FreeStyle™5 Portable
Oxygen Concentrator
Service ManualExpedited Product Warranty Check service is available at 800-482-2473

MN179-1

Rev E

FreeStyle 5 Service Manual

MN179-1 E

Table of Contents
Section 1.0
Introduction
1.1

Equipment Provider Responsibility

1.2

Important Notice and Symbol Explanations

1.3

Definitions of Symbols

1.4

FreeStyle 5 Specifications

1.5

FreeStyle 5 Classifications

Section 2.0
Operation Check andTest of Oxygen Concentration
2.1

Description of Operation

2.2

Operation Check

2.3

Alarm System

2.4

FreeStyle 5 Service Manual

MN179-1 E

2.3.1

Start-up

2.3.2

Battery Status

2.3.3

Low Battery

2.3.4

Discharged Battery

2.3.5

Battery Charging

2.3.6

Battery Fully Charged

2.3.7

Cannula Disconnect

2.3.8

Performance Warning

2.3.9

FreeStyle 5 Capacity Exceeded

2.3.10General Malfunction
Oxygen Concentration Test andSpecificationi – table of contents

Section 3.0
Patient Instructions
3.1

General Instructions
3.1.1 Connecting to external Power
3.1.2

3.2

Optional AirBelt Battery

Routine Maintenance by the Patient
3.2.1
Cleaning the Air Intake
Gross Particle Filter
3.2.2

Alarm/Service Indicator

3.2.3

Usage with Extended Tubing

3.2.4

Usage at Night

Section 4.0
Equipment Provider
Maintenance
4.1

ii – table of contents

Routine Maintenance
4.1.1

Air Intake / Gross Particle Filter

4.1.2

Product Filter Replacement

4.1.3

Compressor Servicing

4.1.4

Recording Maintenance

4.2

Infection Control

4.3

Cleaning and Preparing for New Patient Use

MN179-1 E

FreeStyle 5 Service ManualSection 5.0
Service

FreeStyle 5 Service Manual

5.1

Components

5.2

Housing Removal
5.2.1

Removing Front Cover

5.2.2

Removing Back Cover

5.3

Internal Battery Replacement

5.4

PSA Removal

5.5Compressor Replacement
5.5.1

Compressor Assembly Removal

5.5.2

Compressor Assembly Installation

5.6

Product Manifold Replacement

5.7

Solenoid Valve Replacement

5.8

Adsorbent Bed Replacement

5.9

Feed/Waste Manifold Replacement

5.10
5.11

Measuring System Pressure
Circuit Board Replacement

5.12

Motor Controller Board Replacement

5.13

Control/Key Panel Replacement

5.14

Fan Replacement

MN179-1 E

iii – table of contents

Section 6.0
Typical Pressure Profiles
6.1

Pressure Profile Quadrant

7.1

General Troubleshooting

7.2

Troubleshooting Chart

8.1

Tools for FreeStyle 5 Service and Maintenance

Section 7.0
Troubleshooting

Section 8.0
Recommended Tools

1.0

Introduction
1.1

Equipment Provider Responsibility
All Equipment Providers of the FreeStyle™5 Portable Oxygen Concentrator must
assume responsibilities for handling, operational check-out, patient instruction, 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 tocommunicate discomfort while using this unit may require additional monitoring. Patients withhearing and/or sight impairment(s) may need assistance with monitoring alarms.

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

MN179-1■

Inspect the condition of each FreeStyle 5 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 5 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 5 units only to patients authorized by a physician’sprescription. FreeStyle 5 must not be used as a life-supporting
device.

■Instruct patients how to use FreeStyle 5 in conjunction with thePatient Manual.

■

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

■

Be available to service each patient at any time.

■

Maintain FreeStyle 5 in accordance with Section 4.0.

■

Repair components and replace parts only as outlined in thismanual. Use only AirSep parts for replacement in FreeStyle 5 Oxygen
Concentrators.

FreeStyle 5 Service Manual

Rev E

1.2

Important Notice and Symbol Explanations

As you review both the FreeStyle 5 Patient Manual and this FreeStyle 5 Service
Manual, pay special attention to the WARNING, CAUTION, and NOTE messages.
They identify safety guidelines or other important information as follows:
Warning – Describes a hazard or unsafe
practice that if not avoided can result insevere bodily injury, death or property
damageCaution – Describes a hazard or unsafe
practice that if not avoided can result inminor bodily injury or property damage

Note – Provides information importantenough 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.

