AirSep QuietLife 5 Service manual

QuietLife™ 5

Oxygen Concentrator

Service Manual

AirSep Corporation • 401 Creekside Drive • Buffalo, NY 14228-2085 USA Telephone: [phone] • 24-Hour Fax: [phone]

AirSep® is a registered trademark of AirSep Corporation.

QuietLife™ 5 is a trademark of AirSep Corporation.

MN098-1

Rev04/03

Table of Contents

Section 1.0

Introduction

1.1	Equipment Provider Responsibility		1-1
1.2	Important Notice and Symbol Explanations		1-2
1.3	QuietLife™ 5 Product Warranty		1-4
1.4	Functional Specifications		1-5
Section 2.0
Operation Check
and Purity Test
2.1	Description of Operation		2-1
2.2	Operation Check		2-1
2.3	Alarm System		2-2
	2.3.1	Battery Test	2-2
	2.3.2	Power FailureAlarm Test	2-2
2.4	Oxygen Purity Test and Specification		2-3
Section 3.0
Patient Instructions
3.1	General Instructions		3-1
3.2	Routine Maintenance by the Patient		3-1
	3.2.1	Cleaning the Air Intake
		Gross Particle Filter	3-1
	3.2.2	Checking the Alarm System Battery	3-2
Section 4.0
Equipment Provider
Maintenance
4.1	Routine Maintenance		4-1
	4.1.1	Air Intake Gross Particle Filter/GPF	4-1
	4.1.2	Product Filter Replacement	4-1
	4.1.3	Internal Felt Filter Replacement	4-2
	4.1.4	Battery Replacement	4-2
	4.1.5	Recording Maintenance	4-3
4.2	Cleaning and Infection Control		4-3
	4.2.1	Preparing for New Patient Use	4-4

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i – table of contents

Section 5.0

Service

5.1	Components		5-1
5.2	Cabinet Removal		5-1
	5.2.1	Removing Side Panel(s)	5-1
	5.2.2	Removing Back Panel	5-1
	5.2.3	Removing Lower Front Cover	5-1
	5.2.4	Removing Control Panel	5-1
	5.2.5	Superstructure	5-1
	5.2.6	Caster Replacement	5-2
5.3	Compressor		5-3
	5.3.1	Compressor Replacement	5-4
	5.3.2	Capacitor Replacement	5-5
5.4	Solenoid Valves		5-5
	5.4.1	Feed or Waste Valve Rebuilding	5-6
	5.4.2	Feed or Waste Valve Reassembly	5-6
	5.4.3	Solenoid Valve Coil Replacement	5-6
5.5	Sieve Bed Replacement		5-7
	5.5.1	Sieve Bed Removal	5-7
	5.5.2	Sieve Bed Installation	5-8
5.6	Cabinet Fan Replacement		5-8
5.7	Circuit Board Replacement		5-9
	5.7.1	Circuit Board Removal	5-10
	5.7.2	Circuit Board Installation	5-10
5.8	Product Regulator Check and Setting		5-11

5.8.1Setting Product Regulator for

	Normal Operation	5-11
5.8.2	Product Regulator Lockout	5-11
5.8.3	Back Pressure Correction at 5 lpm	5-12

5.8.4Product Regulator Cleaning or

		Rebuilding	5-13
5.9	Circuit Breaker Replacement		5-14
	5.9.1	Circuit Breaker Removal	5-14
	5.9.2	Circuit Breaker Installation	5-15
5.10	ON/OFF Power Switch Replacement		5-15
	5.10.1	ON/OFF Power Switch Removal	5-15
	5.10.2	ON/OFF Power Switch Installation	5-15
5.11	Buzzer Replacement		5-15

ii – table of contents

AirSep Corporation

5.12	Hour Meter Replacement		5-16
5.13	Flowmeter Replacement		5-16
	5.13.1	Flowmeter Removal	5-16
	5.13.2	Flowmeter Installation	5-17
5.14	Power Cord Replacement		5-17

Section 6.0

Troubleshooting

6.1	Operating Pressure Test		6-1
	6.1.1	High Operating Pressure	6-1
	6.1.2	Low Operating Pressure	6-2
6.2	General Troubleshooting		6-2
6.3	Troubleshooting Chart		6-4
6.4	Tool Kit and Pressure Test Gauge		6-7

Appendix

Exploded

Drawings

Figure 1: Control PanelAssembly	A-1
Figure 2: Main Structure Assembly	A-2
Figure 3: Base and Cabinet Components	A-3
Figure 4: Test Block Assembly	A-4
Figure 5: Valve Block Assembly	A-5
Figure 6: Compressor Assembly	A-6
Figure 7: Adsorption Bed Assembly	A-7
Figure 8: Compressor Cabinet	A-8

AirSep Corporation

iii – table of contents

1.0Introduction

1.1 Equipment Provider Responsibility

All Equipment Providers of the QuietLife™ 5 Oxygen Concentrator must assume responsibilities for handling, operational check-out, patient instruction, and maintenance. These responsibilities are outlined below and throughout this manual.

