FreeStyle™ Portable
Oxygen Concentrator
Service ManualExpedited Product Warranty Check service is available at 800-482-2473

Air Travel with FreeStyleFreeStyle is approved for use on-board commercial aircraft per an addendum to FAA SFAR106.

MN126-1

Rev. G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

Definitions of Symbols

1-3

1.4

FreeStyle Specifications

1-4

1.5

FreeStyle Classifications

1-5

2.1

Description of Operation

2-1

2.2

Operation Check

2-1

2.3

Alarm System

2-2

Section 2.0
Operation Check andTest of Oxygen Concentration

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

2.3.8

Performance Warning

2-4

2.3.9

FreeStyle Capacity Exceeded

2-4

2.3.10General Malfunction

2-4

2.4

Oxygen Concentration Test and Specification

2-5

3.1

General Instructions

3-1

3.1.1 Connecting t o E x t e r n a l Power

3-1

3.1.2

3-1

Section 3.0
Patient Instructions

3.2

Optional AirBelt Battery

Routine Maintenance by the Patient

3-4
i – table of contents

3.2.1

Cleaning the Air Intake
Gross Particle Filter

3-4

3.2.2

Alarm/Service Indicator

3-5

3.2.3

Nasal Cannula

3-5

3.2.4

Usage During Sleep

3-5

Section 4.0
Equipment Provider

Maintenance
4.1

No Scheduled Maintenance

4-1

4.1.1

Air Intake / Gross Particle Filter

4-1

4.1.2

Product Filter Replacement

4-1

4.1.3

Compressor Servicing

4-2

4.1.4

Recording Maintenance

4-2

4.2

Cleaning and Preparing for New Patient Use

4-2

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

Section 5.0
Service

5.3Internal Battery Replacement

5-3

5.4

PSA Removal

5-4

5.5

Compressor Replacement

5-10

5.5.1

Compressor Assembly Removal

5-10

5.5.2

Compressor Assembly Installation

5-12

5.6

Product Manifold Replacement

5-13

5.7

Solenoid Valve Replacement

5-14

5.8

Adsorbent Bed Replacement

5-15

5.9

Feed/Waste Manifold Replacement

5-17

5.10

Measuring System Pressure

5-18

5.11

Hour Meter Functionality

5-19

5.11.1

Icons

5-19

5.11.2

Power

5-19

5.11.3Service LED

5-19

5.11.4

Toggle/Reset Switch

5-20

5.12
ii – table of contents

Hour Meter Replacement

5-20

5.13

Circuit Board Replacement

5-21

5.14

Motor Controller Board Replacement

5-25

5.15

Control/Key Panel Replacement

5-27

5.16

Fan Replacement

5-31

6.1

Pressure Profile Quadrant

6-1

7.1

General Troubleshooting

7-1

7.2

Troubleshooting Chart

7-2

8.1

Tools for FreeStyle Service and Maintenance

8-1

Section 6.0
Typical Pressure Profiles

Section 7.0
Troubleshooting

Section 8.0
Recommended Tools

iii – table of contents

1.0

Introduction

1.1

Equipment Provider Responsibility
All Equipment Providers of the FreeStyle™ Portable Oxygen Concentrator must
assume responsibilities for handling, operational check-out, patient instruction, andmaintenance. 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. Patientswith 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 unit immediately upondelivery 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 unit before delivery to apatient. 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 units only to patients authorized by a physician’sprescription. FreeStyle must not be used as a life-supporting
device.

■Instruct patients how to use FreeStyle in conjunction with thePatient Manual.

■

Instruct patients to notify their physicians and/or Equipment
Providers if they experience any signs of discomfort.
Instruct each patient to perform routine maintenance of the air intake grossFilter. (Refer to Section 3.2.)■■

Be available to service each patient at any time.

■

Maintain FreeStyle in accordance with Section 4.0.

■

Repair components and replace parts only as outlined in thismanual. Use only AirSep parts for replacement in FreeStyle Oxygen
Concentrators.

FreeStyle Service Manual MN126-1 G

1-1

1.2

Important Notice and Symbol Explanations

As you review both the FreeStyle Patient Manual and this FreeStyle Service
Manual, pay special attention to the WARNING, CAUTION, and NOTE messages.
They identify safety guidelines or other important information as follows:
Warning – 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

DO NOT OPERATE THIS EQUIPMENT WITHOUT FIRST READING AND UNDERSTANDING THISMANUAL. 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 andrelated deaths. You must follow these safety warnings:
Do not allow smoking, candles, or open flames in the same room with the device orwithin 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 willcause 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 thisdevice is located.

“No Smoking – Oxygen in Use” signs must be prominently displayed in the home, orwhere 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.

