AirSep FreeStyle Service Manual
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AirSep FreeStyle Service Manual

Portable oxygen concentrator
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See also: Instructions for Use Manual , Patient Manual
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

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Summary of Contents for AirSep 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 FreeStyle is approved for use on-board commercial aircraft per an addendum to FAA SFAR 106. For a current list of airlines that allow the FreeStyle POC for in-flight use by patient/ passengers with a valid medical prescription upon notifying the airline’s oxygen desk, visit the following on AirSep web site at the link below: http://www.airsep.com/medical/AirLinePOCs.html...

  • Page 3: Table Of Contents

    Table of Contents Section 1.0 Introduction Equipment Provider Responsibility Important Notice and Symbol Explanations Definitions of Symbols FreeStyle Product Limited Warranty FreeStyle Specifications FreeStyle Classifications Section 2.0 Operation Check and Test of Oxygen Concentration Description of Operation Operation Check Alarm System 2.3.1...
  • Page 4 Feed/Waste Manifold Replacement 5-17 5.10 Measuring System Pressure 5-18 5.11 Hour Meter Functionality 5-19 5.11.1 Icons 5-19 5.11.2 Power 5-19 5.11.3 Service LED 5-19 5.11.4 Toggle/Reset Switch 5-20 5.12 Hour Meter Replacement 5-20 ii – table of contents AirSep Corporation...
  • Page 5 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 iii – table of contents iii –...

  • Page 7: Introduction

    AirSep Corporation immediately. ■ Check the operation of each FreeStyle unit before delivery to a patient. Always operate the unit for a minimum of 10 minutes, and check that the oxygen concentration level is within specifications, as described in Section 5 of this manual.

  • Page 8: Important Notice And Symbol Explanations

    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 as follows: Warning –...

  • Page 9: Definitions Of Symbols

    Symbols can also permit easier comprehension of a concept within a restricted space. The following table is a list of symbols and definitions used with the FreeStyle Portable Oxygen Concentrator. Symbol...

  • Page 10: Freestyle Product Limited Warranty

    Each item of equipment for which a warranty claim is asserted shall, at the request of AirSep Corporation, be returned on a prepaid basis with proof of purchase date to the AirSep factory at the expense of the purchaser. The purchaser will be responsible for return freight charges.

  • Page 11: Freestyle Specifications

    DC Power Supply: 11-16 VDC (6.0 amps max. at 13.5 VDC Universal Power Supply: nominal) FreeStyle unit: 28 W nominal at 3 setting Battery duration: 3 setting - 2 hours; 2 setting - 2.5 hours; 1 setting - 3.5 hours Optional AirBelt when combined with the internal battery: 3 setting - 5 hours;...

  • Page 12: Freestyle Classifications

    FCC Part 15, Subpart B – Class B Unintentional Radiators Method of cleaning and infection control allowed: Please refer to the “Cleaning, Care, and Proper Maintenance” section of this FreeStyle Service Manual. Degree of safety of application in the presence of flammable anesthetic gases: Equipment not suitable for such application.

  • Page 13: Operation Check And Test Of Oxygen Concentration

    1. Connect the power cord of the unit, and turn the unit on by pressing flow setting [-2]. Check to see that the following sequence occurs: a. A brief, continuous alarm sounds to indicate that FreeStyle has been turned on. b. The compressor runs.

  • Page 14: Alarm System

    1-3 settings on the keypad are pressed. After the alarm is turned off, connect the FreeStyle unit to its Universal AC or / DC power supply or change to another source of oxygen immediately. When the FreeStyle unit is connected to the Universal AC or / DC power supply, FreeStyle operates and the internal battery recharges simultaneously.

  • Page 15: Battery Charging

    3½ hours. Depending upon the temperature of the FreeStyle 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.

  • Page 16: Battery Fully Charged

    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 inspiration detected) When FreeStyle is operating and does not sense breathing within 15 minutes, a red light will illuminate with a constant audible alarm.

  • Page 17: Oxygen Concentration Test And Specification

    1. Connect the FreeStyle Oxygen Concentrator using an AirSep-supplied Universal AC or / DC power supply only (AirSep Part No. PW017-1) to a 100-240 volt, 50/60 Hz electrical outlet. Note Previous AC to DC power AirSep P/N PW010-1 can be used as well.

