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AirSep FreeStyle Service Manual

Manual is about: Portable Oxygen Concentrator

Summary of FreeStyle

  • Page 1

    Freestyle ™ portable oxygen concentrator service manual airsep corporation • 401 creekside drive • buffalo, ny 14228-2085 usa telephone: 716.691.0202 • 24-hour fax: 716.691.4141 • www.Airsep.Com.

  • Page 2

    Expedited product warranty check service is always at your fingertips with airsep: type www.Airsep.Info/warranty_check/main.Asp or in the us or canada, dial 866-873-9277 air travel with freestyle freestyle is approved for use on-board commercial aircraft per an addendum to faa sfar 106. For a curren...

  • Page 3: Table Of Contents

    Table of contents section 1.0 introduction section 2.0 operation check and 1.1 equipment provider responsibility 1-1 1.2 important notice and symbol explanations 1-2 1.3 definitions of symbols 1-3 1.4 freestyle product limited warranty 1-4 1.5 freestyle specifications 1-5 1.6 freestyle classificatio...

  • Page 4

    Section 4.0 equipment provider maintenance 3.2.1 cleaning the air intake gross particle filter 3-4 3.2.2 alarm/service indicator 3-5 3.2.3 nasal cannula 3-5 3.2.4 usage during sleep 3-5 4.1 no scheduled maintenance 4-1 4.1.1 air intake / gross particle filter 4-1 4.1.2 product filter replacement 4-1...

  • Page 5

    Iii – table of contents airsep corporation iii – table of contents 5.13 circuit board replacement 5-21 5.14 motor controller board replacement 5-25 5.15 control/key panel replacement 5-27 5.16 fan replacement 5-31 section 6.0 typical pressure profiles 6.1 pressure profile quadrant 6-1 section 7.0 tr...

  • Page 7: 1.0      Introduction

    Airsep corp. — freestyle service manual 1-1 1.0 introduction 1.1 equipment provider responsibility all equipment providers of the freestyle ™ portable oxygen concentrator must assume responsibilities for handling, operational check-out, patient instruction, and maintenance. These responsibilities ar...

  • Page 8

    Airsep corp. — freestyle service manual 1-2 1.2 important notice and symbol explanations as you review both the freestyle patient manual and this freestyle service manual, pay special attention to the warning, caution, and note messages. They identify safety guidelines or other important information...

  • Page 9

    Airsep corp. — freestyle service manual 1-3 1.3 definitions of symbols symbols are frequently used on equipment and/or the manual in preference to words with the intention of decreasing the possibility of misunderstanding caused by language differences. Symbols can also permit easier comprehension o...

  • Page 10

    Airsep corp. — freestyle service manual 1-4 1.4 freestyle product limited warranty airsep corporation warrants the freestyle oxygen concentrator to be free from defect in parts for three years (as specified on the original invoice provided) from the date of delivery to the original purchaser, under ...

  • Page 11

    Airsep corp. — freestyle service manual 1-5 1.5 freestyle specifications max operational altitude: up to 12,000 ft (3,657.6 m) (483mmhg) higher altitudes may affect performance * based on an atmospheric pressure of 14.7 psia (101 kpa) at 70 o f (21 o c) * operating unit outside of normal operational...

  • Page 12

    Airsep corp. — freestyle service manual 1-6 1.6 freestyle classifications classification type of protection against electric shock: class ii protection from electric shock is achieved by double insulation. Degree of protection against electric shock: type bf equipment providing a particular degree o...

  • Page 13

    Airsep corp. — freestyle service manual 2-1 2.0 operation check and test of oxygen concentration 2.1 description of operation air enters the freestyle oxygen concentrator through an external air intake / gross particle filter. This filtered air enters the compressor via a suction intake muffler that...

  • Page 14

    Airsep corp. — freestyle service manual 2-2 2 2 2 2.3 alarm system an audible alarm sounds if freestyle has a low battery, senses no inspiration, or if performance is outside specifications. If an alarm sounds, observe which lights are on. The visual and audible alarm conditions are explained in det...

  • Page 15

    Airsep corp. — freestyle service manual 2-3 2.3.5 battery charging to check the level of charge of the battery, press the batt button on the keypad. The battery gauge/indicator(s) illuminate to indicate the level of battery charge (25-100%). To charge the freestyle’s internal battery: connect its ...

  • Page 16

    Airsep corp. — freestyle service manual 2-4 2 2 2 2.3.6 battery fully charged when freestyle is connected to an ac or dc outlet and is either in operation or is off, the green 100% battery gauge/indicators displays to indicate that the battery is fully charged. 2.3.7 cannula disconnect (no inspirati...

  • Page 17

    Airsep corp. — freestyle service manual 2-5 2.4 oxygen concentration test and specification to ensure that freestyle’s oxygen output is within specification, you must perform an oxygen concentration test. Test the unit upon delivery to a patient and at periodic intervals. Equipment providers, based ...