1-2

FreeStyle Service Manual

MN126-1 G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 bylanguage 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
Portable Oxygen Concentrator.
SymbolDescription
ON (power switch on)

Warning – Describes a hazard or unsafe

SymbolDescription
OFF (power switch off)

practice that if not avoided can result insevere bodily injury, death or property
damageClass II Equipment, double insulated

Caution – Describes a hazard or unsafe

Safety agency for CAN/CSA C22.2 No.
601.1 M90 for medical electricalequipment

practice that if not avoided can result inminor bodily injury or property damage

Note – Provides information importantenough to emphasize or repeat

Keep unit and accessories dry

Consult the accompanying
documents

Proper disposal of waste of electrical andelectronic equipment required

Use no oil or grease

Do not disassemble

No smoking

Consult instructions for use

Type BF equipment

Do not expose to open flames

Oxygen outlet connection to thecannulaDo not block fan

Caution: Federal law (USA) restricts
this for sale or rental by or on the orderof a physician or licensed health careprovider.

RTCA DO160 Section 21
Category M Compliant. FAA
SFAR 106 requirement

FreeStyle Service Manual MN126-1 G

If the product unique device identifier(UDI) label has the CE#### symbol on it,
the device complies with the requirementsof Directive 93/42/EEC concerning medical
devices. The CE#### symbol indicatesnotified body number.
Safety agency for CAN/CSA C22.2 No.
601.1 M90 for medical electricalequipment

1-3

1.4

FreeStyle Specifications
Oxygen Concentration: * 1-3 pulse settings; equivalent to a continuous flow of
90% +5.5/-3% Oxygen Concentration
Dimensions:

8.6 in. high x 6.1 in. wide x 3.6 in. deep
(21.8 cm high x 15.5 cm wide x 9.1 cm deep)

Weight:4.4 lb (2.0 kg); 1.8 lb (.8 kg) optional Airbelt

AC Power Supply: 100 – 240 VAC (1.0 amp at 120 VAC)
Universal Power Supply: DC Power Supply: 11-16 VDC (6.0 amps max. at 13.5 VDC
nominal)FreeStyle unit: 28 W nominal at 3 setting
Battery duration:

3 setting - 2 hours; 2 setting - 2.5 hours; 1 setting - 3.5 hours
Optional AirBelt when combined with the internal battery:
3 setting - 5 hours; 2 setting - 6 hours; 1 setting -10 hours

Battery charge time:

3.5 hours; optional AirBelt: 3 hours

Warm-up time:

2 minutes

Battery cycle life:

Approximately 300 cycles, then 80% capacity or below

Audible alarms andpulse visual indicators:

Start-up – audible and visual (GREEN indicator light); Pulse
flow – visual (GREEN light); Battery condition – battery
level (GREEN indicator lights); Cannula disconnect- audible
and visual (RED alarm light); System overdraw –audible and visual (RED warning and alarm lights); High andlow pressure – audible and visual (RED alarm light);
Service required: visual (YELLOW alarm light)

Sound:

38 dBA at 1 Setting: 41 dBA at 2 setting: 44 dBA at 3 setting

Temperature range
intended for use:

Operational temperature: 41oF to 104oF (5oC to 40oC)
Storage temperature:-4oF to 140oF (-20oC to 60oC)

Max Operational
Altitude:

up to 12,000 ft (3,657.6 m) (483mmHg) Higher altitudes may affectperformance* Based on an atmospheric pressure of 14.7 psia (101 kPa) at 70oF (21oC)* Operating unit outside of normal operational temperature range can affect performance.

1-4

FreeStyle Service Manual

MN126-1 G

1.5

FreeStyle Classifications

Classification
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 regarding1) 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. 601.1-M90 Medical Electrical Equipment – Part 1: General
Requirements for Safety

Protection against potential electromagnetic or other interference between the equipment and otherdevices:
Device with accessories tested to be in compliance with
EN 60601-1-2 Medical Electrical Equipment, Part 1: General Requirements for Safety-CollateralStandard: 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 allowed:
Please refer to the “Cleaning, Care, and Proper Maintenance” section of this FreeStyle
Service Manual.
Degree of safety of application in the presence of flammable anesthetic gases:
Equipment not suitable for such application.
Mode of operation:
Continuous duty.

2.0

Operation Check and Test of Oxygen Concentration

2.1 Description of Operation
Air enters the FreeStyle Oxygen Concentrator through an external air intake /gross particle filter. This filtered air enters the compressor via a suction intake
muffler that quiets the compressor’s suction sound. Pressurized air then exits
the compressor and passes through a heat exchanger to reduce thetemperature.
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, theother is purged of the nitrogen it adsorbed (collected) while 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 fromair, FreeStyle 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 delivers a gas consisting of 90% (+5.5/-3% )oxygen at pulse flow
rates from approximately 1–3 LPM equivalency.

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

1. Connect the power cord of the unit, and turn the unit on by pressing
flow setting [-2]. Check to see that the following sequence occurs:a. A brief, continuous alarm sounds to indicate that FreeStyle has been turned on.
b. The compressor runs.
c. After a 10 second start up is complete.
d. Exhaust air flows from the unit.
2.

Perform an oxygen concentration test, as described in Section 2.4.

