NewLife® Elite / NewLife® Oxygen Concentrator Service Manual 0459 AirSep Corporation • 401 Creekside Drive • Buffalo, NY 14228-2085 USA Telephone: (716) 691-0202 • 24-Hour Fax: (716) 691-4141
NewLife® Elite Service Manual Expedited Product Warranty Check service is always at your fingertips with AirSep: http://www.airsep.com/Support/Warranty_Information.aspx OR In the US or Canada, dial 866-873-9277 AirSep® is a registered trademark of AirSep Corporation. NewLife Elite and NewLife are registered trademarks of AirSep Corporation. ® MN105-1 ® AirSep® Corporation Rev.
NewLife® Elite Service Manual Table of Contents Section 1.0 Introduction 1.1 Equipment Provider Responsibility 1-1 1.3 Functional Specifications 1-4 Section 2.0 Operation Check and Oxygen Concentration Test 1.2 Important Notice and Symbol Explanations 1-2 2.1 Description of Operation 2-1 2.3 Alarm System 2-2 2.2 Section 3.0 Patient Instructions 2.4 3.1 3.2 Operation Check 2.3.1 2.3.2 Section 4.0 Equipment Provider Maintenance 4.
NewLife® Elite Service Manual Section 5.0 Service 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Components 5-1 5.2.1 Removing Side Panel(s) 5-1 5.2.3 Removing Lower Front Cover Cabinet Removal 5.2.2 5.2.4 5.2.5 5.2.6 Removing Back Panel Removing Control Panel Superstructure Caster Replacement Compressor 5.3.1 5.3.2 Compressor Replacement Capacitor Replacement Solenoid Valves 5.4.
NewLife® Elite Service Manual 5.11.2 ON/OFF Power Switch Installation 5.12 Buzzer Replacement 5.14 Flowmeter Replacement 5.13 Hour Meter Replacement 5.14.1 5.14.2 Flowmeter Removal Flowmeter Installation 5.15 Power Cord Replacement 5-15 5-15 5-15 5-16 5-16 5-16 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.
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 lifesupporting applications.
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: 1-2 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.
NewLife® Elite Service Manual The following harmonized symbols (pictograms), used for nonEnglish language countries, will be located on the exterior of the NewLife unit: Read the Patient Instruction Manual. No smoking within five feet of this device, oxygencarrying tubing, or accessories. No open flames within five feet of this device, oxygencarrying tubing, or accessories. No oil, grease or petroleum-based products on or near the unit.
NewLife® Elite Service Manual 1.3 Functional Specifications 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 Requirements: 120 VAC, 60 Hz, 4 amps, 350 watts 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.
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 filter. This filtered air enters the compressor via a suction resonator, which quiets the compressor’s suction sound. Pressurized air then exits the compressor and passes through a heat exchanger. The heat exchanger reduces the temperature of the compressed air.
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 flowmeter adjustment knob counterclockwise until it stops (wide open). The maximum flow should register 5.5 lpm (the 5.5 lpm line should appear to split the middle of the flowmeter ball) with no connections at the oxygen outlet. If not, refer to Section 5.8.1 to set the product regulator. 4 2.
NewLife® Elite Service Manual 2.4 Oxygen Concentration Test and Specification To ensure that the unit’s output of oxygen is within specification, 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.
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 qualified, licensed physician. You must explain that the purpose of this therapy is to alleviate symptoms. If patients experience any discomfort or the unit alarms, they must notify their Equipment Provider and/or physician immediately.
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 five seconds to indicate a good battery. If the alarm does anything other than sound loudly for five seconds, instruct the patient to call the Equipment Provider immediately.
NewLife® Elite Service Manual 4.0 Provider Maintenance 4.1 Routine Maintenance The NewLife Elite unit has two or three filters and a 9-volt battery that require scheduled maintenance and replacement. To ensure that the unit’s output of oxygen is within specification, you must perform a test of oxygen concentration. Test the unit upon delivery to a patient and at periodic intervals.
NewLife® Elite Service Manual 4 Install the new filter with the inlet side in the same position as before. Push the tubing together so that the tubing overlaps the product filter connections, and secure it with the tie-wraps. 5 Record information about the product filter replacement on the History Record Label, which is discussed in Section 4.1.5. 6 Reconnect the back and side panels. 4.1.3 Optional Filter Replacement The optional internal felt filter requires changing every 5,000 hours of use.
