!
FreeStyle™5 Portable
Oxygen Concentrat
or
Service Manual
AirSep
Corporation • 401 Creekside
Drive
• Buffalo, NY
14228-2085 USA
T
elephone:
716.691.0202 • 24-Hour
Fax:
716.691.4141 • www
.airsep.com
AirSep Corp. — FreeStyle 5 Service Manual
Expedited Product Warranty Check service is always at your fingertips with AirS
ep:
http://www.airsep.com/Support/Warranty_Information.aspx
OR
In the
US
or Canada,
dial
866-873-9277
A
irS
ep
®
is a registered trademark of
AirSep Cor
pora
tion.
!
FreeStyle 5™ is a trademark of
AirSep Cor
pora
tion.
MN179-1 _ 02/14 Rev B
AirSep Corp. — FreeStyle 5 Service Manual i – table of contents
Table of Contents
Section 1.0
Intr
oduc
tion
Section 2.0
Operation Check
and
1.1 Equipment Provider Responsibility
1.2
I
mpor
tant Notice and Symbol Explanations
1.3 Definitions of Symbols
1.4 FreeStyle 5 Specifications
1.5 FreeStyle 5 Classifications
T
est
of Oxygen Concentration
2.1
Description of
Operation
2.2
Operation Check
2.3
Alarm Sy
stem
2.3.1
S
tart-up
2.3.2
Battery Sta
tus
2.3.3
Low Batter
y
2.3.4
Discharged Battery
2.3.5
Battery Charging
2.3.6
Battery
Fully Char
ged
2.3.7
Cannula
Disc
onnec
t
2.3.8
Performance War
ning
2.3.9
FreeStyle 5 Capacity Exc
eeded
2.3.10
General Malfunc
tion
2.4
Oxygen Concentration T
est
and
Specification
Section 3.0
Patient Instructions
3.1 General
I
nstructions
3.1.1 Connecting to external Power
3.1.2 Optional
AirBelt
Battery
3.2
R
outine
Maintenance by the Patient
3.2.1 Cleaning the
Air In
take
Gross Particle Filter
3.2.2 Alarm/Service
I
ndicator
3.2.3 Usage with Extended
T
ubing
3.2.4 Usage at Night
Section 4.0
E
quipment Provider
M
aintenance
4.1 Routine
Maintenance
4.1.1
Air In
take
/ Gross Particle Filter
4.1.2 Product Filter Replac
emen
t
4.1.3 Compressor Servicing
4.1.4 Recording M
aintenanc
e
4.2
Infection Contr
ol
4.3
Cleaning and Preparing for New Patient Use
ii – table of contents AirSep Corp. — FreeStyle 5 Service Manual
AirSep Corp. — FreeStyle 5 Service Manual iii – table of contents
Section 5.0
Service
5.1
C
omponen
ts
5.2
Housing Removal
5.2.1 Remo
ving
Front Cover
5.2.2 Remo
ving Back
Cover
5.3
Internal
Battery Replac
emen
t
5.4
PSA Removal
5.5
Compressor Replac
emen
t
5.5.1 Compressor Assembly Removal
5.5.2 Compressor Assembly Installa
tion
5.6
Product Manifold Replac
emen
t
5.7
Solenoid Valve Replac
emen
t
5.8
Adsorbent Bed R
eplac
emen
t
5.9
Feed/Waste Manifold Replac
emen
t
5.10
Measuring System Pr
essur
e
5.11!
Circuit Board Replac
ement !
5.12!
Motor Controller Board Replac
ement
! 5.13!
Control/Key Panel Replac
ement
!
5.14!
Fan Replac
ement
!
iv – table of contents AirSep Corp. — FreeStyle 5 Service Manual
Section 6.0
Typical
Pressure Profiles
6.1 Pressure
Profile
Quadrant
Section 7.0
Troubleshooting
7.1 General Tr
oubleshooting
7.2 Tr
oubleshooting
Chart
Section 8.0
Recommended Tools
8.1
Tools f
or FreeStyle 5 Service and Maintenance
A
ppendix
Exploded Dra
wings
Figure
1:
FreeStyle 5 — Inter
nal
Front View
A-1
Figure
2:
FreeStyle 5 — Inter
nal R
ear V
iew
A-2
Figure
3:
FreeStyle 5 —
PSA
Assembly - Pr
oduct
Manifold A-3
Figure
4:
FreeStyle 5 —
PSA
Assembly - Feed/W
aste
Manifold A-4
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
1.0 Introduc
tion
1.1 Equipment Provider Responsibility
All Equipment Providers of the FreeStyle™5 Portable Oxygen
Concentrator
must
assume
responsibilities
for handling, operational check-out, patient instruction, and
maintenance.
These
responsibilities
are outlined below and throughout this manual.
This unit is not to be used for life support. Geriatric, pediatric, or any other patients unable to
communicate discomfort while using this unit may require additional monitoring. Patients with
hearing and/or sight impairment(s) may need assistance with monitoring alarms.
As an Equipment Provider, you must do all of the following:
■ Inspect the condition of each FreeStyle 5 unit immediately upon
delivery to your business location. Note any sign of damage,
external or internal, on the delivery receipt, and report it
directly to both the freight company and AirSep Corporation
immediately.
■ Check the operation of each FreeStyle 5 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.
■ Deliver FreeStyle 5 units only to patients authorized by a physician’s
prescription. FreeStyle 5 must not be used as a life-supporting
device.
■ Instruct patients how to use FreeStyle 5 in conjunction with the
Patient Manual.
■ Instruct patients to notify their physicians and/or Equipment
Providers if they experience any signs of discomfort.
■ Be available to service each patient at any time.
■ Maintain FreeStyle 5 in accordance with Section 4.0.
■ Repair components and replace parts only as outlined in this
manual. Use only AirSep parts for replacement in FreeStyle 5 Oxygen
Concentrators.
!
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
1.2 Impor
tant Notice and Symbol Explana
tions
As you review both the FreeStyle 5 Patient Manual and this FreeStyle 5 Service
Manual, pay special attention to the WARNING, CAUTION, and NOTE messages.
