AirSep QuietLife 5 Service manual
QuietLife™ 5
Oxygen Concentrator
Service Manual
AirSep Corporation • 401 Creekside Drive • Buffalo, NY 14228-2085 USA
Telephone: (716) 691-0202 • 24-Hour Fax: (716) 691-4141
AirSep® is a registered trademark of AirSep Corporation.
QuietLife™ 5 is a trademark of AirSep Corporation.
MN098-1 Rev- 04/03
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
Section 3.0
Patient Instructions
Section 4.0
Equipment Provider
Maintenance
2.3.2 Power Failure Alarm Test 2-2
2.4 Oxygen Purity Test and Specification 2-3
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
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
AirSep Corporation 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
5.8.1 Setting 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
5.8.4 Product 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
Section 6.0
Troubleshooting
Appendix
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
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
Exploded
Drawings
Figure 1: Control Panel Assembly 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
1.0 Introduction
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.
As an Equipment Provider, you must do all of the following:
Inspect the condition of each QuietLife
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 Provid-
ers 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.
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.
5 unit immediately upon
1-1
Refer to the QuietLife 5 Product Warranty if parts replacement is
required within the warranty period.
1.2 Important 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
1.3 QuietLife 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
1.4 Functional Specifications
Sound Level: <40 dbA
(measured at 39.4 in. (1 m) from the front of the concentrator 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
2.0 Operation Check and Purity Test
2.1 Description 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.
2.2 Operation 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.
1 Open and inspect all cartons (that contain units) upon delivery. Un-
pack 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.
2 Plug 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
3 Turn 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.
4 Perform an oxygen purity test, as described in Section 2.4.
2.3 Alarm 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.
2.4 Oxygen 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.
1 If an oxygen humidifier bottle is used, remove it from the oxygen
outlet.
2 Connect a calibrated oxygen purity analyzer to the oxygen outlet.
3 Verify that the product flow rate delivered by the unit matches the
patient’s prescription and does not exceed the capacity of the unit.
4 Set 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.
5 Disconnect the oxygen analyzer, and reconnect the humidifier bottle
(if used) and any other equipment/ accessories that may be required.
6 Adjust 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
3.1 General 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.
3.2 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
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.
1 Remove 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.
2 Wash the dirty filter in warm soapy water, and rinse.
3 Use a soft absorbent towel to remove excess water.
4 Place 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
4.1 Routine 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.
1 Set the unit’s ON/OFF switch to the OFF position, and unplug
the power cord.
2 Remove the side panels to locate the product filter.
NOTE
Observe the position of the filter before
removal.
3 Cut the tie-wraps, and separate the green tubing from both
sides of the filter.
4-1
4 Install 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.
5 Remove the back panel to record information about the prod-
uct 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.)
6 Reconnect the panels.
4.1.3 Internal 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.
1 Set the unit’s ON/OFF switch to the OFF position, and unplug
the power cord.
2 Remove right side panel to locate the felt intake filter.
3 Remove filter in the unit, and replace with a new filter.
4 Record 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.)
5 Reconnect side panel.
4.1.4 Battery 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
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