MN179-1

FreeStyle 5 Service Manual

Rev E

1.3

Definitions of Symbols

Symbols are frequently used on equipment and/or the manual in preference to words with the intentionof decreasing the possibility of misunderstanding caused by language differences. Symbols can also
permit easier comprehension of a concept within a restricted space.
The following table is a list of symbols and definitions used with the FreeStyle 5 Portable Oxygen
Concentrator.
SymbolDescription

SymbolWarning – Describes a hazard or
unsafe practice that if not avoided canresult in severe bodily injury, death orproperty damage

Class II Equipment, double insulated

Caution – Describes a hazard or unsafe

Safety agency for CAN/CSA C22.2 No.
60601-1-08 M90 for medical electricalequipment

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

Note – Provides information
important enough to emphasize or
repeatKeep unit and accessories dry

Consult the accompanying
documents

Proper disposal of waste of electricaland electronic equipment required
Do not disassemble

Use no oil or grease

RTCA/DO-160 Section 21
Category M Compliant

MN179-1

Description

No smoking

Consult instructions for use

Type BF equipment

Do not expose to open flames

Fragile - handle with careThis side up

FAA-Approved POC

See Instructions

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

FreeStyle 5 Service Manual

Rev E

1.4

FreeStyle 5 Specifications
OxygenConcentration:*

1-5 pulse settings; equivalent to a continuous flow of 90% oxygen +5.5 / 3%
Flow Rate Settings: 1 ,2, 3, 4 & 5 LPM (equivalent to continuous flow)
Setting 1±15%. Settings 2 through 5±10%

Dimensions:10.7 in. high x 6.6 in. wide x 4.4 in. deep (27.2 cm high x 16.8 cm wide x
11.2 cm deep)

Weight:6.2 lb (2.8 kg); 1.8 lb (.8 kg) optional AirBelt

Power:AC Power Supply: Input: 100-240VAC, 50-60Hz, 2A | Output: 15V
DC Power Supply: Input: 12VDC-24VDC, 15A max | Output: 15V, 8A max

Battery duration(Rechargeable
lithium Battery)

5 LPM – 1 hour; 4 LPM – 1 hour, 15 minutes; 3 LPM – 1 hour, 30 minutes;
2 LPM – 2 hours; 1 LPM – 3 hours
Optional AirBelt when combined with the internal battery:
5 LPM – 2 hours, 30 minutes; 4 LPM – 3 hours; 3 LPM – 3 hours, 30
minutes; 2 LPM – 4 hours, 30 minutes; 1 LPM – 7 hours

Battery recharge
time:
Initial startup time

3 hours, 15 minutes; optional AirBelt: 3 hours, 30 minutes

Battery cycle life:

Approximately 300 cycles, then 80% capacity or below.

Audible alarms andpulse visualindicators:

Start-up – audible and visual (GREEN indicator light);
Pulse flow – visual (GREEN indicator light);
Battery condition – battery level (GREEN indicator lights);
Battery Low – audible and visual (YELLOW alarm light);
Battery shutdown – audible and visual (YELLOW alarm light);
Cannula disconnect- audible and visual (YELLOW alarm light);
System overdraw – audible and visual (YELLOW alarm light);
General malfunction – audible and visual (RED alarm light).
Operational temperature: 41°F to 104°F (5°C to 40°C)(Up to 95% RH (non-condensing)
Storage temperature:-4°F to 140°F (-20°C to 60°C)
up to 12,000 ft (3,657.6 m) (483mmHg) Higher altitudes may affectperformance**Temperature
range:**Max Operational
Altitude:

2 minutes* Based on an atmospheric pressure of 14.7 psi (101 kPa) at 70°F (21°C)** Operating outside of these specifications can limit the concentrator’s ability to meet Oxygen Concentration specifications at higher liter flow
rates.

MN179-1

FreeStyle 5 Service Manual

Rev E

1.5

FreeStyle 5 Classifications
Type of protection against electric shock:Class II
Protection from electric shock is achieved by double insulation.
Degree of protection against electric shock:Type BF
Equipment providing a particular degree of protection against electric shock 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. 60601-1-08 M90 Medical Electrical Equipment
Protection against potential electromagnetic or other interference between the equipment and other devices.
Tested to be in compliance with:
EN 60601-1-2 Medical Electrical Equipment, Part 1: General Requirements for SafetyCollateral Standard: Electrical Compatibility - Requirements and Tests
RTCA/DO160 Airborne Equipment, Sec. 21, Emission of Radio Frequency Energy
CISPR 11 / EN 55011 Class B Group 1, “Industrial, Scientific, and Medical (ISM) Equipment”
FCC Part 15, Subpart B – Class B Unintentional Radiators
Method of cleaning and infection control allowed:
Please refer to “Cleaning, Care, and Proper Maintenance” section of this FreeStyle 5 Patient
Manual.
Degree of safety of application in the presence of flammable anesthetic gases:
Equipment not suited for such application.
Mode of operation:
Continuous duty.

MN179-1

FreeStyle 5 Service Manual

Rev E

2.0 Operation Check and Test of Oxygen Concentration
2.1

Description of Operation
Air enters the FreeStyle 5 Oxygen Concentrator through an external air intake /gross particle filter. This filtered air enters the compressor via a muffler that quiets
the compressor’s suction sound.
Next, a two-way solenoid feed valve directs the air into one of two sieve beds that
contain molecular sieve. The unique property of molecular sieve enables it tophysically 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.
In addition to the molecular sieve beds that allow oxygen to be separated fromair, FreeStyle 5 contains an Oxygen Conserving Device (OCD) valve that
controls delivery of high-concentration oxygen to the patient at the point in thebreathing cycle when the patient starts to inhale.
FreeStyle 5 delivers a gas consisting of 90% (+5. 5 -3%) oxygen
at pulse flow rates equivalent from approximately 1–5 LPM.

