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FreeStyle Service Manual MN126-1

E

CAIRE Inc.

2200 Airport Industrial Dr., Ste 500

Ball Ground, GA 30107

www.chartindustries.com/RespiratoryHealthcare

CAIRE reserves the right to discontinue its products, or change the prices, materials, equipment, quality, descriptions,
specifications and/or, processes to its products at any time without prior notice and with no further obligation or consequence.
All rights not expressly stated herein are reserved by us, as applicable.

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Summary of Contents for MN126-1

Page 1: ...FreeStyle Portable Oxygen Concentrator Service Manual...

Page 2: ...Expedited Product Warranty Check service is available at 800 482 2473 Air Travel with FreeStyle FreeStyle is approved for use on board commercial aircraft per an addendum to FAA SFAR 106 MN126 1 Rev E...

Page 3: ...arm System 2 2 2 3 1 Start up 2 2 2 3 2 Battery Status 2 2 2 3 3 Low Battery 2 2 2 3 4 Discharged Battery 2 2 2 3 5 Battery Charging 2 3 2 3 6 Battery Fully Charged 2 4 2 3 7 Cannula Disconnect 2 4 2...

Page 4: ...Service 5 1 Components 5 1 5 2 Housing Removal 5 2 5 2 1 Removing Front Cover 5 2 5 2 2 Removing Back Cover 5 2 5 3 Internal Battery Replacement 5 3 5 4 PSA Removal 5 4 5 5 Compressor Replacement 5 10...

Page 5: ...nt 5 25 5 15 Control Key Panel Replacement 5 27 5 16 Fan Replacement 5 31 Section 6 0 Typical Pressure Profiles 6 1 Pressure Profile Quadrant 6 1 Section 7 0 Troubleshooting 7 1 General Troubleshootin...

Page 6: ......

Page 7: ...ivery receipt and report it directly to both the freight company and AirSep Corporation immediately Check the operation of each FreeStyle unit before delivery to a patient Always operate the unit for...

Page 8: ...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 mat...

Page 9: ...ning 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 prac...

Page 10: ...g Battery duration 3 setting 2 hours 2 setting 2 5 hours 1 setting 3 5 hours Optional AirBelt when combined with the internal battery 3 setting 5 hours 2 setting 6 hours 1 setting 10 hours Battery cha...

Page 11: ...N CSA C22 2 No 601 1 M90 Medical Electrical Equipment Part 1 General Requirements for Safety Protection against potential electromagnetic or other interference between the equipment and other devices...

Page 12: ......

Page 13: ...it made oxygen Oxygen exits the product tank after first passing through the integrated product filter In addition to the molecular sieve beds that allow oxygen to be separated from air FreeStyle con...

Page 14: ...battery power approaches a low level a second beep is emitted every five seconds and a yellow LED on the battery gauge indicator s will blink for a second every five seconds When this occurs the patie...

Page 15: ...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 hours then all four LEDs will turn off If the Universal...

Page 16: ...rning If the user s breathing rate causes the Freestyle unit s capacity to be exceeded The amount of oxygen that FreeStyle supplies is dependent on the flow control switch setting and the breathing ra...

Page 17: ...ersal AC or DC power supply only AirSep Part No PW017 1 to a 100 240 volt 50 60 Hz electrical outlet 2 Turn unit on by pressing setting 2 on keypad 3 Simultaneously press and hold settings 1 and 3 for...

Page 18: ......

Page 19: ...er supply to the FreeStyle 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 s inlet con...

Page 20: ...imately 3 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 abo...

Page 21: ...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 hour Lithium...

Page 22: ...n the photo below Air Intake Gross Particle Filter Cover Figure 3 3 2 Pull the filter cover off the front of the FreeStyle and remove the filter Wash filter in a warm water and soap solution 3 Rinse t...

Page 23: ...her 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 should be used while sleeping with...

Page 24: ...nd Instruct the patient to clean this filter weekly Refer to Section 3 2 1 Cleaning the Air Intake Gross Particle Filter of this manual 4 1 2 Product Filter Replacement The product filter must be repl...

Page 25: ...ruses 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...

Page 26: ...ion 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 t...

Page 27: ...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 Remov...

Page 28: ......

Page 29: ...sing Velcro To remove the pack simply pull on battery See Figure 5 4 Figure 5 4 4 Take new battery pack with the wire harnesses to the left and press firmly into the battery cradle Gently pull on batt...

Page 30: ...e front housing 3 Remove the battery Care must be taken when removing J1 and J2 connector 4 Disconnect the 8 pin connector J5 with multi color wires from the circuit board Care must be taken not to pu...

Page 31: ...ve 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 S...

Page 32: ...ocated in the center of outlet nozzle cradle Figure 5 9 Figure 5 9 9 Turn unit over and remove the back housing 10 Disconnect the black ground wire connected to the compressor on its upper right side...

Page 33: ...SA system that connects to the pressure transducer on the left side 12 Remove each tie wrap around the upper top screw bosses See Figure 5 11 Figure 5 11 13 Using needle nose pliers disconnect all the...

Page 34: ...move the complete PSA assembly from the center housing by pulling it upwards and slipping compressor molex connector through center section See Figure 5 13 Figure 5 13 15 Remove the compressor plate b...

