AirSep NewLife Elite User manual

AirSep Corporation • 401 Creekside Drive • Buffalo, NY 14228-2085 USA
Telephone: [phone] • 24-Hour Fax: [phone]
NewLife® Elite / NewLife®
Oxygen Concentrator
Service Manual
0459

AirSep®Corporation
NewLife®Elite Service Manual
AirSep®is a registered trademark of AirSep Corporation.

NewLife®Elite and NewLife®are registered trademarks of AirSep Corporation.
MN105-1 Rev. C 02/14
Expedited Product Warranty Check service is always at your ngertips with AirSep:
http://www.airsep.com/Support/Warranty_Information.aspx
OR
In the US or Canada,
dial 866-873-9277

AirSep®Corporation
NewLife®Elite Service Manual
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 Functional Specications 1-4
Section 2.0
Operation Check
and Oxygen
Concentration Test
2.1 Description of Operation 2-1
2.2 Operation Check 2-1
2.3 Alarm System 2-2
2.3.1 Battery Test 2-2
2.3.2 Power Failure Alarm Test 2-2
2.4 Oxygen Concentration Test and Specication 2-3
Section 3.0
Patient Instructions
3.1 General Instructions 3-1
3.2 Routine Maintenance by the Patient 3-1
3.2.1 Cleaning the Air Intake
Gross Particle Filter 3-1
3.2.2 Checking the Alarm System Battery 3-2
Section 4.0
Equipment Provider
Maintenance
4.1 Routine Maintenance 4-1
4.1.1 Air Intake Gross Particle Filter/GPF 4-1
4.1.2 Product Filter Replacement 4-1
4.1.3 Optional Filter Replacement 4-2
4.1.4 Battery Replacement 4-2
4.1.5 Recording Maintenance 4-3
4.2 Cleaning and Infection Control 4-3
4.2.1 Preparing for New Patient Use 4-4
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AirSep®Corporation
NewLife®Elite Service Manual
Section 5.0
Service
5.1 Components 5-1
5.2 Cabinet Removal 5-1
5.2.1 Removing Side Panel(s) 5-1
5.2.2 Removing Back Panel 5-1
5.2.3 Removing Lower Front Cover 5-1
5.2.4 Removing Control Panel 5-1
5.2.5 Superstructure 5-1
5.2.6 Caster Replacement 5-2
5.3 Compressor 5-2
5.3.1 Compressor Replacement 5-3
5.3.2 Capacitor Replacement 5-4
5.4 Solenoid Valves 5-4
5.4.1 Feed or Waste Valve Rebuilding 5-4
5.4.2 Feed or Waste Valve Reassembly 5-5
5.4.3 Solenoid Valve Coil Replacement 5-5
5.5 Sieve Bed Replacement 5-6
5.5.1 Sieve Bed Removal 5-6
5.5.2 Sieve Bed Installation 5-7
5.6 Cabinet Fan Replacement 5-7
5.7 Circuit Board Replacement 5-8
5.7.1 Circuit Board Removal 5-8
5.7.2 Circuit Board Installation 5-9
5.8 Product Regulator Check and Setting 5-10
5.8.1 Setting Product Regulator for
Normal Operation 5-10
5.8.2 Product Regulator Lockout 5-10
5.8.3 Back Pressure Correction at 5 lpm 5-11
5.8.4 Product Regulator Cleaning or
Rebuilding 5-12
5.9 High or Low Pressure Switch Replacement
(In Equipped Units) 5-13
5.10 Circuit Breaker Replacement 5-14
5.10.1 Circuit Breaker Removal 5-14
5.10.2 Circuit Breaker Installation 5-14
5.11 ON/OFF Power Switch Replacement 5-14
5.11.1 ON/OFF Power Switch Removal 5-14
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AirSep®Corporation
NewLife®Elite Service Manual
5.11.2 ON/OFF Power Switch Installation 5-15
5.12 Buzzer Replacement 5-15
5.13 Hour Meter Replacement 5-15
5.14 Flowmeter Replacement 5-16
5.14.1 Flowmeter Removal 5-16
5.14.2 Flowmeter Installation 5-16
5.15 Power Cord Replacement 5-16
Section 6.0
Troubleshooting
6.1 Operating Pressure Test 6-1
6.1.1 High Operating Pressure 6-1
6.1.2 Low Operating Pressure 6-2
6.2 General Troubleshooting 6-2
6.3 Troubleshooting Chart 6-4
6.4 Tool Kit and Pressure Test Gauge 6-7
Appendix
Exploded
Drawings Figure 1: Control Panel Assembly A-1
Figure 2: Main Structure Assembly A-2
Figure 3: Base and Cabinet Components A-3
Figure 4: Test Block Assembly A-4
Figure 5: Valve Block Assembly A-5
Figure 6: Compressor Assembly A-6
Figure 7: Adsorption Bed Assembly A-7
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AirSep®Corporation
NewLife®Elite Service Manual
1.0 Introduction
1.1 Equipment Provider Responsibility
All Equipment Providers of the NewLife®Elite/NewLife®Oxygen Concentrator
must assume responsibilities for handling, operational check-out, patient
instruction, and maintenance. These responsibilities are outlined below and
throughout this manual.