2.2

Operation Check
AirSep tests every FreeStyle 5 Oxygen Concentrator thoroughly after
manufacture. You must perform the following test to ensure that no damage
occurred in shipping or handling.
1.

Open and inspect all cartons upon delivery. Unpack the unit andremove it from the carton. Inspect the unit itself for damage. If
the exterior of a unit’s carton is damaged, or if the unit itself isdamaged, note this on the freight bill signed by the driver.

2.

Connect the power supply to the unit, and turn the unit on by pressing
flow setting [5]. Check to see that the following sequence occurs:

3.

MN179-1a.

A brief, continuous alarm sounds to indicate that FreeStyle 5
has been turned on.

b.

The compressor runs.

c.

After a 10 second start up is complete,
the fan turns on.

d.

Exhaust air flows from the unit.

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

FreeStyle 5 Service Manual

Rev E

2.3

Alarm System
An audible alarm sounds if FreeStyle 5 has a low battery, senses noinspiration, high temperature ,system overdraw, high or low pressure. If an
alarm sounds, observe which lights are on. The visual and audible alarm
conditions are explained in detail below.

2.3.1

Start-Up

A one-second, audible alarm sounds to indicate start-up. FreeStyle 5 begins
to operate when the alarm stops.

2.3.2

Battery Status

To check the level of charge of the internal battery, press the BATT button on
FreeStyle 5’s keypad. The battery gauge / indicator(s) LEDs above the BATT
button illuminate from 25-100% to indicate the level (capacity) of the internal
battery. At less than 25% capacity, the 25% LED blinks.

2.3.3

Low Battery

As the battery power approaches a low level, a ½ second beep is emitted every
five seconds, and a yellow LED on the battery gauge / indicator(s) will blink
for a ½-second every five seconds. When this occurs, the patient is instructedto connect the FreeStyle 5 AC or DC power supply or change to anothersource of oxygen. The low battery alarm will continue for approximately 2
minutes before FreeStyle 5 stops operating.

2.3.4

Discharged Battery

When the battery is discharged, the unit shuts down. Before this occurs, a ½
second beep sounds every ½ second and the yellow battery LED blinks at thesame rate until any one of the 1-5 settings on the keypad are pressed. After thealarm is turned off, connect the FreeStyle 5 unit to its AC or DC power supply
or change to another source of oxygen immediately. When the FreeStyle 5unit is connected to the AC or DC power supply, FreeStyle 5 operates andthe internal battery recharges simultaneously.

MN179-1

FreeStyle 5 Service Manual

Rev E

2.3.5

Battery Charging

To check the level of charge of the battery, press the button on the battery’s keypad.
The battery gauge/indicator(s) illuminate to indicate the level of battery charge (25-100%).
To charge the FreeStyle 5’s internal battery:§ Connect its AC power supply or DC (auto) power supply into theunit’s power receptacle located on the right side of the FreeStyle
5 unit, and the other end to its proper AC or DC power outlet.
(See Figure 3.1).
§ The FreeStyle 5 internal battery will completely charge from a fully
depleted state in approximately 3 hours and 15 minutes.
Depending upon the temperature of the FreeStyle 5 battery, it can take several minutes for the
charging cycle to start after connecting to power. This is a normal condition and is intended forsafe 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 AC or DC power supply is not connected, the LEDs will turn off within fiveseconds.
The lithium ion rechargeable battery that is used in the FreeStyle 5 unit does not need
to be fully depleted before recharging. It is recommended to charge the battery regardless of thebattery’s capacity level after use.
The battery will charge when the unit is off as well as while the unit is running off the AC or DC
power supply.
Lithium batteries may permanently lose capacity when exposed to extremely hot temperatures withthe batteries fully charged or completely depleted. For extended storage, it is recommended thatbatteries be charged 25 to 50% and remain within a temperature range of 73°F (23°C).

MN179-1

FreeStyle 5 Service Manual

Rev E

2.3.6

Battery Fully Charged

When FreeStyle 5 is connected to an AC or DC outlet and is either inoperation or is off, the green 100% battery gauge/indicators displays toindicate that the battery is fully charged.

2.3.7

Cannula Disconnect (No inspiration detected)

When FreeStyle 5 is operating and does not sense breathing within 15,
consecutive minutes, a constant alarm (beep) sounds, and the yellow alarm
light illuminates simultaneously. If this occurs, check the connection fromthe cannula to the FreeStyle 5 unit, make sure that the nasal cannula ispositioned properly on your face, and ensure that you are breathing
through your nose. (Your physician may recommend the use of a chin strap 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

The performance of FreeStyle 5 can be affected by two conditions.
1) If the user’s breathing rate causes the FreeStyle 5 unit’s capacity to be exceeded.
The amount of oxygen that FreeStyle 5 supplies is dependent on the flow control switch
setting and the breathing rate. If the breathing rate is too fast for the flow selector setting,the capacity of FreeStyle 5 can be exceeded. The patient should reduce activity or consider
locating another source of oxygen.
2) The second condition that can result in decreased performance is a general malfunction(i.e. High temperature, High or Low pressure).
If either of these events occurs, an alarm sounds every five seconds. If
breathing is too fast for the flow selector setting and FreeStyle 5 capacity is
exceeded, the yellow light flashes. If a general malfunction occurs,
a continuous red alarm light appears

2.3.9

FreeStyle 5 Capacity Exceeded

When the patient’s breathing rate has caused the capacity of FreeStyle 5
to be exceeded, a rapid intermittent beep, beep, beep alarm sounds withan intermittent yellow alarm light. When this occurs, oxygen
concentration is outside specifications. The patient should reduce activity,
then if necessary use another source of oxygen as available. Contact yourEquipment Provider.