Page 35: ...FreeStyle Service Manual MN126 1 E 5 9 16 Remove the two mounts from the compressor See Figure 5 15 Figure 5 15...

Page 36: ...r time the cup seals wear and the compressor does not operate properly 5 5 1 Compressor Assembly Removal 1 Remove PSA system assembly per Section 5 4 2 Stand the PSA assembly upright and loosen the ce...

Page 37: ...gs connecting the compressor to the manifold is connected to the compressor remove it and insert it into the manifold See Figure 5 18 Figure 5 18 5 Connect the new compressor to the PSA assembly and t...

Page 38: ...1 E 5 5 2 Compressor Assembly Installation To install the new compressor assembly perform the compressor removal procedure in reverse order After replacing the units compressor you must reset the hour...

Page 39: ...the tubing assembly from the two barbs on the product manifold mixing tank and one end of the purge tube Figure 5 20 a b c Figure 5 20a Figure 5 20b Figure 5 20c 3 Remove the tie wraps that bundle the...

Page 40: ...ect tubing assembly to new product manifold 8 Place center bolt through product manifold and tighten to 15 in lbs Figure 5 21 5 7 Solenoid Valve Replacement It may not be necessary to completely remov...

Page 41: ...ews provided 9 Re bundle wires and tie wrap 10 Start FreeStyle unit and leak test around the area where the gasket is located on the valve 5 8 Adsorbent Bed Replacement 1 Remove the PSA system assembl...

Page 42: ...D 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 g...

Page 43: ...refully 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...

Page 44: ...ocate 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 i...

Page 45: ...e timer is reset Note that the historical channel cannot be reset 5 11 1 Icons Two LCD icons are used to indicate each mode In historical mode an h is displayed to indicate hours While enabled the h w...

Page 46: ...the h icon As with the historical display mode the h icon will flash to indicate that time is being accumulated and the wrench icon will remain on solid The historical channel cannot be reset To rese...

Page 47: ...move the hour meter from the 8 pin connector J3 When removing take care not to bend or break any pins on the J3 connector header 6 Replace the hour meter 5 13 Circuit Board Replacement When replacing...

Page 48: ...ove DC power input connector from location J1 pin 3 connector on circuit board Figure 5 30 Figure 5 30 6 Disconnect control panel keypad flex circuit from J8 Ziff zero insertion force connector by car...

Page 49: ...cutting tie wrap use small size cutter Carefully pull tubing from nozzle barb Figure 5 32 Figure 5 32 11 Disconnect fan connector using needle nose pliers carefully pulling upward on fan connector ho...

Page 50: ...5 24 FreeStyle Service Manual MN126 1 E Figure 5 34 13 Remove main circuit board from center section assembly Figure 5 35 Figure 5 35 14 Replace main circuit board reverse order of steps 1 14...

Page 51: ...gure 5 36 Figure 5 36 2 Before replacing the board ensure that the main circuit board and all J15 and J16 pins are straight and unbroken intact 3 Locate the component side marked top to align to J16 o...

Page 52: ...llowing alignment view the replacement board from the side at an angle to make certain that the pins are aligned properly before seating the connector Figure 5 38 5 Gently press the board into place u...

Page 53: ...s and peel off the control panel keypad from the center enclosure Figure 5 40 Figure 5 40 5 Replace control panel keypad with new control panel keypad 6 Check control recessed area of enclosure center...

Page 54: ...ure all adhesive is in contact with plastic surface Figure 5 42 Figure 5 42 9 Route the flex circuit from control panel keypad notched area of control panel enclosure section Figure 5 43 Figure 5 43 1...

Page 55: ...FreeStyle Service Manual MN126 1 E 5 29 Figure 5 44 11 Insert flex circuit into rib section and connect flex circuit with carbon contacts facing toward you Figure 5 45 Figure 5 45...

Page 56: ...nsert into J8 Ziff zero insertion force connector making sure that the flex circuit seats into the connector Carefully press the Ziff connector locking tab in a downward direction Ensure latch seats F...

Page 57: ...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 from the circuit board to th...

Page 58: ...he front cover This arrow indicates the direction of the airflow of the fan Be sure the two wires coming from the fan are located on the upper left side Figure 5 49a b Figure 5 49a Figure 5 49b 6 Inse...

Page 59: ...sure Profile Quadrant The following pressure profiles illustrate the range of normal operating pressure at sea level These are approximate pressures A unit may be out of the range shown below and stil...

Page 60: ...ust wait 10 seconds before proceeding to step 3 3 Activate the test mode by pressing flow settings 1 and 3 simultaneously for five seconds 4 Make sure that the unit is leak free by testing all tubing...

Page 61: ...ower inlet connector not properly connected to circuit board Defective DC power supply Defective keypad control panel membrane switch Defective motor controller Defective circuit board Check fuse for...

Page 62: ...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 3 hours and all 4 LEDs are lit s...

Page 63: ...t turned on Battery is dead Defective Universal AC DC power supply OCD sensor defective OCD solenoid valve defective Check cannula and the cannula connection Turn FreeStyle on to the prescribed settin...

Page 64: ...n assist you in servicing and maintaining the FreeStyle unit 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 1a 25 inch hexnut screwdriv...

Page 65: ...ratoryHealthcare CAIRE reserves the right to discontinue its products or change the prices materials equipment quality descriptions specifications and or processes to its products at any time without...

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