26
Figure 8 - Interior, Front View - Pressure Intensifier
Fill
Connector
Fill Port
Collar
Support
Grommet
Pressure
Switch
2nd Stage
Cylinder Inter-Stage Tube
Right Sieve
Left Sieve Bed Bed
Four-Way
Valve
Hall Effect Board
Pressure Intensifier
Power Cylinder
1st Stage
Cylinder
27 LT-1929
Figure 9 - Interior, Right Side View
Intake Bacteria
Filter
Extension
Tube
Pressure
Intensifier
Compressor
Pressure Exhaust
Tubing Tubing 1/2” ID
3/8” ID (Silicone)
(Silicone)
LT-1929 28
Figure 10 - Interior, Top View - Check Valves and Orifice
Purge Harness Assembly
Check Valve Check Valve
Sieve Bed Sieve Bed

Test Point Test Point
Pressure
Switch
Fixed
Orifice
Accumulator Tank Test
Point
29 LT-1929
Figure 11 - Interior, Beds and Accumulator Tank
Support Grommet
Cylinder Detect
Switch
O2 Inlet to
2nd Stage
Sieve Bed
Test Point
Left Sieve
Bed
Cable Tie
Tubing 1/8” ID Accumulator Right

Tank Sieve Bed
LT-1929 30
Figure 12 - Interior, Rear Top View
Main PC
Board
Tubing 1/8” ID
OSD
Final Bacteria
Filter
Three-Way
Cooling Fan Valve
Capacitor
DC Power
Supply PC
Board
Plexiglas
Mounting
Platform
Air Inlet
Check Valve
31 LT-1929
Figure 13 - Interior, Compressor
Ladder
Clamps
AC Wire
Harness
PR Valves
Pressure Exhaust
Tubing 1/2” ID
(Silicone) Tubing 3/8”
ID (Silicone)
Support Compressor
Bracket
Compressor
Electrical
Connector Support
Bracket
Mounting Motor
Plate Mount
LT-1929 32
Figure 14 - Interior, Rear Lower View

Exhaust Muffler & Harness (535D)
AC Wire Exhaust Muffler

Harness
Pressure Exhaust
Tubing 1/2” ID
(Silicone)
Ferrite Core
Power Cord
Circuit Base
Breaker
33 LT-1929
Figure 15 - Interior, Four-Way and Rotary Valves
Intensifier
Four-Way
Valve
Four-Way Valve
Wire Harness
Rotary Valve
Ladder Tubing 3/8” ID

Clamps (Silicone)
LT-1929 34
Figure 16 - Interior, Bottom of Intensifier
1st Stage
Cylinder
Tubing 1/2” ID O2 Outlet to 2nd

(Silicone) Stage
Intensifier O2 Inlet to Inter-Stage

Mount Intensifier Tube
35 LT-1929
Figure 17 - Interior, Front Lower View

Intensifier Removed
O2 Accumulator Tank Rotary Valve Tubing 1/2” ID

Outlet Fitting Wire Harness (Silicone)
Tubing 3/8” ID
(Silicone)
Rotary
Valve
Intensifier
Mounting
Supports
LT-1929 36
Figure 18- Interior, Inside View of Right Cover
Fastener
Receptacle
Ribbon
Cable
Hour Meter
Right
Cover
37 LT-1929
Figure 19 - Interior, Left Side View
Fill Connector
Long-Life Cylinder Detect

Intake Filter Switch
Plexiglas Pressure
Mounting Intensifier
Platform
Compressor
LT-1929 38
Figure 20 - Interior, Internal Rear View
Long-Life Intake
Filter
Main PC
Board Final Bacteria
Filter
Extension Tube
Air Inlet Check

Valve
Support Bracket
Compressor
Motor Mount
Mounting
Plate
39 LT-1929
Figure 21 - Pneumatic Diagram
LT-1929 40
Figure 22 - Wiring Diagram
41 LT-1929
O R D E R I N G I N F O R M AT I O N A N D PA R T S L I S T
Ordering Information
When ordering components, instruction guides, or service manuals the following must be provided:
• Unit Catalog Number
• Unit Serial Number
• Part Number
• Quantity Required
DeVilbiss iFill Station Instruction Guide 535D—part # A-535D

English/Spanish/French
DeVilbiss iFill Cylinder Instruction Guide—part # A-535-CYL