MN179-1

FreeStyle 5 Service Manual

Rev E

2.3.10

General Malfunction

If a general malfunction of the FreeStyle 5 unit occurs, Two ½ second alarms
sound every 5 seconds, and the red ALARM light turns on. When this occurs,
oxygen concentration is outside specifications. The patient should change toanother source of oxygen and contact the Equipment Provider.

2.4

Oxygen Concentration Test and Specification
To ensure that FreeStyle 5’s oxygen output is within specification, you must
perform an oxygen concentration test. Test the unit upon delivery to a patient andat periodic intervals. Equipment Providers, based upon their own expertise anddocumentation, may establish and implement their own protocol to check oxygen
concentration.
1. Connect the FreeStyle 5 Oxygen Concentrator using an AirSep-supplied AC
adapter only (AirSep Part No.PW020-1) to a 100-240 volt, 50/60 Hz electricaloutlet.
2. Turn unit on by pressing setting 5 on keypad.
3. Simultaneously press and hold settings 1 and 5 for 10 seconds. After 10 seconds, thealarm will sound and the LEDs above each flow setting will illuminate verifying auto pulse
mode.
Control Panel
Flow Settings 1 - 5
Figure 2.1

4. Allow unit to warm-up for 2 minutes before recording oxygen concentration.
5. Connect a calibrated oxygen analyzer to the oxygen outlet and record theunit’s concentration. The specification in test mode is 87% or higher.

MN179-1

FreeStyle 5 Service Manual

Rev E

3.0

Patient Instructions

3.1

General Instructions
It is important that patients thoroughly understand how to operate AirSep’s FreeStyle 5 unit.
This enables proper treatment as prescribed by a qualified, licensed physician. You must
explain that the purpose of this therapy is to alleviate symptoms. If patients experience any
discomfort or if the unit alarms, they must notify their Equipment Provider and/or physician
immediately.
You, as the Equipment Provider, are responsible to ensure that each patient receives the
FreeStyle 5 Patient Manual. Explain each step in the operation of the unit to the patient withreference to the patient manual.

3.1.1 Connecting to External Power
When connecting the AC or DC power supply to the FreeStyle 5 unit, be certain to first
properly align the power cord to this inlet. To do this, take note of the “D”-shaped plug of boththe power cord connector and the FreeStyle 5’s inlet connection. These must be aligned, andthe button on the power cord must be pressed in for removal. This ensures that neither the unit
nor the power accessories are damaged.
Press to remove
power cord.

FreeStyle 5unit’s power
inlet“D”-shaped power cord plugconnects to the FreeStyle 5unit’s “D”-shaped power inlet.

Figure 3.1

3.1.2 Optional AirBelt™ Battery
Instruct patients that connecting an optional AirBelt to the unit by inserting
the power into the unit’s power inlet provides additional total run time, per the specifications.
Note that the unit battery must still have a charge remaining before the external AirBelt isconnected. The patient should be advised to not fully deplete the unit battery as a small amountof power is needed to engage the AirBelt.
To charge the AirBelt battery:
1) Release safetycap from end of the AirBelt cord.
MN179-1

FreeStyle 5 Service Manual

Rev E

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 tostrong impacts or shocks.

2. Connect the AC/DC power supply (included with the AirBelt Accessory kit)
to the end of AirBelts power cord as shown in Figure 3.2.
3. Connect the AirBelt power supply to an AC electrical outlet to recharge.

AirBelt

Connecting the AirBelt cord to thepower supply cord
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
can be damaged. Use only the AirBelt power supply provided to charge AirBelt.

§
§
§
§

The FreeStyle 5 AirBelt will completely recharge from its fully depleted state in approximately 3 ½ hours.
While charging a fully discharged battery, the LED will continue to blink until 25% capacity is reached. The
LED will then turn solid.
Each of the four LEDs, 25% -100%, will blink as stated above, then turn solid when the battery reaches it’scapacity.
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.

Lithium batteries may permanently lose capacity when exposed to extremely hot temperatures withthe batteries fully charged or completely depleted. For extended storage, it is recommended thatbatteries be charged 25 to 50% and remain within a temperature range of 73°F (23°C) +/- 2°C.

Depending upon the temperature of the AirBelt battery, it can take several minutes for the
charging cycle to start after connecting to power. This is a normal condition and is intended
for safe charging.

MN179-1

FreeStyle 5 Service Manual

Rev E

AirBelt does not need to be fully discharged before recharging. It is recommended to charge itafter each use.