WARNING
NewLife units must not be used for or with any life-
supporting applications. Geriatric, pediatric, or any other
patients unable to communicate discomfort while using
this machine may require additional monitoring. Advise
patients to immediately notify their Equipment Providers
and/or physicians in case of an alarm or any discomfort.
As an Equipment Provider, you must do all of the following:
 Inspect the condition of each NewLife unit immediately upon
delivery to your business location. Note any sign of damage, external
or internal, on the delivery receipt, and report it directly to both the
freight company and AirSep Corporation immediately.
 Check the operation of each NewLife before delivery to a patient.
Always operate the unit for a reasonable length of time and check that
the oxygen concentration level is within specications as referred to in
Section 2.4. (Test the battery and power disconnect alarm as described
in Section 2.3 of this manual.)
 Deliver NewLife units only to patients authorized by a physician’s
prescription. The NewLife must not be used as a life-supporting
device. A backup supply of oxygen must be available.
 Instruct patients how to use the NewLife in conjunction with the
Patient Manual.
 Instruct patients to notify their physicians and/or Equipment
Providers if they experience any signs of discomfort.
 Instruct each patient how to perform routine maintenance of the air
intake gross particle lter and how to check the alarm system battery.
(Refer to Section 3.2.)
 Be available to service each patient at any time.
 Maintain the NewLife in accordance with Section 4.0.
Repair components and replace parts only as outlined in this
manual. Use only AirSep parts for replacement in NewLife Oxygen
Concentrators.
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AirSep®Corporation
NewLife®Elite Service Manual
1.2 Important Notice and Symbol Explanations
As you read the manual, pay special attention to the WARNING, CAUTION, and
NOTE messages. They identify safety guidelines or other important information
as follows:
WARNING: Describes a hazard or unsafe practice that can result in
severe bodily injury or death.
CAUTION: Describes a hazard or unsafe practice that can result in
minor bodily injury or property damage.
NOTE: Provides information important enough to emphasize or
repeat.
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NewLife®Elite Service Manual
The following harmonized symbols (pictograms), used for non-
English language countries, will be located on the exterior of
the NewLife unit:
Read the Patient Instruction Manual.
No smoking within ve feet of this device, oxygen-
carrying tubing, or accessories.
No open ames within ve feet of this device, oxygen-
carrying tubing, or accessories.
No oil, grease or petroleum-based products on or near
the unit.
Oxygen outlet
Oxygen alarm
Nebulizer option
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NewLife®Elite Service Manual
1.3 FunctionalSpecications
Dimensions: 28.5 in. high, 15.7 in. wide, 14.5 in. deep
(72.4 cm high, 40.0 cm wide, 36.8 cm deep)
Weight: 54.0 lb; shipping weight - 59.0 lb
(24.5 kg; shipping weight - 29.0 kg)
Electrical 120 VAC, 60 Hz, 4 amps, 350 watts
Requirements: 230 VAC, 50 Hz, 4 amps, 350 watts
Capacity: 5 liters per minute at 90% oxygen
(Based on 70°F [21°C] at sea level)
Accuracy: Flowmeter ±5% full scale. (Based on
precalibrated analysis.)
Concentration: 1–3 liters per minute at 95% + 0.5/ - 3%
4 liters per minute at 92% + 3.5/ - 3%
5 liters per minute at 90% + 5.5/ - 3%
Response Time: Allow 5 minutes to attain maximum oxygen
concentration.
Positioning: Operate the unit in an upright position, maintaining
at least six inches of open space on all sides for
ventilation.