WARNING

QuietLife 5 units must not be used for or with any lifesupporting applications. Geriatric, pediatric, or any other patients unable to communicate discomfort while using this machine may require additional monitoring. Advise patients to immediately notify their Equipment Providers and/or physicians in case of an alarm or any discomfort.

As an Equipment Provider, you must do all of the following:

Inspect the condition of each QuietLife 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 QuietLife 5 before delivery to a patient. Always operate the unit for a reasonable length of time and check that the oxygen purity level is within specifications as referred to in Section 2.4. (Test the battery and power disconnect alarm as described in Section 2.3 of this manual.)

Deliver QuietLife 5 units only to patients authorized by a physician’s prescription. QuietLife 5 must not be used as a life-supporting device. A backup supply of oxygen must be available.

Instruct patients how to use QuietLife 5 in conjunction with the Patient Manual.

Instruct patients to notify their physicians and/or Equipment Providers if they experience any signs of discomfort.

Instruct each patient how to perform routine maintenance of the air intake gross particle filter and how to check the alarm system battery. (Refer to Section 3.2.)

Be available to service each patient at any time.

Maintain QuietLife 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 QuietLife 5 Oxygen Concentrators.

1-1

Refer to the QuietLife 5 Product Warranty if parts replacement is required within the warranty period.

1.2Important Notice and Symbol Explanations

As you read the manual, pay special attention to the WARNING, CAUTION, and NOTE messages. They identify safety guidelines or other important information as follows:

WARNING: Describes a hazard or unsafe practice that can result in severe bodily injury or death.

CAUTION: Describes a hazard or unsafe practice that can result in minor bodily injury or property damage.

NOTE: Provides information important enough to emphasize or repeat.

1-2

The following harmonized symbols (pictograms), used for nonEnglish language countries, will be located on the exterior of the QuietLife 5 unit:

Read the Patient Instruction Manual.

No smoking within five feet of this device, oxygencarrying tubing, or accessories.

No open flames within five feet of this device, oxygencarrying tubing, or accessories.

No oil, grease or petroleum-based products on or near the unit.

Oxygen outlet

Oxygen alarm

1-3

1.3QuietLife 5 Product Warranty

AirSep Corporation warrants the QuietLife 5 Oxygen Concentrator to be free from defect in parts and workmanship for three years (as specified on the original invoice provided) from the date of delivery to the original purchaser, under normal use and operation. AirSep Corporation’s obligations under this warranty are limited to the repair or replacement of any such item of equipment (or part thereof) shown to be defective or, at AirSep Corporation’s option, to refunding the purchase price of any such defective item of equipment.

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. Replacement parts shall be warranted as stated above for the unexpired portion of the original three-year parts warranty (as specified on the original invoice provided). This warranty does not extend to any item or part subjected to misuse, accident, improper maintenance, or application, or which has been repaired or altered outside of the AirSep Corporation Factory without the express prior written authorization of AirSep Corporation.

THE FOREGOING WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, IN FACT OR IN LAW, INCLUDING WITHOUT LIMITATION THE WARRANTY OF MERCHANTABILITY OR THE WARRANTY OF FITNESS FOR PARTICULAR PURPOSE. IT IS EXPRESSLY UNDERSTOOD THAT PURCHASER’S SOLE AND EXCLUSIVE REMEDY FOR DEFECT IN PARTS IS LIMITED TO ENFORCEMENT OF AIRSEP CORPORATION’S OBLIGATION AS SET FORTH ABOVE, AND AIRSEP CORPORATION SHALL NOT BE LIABLE TO PURCHASER OR OTHERS FOR LOSS OF USE OF THE EQUIPMENT OR FOR OTHER SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.