If the AirBelt power supply remains connected when it is fully charged, the four LEDs will turnoff within ½ hour.

MN179-1

FreeStyle 5 Service Manual

Rev E

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 an alarmindicator 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 5 unit operates in a harsh environment, for example, a house heated bywood, kerosene, or oil, or one with excessive cigarette smoke.

1.

The air intake / gross particle filter can be found on thelower front of the FreeStyle 5, as seen in the photo below.

Air Intake /Gross
Particle Filter
Cover

Figure 3.2

MN179-1

2.

Pull the filter cover off the front of the FreeStyle 5 andremove the filter. Wash filter in a warm water and soap
solution.

3.

Rinse the filter thoroughly, and remove excess water with a soft,absorbent towel. Ensure that the filter is dry before replacing it.

4.

Replace the dry filter into the filter cover.

5.

Place the filter cover back into housing and push back onto the
FreeStyle 5 unit.

FreeStyle 5 Service Manual

Rev E

3.2.3 Nasal Cannula
AirSep recommends a nasal cannula with 7 ft (2.1 m) of tubing, AirSep Part No. CU002-1 orsuitable cannula. Other lengths of non-kinking / star channel cannula can be used for a total
length of up to 25 ft (7.6 m) maximum.

3.2.4 Usage During Sleep
AirSep recommends that FreeStyle 5 should be used while sleeping only under
the direction of their clinician. In addition, some patients who mouth-breathe
may benefit from the use of a chin strap

Always follow the cannula manufacturer’s instructions for proper use. Consult yourlicensed 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 5unit can properly detect inspiration for oxygen delivery.

MN179-1

FreeStyle 5 Service Manual

Rev E

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 theseconcentrators as long as the concentrator remains within specifications. To ensurethat the unit’s output of oxygen is within specification, you must establish andimplement a protocol to check oxygen concentration upon delivery to a patient andat 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 can easily 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 5 unit operates ina harsh environment — a house heated by wood, kerosene, or oil, or one withexcessive 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.

MN179-1

FreeStyle 5 Service Manual

Rev E

4.1.3Compressor Servicing

As the Equipment Provider, you are responsible for monitoring thelife 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 5 unit, including
hours and dates of service.

4.2

Infection Control
With growing concern about possible cross infection from home oxygen
equipment from one home care patient to another, a clarification on this topic isnecessary. The organisms of most concern are M. Tuberculosis, HIV, and Viral
Hepatitis. These are potentially pathogenic.
Tuberculosis can survive outside the human body, but its mode of transmission
is by droplet nuclei. When infected individuals cough, they release droplet nuclei
into the air, and these carry the Tuberculosis organism. These droplet nuclei may
be breathed in by another person, but prolonged exposure to the infected person isusually necessary for infection to occur.
HIV and Viral Hepatitis are both viruses that are not living cells themselves but
can duplicate when in a living “host” cell. Both of these organisms are usually
passed on by person-to-person contact, and both need to be in the human body tosurvive. Once outside the body, viruses do not survive.

4.3

Cleaning and Preparing for New Patient Use
When you remove FreeStyle 5 from a patient’s home, always detach and disposeof the used nasal cannula. Clean the exterior of FreeStyle 5 with a mild householdcleaner applied with a damp cloth or sponge. Pay special attention to the oxygen
outlet for the cannula connection to make sure it remains free of dust, water, andparticles. Be careful not to get any liquid into the interior of the unit.
Next, clean the exterior with a common chemical disinfectant before any other
patient uses the unit. Do not use liquid directly on the FreeStyle 5 unit to cleanit.

MN179-1

FreeStyle 5 Service Manual

Rev E

Do not use liquid directly on the FreeStyle 5 unit to clean it. A list of undesirable chemical
agents includes but is not limited to, the following, according to the plastics manufacturer:
alcohol and alcohol-based products, concentrated chlorine-based products (ethylene
chloride), and oil-based products (Pine-Sol, Lestoil). These are NOT to be used to clean theplastic housing on FreeStyle 5, they can damage the units plastic.

Clean or replace the air intake / gross particle filter with warm soapy water
between each patient’s use. The patients should be instructed to clean this filter at
least once per week, depending on the environment, during normal operation.
Change the felt filter after 5,000 hours of use.
Change the product filter after 10,000 hours of use. It is not necessary to change
this filter between patients even if the previous patient had a communicabledisease or infection.
Allow FreeStyle 5 to air dry, and then re-test oxygen concentration before
you return the unit to your inventory.
*Make the bleach solution a 1:100 dilution of 5.25% sodium hypochlorite. Mix
one part household bleach (e.g., Clorox with 99 parts cold tap water). To measure
the solution easily, take 1/4 cup of household bleach, and mix it with a gallon ofcold tap water. Allow the mixture to sit on potentially contaminated surfaces for
10 minutes.

AirSep does not recommend the sterilization of this equipment.

5.0

Service
5.1

Components
The design of AirSep’s FreeStyle 5 Portable Oxygen Concentrator allows foreasy access and removal of most components. This allows you to performscheduled maintenance and to repair and replace parts with minimal time andeffort.