  • Page 19

    Airsep corp. — freestyle service manual 3-1 3.0 patient instructions 3.1 general instructions it is important that patients thoroughly understand how to operate airsep’s freestyle unit. This enables proper treatment as prescribed by a qualified, licensed physician. You must explain that the purpose ...

  • Page 20

    Airsep corp. — freestyle service manual 3-2 to charge the airbelt battery: 1) release safetycap from end of the airbelt cord. 2) connect the ac/dc power supply (included with the airbelt accessory kit) to the end of airbelts power cord as shown in figure 12. 3) connect the airbelt power supply to an...

  • Page 21

    Airsep corp. — freestyle service manual 3-3 depending upon the temperature of the airbelt battery, it can take several minutes for the charging cycle to start after connecting to power. This is a normal condition and is intended for safe charging. Airbelt does not need to be fully discharged before ...

  • Page 22

    Airsep corp. — freestyle service manual 3-4 3.2 routine maintenance by the patient to ensure accurate output and efficient operation of the unit, the patient must perform two simple, routine maintenance tasks: • clean the air intake / gross particle filter • contact the equipment provider for inspec...

  • Page 23

    Airsep corp. — freestyle service manual 3-5 3.2.2 alarm/service indicator when the unit has reached 5,000 hours of use, a yellow led will illuminate in the upper left hand corner of the unit’s keypad/alarm display. Instruct patients to notify the equipment provider when this unit alarms. As the equi...

  • Page 24

    Airsep corp. — freestyle service manual 4- 1 4.0 equipment provider maintenance 4.1 no scheduled maintenance freestyle model units are maintenance-free due to their technologically advanced design. Airsep does not require preventative maintenance or service on these concentrators as long as the conc...

  • Page 25

    Airsep corp. — freestyle service manual 4- 2 4.1.3 compressor servicing as the equipment provider, you are responsible for monitoring the life of the compressor, which must be checked at every 5,000 hours of use. 4.1.4 recording maintenance as the equipment provider, you should record all routine ma...

  • Page 26: 5.0     Service

    5-1 airsep corp. — freestyle service manual clean or replace the air intake / gross particle filter with warm soapy water between each patient’s use. The patients should be instructed to clean this filter at least once per week, depending on the environment, during normal operation. Change the produ...

  • Page 27

    Airsep corp. — freestyle service manual 5-2 5.2 housing removal 5.2.1 removing front cover 1.Place unit on its back and position the outlet nozzle upwards facing forward. 2.Locate the three screws securing the front cover (top center, lower left, and right). 3.Using a phillips-head screwdriver, loos...

  • Page 29

    Airsep corp. — freestyle service manual 5-3 5.3 internal battery replacement when removing the front cover to remove the battery, always use esd safeguard to protect the electronic circuit board from damage. 1.Remove the front housing. 2.Carefully disconnect the 8-pin (j1) and 2-pin (j2) connector f...

  • Page 30

    5-4 airsep corp. — freestyle service manual 5.4 psa removal 1.Disconnect the freestyle unit from the ac or dc outlet. 2.Remove the front housing. 3.Remove the battery. Care must be taken when removing (j1) and (j2) connector. 4.Disconnect the 8-pin connector (j5) with multi-color wires from the circ...

  • Page 31

    Airsep corp. — freestyle service manual 5-5 the following two steps (6 and 7) require extreme caution to ensure the black pressure sensor (u3) is not damaged. 6.Remove the adjustable nozzle by gently pulling it upward until it comes out of the left side retaining clips. When the left side is out, pu...

  • Page 32

    5-6 airsep corp. — freestyle service manual 8. Remove the 8-32 x ¼” black phillips screws located in the center of outlet nozzle cradle. (figure 5.9) figure 5.9 9.Turn unit over and remove the back housing. 10.Disconnect the black ground wire, (connected to the compressor on its upper right side nea...

  • Page 33

    Airsep corp. — freestyle service manual 5-7 11.Disconnect the 1/8” od black tube from the y-connector or t connector (which is located at the back of the psa system) that connects to the pressure transducer on the left side. 12.Remove each tie-wrap around the upper top screw bosses. (see figure 5.11...

  • Page 34

    5-8 airsep corp. — freestyle service manual 14.Carefully remove the complete psa assembly from the center housing by pulling it upwards and slipping compressor molex connector through center section. (see figure 5.13.) figure 5.13 15.Remove the compressor plate by removing the two screws. (see figur...

  • Page 35

    Airsep corp. — freestyle service manual 5-9 16. Remove the two mounts from the compressor. (see figure 5.15.) figure 5.15.