They identify safety guidelines or other important information as follows:
DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING THIS
MANUAL. IF YOU ARE UNABLE TO UNDERSTAND THE WARNINGS AND INSTRUCTIONS,
CONTACT YOUR EQUIPMENT PROVIDER BEFORE ATTEMPTING TO USE THIS EQUIPMENT;
OTHERWISE, INJURY OR DAMAGE MAY RESULT.
Smoking while using oxygen is the number one cause of fire injuries and
related deaths. You must follow these safety warnings:
Do not allow smoking, candles, or open flames in the same room with the device or
within 5 feet (1.52 meters) of the oxygen-carrying accessories.
Smoking while wearing an oxygen cannula may cause facial burns and possibly death.
Removing the cannula and putting it on bedding, sofas, or other cushion material will
cause a flash fire when exposed to a cigarette, heat source, or flame.
If you smoke, these 3 steps may save your life:
turn off the oxygen concentrator, take off the cannula, and leave the room where this
device is located.
“No Smoking – Oxygen in Use” signs must be prominently displayed in the home, or
where the oxygen concentrator is in use. Patients and their caregivers must be
informed about the dangers of smoking in the presence of, or while using, medical
oxygen.
Warning – Describes a hazard or unsafe
practice that if not avoided can result in
severe bodily injury, death or property
damage
Caution – Describes a hazard or unsafe
practice that if not avoided can result in
minor bodily injury or property damage
Note – Provides information important
enough to emphasize or repeat
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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 of a concept within a restricted space.
The following table is a list of symbols and definitions used with the FreeStyle 5 Portable Oxygen
Concentrator.
Symbol
Description
Symbol Description
Warning – Describes a hazard or unsafe
practice that if not avoided can result in
severe bodily injury, death or property
damage
Class II Equipment, double insulated
Caution – Describes a hazard or unsafe
practice that if not avoided can result in
minor bodily injury or property damage
Complies with the 93/42/EEC directive
drawn up by the approved organization
No. 0459
Note – Provides information important
enough to emphasize or repeat
"#$%&'!#(%)*'!$+,!-./0-".!-1121!/+2!
3434565647!!894!$+,!:%;<*#=!%=%*&,<*#=!
%>?<@:%)&!
Consult the accompanying
documents
Keep unit and accessories dry
Use no oil or grease
Proper disposal of waste of electrical and
electronic equipment required
No smoking
Do not disassemble
Type BF equipment
Consult instructions for use
Fragile - handle with care
Do not expose to open flames
FAA-Approved POC
This side up
RTCA/DO-160 Section 21
Category M Compliant
RTCA DO160 Section 21 Category M
Compliant. FAA SFAR 106
requirement
"%%!A)B&,?*&<+)B
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
1.4 FreeStyle 5 Specifications
Oxygen
Concentration:*
1-5 pulse settings; equivalent to a continuous flow of 90% oxygen +5.5 / -3%
Flow Rate Settings: 1 ,2, 3, 4 & 5 LPM (equivalent to continuous flow)
Setting 1±15%. Settings 2 through 5±10%
Dimensions:
10.7 in. high x 6.6 in. wide x 4.4 in. deep (27.2 cm high x 16.8 cm wide x 11.2
cm deep)
Weight:
6.2 lb (2.8 kg); 1.8 lb (.8 kg) optional AirBelt
Power:
AC Power Supply: Input: 100-240VAC, 50-60Hz, 2A | Output: 15V
DC Power Supply: Input: 12VDC-24VDC, 15A max | Output: 15V, 8A max
Battery duration
(Rechargeable
lithium Battery)
5 LPM – 1 hour; 4 LPM – 1 hour, 15 minutes; 3 LPM – 1 hour, 30 minutes; 2
LPM – 2 hours; 1 LPM – 3 hours
Optional AirBelt when combined with the internal battery:
5 LPM – 2 hours, 30 minutes; 4 LPM – 3 hours; 3 LPM – 3 hours, 30
minutes; 2 LPM – 4 hours, 30 minutes; 1 LPM – 7 hours
Battery recharge
time:
3 hours, 15 minutes; optional AirBelt: 3 hours, 30 minutes
Initial startup time
2 minutes
Battery cycle life:
Approximately 300 cycles, then 80% capacity or below.
Audible alarms and
pulse visual
indicators:
Start-up – audible and visual (GREEN indicator light);
Pulse flow – visual (GREEN indicator light);
Battery condition – battery level (GREEN indicator lights);
Battery Low – audible and visual (YELLOW alarm light);
Battery shutdown – audible and visual (YELLOW alarm light);
Cannula disconnect- audible and visual (YELLOW alarm light);
System overdraw – audible and visual (YELLOW alarm light);
General malfunction – audible and visual (RED alarm light).
**Temperature
range:
Operational temperature: 41°F to 104°F (5°C to 40°C)
(Up to 95% RH (non-condensing)
Storage temperature: -4°F to 140°F (-20°C to 60°C)
**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 psi (101 kPa) at 70°F (21°C)
** Operating outside of these specifications can limit the concentrator’s ability to meet Oxygen Concentration specifications at higher liter flow
rates.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
1.5 FreeStyle 5
Classifications
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 of protection against electric shock regarding
1) allowable leakage current;
2) reliability of protective earth connection (if present).
Not intended for direct cardiac application.
Independent testing for Medical Electrical Equipment Standard:
Tested to be in compliance with,
IEC 60601-1 Medical Electrical Equipment – Part 1: General Requirements for Safety
Tested to be in compliance with applicable requirements of the Standard,
CAN/CSA C22.2 No. 60601-1-08 M90 Medical Electrical Equipment
Protection against potential electromagnetic or other interference between the equipment and other devices.