  • Page 19: Patient Instructions

    You, as the Equipment Provider, are responsible to ensure that each patient receives the FreeStyle Patient Manual. Explain each step in the operation of the unit to the patient with reference to the patient manual. 3.1.1 Connecting to External Power When connecting the Universal AC / DC power supply to the FreeStyle unit, be certain to first properly align the power cord to this inlet.
  • Page 20 Use only the AirBelt power supply provided to charge AirBelt.  The FreeStyle AirBelt will completely recharge from its fully depleted state in approximately 3 ½ hours.  While charging a fully discharged battery, the LED will continue to blink until 25% capacity is reached. The LED will then turn solid.
  • Page 21 AirBelt does not need to be fully discharged before recharging. It is recommended to charge it after each use. If the AirBelt power supply remains connected when it is fully charged, the four LEDs will turn off within ½ hour. AirSep Corp. — FreeStyle Service Manual...

  • Page 22: Routine Maintenance By The Patient

    The patient must clean this filter weekly, as described below. The filter may require daily cleaning if the FreeStyle unit operates in a harsh environment, for example, a house heated by wood, kerosene, or oil, or one with excessive cigarette smoke.

  • Page 23: Alarm/Service Indicator

    5,000 hours of use. 3.2.3 Nasal Cannula AirSep recommends a nasal cannula with 7 ft (2.1 m) of tubing, AirSep Part No. CU002-1 or suitable cannula. Other lengths of non-kinking / star channel cannula can be used for a total length of up to 25 ft (7.6 m) maximum.

  • Page 24: Equipment Provider Maintenance

    (Refer to Section 3.2.1, “Cleaning the Air Intake / Gross Particle Filter,” of this manual.) The filter may require more frequent cleaning if the FreeStyle unit operates in harsh environment – a house heated by wood, kerosene, or oil, or one with excessive cooking or cigarette smoke.

  • Page 25: Compressor Servicing

    Do not use liquid directly on the FreeStyle unit to clean it. Do not use liquid directly on the FreeStyle unit to clean it. A list of undesirable chemical agents includes but is not limited to, the following, according to the plastics manufacturer: alcohol and alcohol-based products, concentrated chlorine- based products (ethylene chloride), and oil-based products (Pine-Sol, Lestoil).

  • Page 26: Components

    This allows you to perform scheduled maintenance and to repair and replace parts with minimal time and effort. For your safety, be sure to disconnect the FreeStyle Universal AC / DC adaptor from the power outlet before you service the concentrator.

  • Page 27: Housing Removal

    5.2.2 Removing Back Cover 1. Place unit on its front. 2. Locate the four screws securing the back cover. 3. Using a Phillips-head screwdriver, loosen and remove the screws. 4. Lift off back cover. AirSep Corp. — FreeStyle Service Manual...

  • Page 29: Internal Battery Replacement

    5. Connect the 8-pin (J1) and 2 pin (J2) connector in their respective connectors on the circuit board. When the battery is disconnect and reconnected to the FreeStyle, it will not power the unit until it is initialized by connecting FreeStyle to external power.

  • Page 30: Psa Removal

    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 circuit board.
  • Page 31 (See Figure 5.7.) Figure 5.7 7. Carefully disconnect the 1/8” OD black tubing coming from the back of the unit to the limiting orifice. (See Figure 5.8.) Figure 5.8 AirSep Corp. — FreeStyle Service Manual...
  • Page 32 9. Turn unit over and remove the back housing. 10. Disconnect the black ground wire, (connected to the compressor on its upper right side near the air inlet filter) using a Phillips screwdriver. (See Figure 5.10.) Figure 5.10 AirSep Corp. — FreeStyle Service Manual...
  • Page 33 Figure 5.11 13. Using needle nose pliers, disconnect all the valves from the circuit board, carefully noting where each valve is connected. Do not disconnect by pulling on the wires. (See Figure 5.12.) Figure 5.12 AirSep Corp. — FreeStyle Service Manual...
  • Page 34 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 Remove the compressor plate by removing the two screws. (See Figure 5.14.) Figure 5.14 AirSep Corp. — FreeStyle Service Manual...
  • Page 35 Remove the two mounts from the compressor. (See Figure 5.15.) Figure 5.15 AirSep Corp. — FreeStyle Service Manual...