English/Spanish/French
DeVilbiss iFill Station Instruction Guide 535I—part # SE-535I

English/Spanish/French/German/Italian/Dutch/Swedish/Finnish/Danish/Norwegian/Greek
DeVilbiss iFill Cylinder Instruction Guide—part # SE-535-CYL

English/Spanish/French/German/Italian/Dutch/Swedish/Finnish/Danish/Norwegian/Greek
DeVilbiss iFill Station Service Manual—part # LT-1929

English
DeVilbiss iFill Station Service Manual—part # LT-1929-FR

French
DeVilbiss iFill Station Service Manual—part # LT-1929-DE

German
Orders may be placed by calling:

• Customer Service 800-338-1988
• Warranty parts - U.S.A. 800-338-1988
• International Department 814-443-4881
• Europe +49-(0)-621-178-98-0
Parts Return and Ordering Policy

ALL DEFECTIVE COMPONENTS THAT ARE STILL UNDER WARRANTY MUST BE RETURNED TO THE FACTORY IN
SOMERSET, PA WITHIN 30 DAYS AFTER SHIPMENT OF THE NEW COMPONENTS. IF THE COMPONENTS ARE NOT
RECEIVED WITHIN THIS PERIOD, AN INVOICE WILL BE ISSUED TO YOUR ACCOUNT.
REBUILT EXCHANGE PARTS PRICING IS AVAILABLE ONLY WITH THE RETURN OF DEFECTIVE PARTS WITHIN 30 DAYS.
COMPONENTS WILL THEN BE BILLED AT THE REBUILT COST; THERE WILL BE A CHARGE FOR SHIPPING. IF THE
DEFECTIVE COMPONENT IS NOT RECEIVED WITHIN 30 DAYS, THEN A NEW COMPONENT INVOICE WILL BE ISSUED TO
YOUR ACCOUNT. COMPONENTS THAT ARE OUT OF WARRANTY AND NOT ON A REBUILT/EXCHANGE PROGRAM DO NOT
HAVE TO BE RETURNED TO THE FACTORY.
Before returning parts or units to the factory, call the DeVilbiss Healthcare Customer Service Department (800-338-1988 or 814-443-
4881) to obtain a return authorization number. Include in the package a note indicating the return authorization number along with
your company name, address, phone number, and account number. The return authorization number should also be written on the
outside of the package.
To expedite your order for warranty or non-warranty parts, the following information should be given to the representative:
• Catalog number
• Serial number
• Hour meter reading for iFill
• Account number
• Company name and address
• Description of problem
LT-1929 42
Parts List
Tools and Accessories

Oxygen Analyzer R217P62 or R218P12
Test Magnets 535D-618
Components 535D 535I

Accumulator Tank 535D-601 535D-601
Bracket Support 535D-633 535D-633
Cabinet Parts
• Base 535D-607 535I-607
• Cradle/Bottle Holder Assembly 535D-608 535D-608
• Fill Connector Cover 535D-606 535D-606
• Left Cover 535D-612 535D-612
• Right Cover 535D-613 535D-613
Cable Tie, (Sieve Beds) (4 each) 505DZ-617 505DZ-617
Capacitor, Motor Start/Run 535D-616 MC44I-626
Carton w/ Shipping Inserts 535D-603 535D-603
Caster, Non-locking (4 each) 501DZ-603 501DZ-603
Check Valves
• Bed Check Valve (2 per package) PVO2D-607 PVO2D-607
• Inlet Check Valve 535DD-608 535DD-608
• Purge Harness Assembly 535D-602 535D-602
Circuit Breaker 515DZ-615 See Fuse
Cooling Fan 535D-634 535D-634
Compressor 535D-604 535I-604
Compressor Rebuild Kit 515ADZ-643 515ADZ-643
Compressor Mounting Plate 535D-614 535D-614
Dust Cap (for cylinder nipple) PD1000A-627 PD1000A-627
Exhaust Muffler 515A-705 515A-705
Fasteners 1/4 Turn
• Stud (Cradle screw) 535D-610 535D-610
• Retainer (Washer) 535D-611 535D-611
• Receptacle (Stud holder) 535D-609 535D-609
Filters
• Cabinet Air Inlet Filter (6 pack) 535D-605 535D-605
• Long-Life Intake Filter 515DZ-605 515DZ-605
• Final Bacteria Filter 535D-615 535D-615
Fuse Package 2.5 Amp see Circuit Breaker 535I-615
Grommet 535D-632 535D-632
Hoses
1/8” ID (Blue) (4’ Lg) 444-554 444-554
3/8” ID (Silicone) (4’ Lg) 535D-619 535D-619
1/2” ID (Silicone) (2’ Lg) 505DZ-634 505DZ-634
Hose Clamps
• Plastic (1/2” ID Hoses) (20 each) 444-538 444-538
• Ladder Clamp (1/2” ID Hoses) (1 each) 444-566 444-566
43 LT-1929
Components 535D 535I