Tested to be in compliance with:
EN 60601-1-2 Medical Electrical Equipment, Part 1: General Requirements for SafetyCollateral Standard: Electrical Compatibility - Requirements and Tests
RTCA/DO160 Airborne Equipment, Sec. 21, Emission of Radio Frequency Energy
CISPR 11 / EN 55011 Class B Group 1, “Industrial, Scientific, and Medical (ISM) Equipment”
FCC Part 15, Subpart B – Class B Unintentional Radiators
Method of cleaning and infection control allowed:
Please refer to “Cleaning, Care, and Proper Maintenance” section of this FreeStyle 5 Patient
Manual.
Degree of safety of application in the presence of flammable anesthetic gases:
Equipment not suited for such application.
Mode of operation:
Continuous duty.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2.0 Operation Check and Test
of Oxygen Conc
entra
tion
2.1 Description of
Operation
Air enters the FreeStyle 5 Oxygen Concentrator through an external air intake /
gross particle
filter.
This filtered air enters the compressor via a muffler that quiets
the compressor’s suction sound.
Next, a two-way solenoid feed valve directs the air into one of two sieve beds that
contain molecular sieve. The unique property of molecular sieve enables it to
physically attract (adsorb) nitrogen when air passes through this material, thereby
separating the nitrogen from the oxygen in ambient air.
There are two sieve beds: While one produces high-concentration oxygen, the
other is purged of the nitrogen it adsorbed (collected) while it made oxygen.
In addition to the molecular sieve beds that allow oxygen to be separated from
air, FreeStyle 5 contains an Oxygen Conserving Device (OCD) valve that
controls delivery of high-concentration oxygen to the patient at the point in the
breathing cycle when the patient starts to inhale.
FreeStyle 5 delivers a gas consisting of 90% (+5. 5 -3%) oxygen
at pulse flow rates equivalent from approximately 1–5 LPM.
2.2 Operation Check
AirSep tests every FreeStyle 5 Oxygen Concentrator thoroughly after
manufacture. You must perform the following test to ensure that no damage
occurred in shipping or handling.
1. Open and inspect all cartons upon delivery. Unpack the unit and
remove it from the carton. Inspect the unit itself for damage. If
the exterior of a unit’s carton is damaged, or if the unit itself is
damaged, note this on the freight bill signed by the driver.
2. Connect the power supply to the unit, and turn the unit on by pressing
flow setting [5]. Check to see that the following sequence occurs:
a. A brief, continuous alarm sounds to indicate that FreeStyle 5
has been turned on.
b. The compressor runs.
c. After a 10 second start up is complete,
the fan turns on.
d. Exhaust air flows from the unit.
3. Perform an oxygen concentration test, as described in Section 2.4.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2.3
Alarm Sy
stem
An audible alarm sounds if FreeStyle 5 has a low battery, senses no
inspiration, high temperature ,system overdraw, high or low pressure. If an
alarm sounds, observe which lights are on. The visual and audible alarm
conditions are explained in detail below.
2.3.1 Start-Up
A one-second, audible alarm sounds to indicate start-up. FreeStyle 5 begins
to operate when the alarm stops.
2.3.2
Battery Status
To check the level of charge of the internal battery, press the BATT button on
FreeStyle 5’s keypad. The battery gauge / indicator(s) LEDs above the BATT
button illuminate from 25-100% to indicate the level (capacity) of the internal
battery. At less than 25% capacity, the 25% LED blinks.
2.3.3 Low Battery
As the battery power approaches a low level, a ½ second beep is emitted every
five seconds, and a yellow LED on the battery gauge / indicator(s) will blink
for a ½-second every five seconds. When this occurs, the patient is instructed
to connect the FreeStyle 5 AC or DC power supply or change to another
source of oxygen. The low battery alarm will continue for approximately 2
minutes before FreeStyle 5 stops operating.
2.3.4 Discharged Battery
When the battery is discharged, the unit shuts down. Before this occurs, a ½
second beep sounds every ½ second and the yellow battery LED blinks at the
same rate until any one of the 1-5 settings on the keypad are pressed. After the
alarm is turned off, connect the FreeStyle 5 unit to its AC or DC power supply
or change to another source of oxygen immediately. When the FreeStyle 5
unit is connected to the AC or DC power supply, FreeStyle 5 operates and
the internal battery recharges simultaneously.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2.3.5 Battery Charging
To check the level of charge of the battery, press the button on the battery’s keypad.
The battery gauge/indicator(s) illuminate to indicate the level of battery charge (25-100%).
To charge the FreeStyle 5’s internal battery:
" Connect its AC power supply or DC (auto) power supply into the
unit’s power receptacle located on the right side of the FreeStyle
5 unit, and the other end to its proper AC or DC power outlet.
(See Figure 3.1).
" The FreeStyle 5 internal battery will completely charge from a fully
depleted state in approximately 3 hours and 15 minutes.
" While charging a fully discharged battery, initially the 25% LED
will start blinking rapidly for a few minutes, then start to blink at a
slower rate (½ second).
" The LED will continue to blink until a 25% capacity is reached. The
LED will then turn solid.
" Each of the four LEDs, 25-100%, will blink as stated above, then
turn solid when they reach their capacity.
" Once all LEDs illuminate solid, the battery is fully charged and the
LEDs will remain on solid for approximately 1 ½ hours, then all
four LEDs will turn off.
" If the AC or DC power supply is not connected, the LEDs will turn off within five
seconds.
Depending upon the temperature of the FreeStyle 5 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.
The lithium ion rechargeable battery that is used in the FreeStyle 5 unit does not need
to be fully depleted before recharging. It is recommended to charge the battery regardless of the
battery’s capacity level after use.
The battery will charge when the unit is off as well as while the unit is running off the AC or DC
power supply.
Lithium batteries may permanently lose capacity when exposed to extremely hot temperatures with
the batteries fully charged or completely depleted. For extended storage, it is recommended that
batteries be charged 25 to 50% and remain within a temperature range of 73°F (23°C).
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2.3.6 Battery Fully Charged
When FreeStyle 5 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 5 is operating and does not sense breathing within 15,
consecutive minutes, a constant alarm (beep) sounds, and the yellow alarm
light illuminates simultaneously. If this occurs, check the connection from
the cannula to the FreeStyle 5 unit, make sure that the nasal cannula is
positioned properly on your face, and ensure that you are breathing
through your nose. CD+?,!@E'B<*<#)!:#'!,%*+:: % ); !&E%!? B%!+ $!#!*E <)!B&,#@ !<$! !