2.3

Alarm System
An audible alarm sounds if FreeStyle has a low battery, senses noinspiration, or if performance is outside specifications. 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 begins tooperate 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’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 instructedto connect the FreeStyle Universal AC or/ DC power supply or change toanother source of oxygen. The low battery alarm will continue forapproximately 2 minutes before FreeStyle 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 thesame rate until any one of the 1-3 settings on the keypad are pressed. After thealarm is turned off, connect the FreeStyle unit to its Universal AC or / DCpower supply or change to another source of oxygen immediately. When the
FreeStyle unit is connected to the Universal AC or / DC power supply,
FreeStyle operates and the internal battery recharges simultaneously.

2-2

FreeStyle Service Manual MN126-1 G

2.3.5

Battery Charging

To check the level of charge of the battery, press the BATT button on the keypad. The
battery gauge/indicator(s) illuminate to indicate the level of battery charge (25-100%).
To charge the FreeStyle’s internal battery: Connect its Universal AC or / DC (auto) power supply into theunit’s power receptacle located on the right side of the FreeStyle
unit, and the other end to its proper AC or DC power outlet.
 The FreeStyle internal battery will completely charge from a fully
depleted state in approximately 3½ hours.
Depending upon the temperature of the FreeStyle battery, it can take several minutes for the charging cycle tostart after connecting to power. This is a normal condition and is intended for safe charging.

 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, thenturn solid when they reach their capacity.
 Once all LEDs illuminate solid, the battery is fully charged and theLEDs will remain on solid for approximately 1 ½ hours, then all
four LEDs will turn off.
 If the Universal AC / DC power supply is not connected, the LEDs will turn of within
5 seconds.
The lithium ion rechargeable battery that is used in the FreeStyle 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 theunit 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 hottemperatures 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).

FreeStyle Service Manual MN126-1 G

2-3

2.3.6

Battery Fully Charged

When FreeStyle is connected to an AC or DC outlet and is either in operation or is off, thegreen 100% battery gauge/indicators displays to indicate that the battery is fully charged.

2.3.7

Cannula Disconnect (No inspiration detected)

When FreeStyle is operating and does not sense breathing within 15
minutes, a red light will illuminate with a constant audible alarm. If this occurs, thepatient should be instructed to check the connection from the cannula to the FreeStyle
unit, make sure that the nasal cannula is positioned properly on the face, and ensure thatyou are breathing through your nose. (Your physician may recommend the use of a chinstrap if needed.) 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

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 rate. If the breathing rate is too fast for the flow selector setting, thecapacity of FreeStyle can be exceeded. The patient should reduce activity or consider
locating another source of oxygen.

2.3.9

FreeStyle Capacity Exceeded

When the patient’s breathing rate has caused the capacity of FreeStyle to be exceeded, a
1/2-second alarm sounds every 1/2 second, and the red alarm/ service light flashes. When
this occurs, oxygen concentration is outside specifications. The patient should reduce
activity or change to another source of oxygen and contact the Equipment Provider.

2.3.10 General Malfunction
If a general malfunction of the FreeStyle unit occurs, a 1/2 second alarm sounds every 1/2
second, 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

FreeStyle Service Manual MN126-1 G

2.4

Oxygen Concentration Test and Specification
To ensure that FreeStyle’s oxygen output is within specification, you must
perform an oxygen concentration test. Test the unit upon delivery to a patientand at periodic intervals. Equipment Providers, based upon their own expertiseand documentation, may establish and implement their own protocol to check
oxygen concentration.

1. Connect the FreeStyle Oxygen Concentrator using an AirSep-supplied
Universal AC or / DC power supply only (AirSep Part No. PW017-1) to a100-240 volt, 50/60 Hz electrical outlet.

Note Previous AC to DC power AirSep P/N PW010-1 can be used as well.

2. Turn unit on by pressing setting 2 on keypad.
3. Simultaneously press and hold settings 1 and 3 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 - 3
Figure 2.1

4. Allow unit to warm – up for 5 minutes before recording oxygen
concentration.
5. Connect a calibrated oxygen analyzer to the oxygen outlet and record theunit’s concentration, a 12” tube is recommended. The specification in test
mode is 87% or higher.

FreeStyle Service Manual MN126-1 G

2-5

3.0

Patient Instructions

3.1

General Instructions
It is important that patients thoroughly understand how to operate AirSep’s FreeStyle 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 experienceany 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 Patient Manual. Explain each step in the operation of the unit to the patient withreference to the patient manual.

3.1.1 Connecting to External Power
When connecting the Universal AC / DC power supply to the FreeStyle unit, be certain to
first properly align the power cord to this inlet. To do this, take note of the “D”-shapedplug of both the power cord connector and the FreeStyle’s inlet connection. These must bealigned, and the button on the power cord must be pressed in for removal. This ensuresthat neither the unit nor the power accessories are damaged.
FreeStyle unit’s
power inlet“D”-shaped power cord plugconnects to the FreeStyle unit’s“D”-shaped power inlet.