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AirSep®Corporation
NewLife®Elite Service Manual
2.0 Operation Check and Oxygen Concentration Test
2.1 Description of Operation
Air enters the NewLife Oxygen Concentrator through an external air intake
gross particulate lter. This ltered air enters the compressor via a suction
resonator, which quiets the compressor’s suction sound. Pressurized air then
exits the compressor and passes through a heat exchanger. The heat exchanger
reduces the temperature of the compressed air. Next, a two-way solenoid
feed valve directs the air into one of two sieve beds that contain molecular
sieve. The unique property of molecular sieve enables it to physically attract
(adsorb) nitrogen when air passes through this material, thus producing high
concentration oxygen.
There are two sieve beds: while one produces high concentration oxygen, the
other is purged of the nitrogen it adsorbed (collected) while it made oxygen.
Each adsorber produces oxygen for approximately eight seconds and delivers it
to the product tank. Oxygen exits the product tank through a pressure regulator,
product lter, ow control valve, owmeter, and nally exits the unit. The ow
control valve, which is part of the owmeter, controls the amount of oxygen
delivered to the patient. The NewLife unit delivers up to 95.5% pure oxygen at
ow rates from 1–5 lpm.
NOTE: NewLife Elite OxiSilent™ option incorporates an additional felt intake
lter prior to air entering the compressor.
2.2 Operation Check
AirSep tests every NewLife Oxygen Concentrator thoroughly after manufac-
ture. You must perform the following test to ensure that no damage occurred
in shipping or handling.
1 Open and inspect all cartons (that contain units) upon delivery. Unpack
the unit and remove it from the carton. Inspect the unit itself for
damage. If the exterior of a unit’s carton is damaged, or the unit itself
is damaged, note it on the freight bill signed by the driver.
2 Plug in the power cord of the unit, and set the ON/OFF switch to the
ON position. Check to see that the following occurs:
a. A continuous alarm loudly sounds for approximately
ve seconds to indicate that the battery for the alarm
is good. See the troubleshooting chart in Section 6.0 of
this manual if the unit’s alarm does anything other than
sound loudly for ve seconds.
b. The compressor runs. Listen for the sound.
c. Exhaust air ows out of the bottom of the unit.
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AirSep®Corporation
NewLife®Elite Service Manual
d. OPTIONAL: The Oxygen Monitor’s amber light
remains on until the oxygen concentration reaches 85%
± 3% (approximately two minutes).
3 Turn the owmeter adjustment knob counterclockwise until it stops
(wide open).
The maximum ow should register 5.5 lpm (the 5.5 lpm line should
appear to split the middle of the owmeter ball) with no connections
at the oxygen outlet. If not, refer to Section 5.8.1 to set the product
regulator.
4 Perform an oxygen concentration test, as described in Section 2.4.
2.3 Alarm System
The NewLife Oxygen Concentrator is equipped with a battery-powered alarm
system, which sounds a continuous and loud alarm when a power failure
occurs. It sounds an intermittent alarm if the high or low pressure indicators
are activated or if the optional oxygen monitor detects lower than therapeutic
levels of oxygen concentration. The alarm remains on until you correct the alarm
condition or you set the ON/OFF switch to the OFF position. Refer to Section
6.0 for a list of probable alarm causes.
2.3.1 Battery Test
Each time the NewLife unit is turned on, a ve-second audible alarm
sounds to indicate the condition of the battery.
NOTE
The audio alarm must sound loudly for
approximately ve seconds each time the unit is
turned to ON to indicate the battery is in good
condition.
2.3.2 Power Failure Alarm Test
To test the power failure alarm, take the following step:
Unplug the unit, and set the ON/ OFF switch to the ON
position.
This should immediately activate the audio alarm. If it does not, refer
to the troubleshooting chart in Section 6.0 of this manual.
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AirSep®Corporation
NewLife®Elite Service Manual
2.4 OxygenConcentrationTestandSpecication
To ensure that the unit’s output of oxygen is within specication, you
must perform a test of oxygen concentration. Test the unit upon delivery
to a patient and at periodic intervals. Equipment Providers, based on
their expertise and documentation, may establish and implement their
own protocol to check oxygen concentration. The interval established
may be longer or shorter than 90 days, which is AirSep’s default time
period for providers who do not choose to establish their own protocol.
1 If an oxygen humidier bottle is used, remove it from the oxygen
outlet.
2 Connect a calibrated oxygen concentration analyzer to the oxygen
outlet.