!!!!!!)%%;%;2F!
If the alarm continues to sound, the patient should change to an alternate
source of oxygen and contact the Equipment Provider.
2.3.8 Performance Warning
The performance of FreeStyle 5 can be affected by two conditions.
1) If the user’s breathing rate causes the FreeStyle 5 unit’s capacity to be exceeded.
The amount of oxygen that FreeStyle 5 supplies is dependent on the flow control switch
setting and the breathing rate. If the breathing rate is too fast for the flow selector setting,
the capacity of FreeStyle 5 can be exceeded. The patient should reduce activity or consider
locating another source of oxygen.
2) The second condition that can result in decreased performance is a general malfunction
(i.e. High temperature, High or Low pressure).
If either of these events occurs, an alarm sounds every five seconds. If
breathing is too fast for the flow selector setting and FreeStyle 5 capacity is
exceeded, the yellow light flashes. If a general malfunction occurs,
a continuous red alarm light appears
2.3.9 FreeStyle 5 Capacity Exceeded
When the patient’s breathing rate has caused the capacity of FreeStyle 5
to be exceeded, a rapid intermittent beep, beep, beep alarm sounds with
an intermittent yellow alarm light. When this occurs, oxygen
concentration is outside specifications. The patient should reduce activity,
then if necessary use another source of oxygen as available. Contact your
Equipment Provider.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2.3.10 General Malfunction
If a general malfunction of the FreeStyle 5 unit occurs, Two ½ second alarms
sound every 5 seconds, and the red ALARM light turns on. When this occurs,
oxygen concentration is outside specifications. The patient should change to
another source of oxygen and contact the Equipment Provider.
2.4 Oxygen Conc
entra
tion T
est
and
Specifica
tion
To ensure that FreeStyle 5’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 upon their own expertise and
documentation, may establish and implement their own protocol to check oxygen
concentration.
1. Connect the FreeStyle 5 Oxygen Concentrator using an AirSep-supplied AC
adapter only (AirSep Part No.PW020-1) to a 100-240 volt, 50/60 Hz electrical
outlet.
2. Turn unit on by pressing setting 5 on keypad.
3. Simultaneously press and hold settings 1 and 5 for 10 seconds. After 10 seconds, the
alarm will sound and the LEDs above each flow setting will illuminate verifying auto pulse
mode.
Control Panel
Flow Settings 1 - 5
Figure
2.1
4. Allow unit to warm-up for 2 minutes before recording oxygen concentration.
5. Connect a calibrated oxygen analyzer to the oxygen outlet and record the
unit’s concentration. The specification in test mode is 87% or higher.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
3.0 Patient Instructions
3.1 General
I
nstructions
It is important that patients thoroughly understand how to operate AirSep’s FreeStyle 5 unit.
This enables proper treatment as prescribed by a qualified, licensed physician. You must
explain that the purpose of this therapy is to alleviate symptoms. If patients experience any
discomfort or if the unit alarms, they must notify their Equipment Provider and/or physician
immediately.
You, as the Equipment Provider, are responsible to ensure that each patient receives the
FreeStyle 5 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 AC or DC power supply to the FreeStyle 5 unit, be certain to first
properly align the power cord to this inlet. To do this, take note of the “D”-shaped plug of both
the power cord connector and the FreeStyle 5’s inlet connection. These must be aligned, and
the button on the power cord must be pressed in for removal. This ensures that neither the unit
nor the power accessories are damaged.
FreeStyle 5
unit’s power
inlet
Press to remove
power cord.
“D”-shaped power cord plug
connects to the FreeStyle 5
unit’s “D”-shaped power inlet.
Figure 3.1
3.1.2 Optional AirBelt™ Battery
Instruct patients that connecting an optional AirBelt to the unit by inserting
the power into the unit’s power inlet provides additional total run time, per the specifications.
Note that the unit battery must still have a charge remaining before the external AirBelt is
connected. The patient should be advised to not fully deplete the unit battery as a small amount
of power is needed to engage the AirBelt.
To charge the AirBelt battery:
1) Release safetycap from end of the AirBelt cord.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
2. Connect the AC/DC power supply (included with the AirBelt Accessory kit)
to the end of AirBelts power cord as shown in Figure 3.2.
3. Connect the AirBelt power supply to an AC electrical outlet to recharge.
Replace safety cap on AirBelt cord when not in use.
Do not attempt to charge the optional AirBelt with the any other power supply or the AirBelt can
be damaged. Use only the AirBelt power supply provided to charge AirBelt.
" The FreeStyle 5 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.
" Each of the four LEDs, 25% -100%, will blink as stated above, then turn solid when the battery reaches
it’s capacity.
" When all LEDs illuminate solid, the battery is fully charged and the LEDs will remain solid for a period of
time, then all four LEDs will turn off.
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.
Lithium batteries may permanently lose capacity when exposed to extremely hot temperatures with
the batteries fully charged or completely depleted. For extended storage, it is recommended that
batteries be charged 25 to 50% and remain within a temperature range of 73°F (23°C) +/- 2°C.
The incorrect use of AirBelt can cause it to get hot, ignite, and may cause serious injury. Be
sure not to pierce, strike, step on, or drop the battery, or otherwise subject the battery to strong
impacts or shocks.
Figure 3.2: AirBelt Battery Charging set up
AirBelt
AC/DC Power Supply
Connecting the AirBelt cord to the
power supply cord
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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 inspection/service when an alarm
indicator illuminates.
3.2.1 Cleaning the
Air In
take
/ Gross Particle Filter
1. The air intake / gross particle filter can be found on the
lower
front of the FreeStyle 5, as seen in the photo below.
Figure 3.2
2. Pull the filter cover off the front of the FreeStyle 5 and
remove the filter. Wash filter in a warm water and soap
solution.