Press to remove
power cord.

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 theexternal 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.

FreeStyle Service Manual MN126-1 G

3-1

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.

To charge the AirBelt battery:

1) Release safetycap from end of the AirBelt cord.
2) Connect the AC/DC power supply (included with the AirBelt Accessory kit) to the end of AirBelts
power cord as shown in Figure 12.
3) Connect the AirBelt power supply to an AC electrical outlet to recharge.

AirBelt

Connecting the AirBelt cord to the power supply cor

AC/DC Power Supply

Figure 3.2: AirBelt Battery Charging set up

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 canbe damaged. Use only the AirBelt power supply provided to charge AirBelt.






3-2

The FreeStyle AirBelt will completely recharge from its fully depleted state in approximately 3 ½ hours.
While charging a fully discharged battery, the LED will continue to blink until 25% capacity is reached. The
LED will then turn solid.
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 oftime, then all four LEDs will turn off.

FreeStyle Service Manual MN126-1 GLithium batteries may permanently lose capacity when exposed to extremely hottemperatures 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) +/- 2C.

Depending upon the temperature of the AirBelt battery, it can take several minutes forthe charging cycle to start after connecting to power. This is a normal condition and isintended for safe charging.
AirBelt does not need to be fully discharged before recharging. It is recommended tocharge 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.

FreeStyle Service Manual MN126-1 G

3-3

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:

3.2.1

•

Clean the air intake / gross particle filter•

Contact the Equipment Provider for inspection/service when the alarm/service
indicator illuminates.

Cleaning the Air Intake / Gross Particle Filter

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

1.

The air intake / gross particle filter can be found on the lower
front of the FreeStyle, as seen in the photo below.

Air Intake / Gross Particle
Filter Cover

Figure 3.3

3-4

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 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 unit.

FreeStyle Service Manual MN126-1 G

3.2.2

Alarm/Service Indicator

When the unit has reached 5,000 hours of use,a yellow LED will illuminate in the upper left hand corner of the unit’s
keypad/alarm display. Instruct patients to notify the Equipment Provider when this unit
alarms.
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.

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 should be used while sleeping with the guidance ofthe prescribing clinician. In addition, some patients who mouth-breathe while asleep 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
unit can properly detect inspiration for oxygen delivery.

FreeStyle Service Manual MN126-1 G

3-5

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 aslong as the concentrator remains within specifications. To ensure that the unit’s output ofoxygen 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 Intake / Gross Particle Filter

The external air intake gross particle filter is located in the air intake/filter cover. You caneasily remove it by hand. Instruct thepatient 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 unit operates in harshenvironment – 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 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.

4-1

FreeStyle Service Manual MN126-1 G

4.1.3Compressor 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 MaintenanceAs the Equipment Provider, you should record all routine maintenance and repairs
performed on the FreeStyle unit, including hours and dates of service.

4.2

Cleaning and Preparing for New Patient Use
When you remove FreeStyle from a patient’s home, always detach and dispose of the usednasal cannula. Clean the exterior of FreeStyle with a mild household cleaner applied witha 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 patientuses the unit. Do not use liquid directly on the FreeStyle unit to clean it.

Do not use liquid directly on the FreeStyle unit to clean it. A list of undesirable
chemical agents includes but is not limited to, the following, according to theplastics manufacturer: alcohol and alcohol-based products, concentrated chlorinebased products (ethylene chloride), and oil-based products (Pine-Sol, Lestoil).
These are NOT to be used to clean the plastic housing on FreeStyle, they candamage the units plastic.
FreeStyle Service Manual MN126-1 G

4-2

Clean or replace the air intake / gross particle filter with warm soapy water between eachpatient’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 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 to air dry, and then re-test oxygen concentration before you return theunit to your inventory.

*Make the bleach solution a 1:100 dilution of 5.25% sodium hypochlorite. Mix one parthousehold 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 Portable Oxygen Concentrator allows for easy accessand removal of most components. This allows you to perform scheduled maintenance andto repair and replace parts with minimal time and effort.

For your safety, be sure to disconnect the FreeStyle Universal AC / DC adaptor fromthe power outlet before you service the concentrator.

Note all scheduled maintenance. (Refer to Section 4.0 of this manual.)

5-1

FreeStyle Service Manual MN126-1 G

5.2
5.2.1

Housing Removal
Removing 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.)

Figure 5.1

4. Lift off the front cover.

5.2.2

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

FreeStyle Service Manual MN126-1 G

5-2

5.3

Internal Battery Replacement
When removing the front cover to remove the battery, always use ESD safeguard toprotect the electronic circuit board from damage.
1. Remove the front housing.
2. Carefully disconnect the 8-pin (J1) and 2-pin (J2) connector from thebattery pack to the circuit board. (See Figures 5.2 and 5.3.)