For your safety, be sure to disconnect the FreeStyle 5 Universal AC / DC adaptor from thepower outlet before you service the concentrator.

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

MN179-1

FreeStyle 5 Service Manual

Rev E

5.2

Housing Removal
5.2.1

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.

Figure 5.2

MN179-1

FreeStyle 5 Service Manual

Rev E

5.3

Internal Battery Replacement
When removing the front cover to remove the battery, always use ESD safeguard to protect
the electronic circuit board from damage.

1. Remove the front housing.
2. Carefully disconnect the 8-pin (J12) and 2-pin (J14) connector from thebattery pack to the circuit board. (See Figures 5.3 and 5.4.)

Figure 5.3

Figure 5.4

3. The battery pack is fastened using Velcro. To remove the pack, simply pullon battery. (See Figure 5.5.)

Figure 5.5

4. Take new battery pack with the wire harnesses to the left, and press firmly
into the battery cradle. Gently pull on battery to ensure the Velcro has engaged.
5. Connect the 8-pin (J12) and 2 pin (J14) connector in their respective
connectors on the circuit board.
When the battery is disconnect and reconnected to the FreeStyle 5, it will not
power the unit until it is initialized by connecting FreeStyle to external power.
6. Place front housing back on and fasten.
7. Plug the FreeStyle 5 AC or DC power supply to initialize and charge battery.
MN179-1

FreeStyle 5 Service Manual

Rev E

5.4

PSA Removal
1. Disconnect the FreeStyle 5 unit from the AC or DC outlet.
2. Remove the front housing.
3. Remove the battery. Care must be taken when removing (J12) and (J14)connector.
4. Disconnect the 8-pin connector (J17) with multi-color wires from thecircuit board. Care must be taken not to pull on wires. (See Figure 5.6.)

Figure 5.6

5. Remove and discard foam from the top of the oval opening.
(See Figure 5.7.)

Figure 5.7

MN179-1

FreeStyle 5 Service Manual

Rev E

The following two steps (6 and 7) require extreme caution to ensure the black pressure
sensor (U9) is not damaged.

6. Remove the adjustable nozzle by gently pulling it upward until it comes out of
the left side retaining clips. When the left side is out, pull the nozzle to the left
to completely remove it from its cradle. (See Figure 5.8.)

Figure 5.8

7. Carefully disconnect the 1/8” OD tubing coming from the back of theunit to the limiting orifice. (See Figure 5.9.)

Figure 5.9

MN179-1

FreeStyle 5 Service Manual

Rev E

8. Remove the 8-32 x ¼” black Phillips screws located in the center of outlet
nozzle cradle. (See Figure 5.10)

Figure 5.10

9. Turn unit over and remove the back housing.

Figure 5.11

10. Disconnect the 1/8” OD tube from the Y-connector or T connector (which is located at theback of the PSA system) that connects to the pressure transducer on the left side.

Figure 5.12

MN179-1

FreeStyle 5 Service Manual

Rev E

11. Using needle nose pliers, disconnect all the valves from the circuit board, carefully noting where eachvalve is connected. Do not disconnect by pulling on the wires. (See Figure 5.13 and 5.14.)

Figure 5.13

Figure 5.14

12. Carefully remove the complete PSA assembly from the center housing by pulling it upwards
and slipping compressor molex connector through center section. (See Figure 5.15.)

Figure 5.15

MN179-1

FreeStyle 5 Service Manual

Rev E

13.

Remove the compressor plate by removing the two screws. (See Figure 5.16.)

Figure 5.16

14.

Remove the two mounts from the compressor. (See Figure 5.17.)

Figure 5.17

MN179-1

FreeStyle 5 Service Manual

Rev E

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 a5/32” Allen wrench. (See Figure 5.18.)

Figure 5.18

2. Remove the compressor by pulling the compressor away from the
PSA assembly. Care should be taken not to separate manifold frombeds. (See Figure 5.19)

F

Figure 5.19

MN179-1

FreeStyle 5 Service Manual

Rev E

4. If either of the two fittings connecting the compressor to the manifold is connected to thecompressor, remove it and insert it into the manifold. (See Figure 5.20.)

Figure 5.20

5. Connect the new compressor to the PSA assembly, and tighten the bolt to a torque of 15 inlbs. (See Figure 5.21.) Be sure the gasket is in place.

Figure 5.21

5.5.2

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

MN179-1

FreeStyle 5 Service Manual

Rev E

After replacing the unit’s compressor, you must reset the hour meter.
(Refer to instructions for reading and recording hours in the CD Kit P/N KI406-1)

5.6

Product Manifold Replacement
1. Remove the PSA system per Section 5.4.
2. Disconnect the tubing from the barb on the product manifold.

Figure 5.22

Figure 5.23

MN179-1

Figure 5.24

FreeStyle 5 Service Manual

Rev E

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

Figure 5.25

5. Holding sieve beds in place, gently pull upward on the product manifold to remove.
Keep tubing assembly in place.
6.

Align new product manifold with the outlet of the sieve beds, and gently push
manifold down into place.