3. Rinse the filter thoroughly, and remove excess water with a soft,
absorbent towel. Ensure that the filter is dry before replacing it.
4. Replace the dry filter into the filter cover.
5. Place the filter cover back into housing and push back onto the
FreeStyle 5 unit.
The patient must clean this filter weekly, as described below. The filter may require daily cleaning if
the FreeStyle 5 unit operates in a harsh environment, for example, a house heated by wood,
kerosene, or oil, or one with excessive cigarette smoke.
Air$Intake$/Gross$
Particle$Filter$
Cover$
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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.
3.2.4 Usage During Sleep
AirSep recommends that FreeStyle 5 should be used while sleeping only
under the direction of their clinician. In addition, some patients who mouthbreathe may benefit from the use of a chin strap
Always follow the cannula manufacturer’s instructions for proper use. Consult your
licensed health care provider to determine how often the cannula should be replaced.
Cannula tubing must be non-kinking, which can be used for a total length of up to
25ft (7.6cm) maximum.
Ensure the cannula is fully inserted and secure. This ensures that the FreeStyle 5
unit can properly detect inspiration for oxygen delivery.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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 concentrator remains within specifications. To ensure
that the unit’s output of oxygen is within specification, you must establish and
implement a protocol to check oxygen concentration upon delivery to a patient and
at periodic intervals (Refer to Section 2.4 of this manual).
4.1.1
Air In
take
/ Gross Particle Filter
The external air intake gross particle filter is located in the air
intake/filter cover. You can easily remove it by hand. Instruct the
patient to clean this filter weekly. (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 5 unit operates in
a harsh environment — a house heated by wood, kerosene, or oil, or one with
excessive cooking or cigarette smoke.
4.1.2 Product Filter
R
eplac
ement
The product filter must be replaced after every 10,000 hours of use.
Product Filter/Volume Tank Replacement
1. Turn unit off and disconnect the power cord.
2. Remove the back housing, and locate the product filter/volume tank.
(See Figure A-3.)
3. Disconnect tubing from the inlet of the product filter/volume tank.
4. Unscrew the product filter/volume tank from the product manifold.
5. Place the o-ring into the o-ring groove located on top of the volume tank.
6. Fasten the new product filter/volume tank to the product manifold.
7. Connect the tubing and secure with a tie-wrap.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
!
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 M
aintenance
As the Equipment Provider, you should record all routine
maintenance and repairs performed on the FreeStyle 5 unit,
including hours and dates of service.
4.2 Inf
ection C
ontrol
With growing concern about possible cross infection from home oxygen
equipment from one home care patient to another, a clarification on this topic is
necessary. The organisms of most concern are M. Tuberculosis, HIV, and Viral
Hepatitis. These are potentially pathogenic.
Tuberculosis can survive outside the human body, but its mode of transmission
is by droplet nuclei. When infected individuals cough, they release droplet nuclei
into the air, and these carry the Tuberculosis organism. These droplet nuclei may
be breathed in by another person, but prolonged exposure to the infected person is
usually necessary for infection to occur.
HIV and Viral Hepatitis are both viruses that are not living cells themselves but
can duplicate when in a living “host” cell. Both of these organisms are usually
passed on by person-to-person contact, and both need to be in the human body to
survive. Once outside the body, viruses do not survive.
4.3 Cleaning and Preparing for New Patient Use
When you remove FreeStyle 5 from a patient’s home, always detach and dispose
of the used nasal cannula. Clean the exterior of FreeStyle 5 with a mild
household cleaner applied with a damp cloth or sponge. Pay special attention to
the oxygen outlet for the cannula connection to make sure it remains free of
dust, water, and particles. Be careful not to get any liquid into the interior of the
unit.
Next, clean the exterior with a common chemical disinfectant before any other
patient uses the unit. Do not use liquid directly on the FreeStyle 5 unit to clean
it.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
!
Do not use liquid directly on the FreeStyle 5 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). These are NOT to be used to clean the plastic
housing on FreeStyle 5, they can damage the units plastic.
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 felt filter after 5,000 hours of use.
Change the product filter after 10,000 hours of use. It is not necessary to change
this filter between patients even if the previous patient had a communicable
disease or infection.
Allow FreeStyle 5 to air dry, and then re-test oxygen concentration before
you return the unit to your inventory.
*Make the bleach solution a 1:100 dilution of 5.25% sodium hypochlorite. Mix
one part household bleach (e.g., Clorox with 99 parts cold tap water). To measure
the solution easily, take 1/4 cup of household bleach, and mix it with a gallon of
cold tap water. Allow the mixture to sit on potentially contaminated surfaces for
10 minutes.
AirSep does not recommend the sterilization of this equipment.
5.0 Service
5.1 Components
The design of AirSep’s FreeStyle 5 Portable Oxygen Concentrator allows for
easy access and removal of most 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 5 Universal AC / DC adaptor from the
power outlet before you service the concentrator.
Note all scheduled maintenance. (Refer to Section 4.0 of this manual.)
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
!
5.2 Housing Removal
5.2.1 Remo
ving
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, loosen, and remove the screws.
(See Figure 5.1.)
4. Lift off the front cover.
Figure 5.1
5.2.2 Remo
ving 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.
Figure 5.2
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
5.3 Inter
nal
Battery Replac
emen
t
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 (J12) and 2-pin (J14) connector from the
battery pack to the circuit board. (See Figures 5.3 and 5.4.)
Figure 5.3 Figure 5.4
3. The battery pack is fastened using Velcro. To remove the pack, simply pull
on battery. (See Figure 5.5.)
Figure
5.5
4. Take new battery pack with the wire harnesses to the left, and press firmly
into the battery cradle. Gently pull on battery to ensure the Velcro has engaged.
5. Connect the 8-pin (J12) and 2 pin (J14) connector in their respective
connectors on the circuit board.
When the battery is disconnect and reconnected to the FreeStyle 5, it will not
power the unit until it is initialized by connecting FreeStyle to external power.