Figure 5.2

Figure 5.3

3. The battery pack is fastened using Velcro. To remove the pack, simply pullon 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 battery to ensure the Velcro has engaged.
5. Connect the 8-pin (J1) and 2 pin (J2) connector in their respective connectors
on the circuit board.
When the battery is disconnect and reconnected to the FreeStyle, it will not power
the unit until it is initialized by connecting FreeStyle to external power.
6. Place front housing back on and fasten.
7. Plug the FreeStyle AC or DC power supply to initialize and charge battery.

5.4

PSA Removal
1. Disconnect the FreeStyle unit from the AC or DC outlet.
2. Remove the front housing.
3. Remove the battery. Care must be taken when removing (J1) and (J2)
connector.
4. Disconnect the 8-pin connector (J5) with multi-color wires from thecircuit board. Care must be taken not to pull on wires. (See Figure 5.5.)

Figure 5.5

5. Remove and discard foam from the top of the oval opening.
(See Figure 5.6.)

Figure 5.6

5-4

FreeStyle Service Manual MN126-1 G

The following two steps (6 and 7) require extreme caution to ensure the black pressure sensor(U3) 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 5.7.)

Figure 5.7

7. Carefully disconnect the 1/8” OD black tubing coming from the back of theunit to the limiting orifice. (See Figure 5.8.)

Figure 5.8

FreeStyle Service Manual MN126-1 G

5-5

8. Remove the 8-32 x ¼” black Phillips screws located in the center of outlet
nozzle cradle. (Figure 5.9)

Figure 5.99. Turn unit over and remove the back housing.
10. Disconnect the black ground wire, (connected to the compressor on its upper rightside near the air inlet filter) using a Phillips screwdriver. (See Figure 5.10.)

Figure 5.10

5-6

FreeStyle Service Manual MN126-1 G11. Disconnect the 1/8” OD black tube from the Y-connector or T connector (which is located at theback of the PSA 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 valves from the circuit board, carefully noting
where each valve is connected. Do not disconnect by pulling on the wires. (See Figure 5.12.)

Figure 5.12

FreeStyle Service Manual MN126-1 G

5-7

14. Carefully remove the complete PSA assembly from the center housing by pulling it upwards andslipping compressor molex connector through center section. (See Figure 5.13.)

Figure 5.13

15.

Remove the compressor plate by removing the two screws. (See Figure 5.14.)

Figure 5.14

5-8

FreeStyle Service Manual MN126-1 G16.

Remove the two mounts from the compressor. (See Figure 5.15.)

Figure 5.15

FreeStyle Service Manual MN126-1 G

5-9

5.5

Compressor Replacement
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 Removal

1. Remove PSA system assembly per Section 5.4.
2. Stand the PSA assembly upright and loosen the center bolt using 5/32” Allen wrench.
(See Figure 5.16.)

Figure 5.16

3. Remove the compressor by pulling the compressor away from the PSA assembly.
Care should be taken not to separate manifold from beds.
(See Figure 5.17.)

Figure 5.17

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FreeStyle Service Manual MN126-1 G

4. If either of the two fittings connecting the compressor to the manifold is connectedto 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 tighten the bolt to a torque of
15 in- lbs. (See Figure 5.19.)

Figure 5.19

FreeStyle Service Manual MN126-1 G

5-11

5.5.2Compressor Assembly Installation
To install the new compressor assembly, perform the compressor removal
procedure in reverse order.

After replacing the units compressor, you must reset the hour meter, as described in
section 5.11

5-12

FreeStyle Service Manual MN126-1 G5.6Product Manifold Replacement
1. Remove the PSA system per Section 5.4.
2. Disconnect the tubing assembly from the two barbs on the productmanifold, mixing tank, and one end of the purge tube.
(Figure 5.20 a, b, c)

Figure 5.20aFigure 5.20c
Figure 5.20b

3. Remove the tie wraps that bundle the solenoid value wire together.
4. Loosen and remove the center bolt from the PSA assembly using a 5/32”
Allen wrench. (Figure 5.21)

FreeStyle Service Manual MN126-1 G

5-13

Figure 5.21

5. Holding sieve beds in place, gently pull upward on the product manifold toremove. 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 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 remove the PSA system assembly to replace thesolenoid valve. The Feed B/Waste B OCD valve will require the PSA system to bepartially removed.

1. Remove back cover panel per Section 5.2.2.
2. Determine which valves need to be replaced.
3. Remove the tie-wraps that bundle the value wires.

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FreeStyle Service Manual MN126-1 G

4. Carefully disconnect the Molex connector from the circuit board by pulling on
the Molex connector, not the valve wires.
5. Using a small Phillips screwdriver, remove the two screws fastening the valve.
6. Remove the valve.
7. Place gasket provided into new valve.
8. Fasten new valve using the two screws provided.
9. Re-bundle wires and tie-wrap.
10. Start FreeStyle unit and leak test around the area where the gasket is locatedon the valve.