7. Reconnect tubing to new product manifold.
8. Place center bolt through product manifold and tighten to 15 in-lbs.

MN179-1

FreeStyle 5 Service Manual

Rev E

5.7

Solenoid Valve Replacement
1. Remove back cover panel per Section 5.2.2.
2. Determine which valves need to be replaced.
3. Remove the tie-wraps that bundle the value wires.
4. Carefully disconnect the Molex connector from the circuit board by pulling on the
Molex connector, not the valve wire.
5. Using a small Phillips screwdriver, remove the two screws fastening the valve.
6. Remove the valve.
7. Verify two o-ring seals are installed on the new valve.
8. Fasten new valve using the two screws provided.
9. Re-bundle wires and tie-wrap.
10. Start FreeStyle 5 unit and leak test around the area where theo-rings are located on the valve.

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 be partiallyremoved.

MN179-1

FreeStyle 5 Service Manual

Rev E

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 5.26

4. Pull upward on the adsorbent beds to remove from the feed/waste manifold.

MN179-1

FreeStyle 5 Service Manual

Rev E

Figure 5.26

Figure 5.27

5. Remove the plugs from the top and bottom of the new adsorbent beds.
6.

Place a 1.5 mm CS X 6 mm ID o-ring on the bottom cap of the adsorbent
bed cap.

7. Place a 1.5 mm CS X 3.5 mm ID o-ring on the top cap of the adsorbent
beds.
8.

Align product manifold with the outlet on the new adsorbent beds andgently push down until the o-rings are completely seated.

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

Figure 5.28

10. Reassemble FreeStyle 5, and leak test at bed connections
MN179-1

FreeStyle 5 Service Manual

Rev E

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 topof sieve bed connected to product the product manifold.

Figure 5.29

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.
6. Place new feed/waste manifold onto compressor. Gently push manifold down
until compressor fittings are seated into compressor head.

Figure 5.30

MN179-1

FreeStyle 5 Service Manual

Rev E

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 [5] simultaneously for 10 seconds.
After 10 seconds, the alarm will sound and the LEDs above each flow setting
will illuminate. The unit will then start to automatically pulse in flow setting[5].
Reference Section 6.1 Pressure Profiles

MN179-1

FreeStyle 5 Service Manual

Rev E

5.11

Circuit Board Replacement
When replacing the circuit board, always use and ESD safe work area. Also, use an ESD
wrist strap to protect electronic circuitry.

1. Remove front and rear cover as per Section 5.2.
2. Remove internal battery per Section 5.3 Internal Battery Replacement.
3. Remove PSA system as per Section 5.4.
4. Remove DC power input connector from location J13, pin 3 connector on
circuit board.

Figure 5.31

5. Disconnect control panel/keypad flex circuit from J9 & 10 Ziff (zero insertion
force) connector by carefully lifting upward on the locking tab.

Figure 5.32

MN179-1

Figure 5.33

FreeStyle 5 Service Manual

Rev E

6. Turn unit over so that the main circuit board is facing up.
7. Remove motor controller board as per Section 5.12.
8. Remove cannula nozzle tubing by cutting tie-wrap (use small-size cutter).
Carefully pull tubing from nozzle barb.

Figure 5.34

9. Disconnect fan connector using needle-nose pliers, carefully pulling upward
on fan connector housing at location J15 on main circuit board.

Figure 5.35

MN179-1

FreeStyle 5 Service Manual

Rev E

10. Remove eight 4-20 self-tapping screws.

Figure 5.36

11. Remove main circuit board from center section assembly.

Figure 5.37

12. Replace main circuit board; reverse order of steps 1-12

MN179-1

FreeStyle 5 Service Manual

Rev E

5.12

Motor Controller Board Replacement
When replacing the motor controller circuit board, always use and ESD safe work area.
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 5.38

2. Before replacing the board, ensure that the main circuit board andall and pins are straight and unbroken (intact).
3. Locate the side with the single row connector. Install on the circuitboard with the single row connector facing the top of the unit.

Figure 5.39

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.
MN179-1

FreeStyle 5 Service Manual

Rev E

5. Gently press the

Figure 5.40

board into place until properly seatedFigure 5.41

MN179-1

FreeStyle 5 Service Manual

Rev E

5.13

Control Panel/Key Pad Replacement

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 J9 & 10 Ziff (zero insertion
force) connectors by carefully lifting upward on locking tab.
4. Remove the flex tab circuit from rib guides, and peel off the control panel/
keypad from the center enclosure.

Figure 5.42

5. Replace control panel/keypad with new control panel keypad.
6. Check control recessed area of enclosure center section to ensure plastic
is clean and all adhesive backing and seal backing from new control panel
keypad.

MN179-1

FreeStyle 5 Service Manual

Rev E

7. Remove adhesive backing and seal backing from new control panel/keypad.

Figure 5.43

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 5.44

9. Route the flex circuit from control panel keypad notched area of control panel
enclosure section.

MN179-1

FreeStyle 5 Service Manual

Rev E

Figure 5.45

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

If creased or folded, the flex circuit will be damaged

Figure 5.46

11. Insert flex circuit into rib section and connect flex circuit with carbon contacts
facing toward you.
12. Insert into J9 & 10 Ziff (zero insertion force) connectors, making sure that the flex
circuit seats into the connectors. Carefully press the Ziff connector locking tabs in a
downward direction. Ensure latch seats.
MN179-1

FreeStyle 5 Service Manual

Rev E

Figure 5.48

Figure 5.47

13. Replace PSA system.

MN179-1

FreeStyle 5 Service Manual

Rev E

5.14

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 (J15) from the circuit board to the fan.