6. Place front housing back on and fasten.
7. Plug the FreeStyle 5 AC or DC power supply to initialize and charge battery.
5.4
PSA Removal
1. Disconnect the FreeStyle 5 unit from the AC or DC outlet.
2. Remove the front housing.
3. Remove the battery. Care must be taken when removing (J12) and (J14)
connector.
4. Disconnect the 8-pin connector (J17) with multi-color wires from the
circuit board. Care must be taken not to pull on wires. (See Figure 5.6.)
Figure
5.6
5. Remove and discard foam from the top of the oval opening.
(See Figure 5.7.)
Figure
5.7
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
The following two steps (6 and 7) require extreme caution to ensure the black pressure sensor
(U9) 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, pull the nozzle to the left
to completely remove it from its cradle. (See Figure 5.8.)
Figure
5.8
7. Carefully disconnect the 1/8” OD tubing coming from the back of the
unit to the limiting orifice. (See Figure 5.9.)
Figure
5.9
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
8. Remove the 8-32 x ¼” black Phillips screws located in the center of outlet
nozzle cradle. (See Figure 5.10)
Figure
5.10
9. Turn unit over and remove the back housing.
Figure
5.11
10. Disconnect the 1/8” OD 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.
Figure 5.
12
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
11. 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 5.13 and 5.14.)
Figure
5.13
Figure
5.14
12. Carefully remove the complete PSA assembly from the center housing by pulling it upwards
and slipping compressor molex connector through center section. (See Figure 5.15.)
Figure
5.15
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
13. Remove the compressor plate by removing the two screws. (See Figure 5.16.)
Figure
5.16
14. Remove the two mounts from the compressor. (See Figure 5.17.)
Figure
5.17
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
5.5 Compressor Replac
ement
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 properly.
5.5.1 Compressor Assembly
R
emoval
1. Remove PSA system assembly per Section 5.4.
2. Stand the PSA assembly upright and loosen the center bolt using a
5/32” Allen wrench. (See Figure 5.18.)
Figure 5.18
2. Remove the compressor by pulling the compressor away from the
PSA assembly. Care should be taken not to separate manifold from
beds. (See Figure 5.19)
F
Figure 5.19
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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 5.20.)
Figure 5.20
5. Connect the new compressor to the PSA assembly, and tighten the bolt to a torque of 15 in-
lbs. (See Figure 5.21.) Be sure the gasket is in place.!
Figure 5.21
5.5.2 Compressor Assembly Installa
tion
To install the new compressor assembly, perform the compressor removal
procedure in reverse order.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.24
Figure 5.23
After replacing the unit’s compressor, you must reset the hour meter.
(Refer to instructions for reading and recording hours in the CD Kit P/N KI406-1)
5.6 Product Manifold Replac
ement
1. Remove the PSA system per Section 5.4.
2. Disconnect the tubing from the barb on the product manifold.
Figure 5.22
3. Remove the tie wraps that bundle the solenoid valve wire together.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.25
4. Loosen and remove the center bolt from the PSA assembly using a 5/32”
Allen wrench.
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 to new product manifold.
8. Place center bolt through product manifold and tighten to 15 in-lbs.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
5.7 Solenoid Valve Replac
ement
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.
4. Carefully disconnect the Molex connector from the circuit board by pulling on the
Molex connector, not the valve wire.
5. Using a small Phillips screwdriver, remove the two screws fastening the valve.
6. Remove the valve.
7. Verify two o-ring seals are installed on the new valve.
8. Fasten new valve using the two screws provided.
9. Re-bundle wires and tie-wrap.
10. Start FreeStyle 5 unit and leak test around the area where the
o-rings are located on the valve.
It may not be necessary to completely remove the PSA system assembly to replace the
solenoid valve. The Feed B/Waste B OCD valve will require the PSA system to be partially
removed.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.26
5.8 Adsorbent Bed Replacement
1. Remove the PSA system assembly per Section 5.4.
2. Loosen and remove the center bolt from the PSA system assembly using a
5/32” Allen wrench.
3. While holding the adsorbent beds, gently pull up on the product manifold to
remove from top of product manifold.
4. Pull upward on the adsorbent beds to remove from the feed/waste manifold.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.26
Figure 5.28
Figure 5.27
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 product manifold with the outlet on the new adsorbent beds and
gently push down until the o-rings are completely seated.
9. Place center bolt through product manifold and tighten to 15 in-lbs.
10. Reassemble FreeStyle 5, and leak test at bed connections
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.29
Figure 5.30
5.9 Feed/Waste Manifold Replac
ement
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”
Allen wrench.
4. Holding both sieve beds, gently pull upward, removing the product manifold
and sieve beds. Set product manifold and sieve bed assembly aside, keeping top
of sieve bed connected to product the product manifold.
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.
6. Place new feed/waste manifold onto compressor. Gently push manifold down
until compressor fittings are seated into compressor head.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
5.10 Measuring System Pr
essure
1. Remove the back cover.
2. Locate the brass fitting with the orange plug on the left side of the feed/waste
manifold.
3. Remove the plug.
4. Using the pressure gauge with 1/8” OD tubing, push tube into the fitting.
5. Turn the unit on in the [2] setting.
6. Make sure that the connection front the pressure gauge to the manifold is
leak-free. Part
No. K1036-1
Pressure Test Kit
(gauge and connec
tor) and
KI340-1 Adaptor.
7. Put unit into test mode by pressing [1] and [5] simultaneously for 10 seconds.
After 10 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
[5].
Reference Section 6.1 Pressure Profiles
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.31
Figure 5.32
Figure 5.33
5.11 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.
2. Remove internal battery per Section 5.3 Internal Battery Replacement.
3. Remove PSA system as per Section 5.4.
4. Remove DC power input connector from location J13, pin 3 connector on
circuit board.
5. Disconnect control panel/keypad flex circuit from J9 & 10 Ziff (zero insertion
force) connector by carefully lifting upward on the locking tab.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.34
Figure 5.35
6. Turn unit over so that the main circuit board is facing up.
7. Remove motor controller board as per Section 5.12.
8. Remove cannula nozzle tubing by cutting tie-wrap (use small-size cutter).
Carefully pull tubing from nozzle barb.