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 a5/32” Allen wrench.
3. While holding the adsorbent beds, gently pull up on the product manifold toremove from top of product manifold. (Figure 5.22)

Figure 5.22

4. Pull upward on the adsorbent beds to remove from the feed/waste manifold.
(Figure 5.23)
FreeStyle Service Manual MN126-1 G

5-15

Figure 5.23

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 andgently push down until the o-rings are completely seated.
(Figure 5.25)

Figure 5.24

9. Place center bolt through product manifold and tighten to 15 in-lbs.

5-16

FreeStyle Service Manual MN126-1 GFigure 5.25

10. Reassemble FreeStyle, and leak test at bed connections.

5.9

Feed/Waste Manifold Replacement
1. Remove PSA system per Section 5.4.
2. Carefully remove tie-wraps that bundle the solenoid valve wires together.
3. Loosen and remove the center bolt from the PSA assembly using a 5/32”
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. (Figure 5.26)

Figure 5.26

FreeStyle Service Manual MN126-1 G

5-17

5. Remove feed/waste manifold by pulling upward on the manifold. Both fittingsfrom the manifold to the compressor should still be connected to the manifold. If
not, remove fitting(s) from the compressor. (Figure 5.27)
6. Place new feed/waste manifold onto compressor. Gently push manifold down
until compressor fittings are seated into compressor head.

Figure 5.27

5.10

Measuring System Pressure
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 isleak-free. Part No. K1036-1 Pressure Test Kit (gauge and connector) andKI340-1 Adaptor.
7. Put unit into test mode by pressing [1] and [3] simultaneously for five seconds.
After five seconds, the alarm will sound and the LEDs above each flow setting
will illuminate. The unit will then start to automatically pulse in flow setting[3].
Reference Section 6.1 Pressure Profiles.

5-18

FreeStyle Service Manual MN126-1 G5.11

Hour Meter Functionality
GeneralFreeStyle’s hour meter includes two monitoring channels: a historical channel
that cannot be reset, and a maintenance channel ( See Figure A-1). An onboard,
momentary-action pushbutton can be used to toggle the display between the twochannels. While displaying the maintenance channel, the switch can be used toreset the accumulated maintenance hours to zero. Reset the hour meter at each
5,000-hour interval. The historical channel is generally used to monitor total
operating hours over the life of the FreeStyle unit, while maintenance channel
provides the hours logged between service intervals. When the preset maintenanceinterval is reached, an external yellow alarm/service indicator at or displays on the
keypad. This light remains on until the maintenance timer is reset. Note that thehistorical 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” will illuminate
intermittently. In maintenance mode, both a “wrench” symbol and an “h”
are displayed.

5.11.2 Power
When the FreeStyle is connected to AC or DC power, the historical hourmeter reading is displayed along with the “h” icon.
When the FreeStyle isconnectedtoAC or DC power supply, the hour count isdisplayed, but the time does not accumulate. When the FreeStyle compressor
is started when the unit is turned on, the historical hour meter will function.
The “h” icon will flash to indicate that time is being accumulated.

5.11.3 Service LED
When the FreeStyle unit has reached the predetermined interval of 5,000
hours, the alarm/service indicator in the upper left hand corner of the
keypad will display yellow to indicate that the expected checkperformance period has been reached. This light remains on until reset inmaintenance mode.

FreeStyle Service Manual MN126-1 G

5-19

5.11.4 Toggle/Reset Switch
This switch toggles the display or resets the maintenance channel dependingon the activation time and the current display mode.
Upon power-up, the display defaults to the historical display mode. The
display will remain in historical mode until the pushbutton is used to toggle
the display into maintenance mode. The hour meter will remain in thismode until toggled or until power is removed. The “h” icon will remain
on and a “wrench” icon will be displayed below the “h” icon. As with thehistorical display mode, the “h” icon will flash to indicate that time isbeing accumulated and the “wrench” icon will remain on solid. The
historical channel cannot be reset. To reset the maintenance channel,
begin with the module in maintenance mode, and then press thetoggle/reset switch for five seconds. A reset is indicated by a “0” display.

5.12

Hour Meter Replacement

When removing the front cover to replace the hour meter, always use and ESD
safe work area. Also, use an ESD wrist strap to protect electronic circuitry.
1. Remove the front cover housing. (Refer to Section 5.2.)
2. Ensure that all power sources are disconnected. Also disconnect (J2)2 pin connector.
3. Locate the hour meter. (Figure 5.28)

Figure 5.28

5-20

FreeStyle Service Manual MN126-1 G

4. Using a small-head Phillips screwdriver remove (2) 2-56 plastic screws.
(Figure 5.29)

Figure 5.29

5. Gently pull upward to remove 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 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.

FreeStyle Service Manual MN126-1 G

5-21

2. Remove inlet screen
3. Remove internal battery per Section 5.3 Internal Battery Replacement.
4. Remove PSA system as per Section 5.4.
5. Remove 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 carefully lifting upward on the locking tab.
(Figure 5.31)

Figure 5.31

7. Turn unit over so that the main circuit board is facing up.
8. Remove motor controller board as per Section 5.14.

5-22

FreeStyle Service Manual MN126-1 G

9. Remove hour meter as per Section 5.12.
10. Remove cannula nozzle tubing by 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 housing at location J6 on main circuit board.