Hour Meter PV5LD-617 PV5LD-617
Labels
• Indicator LED Panel Label 535D-620 535D-620
• Instruction Label 535D-626 535D-626
Mounts
• Compressor Mounts (4 each w/4 nuts) 505IZ-609 505IZ-609
• Intensifier Mounts 535D-627 535D-627
Nut (Compressor Mounting) (4 each) 303DZ-630 303DZ-630
PC Boards
• Main PC Board 535D-622 535D-622
• DC Power Supply PC Board 535D-621 535D-621
Power Cord PV5LD-618 N/A
Power Cord Strain Relief 505DZ-645 N/A
Pressure Intensifier 535D-628 535D-628
Screws (Cover) (6 pack) 303DZ-628 303DZ-628
Screw Rivet 535D-635 535D-635
Sieve Bed (1 each) 501DZ-619 501DZ-619
Valves
• Four-Way 535D-629 535D-629
• Rotary 535D-630 535D-630
• Three-Way 535D-631 535D-631
Wire Harnesses
• AC Wire Harness 535D-623 535I-623
• DC Harness 535D-625 535D-625
• Board Interconnect Harness 535D-624 535D-624
LT-1929 44
SPECIFICATIONS
SPECIFICATIONS
DeVilbiss iFill Personal Oxygen Station
Operating Temperature:.................................................................................................................................41º to 95ºF (5º to 35ºC)
Operating Humidity Range:.............................................................................................................. 15 to 95% R.H. non-condensing
Operating Altitude:....................................................................................................................... 0 to 6,562 Feet (0 to 2,000 Meters)
Storage Temperature Range:......................................................................................................... -40ºF to +140ºF (-40ºC to +60ºC)
Storage Humidity Range:..........................................................................................................................10 to 95% non-condensing
Electrical Rating:
535D............................................................................................................................................................115V~ 60Hz 4.1 Amps
535I...................................................................................................................... 230V~ 50Hz 2.0 Amps; 220V~ 60Hz 2.7 Amps
Operating Voltage Range:
535D................................................................................................................................................................... 97 – 132V~ 60HZ
535I............................................................................................................................................................. 187 – 264V~ 50/60Hz
Power Range (when filling M6 cylinder):
535D.......................................................................................................................................400 Watts Average @ 115V~ 60 Hz
535I....................................................................................................................................... 400 Watts Average @ 230V~ 50 Hz
Oxygen Purity:............................................................................................................................................................... 93% O2 ± 3%
Dimensions: (including casters) w/o cylinder........................................................................................... 12.25”W x 28.5”H x 22.5”D
Weight:.......................................................................................................................................................................................66 lbs
Shipping Weight:........................................................................................................................................................................ 76 lbs
This unit is classified as nonprotected (ordinary equipment) per EN60601-1.............................................................................IPX0
Approvals:
535D.................................................................................................................................... CAN/CSA-C22.2 60601.1-M90 - CSA
535I (50Hz only).................................................................................................................................................EN60601-1 - TUV
Specifications subject to change without notice.
iFill Oxygen Cylinder typical Fill Times

NOTE– All filling times are approximate and may vary depending on altitude and environmental conditions.
Typical cylinder fill time from empty to 2,000 +/- 200 psig are as follows:
M4 (0.7 L) 60 Minutes
M6 (1.0 L) 75 Minutes
ML6 (1.2 L) 90 Minutes
C (1.8 L) 130 Minutes
D (2.9 L) 215 Minutes
E (4.7 L) 350 Minutes
NOTE- Degradation of performance may occur if unit is operated outside of specified operating parameters.
45 LT-1929
DeVilbiss Healthcare LLC
100 DeVilbiss Drive
Somerset, PA 15501-2125
USA
800-338-1988 • 814-443-4881
DeVilbiss Healthcare Ltd DeVilbiss Healthcare Pty. Limited