9. Disconnect fan connector using needle-nose pliers, carefully pulling upward
on fan connector housing at location J15 on main circuit board.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.36
Figure 5.37
10. Remove eight 4-20 self-tapping screws.
11. Remove main circuit board from center section assembly.
12. Replace main circuit board; reverse order of steps 1-12
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.38
Figure 5.39
5.12 Motor Controller Board Replac
emen
t
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.
2. Before replacing the board, ensure that the main circuit board and
all and pins are straight and unbroken (intact).
3. Locate the side with the single row connector. Install on the circuit
board with the single row connector facing the top of the unit.
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.
When replacing the motor controller circuit board, always use and ESD safe work area.
Also, use an ESD wrist strap to protect electronic circuitry.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.40
Figure 5.41
5. Gently press the board into place until properly seated
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.42
5.13 Control Panel/Key
Pad R
eplac
ement
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 J9 & 10 Ziff (zero insertion
force) connectors by carefully lifting upward on locking tab.
4. Remove the flex tab circuit from rib guides, and peel off the control panel/
keypad from the center enclosure.
5. Replace control panel/keypad with new control panel keypad.
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.
When replacing the control panel keypad, always use and ESD safe work area. Also, use an
ESD wrist strap to protect electronic circuitry.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.45
Figure 5.43
Figure 5.44
7. Remove adhesive backing and seal backing from new control panel/keypad.
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.
9. Route the flex circuit from control panel keypad notched area of control panel
enclosure section.
10. Bend flex circuit 180o, being careful not to crease or fold the flex circuit.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.46
Figure 5.47
Figure 5.48
11. Insert flex circuit into rib section and connect flex circuit with carbon contacts
facing toward you.
12. Insert into J9 & 10 Ziff (zero insertion force) connectors, making sure that the flex
circuit seats into the connectors. Carefully press the Ziff connector locking tabs in a
downward direction. Ensure latch seats.
13. Replace PSA system.
If creased or folded, the flex circuit will be damaged
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.49
Figure 5.50
5.14 Fan Replac
ement
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 connector (J15) from the circuit board to the fan.
4. Remove the four Phillips screws securing the fan to the center section.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
Figure 5.51
Figure 5.52
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 right
side.
6. Insert screws through each of the four corners of the fan. Secure with kep nut.
Do not over tighten.
7. Connect Molex connector (J15) to the circuit board.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
6.0 Pressure Profiles
6.1 Pressure
Profile Quadr
ant
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.
MN179-1 _ 02/14 AirSep Corp. - FreeStyle 5 Service Manual Rev B
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 [5]. A brief, continuous alarm sounds
to indicate that the FreeStyle 5 has been turned on. The compressor will start to
run, you must wait 10 seconds before proceeding to step 3.
3. Activate the test mode by pressing flow settings [1] and [5] simultaneously
for 10 seconds.
4. Make sure that the unit is leak-free by testing all tubing connections and
fittings with leak-testing solution. Protect the circuit board from solution, and
start the leak test at the compressor, following the air flow of the unit to the
oxygen outlet. Repair all leaks by tightening connections and fittings.
5. After five minutes, measure the oxygen concentration.
6. Review the Troubleshooting Chart that follows to isolate and repair any other
malfunctions.
7.2 Tr
oubleshooting
Char
t
Problem
Possible Cause
Solution
Unit does not turn on, and
AC power supply is properly
connected to a wall outlet.
Wall switch power is off.
No power to unit.
AC power supply is not
properly connected to
FreeStyle 5.
Defective AC power supply.
Turn on wall or outlet switch.
Reset household circuit
breaker.
Check connection from the
AC adapter to FreeStyle 5.
Replace AC adapter.
Unit does not turn on, and
DC power supply is properly
connected to an automobile,
RV, accessory outlet.
No power at DC outlet.
DC power supply is not
connected to accessory
outlet or not connected to
FreeStyle 5.
FreeStyle 5 DC power
inlet connector not
properly connected to
circuit board. Check
harness.
Defective DC power supply
Bad connection at keypad
control connector
Defective keypad control
panel membrane switch.
Defective motor controller.
Defective circuit board.
Check fuse for DC outlet.
Connect DC power supply to
outlet of automobile after
ignition is started.
Replace FreeStyle 5 DC inlet
harness; connect harness to
circuit board.
Replace power supply.
Check keypad connection
Replace keypad control
panel membrane switch.
Replace motor controller.
Replace circuit board.
General malfunction;
alarm is activated.
Unit overheats and will shut
down. Check air inlet and
exhaust vents for obstruction.
Also check inlet filter.
Check for leaks.
Restricted inlet filter.
Compressor failure.
Clear obstructed area of air
inlet and exhaust or replace
dirty filter. Replace fan if not
operating.
Correct any leaks.
Replace inlet filter.
Replace compressor.
Problem
Possible Cause
Solution
Battery duration is less
than per specification.
Note: While charging,
battery may not initiate a
charge. Allow unit battery
time to drop to operating
temperature before charging.
Will initiate in approx. (20
min).
Note: Whenever storing
FreeStyle 5 for an extended
period of time, ensure that
the battery the state of
charge (SOC) is not depleted
or stored at 100%. Both
these conditions can result in
unrecoverable capacity loss.
The recommend SOC is
25% to 50% for long-term
storage. The recommended
storage temperature is 23º C
± 2º C.
Battery not fully charged.
Battery has been stored in
a discharged or 100%
charged state for
prolonged period of time or
stored in a very high
temperature environment.
Battery reached cycle life.
Ensure that battery
charges for at least
3½ hours and all (4) LEDs
are lit solid.
Replace battery.
Replace battery.
Unit does not
start on battery.
Unit temperature has
exceeded battery operating
temperature
5 to 40ºC.
Battery reached cycle life
Battery is defective
Allow unit to cool
before starting.
Replace battery.
Battery does not charge.
Unit temperature has
exceeded battery operating
temperature
5 to 40ºC.