  • Page 36: Compressor Replacement

    (See Figure 5.16.) Figure 5.16 3. Remove the compressor by pulling the compressor away from the PSA assembly. Care should be taken not to separate manifold from beds. (See Figure 5.17.) Figure 5.17 AirSep Corp. — FreeStyle Service Manual 5-10...
  • Page 37 (See Figure 5.18.) Figure 5.18 5. Connect the new compressor to the PSA assembly, and tighten the bolt to a torque of 15 in- lbs. (See Figure 5.19.) Figure 5.19 AirSep Corp. — FreeStyle Service Manual 5-11...

  • Page 38: Compressor Assembly Installation

    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 5-12 AirSep Corp. — FreeStyle Service Manual...

  • Page 39: Product Manifold Replacement

    Figure 5.20c Figure 5.20b 3. Remove the tie wraps that bundle the solenoid value wire together. 4. Loosen and remove the center bolt from the PSA assembly using a 5/32” Allen wrench. (Figure 5.21) AirSep Corp. — FreeStyle Service Manual 5-13...

  • Page 40: Solenoid Valve Replacement

    The Feed B/Waste B OCD valve will require the PSA system to be partially removed. 1. Remove back cover panel per Section 5.2.2. 2. Determine which valves need to be replaced. 3. Remove the tie-wraps that bundle the value wires. 5-14 AirSep Corp. — FreeStyle Service Manual...

  • Page 41: Adsorbent Bed Replacement

    7. Place gasket provided into new valve. 8. Fasten new valve using the two screws provided. 9. Re-bundle wires and tie-wrap. 10. Start FreeStyle unit and leak test around the area where the gasket is located on the valve. Adsorbent Bed Replacement 1.
  • Page 42 8. Align product manifold with the outlet on the new adsorbent beds and gently push down until the o-rings are completely seated. (Figure 5.25) Figure 5.24 9. Place center bolt through product manifold and tighten to 15 in-lbs. 5-16 AirSep Corp. — FreeStyle Service Manual...

  • Page 43: Feed/Waste Manifold Replacement

    Figure 5.25 10. Reassemble FreeStyle, and leak test at bed connections. 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 bolt from the PSA assembly using a 5/32”...

  • Page 44: Measuring System Pressure

    After five seconds, the alarm will sound and the LEDs above each flow setting will illuminate. The unit will then start to automatically pulse in flow setting [3]. Reference Section 6.1 Pressure Profiles. 5-18 AirSep Corp. — FreeStyle Service Manual...

  • Page 45: Hour Meter Functionality

    When the FreeStyle is connected to AC or DC power, the historical hour meter reading is displayed along with the “h” icon. When the FreeStyle is connected to AC or DC power supply, the hour count is displayed, but the time does not accumulate. When the FreeStyle compressor is started when the unit is turned on, the historical hour meter will function.

  • Page 46: Toggle/Reset Switch

    1. Remove the front cover housing. (Refer to Section 5.2.) 2. Ensure that all power sources are disconnected. Also disconnect (J2) 2 pin connector. 3. Locate the hour meter. (Figure 5.28) Figure 5.28 5-20 AirSep Corp. — FreeStyle Service Manual...

  • Page 47: Circuit Board Replacement

    5.13 Circuit Board Replacement When replacing the circuit board, always use and ESD safe work area. Also, use an ESD wrist strap to protect electronic circuitry. 1. Remove front and rear cover as per Section 5.2. AirSep Corp. — FreeStyle Service Manual 5-21...
  • Page 48 (Figure 5.31) Figure 5.31 7. Turn unit over so that the main circuit board is facing up. 8. Remove motor controller board as per Section 5.14. 5-22 AirSep Corp. — FreeStyle Service Manual...
  • Page 49 Figure 5.32 11. Disconnect fan connector using needle-nose pliers, carefully pulling upward on fan connector housing at location J6 on main circuit board. Figure 5.33 12. Remove six 4-20 self-tapping plastic screws. (Figure 5.33) AirSep Corp. — FreeStyle Service Manual 5-23...
  • Page 50 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. 5-24 AirSep Corp. — FreeStyle Service Manual...