1-4

1.4Functional Specifications

Sound Level:	<40 dbA
	(measured at 39.4 in. (1 m) from the front of the concen-
	trator and 15.7 in (40 cm) above the floor)
Dimensions:	27.5 in. high, 16.5 in. wide, 14.5 in. deep
	(69.9 cm high, 41.9 cm wide, 36.8 cm deep)
Weight:	57.0 lb; shipping weight - 67.0 lb
	(26 kg; shipping weight - 30 kg)
Electrical	120 VAC, 60 Hz, 4 amps, 285 watts
Requirements:	220-240 VAC, 50 Hz, 2 amps, 285 watts
Capacity:	5 liters per minute at 90% oxygen
	(Based on 70°F [21°C] at sea level)
Accuracy:	Flowmeter ±10% full scale. (Based on
	precalibrated analysis.)
Concentration:	1-4 liters per minute at 92% + 3.5/ - 3%
	5 liters per minute at 90% + 5.5/ - 3%
Response Time:	Allow 5 minutes to attain maximum purity.
Positioning:	Operate the unit in an upright position, maintaining at
	least six inches of open space on all sides for ventilation.
Alarms:	Power failure
	High and low pressure
	Battery test
	Low oxygen purity (with Oxygen Monitor)

CE (IEC 601-1) QuietLife 5 220V

0459

1-5

2.0Operation Check and Purity Test

2.1Description of Operation

Air enters the QuietLife 5 Oxygen Concentrator through an external air intake gross particulate filter. This filtered air enters the compressor via a suction resonator, which quiets the compressor’s suction sound. Pressurized air then exits the compressor and passes through a heat exchanger. The heat exchanger reduces the temperature of the compressed air. 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, thus producing high purity oxygen.

There are two sieve beds: while one produces high purity oxygen, the other is purged of the nitrogen it adsorbed (collected) while it concentrated oxygen. Each adsorber produces oxygen for approximately six seconds and delivers it to the product tank. Oxygen exits the product tank through a pressure regulator, flow control valve, flowmeter, and product filter. The flow control valve, which is part of the flowmeter, controls the amount of oxygen delivered to the patient. The QuietLife 5 unit delivers up to 95% pure oxygen at flow rates from 1–5 lpm.

2.2Operation Check

AirSep tests every QuietLife 5 Oxygen Concentrator thoroughly after manufacture. You must perform the following test to ensure that no damage occurred in shipping or handling.

1Open and inspect all cartons (that contain units) upon delivery. Unpack the unit and remove it from the carton. Inspect the unit itself for damage. If the exterior of a unit’s carton is damaged, or the unit itself is damaged, note it on the freight bill signed by the driver.

2Plug in the power cord of the unit, and set the ON/OFF switch to the ON position. Check to see that the following occurs:

a.A continuous alarm loudly sounds for approximately five seconds to indicate that the battery for the alarm is good. See the troubleshooting chart in Section 6.0 of this manual if the unit’s alarm does anything other than sound loudly for five seconds.

b.The compressor runs. Listen for the sound.

c.Exhaust air flows out of the bottom of the unit.

d.OPTIONAL: The Oxygen Monitor’s amber light remains on until the oxygen purity reaches 80% ± 3% (approximately two minutes).

2-1

3Turn the flowmeter adjustment knob counterclockwise until it stops (wide open).

The maximum flow should register 5.5 lpm (the 5.5 lpm line should appear to split the middle of the flowmeter ball) with no connections at the oxygen outlet. If not, refer to Section 5.8.1 to set the product regulator.

4Perform an oxygen purity test, as described in Section 2.4.

2.3Alarm System

The QuietLife 5 Oxygen Concentrator is equipped with a battery-powered alarm system, which sounds a continuous and loud alarm when a power failure occurs. It sounds an intermittent alarm if the high or low pressure indicators are activated or if the optional oxygen monitor detects lower than therapeutic levels of oxygen purity. The alarm remains on until you correct the alarm condition or you set the ON/OFF switch to the OFF position. Refer to Section 6.0 for a list of probable alarm causes.

2.3.1 Battery Test

Each time the QuietLife 5 unit is turned on, a five-second audible alarm sounds to indicate the condition of the battery.

NOTE

The audio alarm must sound loudly for approximately five seconds each time the unit is turned to ON to indicate the battery is in good condition.

2.3.2 Power Failure Alarm Test

To test the power failure alarm, take the following step:

Unplug the unit, and set the ON/ OFF switch to the ON position.

This should immediately activate the audio alarm. If it does not, refer to the troubleshooting chart in Section 6.0 of this manual.

2.4Oxygen Purity Test and Specification

2-2

To ensure that the unit’s output of oxygen is within specification, you must perform an oxygen purity test. Test the unit upon delivery to a patient and at periodic intervals. Equipment Providers, based on their expertise and documentation, may establish and implement their own protocol to check oxygen purity. The interval established may be longer or shorter than 90 days, which is AirSep’s default time period for providers who do not choose to establish their own protocol.

1If an oxygen humidifier bottle is used, remove it from the oxygen outlet.

2Connect a calibrated oxygen purity analyzer to the oxygen outlet.

3Verify that the product flow rate delivered by the unit matches the patient’s prescription and does not exceed the capacity of the unit.