Battery is defective.
AC adapter connector is
defective or contact pin is
bent.
Defective AC adapter
Allow battery to cool before
charging.
Replace battery
Replace battery.
Replace AC adapter.
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.
Leak
Restriction in exhaust
felt.
Compressor has reached its
expected life.
Contaminated absorbent beds.
Defective solenoid valve.
Clear any obstruction in
air intake or outlet filter; or
replace fan as needed.
Correct any leaks.
Replace exhaust filter.
Replace compressor.
Replace absorbent beds.
Replace manifold or solenoid
valve.
Unit does not deliver
oxygen.
Cannula kinked or not properly
connected.
FreeStyle 5 is not turned on.
Battery is dead.
Defective AC or DC
power supply.
OCD sensor defective.
OCD solenoid valve defective.
Check cannula and the
cannula connection.
Turn FreeStyle 5 on to the
prescribed setting.
Replace battery.
Replace AC or DC power
supply.
Replace FreeStyle 5
main circuit board.
Replace product manifold or
OCD defective valve.
Unit continuously flows
oxygen (instead of pulse
flow delivery).
Defective OCD valve and
volume tank.
.
Replace product manifold.
MN179-1 _ 11/12 AirSep Corp. - FreeStyle 5 Service Manual Rev A
8.0 Recommended Tools
8.1
Tools
for FreeStyle 5 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 5 unit.
Figure
8.1a
.25-inch hexnut scr
ewdriver
and Phillips-head scr
ewdriver
Figure
8.1b
5/32-inch Allen-head
driver
Figure
8.1c
0-50 lb torque
driver
or fixed 15 lb torque
driver
Figure
8.1d
needle nose pliers and side
cutt
ers
Figure 8.2
Pressure test
gauge
Available from AirSep:
Part
No. K1036-1
--Pressure Test Kit
(gauge and connec
-
tor) and
KI340-1
(adapt
er)
Figure
8.1e
tie-wrap
gun
MN179-1 _ 11/12 AirSep Corp. - FreeStyle 5 Service Manual Rev A
A
ppendix
!
Exploded Dra
wings
Figure 1: FreeStyle 5 — Inter
nal
Front View
Figure 2: FreeStyle 5 — Inter
nal R
ear V
iew - Exploded
Figure 3: FreeStyle 5 —
PSA
Assembly - Exploded
Figure 4: FreeStyle 5 —
PSA
Assembly – Valves Identification
A-1
A-2
A-3
A-4
AirSep Corp. FreeStyle 5 Service Manual A-1
ITEM
PART
NUMBER
DESCRIPTION
ITEM
PART
NUMBER
DESCRIPTION
1
BT021-1
BATTERY, ASSY, PACK
5 OR029-1
O-RING, -009, SILICONE
2
CA296-1
CABINET, SUB-ASSY, HOUSING, CENTER
6 SC063-2
SCREW, PNH, PHIL, 8-32, 1/4" LG.
3
F0589-1
FITTING, NOZZLE, ASSY
7 TW011-1
TIE WRAP, NYLON, 2.83 LG.
4
FO139-1
FOAM, COMPRESSOR, WIRING
Figure
A.1: Inter
nal
Front View
AirSep Corp. FreeStyle 5 Service Manual A-2
Figure
A.2: Inter
nal R
ear V
iew
-
Exploded
ITEM
PART
NUMBER
DESCRIPTION
ITEM
PART
NUMBER
DESCRIPTION
1
CA295-1
CABINET, HOUSING, CENTER
7 FN038-1
FAN, ASSY
2
CB115-1
CIRCUIT BOARD, ASSY, MAIN, TUBING
8 GS030-1
GASKET, NOZZLE
3
CB134-1
CIRCUIT BOARD, MOTOR CONTROLLER
9 NU003-1
NUT, STEEL, HEX, KEP, 6-32
4
CN089-1
CONNECTOR, RECEPTACLE, 3-PIN, .156 PITCH
10
SC002-1
SCREW, PNH, PHIL, 6-32, 1.0" LG
5
CP157-1
CONTROL PANEL, KEYPAD w/ RIBBON
11
SC037-3
SCREW, PNH, PHIL, PLASTITE, 4-20, 1/4"
LG
6
FA029-3
FASTENER, VELCRO, HOOKS
12
WH101-2
WIRE HARNESS, DC INPUT PLUG
AirSep Corp. FreeStyle 5 Service Manual A-3
Figure
A.3: PSA
Assembly - Exploded
ITEM
PART
NUMBER
DESCRIPTION
ITEM
PART
NUMBER
DESCRIPTION
1
BE214-1
BEDS, ASSY, MULTIPLE, 1.62” BED OD
10
OR027-1
O-RING, 1.5mm ID, 3.5mm ID
2
CA232-1
CABINET, COMPRESSOR, MOUNTING PLATE
11
OR027-2
O-RING, 1.5mm ID, 6.0mm ID
3
CO386-1
COMPRESSOR, ASSY, 1.252” BORE
12
OR028-1
O-RING, .045” CS, .167” ID
4
F0593-1
FITTING, COMPRESSOR
13
SC002-4
SCREW, PNH, PHILLIPS, 6-32, 1/4” LG
5
GS024-1
GASKET, NITRILE, COMPRESSOR/FW MANIFOLD
14
SC105-2
SCREW, CAP, SOCKET HD, HEX, 10-32, 7”
LG
6
MA215-1
MANIFOLD, ASSY, PRODUCT
15
TA155-1
TANK, VOLUME, ASSY, 1.125” OD
7
MA216-1
MANIFOLD, ASSY, FEED/WASTE
16
TU202-1
TUBING, ASSY,
8
OR025-3
O-RING, -008
17
TW011-1
TIE WRAP, NYLON, 2.83” LG, 0.065 W,
BLACK
9
OR026-1
O-RING, 1.0mm CS, 8.0mm ID
AirSep Corp. FreeStyle 5 Service Manual A-4
Figure
A.4: PSA
Assembly –
Valves Identification
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