3 Verify that the product ow rate delivered by the unit matches the
patient’s prescription and does not exceed the capacity of the unit.
4 Set the unit’s ON/OFF power switch to the ON position. (It takes
approximately five minutes for the oxygen concentration to
stabilize.) Take oxygen concentration readings every 60 seconds
until the analyzer shows that two consecutive readings are the
same.
5 Disconnect the oxygen analyzer, and reconnect the humidier
bottle (if used) and any other equipment/ accessories that may be
required.
6 Adjust the owmeter adjustment knob to the prescribed level.
NOTE
Do not measure oxygen concentration output
after the product stream passes through a
humidier bottle, or erroneous readings will
result.
AirSep NewLife Oxygen Concentration Specications
Liter
Flow Specication In Spec
1–3 lpm 95% + 0.5/ - 3% 92% or higher
4 lpm 92% + 3.5/ - 3% 89% or higher
5 lpm 90% + 5.5/ - 3% 87% or higher
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AirSep®Corporation
NewLife®Elite Service Manual
3.0 Patient Instructions
3.1 General Instructions
It is important that patients thoroughly understand how to operate the AirSep
NewLife unit. This enables proper treatment as prescribed by a qualied,
licensed physician. You must explain that the purpose of this therapy is to
alleviate symptoms. If patients experience any discomfort or the unit alarms,
they must notify their Equipment Provider and/or physician immediately.
You, as the Equipment Provider, are responsible to see that each patient receives
the Patient Manual. Locate the Patient Manual in the pocket on the back of each
unit. Explain each step in the operation of the unit to the patient in reference to
this manual.
3.2 Routine Maintenance by the Patient
To ensure accurate output and efcient operation of the unit, the patient must
perform two simple routine maintenance tasks:
 Clean the air intake gross particle lter
 Check the alarm system battery
3.2.1 Cleaning the Air Intake Gross Particle Filter
NOTE
The patient must clean this lter weekly, as
described below. The lter may require daily
cleaning if the NewLife unit operates in a harsh
environment such as a house heated by wood,
kerosene, or oil, or one with excessive cigarette
smoke.
1 Remove the dirty air intake gross particle lter from the back
of the NewLife unit, and install the clean lter stored in the
pocket on the back of the unit.
2 Wash the dirty lter in warm soapy water, and rinse.
3Use a soft absorbent towel to remove excess water.
4 Place the clean air intake gross particle lter in the pocket on
the back of the unit.
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AirSep®Corporation
NewLife®Elite Service Manual
3.2.2 Checking the Alarm System Battery
The alarm system battery is tested each time the ON/OFF switch is
set to the ON position. A continuous alarm sounds for approximately
ve seconds to indicate a good battery. If the alarm does anything
other than sound loudly for ve seconds, instruct the patient to call
the Equipment Provider immediately.
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AirSep®Corporation
NewLife®Elite Service Manual
4.0 Provider Maintenance
4.1 Routine Maintenance
The NewLife Elite unit has two or three lters and a 9-volt battery that require
scheduled maintenance and replacement.
To ensure that the unit’s output of oxygen is within specication, you must
perform a test of oxygen concentration. Test the unit upon delivery to a patient
and at periodic intervals. Equipment Providers, based on their expertise and
documentation, may establish and implement their own protocol to check
oxygen concentration. The interval established may be longer or shorter than
90 days, which is AirSep’s default time period for providers who do not choose
to establish their own protocol.
AirSep does not require preventative maintenance on the concentrator. You
do not need to perform any maintenance as long as the NewLife unit remains
within specications at the desired ow rate.
4.1.1 Air Intake Gross Particle Filter/GPF
The external air intake gross particle lter is located on the back of the
unit. You can easily remove it by hand. Instruct the patient to clean
this lter weekly. (Refer to Section 3.2.1.)
NOTE
The lter may require more frequent cleaning if
the NewLife unit operates in a harsh environment
such as a house heated by wood, kerosene, or oil,
or one with excessive cooking or cigarette smoke.
4.1.2 Product Filter Replacement
The product lter must be replaced after every 25,000 hours of use.
1Set the unit’s ON/OFF switch to the OFF position, and unplug
the power cord.
2 Remove the side panels to locate the product lter.
NOTE
Observe the position of the lter before
removal.
3Cut the tie-wraps, and separate the green tubing from both
sides of the lter.
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NewLife®Elite Service Manual
4 Install the new lter with the inlet side in the same position as
before. Push the tubing together so that the tubing overlaps
the product lter connections, and secure it with the tie-wraps.