4Set the unit’s ON/OFF power switch to the ON position. (It takes approximately five minutes for the oxygen purity to stabilize.) Take oxygen purity readings every 60 seconds until the analyzer shows that two consecutive readings are the same.

5Disconnect the oxygen analyzer, and reconnect the humidifier bottle (if used) and any other equipment/ accessories that may be required.

6Adjust the flowmeter adjustment knob to the prescribed level.

NOTE

Do not measure oxygen purity output after the product stream passes through a humidifier bottle, or erroneous readings will result.

		AirSep QuietLife 5 Purity Specifications
Liter
Flow		Specification	In Spec
1-4	lpm	92% + 3.5/ - 3%	89% or higher
5	lpm	90% + 5.5/ - 3%	87% or higher

3.0 Patient Instructions

2-3

3.1General Instructions

It is important that patients thoroughly understand how to operate the AirSep QuietLife 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 the unit alarms, they must notify their Equipment Provider and/or physician immediately.

You, as the Equipment Provider, are responsible to see that each patient receives the Patient Manual. Locate the Patient Manual in the pocket on the back of each unit. Explain each step in the operation of the unit to the patient in reference to this manual.

3.2Routine 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

Check the alarm system battery

3.2.1 Cleaning the Air Intake Gross Particle Filter

NOTE

The patient must clean this filter weekly, as described below. The filter may require daily cleaning if the QuietLife 5 unit operates in a harsh environment such as a house heated by wood, kerosene, or oil, or one with excessive cigarette smoke.

1Remove the dirty air intake gross particle filter from the back of the QuietLife 5 unit, and install the clean filter stored in the pocket on the back of the unit.

2Wash the dirty filter in warm soapy water, and rinse.

3Use a soft absorbent towel to remove excess water.

4Place the clean air intake gross particle filter in the pocket on the back of the unit.

3-1

3.2.2 Checking the Alarm System Battery

The alarm system battery is tested each time the ON/OFF switch is set to the ON position. A continuous alarm sounds for approximately five seconds to indicate a good battery. If the alarm does anything other than sound loudly for five seconds, instruct the patient to call the Equipment Provider immediately.

3-2

4.0 Provider Maintenance

4.1Routine Maintenance

The QuietLife 5 unit has three filters and a 9-volt battery that require scheduled maintenance and replacement.

To ensure that the unit’s output of oxygen is within specification, you must perform an oxygen purity test. Test the unit upon delivery to a patient and at periodic intervals. Equipment Providers, based on their expertise and documentation, may establish and implement their own protocol to check oxygen purity. The interval established may be longer or shorter than 90 days, which is AirSep’s default time period for providers who do not choose to establish their own protocol.

AirSep does not require preventative maintenance on the concentrator. You do not need to perform any maintenance as long as the QuietLife 5 unit remains within specifications at the desired flow rate.

4.1.1 Air Intake Gross Particle Filter/GPF

The external air intake gross particle filter is located on the back of the unit. You can easily remove it by hand. Instruct the patient to clean this filter weekly. (Refer to Section 3.2.1.)

NOTE

The filter may require more frequent cleaning if the QuietLife 5 unit operates in a harsh environment such as a house heated by wood, kerosene, or oil, or one with excessive cooking or cigarette smoke.

4.1.2 Product Filter Replacement

The product filter must be replaced after every 25,000 hours of use.

1Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord.

2Remove the side panels to locate the product filter.

NOTE

Observe the position of the filter before removal.

3Cut the tie-wraps, and separate the green tubing from both sides of the filter.

4-1

4Install the new filter with the inlet side in the same position as before. Push the tubing together so that the tubing overlaps the product filter connections, and secure it with the tie-wraps.

5Remove the back panel to record information about the product filter replacement on either the History Record label (located near the base of the unit) or on the QuietLife 5 Oxygen Concentrator Maintenance Check log sheet at the end of this manual. (Make additional copies of this log sheet as needed.)

6Reconnect the panels.

4.1.3Internal Felt Filter Replacement

The internal felt filter requires changing every 6 months or 5,000 hours of use. See below on instructions for changing the filter.

1Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord.

2Remove right side panel to locate the felt intake filter.

3Remove filter in the unit, and replace with a new filter.

4Record information about the filter replacement on either the History Record label (located near the base of the unit) or on the QuietLife 5 Oxygen Concentrator Maintenance Check log sheet at the end of this manual. (Make additional copies of this log sheet as needed.)

5Reconnect side panel.

4.1.4Battery Replacement

Each time the QuietLife 5 unit is turned on, the alarm must sound loudly for approximately five seconds to indicate a good battery. An alarm that does anything other than sound loudly for five seconds indicates a weak battery and requires replacement.

To replace the battery, take the following steps:

4-2