  • Page 36

    5-10 airsep corp. — freestyle service manual 5.5 compressor replacement the compressor is the “pump” within the oxygen concentrator that pushes room air into the bottom of the sieve beds. This allows oxygen to flow out the top. Over time, the cup seals wear and the compressor does not operate proper...

  • Page 37

    Airsep corp. — freestyle service manual 5-11 4. If either of the two fittings connecting the compressor to the manifold is connected to the compressor, remove it and insert it into the manifold. (see figure 5.18.) figure 5.18 5. Connect the new compressor to the psa assembly, and tighten the bolt to...

  • Page 38

    5-12 airsep corp. — freestyle service manual 5.5.2 compressor assembly installation to install the new compressor assembly, perform the compressor removal procedure in reverse order. After replacing the units compressor, you must reset the hour meter, as described in section 5.11.

  • Page 39

    Airsep corp. — freestyle service manual 5-13 5.6 product manifold replacement 1.Remove the psa system per section 5.4. 2.Disconnect the tubing assembly from the two barbs on the product manifold, mixing tank, and one end of the purge tube. (figure 5.20 a, b, c) figure 5.20a figure 5.20b figure 5.20c...

  • Page 40

    5-14 airsep corp. — freestyle service manual figure 5.21 5.Holding sieve beds in place, gently pull upward on the product manifold to remove. Keep tubing assembly in place. 6.Align new product manifold with the outlet of the sieve beds, and gently push manifold down into place. 7.Reconnect tubing as...

  • Page 41

    Airsep corp. — freestyle service manual 5-15 4.Carefully disconnect the molex connector from the circuit board by pulling on the molex connector, not the valve wires. 5.Using a small phillips screwdriver, remove the two screws fastening the valve. 6. Remove the valve. 7.Place gasket provided into ne...

  • Page 42

    5-16 airsep corp. — freestyle service manual figure 5.23 5.Remove the plugs from the top and bottom of the new adsorbent beds. 6. Place a 1.5 mm cs x 6 mm id o-ring on the bottom cap of the adsorbent bed cap. 7.Place a 1.5 mm cs x 3.5 mm id o-ring on the top cap of the adsorbent beds. 8. Align produ...

  • Page 43

    Airsep corp. — freestyle service manual 5-17 figure 5.25 10. Reassemble freestyle, and leak test at bed connections. 5.9 feed/waste manifold replacement 1.Remove psa system per section 5.4. 2.Carefully remove tie-wraps that bundle the solenoid valve wires together. 3.Loosen and remove the center bol...

  • Page 44

    5-18 airsep corp. — freestyle service manual 5. Remove feed/waste manifold by pulling upward on the manifold. Both fittings from the manifold to the compressor should still be connected to the manifold. If not, remove fitting(s) from the compressor. (figure 5.27) 6. Place new feed/waste manifold ont...

  • Page 45

    Airsep corp. — freestyle service manual 5-19 5.11 hour meter functionality general freestyle’s hour meter includes two monitoring channels: a historical channel that cannot be reset, and a maintenance channel ( see figure a-1). An onboard, momentary-action pushbutton can be used to toggle the displa...

  • Page 46

    5-20 airsep corp. — freestyle service manual 5.11.4 toggle/reset switch this switch toggles the display or resets the maintenance channel depending on the activation time and the current display mode. Upon power-up, the display defaults to the historical display mode. The display will remain in hist...

  • Page 47

    Airsep corp. — freestyle service manual 5-21 4.Using a small-head phillips screwdriver remove (2) 2-56 plastic screws. (figure 5.29) figure 5.29 5.Gently pull upward to remove the hour meter from the 8-pin connector (j3). When removing, take care not to bend or break any pins on the j3 connector hea...

  • Page 48

    5-22 airsep corp. — freestyle service manual 2.Remove inlet screen 3.Remove internal battery per section 5.3 internal battery replacement. 4.Remove psa system as per section 5.4. 5.Remove dc power input connector from location j1, pin 3 connector on circuit board. (figure 5.30) figure 5.30 6.Disconn...

  • Page 49

    Airsep corp. — freestyle service manual 5-23 9.Remove hour meter as per section 5.12. 10.Remove cannula nozzle tubing by cutting tie-wrap (use small-size cutter). Carefully pull tubing from nozzle barb. (figure 5.32) figure 5.32 11.Disconnect fan connector using needle-nose pliers, carefully pulling...

  • Page 50

    5-24 airsep corp. — freestyle service manual figure 5.34 13.Remove main circuit board from center section assembly. (figure 5.35) figure 5.35 14.Replace main circuit board; reverse order of steps 1-14..

  • Page 51

    Airsep corp. — freestyle service manual 5-25 5.14 motor controller board replacement 1.Lift the motor controller board from the circuit board, being careful not to break the connector pins while gently rocking it back and forth to loosen and disconnect. (figure 5.36) figure 5.36 2.Before replacing t...