5 Record information about the product lter replacement on
the History Record Label, which is discussed in Section 4.1.5.
6Reconnect the back and side panels.
4.1.3 Optional Filter Replacement
The optional internal felt lter requires changing every 5,000 hours of
use. See below on instructions for changing the lter.
1Set the unit’s ON/OFF switch to the OFF position, and unplug
the power cord.
2 Remove right side panel to locate the felt intake lter.
3 Remove lter in the unit, and replace with a new lter.
4 Remove left side panel and record information about the lter
replacement on the History Record Label.
5Reconnect both side panels.
4.1.4 Battery Replacement
Each time the NewLife unit is turned on, the alarm must sound loudly
for approximately ve seconds to indicate a good battery. An alarm
that does anything other than sound loudly for ve seconds indicates
a weak battery and requires replacement.
To replace the battery, take the following steps:
1Set the unit’s ON/OFF switch to the OFF position, and unplug
the power cord.
2Remove the left side panel.
3Lift the battery out of the battery holder.
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NewLife®Elite Service Manual
4Install the new battery, maintaining proper polarity, and
secure it with the Velcro strap.
5Set the ON/OFF switch to the ON position to test the alarm.
6Record the battery replacement information on the History
Record Label.
7Reconnect the side panel.
4.1.5 Recording Maintenance
As the Equipment Provider, you can record all routine maintenance
and repairs performed on the NewLife unit, including hours and dates
of service.
A History Record Label is located inside the unit. Keep this label
current to avoid unnecessary replacement of parts (i.e., product lter
and battery).
4.2 Cleaning and Infection Control
With the growing concern about possible cross infection from home oxygen
equipment (i.e., oxygen concentrators) from one home care patient to another,
a clarication on this topic is necessary.
The organisms of most concern are M. Tuberculosis, HIV, and Viral Hepatitis.
These are potentially pathogenic.
Tuberculosis can survive outside of 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 is usually necessary for infection to occur.
HIV and Viral Hepatitis are both viruses, which are not living cells themselves
but which 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 to survive. Once outside the body, viruses do not survive.
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4.2.1 Preparing for New Patient Use
When you remove the NewLife from a patient’s home, always dispose
of the used nasal cannula and humidier bottle. Clean the exterior of
the NewLife with a soapy water solution or commercial cleaner to
remove any gross debris, organic or otherwise. Be careful not to get
any liquid into the interior of the unit.
Next, clean the exterior with either a common chemical disinfectant
or a bleach solution* before other patients use the unit. For the bleach
solution, wear eye and skin protection to prevent exposure to the
chlorine. Allow the NewLife to air dry, and then retest it before you
return it to inventory.
Clean the air inlet gross particle lter with warm soapy water between
each patient’s use. Clean this lter at least once per week, depending
on the environment, during normal operation.
Change the product lter after 25,000 hours of use. It is not necessary
to change this lter between patients even if the pre vious patient had
a communicable disease or infection.
________________________________
*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 of cold tap water. Allow the mixture to sit on potentially contaminated surfaces for 10 minutes.
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AirSep®Corporation
NewLife®Elite Service Manual
5.0 Service
5.1 Components
The design of the AirSep NewLife Oxygen Concentrator allows for easy access
and removal of most components. This allows you to perform scheduled
maintenance, repair, and replacement of parts with minimal time and effort.
CAUTION
For your safety, be sure to set the ON/OFF switch to
the OFF position and unplug the power cord of the unit
before you service the NewLife Oxygen Concentrator.
NOTE
Record all scheduled maintenance. (Refer to Section 4.0.)
5.2 Cabinet Removal
5.2.1 Removing Side Panel(s)
To remove one or both side panels, unscrew the 1/4 turn fastener(s)
and remove the panel(s).
5.2.2 Removing Back Panel
Remove both side panels, and lift off the back panel. Make sure the
power cord can pass freely through the power cord cutout.
5.2.3 Removing Lower Front Cover
Firmly grasp panel with both hands, and slightly bow panel outward
to remove.
5.2.4 Removing Control Panel
Four screws hold the control panel in place. Remove them and the
control panel to re-install or replace if necessary.
5.2.5 Superstructure
The weight and forces of the internal components rest solely on three
parts: the superstructure, compressor plate, and the base. These parts
were specially designed and formed. They should never require
replacement under normal use.
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