Figure 5.33

12. Remove six 4-20 self-tapping plastic screws.
(Figure 5.33)

FreeStyle Service Manual MN126-1 G

5-23

Figure 5.34

13. Remove main circuit board from center section assembly.
(Figure 5.35)

Figure 5.35

14. Replace main circuit board; reverse order of steps 1-14.

5-24

FreeStyle Service Manual MN126-1 G

5.14

Motor Controller Board Replacement
When replacing the motor controller circuit board, always use and ESD safe workarea. Also, use an ESD wrist strap to protect electronic circuitry.

1. Lift the motor controller board from the circuit board, being careful not tobreak the connector pins while gently rocking it back and forth to loosen
and disconnect. (Figure 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 on the circuitboard, and the bottom correctly on to J15 on the main circuit board.
(Figure 5.37)

Figure 5.37

FreeStyle Service Manual MN126-1 G

5-25

4. Following alignment, view the replacement board from the side at an angle to
make certain that the pins are aligned properly before seating the connector.

Figure 5.38

5. Gently press the board into place until properly seated. (Figure 5.38)

Figure 5.39

5-26

FreeStyle Service Manual MN126-1 G5.15

Control Panel/Key padReplacement
When replacing the control panel keypad, always use and ESD safe
work area. Also, use an ESD wrist strap to protect electronic circuitry.

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 J8 Ziff (zero insertion force)
connector 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. (Figure 5.40)

Figure 5.40

5. Replace control panel/keypad with new control panel keypad.
6. Check control recessed area of enclosure center section to ensure plastic isclean and all adhesive backing and seal backing from new control panel
keypad.
7. Remove adhesive backing and seal backing from new control
panel/keypad. (Figure 5.41)

Figure 5.41

FreeStyle Service Manual MN126-1 G

5-27

8. Carefully align control/keypad to enclosure recessed control panel area, andpress keypad evenly to ensure 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

10. Bend flex circuit 180o, being careful not to crease or fold the flex circuit.
(Figure 5.44)

If creased or folded, the flex circuit will be damaged

5-28

FreeStyle Service Manual MN126-1 G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

FreeStyle Service Manual MN126-1 G

5-29

12. Insert into J8 Ziff (zero insertion force) connector, making sure that the flex
circuit seats into the connector. Carefully press the Ziff connector locking tab
in a downward direction. Ensure latch seats. (Figure 5.46)

Figure 5.46

13. Replace PSA system.

5-30

FreeStyle Service Manual MN126-1 G

5.16

Fan Replacement

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 from the circuit board to the fan. (Figure 5.47)

Figure 5.47

4.

Remove the four Phillips screws securing the fan to the center section.
(Figure 5.48)

Figure 5.48

FreeStyle Service Manual MN126-1 G

5-31

5. When installing the new fan, be sure the arrow on the side of the fan ispointing 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 locatedon the upper left side.
(Figure 5.49a, b)

Figure 5.49b
Figure 5.49a

6.

Insert screws through each of the four corners of the fan. Secure with kep nut.
Do not over tighten.

7. Connect Molex connecter to the circuit board.

5-32

FreeStyle Service Manual MN126-1 G

6.0 Pressure Profiles
6.1

Pressure Profile Quadrant
The following pressure profiles illustrate the range of normal operating pressure at sea
level. These are approximate pressures. A unit may be out of the range shown below
and still be within specification, for example, in higher altitude environments.

FreeStyle Service Manual MN126-1 G

6-1

7.0 Troubleshooting
7.1

General Troubleshooting
Before reviewing the Troubleshooting Chart, the following steps may be useful toisolate any malfunctions:

1. Make sure all filters are clean.
2. Turn the unit on by pressing flow setting [ 2]. A brief, continuous alarm sounds
to indicate that the FreeStyle has been turned on. The compressor will start torun, you must 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 connections andfittings with leak-testing solution. Protect the circuit board from solution, andstart the leak test at the compressor, following the air flow of the unit to theoxygen 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 othermalfunction.

FreeStyle Service Manual MN126-1 G

7-1

7.2

Troubleshooting Chart
Problem

Unit does not turn on whenconnected to AC power outlet.

Possible Cause
Wall switch power is off.

Solution
Turn on wall or outlet switch
or reset circuit breaker.

No power at outlet.
Universal AC or /DC Power
Supply:AC power supply is notproperly connected to
FreeStyle.

Check connection fromthe AC power supply to
FreeStyle.

Replace AC power supply.

Defective AC power supply.
Unit does not turn on, andDC power supply is properly
connected to an automobile,
RV, accessory outlet.

General malfunction;
alarm is activated.

No power at DC outlet.

Check fuse for DC outlet.