  • Page 51: Motor Controller Board Replacement

    J16 pins are straight and unbroken (intact). 3. Locate the component side marked “top” to align to J16 on the circuit board, and the bottom correctly on to J15 on the main circuit board. (Figure 5.37) Figure 5.37 AirSep Corp. — FreeStyle Service Manual 5-25...
  • Page 52 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 5-26 AirSep Corp. — FreeStyle Service Manual...
  • Page 53 6. Check control recessed area of enclosure center section to ensure plastic is clean and all adhesive backing and seal backing from new control panel keypad. 7. Remove adhesive backing and seal backing from new control panel/keypad. (Figure 5.41) Figure 5.41 AirSep Corp. — FreeStyle Service Manual 5-27...
  • Page 54 (Figure 5.43) Figure 5.43 10. Bend flex circuit 180 , being careful not to crease or fold the flex circuit. (Figure 5.44) If creased or folded, the flex circuit will be damaged 5-28 AirSep Corp. — FreeStyle Service Manual...
  • Page 55 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 AirSep Corp. — FreeStyle Service Manual 5-29...
  • Page 56 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 system. 5-30 AirSep Corp. — FreeStyle Service Manual...

  • Page 57: Fan Replacement

    3. Disconnect the Molex connector from the circuit board to the fan. (Figure 5.47) Figure 5.47 4. Remove the four Phillips screws securing the fan to the center section. (Figure 5.48) Figure 5.48 AirSep Corp. — FreeStyle Service Manual 5-31...
  • Page 58 (Figure 5.49a, b) Figure 5.49b Figure 5.49a 6. Insert screws through each of the four corners of the fan. Secure with kep nut. Do not over tighten. 7. Connect Molex connecter to the circuit board. 5-32 AirSep Corp. — FreeStyle Service Manual...

  • Page 59: 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 specification, for example, in higher altitude environments. AirSep Corp. — FreeStyle Service Manual...

  • Page 60: General Troubleshooting

    2. Turn the unit on by pressing flow setting [ 2]. A brief, continuous alarm sounds to indicate that the FreeStyle has been turned on. The compressor will start to run, you must wait 10 seconds before proceeding to step 3.

  • Page 61: Troubleshooting Chart

    Replace fan if not Also check inlet filter. operating. Dirty or restricted inlet filter. Correct any leaks. Replace inlet filter. Restricted blowdown muffler. Replace blowdown muffler. Compressor failure. Replace compressor. AirSep Corp. — FreeStyle Service Manual...
  • Page 62 5 to 40ºC. Battery is defective. Replace battery AC adapter connector is Replace battery. defective or contact pin is bent. Defective AC adapter Replace AC adapter. Circuit Board Replace main circuit board AirSep Corp. — FreeStyle Service Manual...
  • Page 63 Service LED is on. and reset hour meter in maintenance mode. Defective keypad Service LED does not light Replace keypad at required 5,000-hour service. No hour meter display. Defective hour meter display. Replace hour meter. AirSep Corp. — FreeStyle Service Manual...

  • Page 64: Tools For Freestyle Service And Maintenance

    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 unit.
  • Page 65 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 AirSep Corp. — FreeStyle Service Manual...
  • Page 66 Figure A.1: Internal Front View AirSep Corp. — FreeStyle Service Manual...
  • Page 67 Figure A.2: Internal Rear View - Exploded AirSep Corp. — FreeStyle Service Manual...
  • Page 68 SC105-1 SCREW, SS, CAP, SOCKET HD, HEX, 10-32, 5” LG MANIFOLD, FREESTYLE MA181-1 MANIFOLD, ASSY, PRODUCT, FREESTYLE TA115-1 TANK, VOLUME, ASSY, 1.125” OD, FREESTYLE MA183-1 MANIFOLD, ASSY, FEED/WASTE, FREESTYLE TW011-1 TIE WRAP, NYLON, 2.83” LG, 0.065 W, BLACK OR025-3 O-RING, -008, BUNA N, 70 DURO, 1/16”CS, 3/16”ID Figure A.3: PSA Assembly –...
  • Page 69 Figure A.4: PSA Assembly Feed / Waste AirSep Corp. — FreeStyle Service Manual...

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