Figure 5.49

4.

Remove the four Phillips screws securing the fan to the center section.

Figure 5.50

MN179-1

FreeStyle 5 Service Manual

Rev E

5. When installing the new fan, be sure the arrow on the side of the fan is pointing
outwards toward the front cover. This arrow indicates the direction of the airflow of
the fan. Be sure the two wires coming from the fan are located on the upper rightside.

Figure 5.51

Figure 5.52

6. Insert screws through each of the four corners of the fan. Secure with kep nut.
Do not over tighten.
7. Connect Molex connector (J15) to the circuit board.

MN179-1

FreeStyle 5 Service Manual

Rev E

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.

MN179-1

FreeStyle 5 Service Manual

Rev E

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 [5]. A brief, continuous alarm sounds
to indicate that the FreeStyle 5 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 [5] simultaneouslyfor 10 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 othermalfunctions.

MN179-1

FreeStyle 5 Service Manual

Rev E

7.2

Troubleshooting Chart
Problem

Unit does not turn on, andAC power supply is properly
connected to a wall outlet.

Possible Cause
Wall switch power is off.

Turn on wall or outlet switch.

No power to unit.

Reset household circuit
breaker.

AC power supply is notproperly connected to
FreeStyle 5.

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

General malfunction;
alarm is activated.

MN179-1

Solution

Check connection from theAC adapter to FreeStyle 5.

Defective AC power supply.

Replace AC adapter.

No power at DC outlet.

Check fuse for DC outlet.

DC power supply is notconnected to accessory
outlet or not connected to
FreeStyle 5.

Connect DC power supply tooutlet of automobile after
ignition is started.

FreeStyle 5 DC power
inlet connector notproperly connected tocircuit board. Checkharness.

Replace FreeStyle 5 DC inlet
harness; connect harness tocircuit board.

Defective DC power supply

Replace power supply.

Bad connection at keypadcontrol connector

Check keypad connection

Defective keypad control
panel membrane switch.

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.

Check for leaks.

Correct any leaks.

Restricted inlet filter.

Replace inlet filter.

Compressor failure.

Replace compressor.

FreeStyle 5 Service Manual

Rev E

ProblemBattery duration is lessthan per specification.

Possible Cause

Solution

Battery not fully charged.

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

Battery has been stored ina discharged or 100%charged state forprolonged period of time orstored in a very hightemperature environment.

Replace battery.

Note: Whenever storing
FreeStyle 5 for an extended
period of time, ensure thatthe battery the state ofcharge (SOC) is not depleted
or stored at 100%. Boththese conditions can result in
unrecoverable capacity loss.
The recommend SOC is
25% to 50% for long-term
storage. The recommended
storage temperature is 23º C± 2º C.

Battery reached cycle life.

Replace battery.

Unit does notstart on battery.

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

Allow unit to cool
before starting.

Battery reached cycle life
Battery is defective

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.

Note: While charging,battery may not initiate acharge. Allow unit battery
time to drop to operating
temperature before charging.
Will initiate in approx. (20min).

Battery does not charge.

Defective AC adapter

MN179-1

FreeStyle 5 Service Manual

Replace AC adapter.

Rev E

Problem
Oxygen concentration
is below specificationsin test mode.

Possible Cause

Solution

Unit’s temperature is toohigh. Blocked air intake oroutlet; or defective fan.

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

Leak

Correct any leaks.

Restriction
felt.

Unit does not deliver
oxygen.

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

inexhaustReplace exhaust filter.

Compressor has reached its
expected life.

Replace compressor.

Contaminated absorbent beds.

Replace absorbent beds.

Defective solenoid valve.

Replace manifold or solenoid
valve.

Cannula kinked or not properly
connected.

Check cannula and thecannula connection.

FreeStyle 5 is not turned on.

Turn FreeStyle 5 on to theprescribed setting.

Battery is dead.

Replace battery.

Defective AC or DC
power supply.

Replace AC or DC power
supply.

OCD sensor defective.

Replace FreeStyle 5
main circuit board.

OCD solenoid valve defective.

Replace product manifold or
OCD defective valve.

Defective OCD valve andvolume tank.

Replace product manifold.

.

MN179-1

FreeStyle 5 Service Manual

Rev E

8.0 Recommended Tools
8.1

Tools for FreeStyle 5 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 5 unit.

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

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

Figure 8.1d
needle nose pliers and side cutters

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

Figure 8.1etie-wrap gun

Figure 8.2
Pressure test gauge
Available from AirSep:
Part No. K1036-1 --Pressure Test Kit (gauge and connector) and KI340-1 (adapter)

MN179-1

FreeStyle 5 Service Manual

Rev E

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

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.

CAIRE Copyright ã 2019 MN 179-1 E