  • Page 52

    5-26 airsep corp. — freestyle service manual 4. Following alignment, view the replacement board from the side at an angle to make certain that the pins are aligned properly before seating the connector. Figure 5.38 5.Gently press the board into place until properly seated. (figure 5.38) figure 5.39.

  • Page 53

    Airsep corp. — freestyle service manual 5-27 5.15 control panel/key pad replacement 1.Remove the front and rear cover per section 5.2. 2.Remove psa system per section 5.4. 3.Remove control panel/keypad flex circuit from j8 ziff (zero insertion force) connector by carefully lifting upward on locking ...

  • Page 54

    5-28 airsep corp. — freestyle service manual 8. Carefully align control/keypad to enclosure recessed control panel area, and press keypad evenly to ensure all adhesive is in contact with plastic surface. (figure 5.42) figure 5.42 9. Route the flex circuit from control panel keypad notched area of co...

  • Page 55

    Airsep corp. — freestyle service manual 5-29 figure 5.44 11. Insert flex circuit into rib section and connect flex circuit with carbon contacts facing toward you. (figure 5.45) figure 5.45.

  • Page 56

    5-30 airsep corp. — freestyle service manual 12.Insert into j8 ziff (zero insertion force) connector, making sure that the flex circuit seats into the connector. Carefully press the ziff connector locking tab in a downward direction. Ensure latch seats. (figure 5.46) figure 5.46 13.Replace psa syste...

  • Page 57

    Airsep corp. — freestyle service manual 5-31 5.16 fan replacement when replacing the fan, always use and esd safe work area. Also, use an esd wrist strap to protect electronic circuitry. 1.Remove psa system assembly per section 5.4. 2.Remove internal battery per section 5.3. 3.Disconnect the molex c...

  • Page 58

    5-32 airsep corp. — freestyle service manual 5. When installing the new fan, be sure the arrow on the side of the fan is pointing outwards toward the front cover. This arrow indicates the direction of the airflow of the fan. Be sure the two wires coming from the fan are located on the upper left sid...

  • Page 59: 6.0  Pressure Profiles

    6-1 airsep corp. — freestyle service manual 6.0 pressure profiles 6.1 pressure profile quadrant the following pressure profiles illustrate the range of normal operating pressure at sea level. These are approximate pressures. A unit may be out of the range shown below and still be within specificatio...

  • Page 60: 7.0  Troubleshooting

    Airsep corp. — freestyle service manual 7-1 7.0 troubleshooting 7.1 general troubleshooting before reviewing the troubleshooting chart, the following steps may be useful to isolate any malfunctions: 1. Make sure all filters are clean. 2. Turn the unit on by pressing flow setting [ 2]. A brief, conti...

  • Page 61

    7.2 troubleshooting chart problem possible cause solution unit does not turn on when connected to ac power power outlet. Wall switch power is off. No power at outlet. Universal ac or /dc power supply: ac power supply is not properly connected to freestyle. Defective ac power supply. Turn on wall or ...

  • Page 62

    Problem possible cause solution battery duration is less than per specification. Note: while charging, battery may not initiate a charge. Allow unit to cool to operating temperature before charging. Will initiate in approx. (20 min). Note: whenever storing freestyle for an extended period of time, e...

  • Page 63

    Problem possible cause solution oxygen concentration is below specifications in test mode. Unit’s temperature is too high. Blocked air intake or outlet; or defective fan. Leaks. Restriction exhaust filter. Defective compressor contaminated adsorbent beds. Defective solenoid valve. Clear any obstruct...

  • Page 64: 8.0  Recommended Tools

    8-1 airsep corp. — freestyle service manual 8.0 recommended tools 8.1 tools for freestyle service and maintenance in additional to a pressure test gauge, the following tools are generally readily available for purchase in your local area, and can assist you in servicing and maintaining the freestyle...

  • Page 65

    Airsep corp. — freestyle service manual appendix exploded drawings figure 1: freestyle — internal front view figure 2: freestyle — internal rear view figure 3: freestyle — psa assembly - product manifold figure 4: freestyle — psa assembly - feed/waste manifold a-1 a-2 a-3 a-4.

  • Page 66

    Figure a.1: internal front view airsep corp. — freestyle service manual a-1.

  • Page 67

    Figure a.2: internal rear view - exploded a-2 airsep corp. — freestyle service manual.

  • Page 68

    Item part number description item part number description 1 be227-1 beds, assy, multiple, 1.500” bed od, annulus, freestyle 10 or026-1 o-ring, buna n, 70 duro, 1.0mm cs, 8.0mm id, 10mm od 2 ca232-1 cabinet, compressor, mounting plate, freestyle 11 or027-1 o-ring, buna n, 70 duro, 1.5mm id, 3.5mm id ...

  • Page 69

    Figure a.4: psa assembly feed / waste a-4 airsep corp. — freestyle service manual.