DC power supply is notconnected to accessory
outlet or not connected to
FreeStyle.

Connect DC power supply
to outlet of automobile after
ignition is started.

Universal AC or /DC Power
Supply:DC input cable is notconnected to Universal AC or/DC power supply.

Connect DC cable to
Universal Power supply.

FreeStyle DC power inlet
connector not properly
connected to circuit board.

Replace FreeStyle DC input
cable; connect harness tocircuit board.

Defective DC power supply
Defective keypad control
panel membrane switch.

Replace power supply.
Replace keypad control
panel membrane switch.

Defective motor controller.

Replace motor controller.

Defective circuit board.

Replace circuit board.

Unit overheats and will shut
down. Check air inlet andexhaust vents for obstruction.
Also check inlet filter.

Clear obstructed area of air
inlet and exhaust or replace
dirty filter. Replace fan if notoperating.

Dirty or restricted inlet filter.

Correct any leaks.
Replace inlet filter.

Restricted blowdown muffler.

Replace blowdown
muffler.

Compressor failure.

7-2

Replace compressor.

FreeStyle Service Manual MN126-1 G

ProblemPossible Cause

Solution

Battery duration is lessthan per specification.

Battery not fully charged.

Ensure that battery
charges for at least
3½ hours and all (4) LEDs
are lit solid.

Note: While charging, battery
may not initiate a charge.
Allow unit to cool to operating
temperature before charging.
Will initiate in approx. (20min).

Battery has been stored in adischarged or 100% charged
state for prolonged period oftime or stored in a very hightemperature environment.

Replace battery.

Battery reached cycle life.

Replace battery.

Unit temperature has exceeded
battery operating temperature
5 to 40ºC.

Allow unit to cool
before starting.

Note: Whenever storing
FreeStyle for an extended
period of time, ensure that thebattery the state of charge(SOC) is not depleted orstored 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.

Unit does not starton battery.

Battery reached cycle life
Battery is defective
Battery does not charge.

FreeStyle Service Manual MN126-1 F

Replace Battery

Unit temperature has exceeded
battery operating temperature
5 to 40ºC.

Allow battery to cool before
charging.

Battery is defective.

Replace battery

AC adapter connector isdefective or contact pin is bent.

Replace battery.

Defective AC adapter

Replace AC adapter.

Circuit Board

Replace main circuit
board

7-3

ProblemPossible Cause

Solution

Unit’s temperature is too high.
Blocked air intake or outlet; ordefective fan.

Clear any obstruction in
air intake or outlet filter; or
replace fan as needed.

Leaks.

Correct any leaks.

Restriction exhaust filter.

Replace exhaust filter.

Defective
Compressor

Replace Compressor

Contaminated adsorbent beds.

Replace adsorbent beds.

Defective solenoid valve.

Replace solenoid
valve.

Cannula kinked or not properly
connected.

Check cannula and thecannula connection.

FreeStyle is not turned on.

Turn FreeStyle on to theprescribed setting.

Battery is dead.

Replace battery.

Defective Universal AC /DC power supply.

Replace Universal AC /DC power supply.

OCD sensor defective.

Replace main circuitboard.

OCD solenoid valve defective.

Replace defective
OCD solenoid valve.

Unit continuously flows
oxygen (instead of pulse flow
delivery).

Defective OCD valve.
.

Replace defective OCD
solenoid valve.

Service LED is on.

Service check required.

Service LED does not lightat required 5,000-hourservice.
No hour meter display.

Defective keypad

Replace keypad

Defective hour meter display.

Replace hour meter.

Oxygen concentration is
below specifications intest mode.

Unit does not deliver
oxygen.

7-4

Perform routine service
and reset hour meter inmaintenance mode.

FreeStyle Service Manual MN126-1 G

8.0 Recommended Tools
8.1

Tools for FreeStyle Service and MaintenanceIn 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 andmaintaining the FreeStyle unit.

Figure 8.1a.25-inch hexnut screwdriverand Phillips-head screwdriver

Figure 8.1d
needle nose pliers and side cutters

Figure 8.2
Pressure test gauge
Available from AirSep:
Part No. KI036-1 --Pressure Test Kit (gauge and connector) and KI340-1 (adapter)

FreeStyle Service Manual MN126-1 G

Figure 8.1b
5/32-inch Allen-head driver

Figure 8.1c
0-50 lb torque driveror fixed 15 lb torque driver

Figure 8.1etie-wrap gun

CAIRE Inc.
2200 Airport Industrial Dr., Ste 500
Ball Ground, GA 30107
www.careinc.com

CAIRE and CAIRE Inc. are registered trademarks of CAIRE Inc.
Please visit our website below for a full listing of trademarks.
Trademarks: www.caireinc.com/corporate/trademarks/.

Copyright © CAIRE, Inc. 2020. CAIRE Inc. 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 priornotice and with no further obligation or consequence. All rights not expressly stated herein are reserved by us, asapplicable.

9 July 2020 FreeStyle Service Manual MN126-1 G