Unit 3, Bloomfield Park 15 Carrington Road, Unit 8
Bloomfield Road Castle Hill NSW 2154
Tipton, West Midlands DY4 9AP AUSTRALIA
United Kingdom +61-2-9899-3144
+44 (0) 121 521 3140
EC REP 0044
DeVilbiss Healthcare SAS DeVilbiss Healthcare GmbH

13/17, Rue Joseph Priestley Kamenzer Straße 3
37100 Tours 68309 Mannheim
FRANCE Germany
+33 (0) 2 47 42 99 42 +49-(0)-621-178-98-0
D e Vi l b i ss H eal t hcare LLC • 100 De Vilb iss Dr ive • S o me r set, PA 15 5 0 1 • USA

800-338-1988 • 814-44 3 - 4 8 8 1 • www.DeVilbissHea lthcar e .co m
DeVilbiss®, OSD®, PulseDose® and DeVilbiss iFill® are registered trademarks of DeVilbiss Healthcare.
Snoop® is a registered trademark of SWAGELOK
© 2015 DeVilbiss Healthcare LLC. 03.15 All Rights Reserved. LT-1929 Rev. D

DeVilbiss 535D Oxygen Concentrator - Service Manual

Uploaded by

Copyright:

Available Formats

DeVilbiss 535D Oxygen Concentrator - Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DeVilbiss 535D Oxygen Concentrator - Service Manual

Uploaded by

Copyright:

Available Formats

DeVilbiss iFill® Personal Oxygen Station

Downloaded from www.Manualslib.com manuals search engine

Attention, consult instruction guide Type BF applied part

AC current Double Insulated

Electric S­hock Hazard. Do Not Open Danger-No Smoking

READ ALL INSTRUCTIONS BEFORE SERVICING.

WARNING - Handling Warnings

WARNING - Storage and Handling

WARNING - service Warnings

CAUTIONS & NOTES

Initial Inspection CAUTION–When transporting the DeVilbiss iFill Personal

Routine Patient Maintenance

Periodic Homecare Provider

Between Patient Maintenance

• Small Magnet: Placed on the intensifier center drive 

Proper Repair Procedures To replace covers (Figures 18):

Figures, diagrams, and views index

Figure 1 - Exterior, Left Side View

Fill Port Collar

Figure 2 - Exterior, Right Side View

Figure 3 - Exterior, Top View

Fill Connector Cover

Instruction Label Service Required Light (Red)

Standby Light (Green)

Full Light (Green)

Filling Light (Green)

Left Cover Right Cover

Figure 4A-Exterior, Lower Rear View (535D)

Figure 4B - Exterior, Lower Rear View (535I)

Serial Number and

Fuse Serial Number

Figure 5 - Exterior, Top View - Cradle Removed

Figure 6 - Exterior, Cylinder Attached to Fill Connector

Fill Connector Cover

Figure 7 - Exterior, iFill Cylinders w/Conserving

Figure 8 - Interior, Front View - Pressure Intensifier

Figure 9 - Interior, Right Side View

Figure 10 - Interior, Top View - Check Valves and Orifice

Purge Harness Assembly

Check Valve Check Valve

Sieve Bed Sieve Bed

Figure 11 - Interior, Beds and Accumulator Tank

Tubing 1/8” ID Accumulator Right

Figure 12 - Interior, Rear Top View

Figure 13 - Interior, Compressor

Figure 14 - Interior, Rear Lower View

AC Wire Exhaust Muffler

Figure 15 - Interior, Four-Way and Rotary Valves

Ladder Tubing 3/8” ID

Figure 16 - Interior, Bottom of Intensifier

Tubing 1/2” ID O2 Outlet to 2nd

Intensifier O2 Inlet to Inter-Stage

Figure 17 - Interior, Front Lower View

O2 Accumulator Tank Rotary Valve Tubing 1/2” ID

Figure 18- Interior, Inside View of Right Cover

Figure 19 - Interior, Left Side View

Long-Life Cylinder Detect

Figure 20 - Interior, Internal Rear View

Air Inlet Check

Electric Shock Hazard. Do Not Open Danger-No Smoking

• Small Magnet: Placed on the intensifier center drive

Figure 7 - Exterior, iFill Cylinders w/Conserving