NewLife® Elite Service Manual 4 Install the new battery, maintaining proper polarity, and secure it with the Velcro strap. 5 Set the ON/OFF switch to the ON position to test the alarm. 6 Record the battery replacement information on the History Record Label. 7 Reconnect 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.
NewLife® Elite Service Manual 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 humidifier 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.
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.
NewLife® Elite Service Manual 5.2.6 Caster Replacement 5.3 1 Remove the cabinet panels to expose the caster nut. 2 Remove the caster nut with a 9/16-inch socket. Use an extension for the two front caster nut removals. 3 Install the new caster and washer, and tighten the nut. 4 Reconnect the cabinet panels. Compressor The compressor is the “pump” within the oxygen concentrator that pushes the room air into the bottom of the sieve beds. This allows oxygen to flow out of the top.
NewLife® Elite Service Manual 5.3.1 Compressor Replacement Compressor Assembly Removal To remove the compressor assembly for exchange, follow the steps listed below: 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the side and lower front panels. 3 Disconnect the suction tube. 4 Disconnect the blue compressor lead at the terminal strip and the brown lead at the temperature switch. 5 Disconnect the two leads to the capacitor and remove if necessary.
NewLife® Elite Service Manual 5.3.2 Capacitor Replacement The capacitor starts the compressor. If the compressor cannot start, the capacitor may be defective and require replacement. To replace the capacitor, take the following steps: 5.4 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the side and lower front panels. 3 Disconnect the two leads to the capacitor and slide capacitor out of the tie wrap holding it in place.
NewLife® Elite Service Manual 5 Loosen and remove the solenoid base with a one-inch deep well socket. 6 Install the rebuild kit, which contains all parts of the solenoid assembly except the solenoid coil. 5.4.2 Feed or Waste Valve Reassembly To reassemble the feed or waste valves, follow the feed or waste valve rebuilding procedure in reverse order, and test for leaks. 5.4.
NewLife® Elite Service Manual 5.5 Sieve Bed Replacement WARNING Do not refill the snap-ring-style sieve beds. Special tooling is required to remove and re-install the springloaded top cap and snap-ring. CAUTION Do not expose molecular sieve (contents of bed) to air for an extended period of time. Prolonged exposure of molecular sieve to the moisture in room air results in contamination and permanent damage to the sieve material. Keep all openings to the sieve beds sealed.
NewLife® Elite Service Manual 5.5.2 Sieve Bed Installation To install the sieve beds, follow the sieve bed removal procedure in reverse order. It is very important to tighten all tubes to eliminate leaks. However, do not over tighten. To check for leaks, take the following steps: 1 Plug in the unit. 2 Set the unit’s ON/OFF switch to ON for three minutes with the flowmeter closed to pressurize the system. 3 Set the unit’s ON/OFF switch to OFF, and unplug the power cord.
NewLife® Elite Service Manual 5.7 6 Connect the fan leads, and install the cabinet fan screws. 7 Reconnect the back and side panels. Circuit Board Replacement The solid-state printed circuit board controls the sequential timing operation of the five solenoid valves and the alarm system functions. The five-green-light matrix corresponds to the valve configuration of the NewLife unit. Two green lights should always illuminate and rotate (cycle) during normal operation.
NewLife® Elite Service Manual NOTE If a pressure transducer circuit board, cut tie-wrap at circuit board and disconnect green 1/4-inch tube. Plug/ cap open end of tube until new circuit board is replaced. 4 Push in on the locking tab to the alarm 6-pin connector to disconnect it. 5 With a slotted screwdriver, push in on the board support tabs, while you lift each corner of the circuit board. 6 Remove the circuit board.
NewLife® Elite Service Manual 5.8 Product Regulator Check and Setting The product regulator enables you to set the maximum flow of oxygen output by the NewLife unit. To check for proper adjustment of the product regulator, take the following steps: 1 Set the ON/OFF switch to the ON position. 2 Allow the unit to run for three minutes. 3 Turn the flowmeter adjustment knob counterclockwise until it stops (wide open). 4 The flowmeter ball centers itself on the 5.5 lpm line.
NewLife® Elite Service Manual NOTE It may be desirable to provide one additional liter of flow if you use the lockout feature. 1 Plug in the unit. 2 Set the unit’s ON/OFF switch to the ON position, and allow the unit to run at least three minutes to build up pressure. 3 If used, connect the humidifier bottle, oxygen tubing, and cannula to the oxygen outlet. 4 Remove the right side panel. 5 Turn the flowmeter adjustment knob counterclockwise until it stops (wide open).
NewLife® Elite Service Manual 2 Set the ON/OFF switch to the ON position, and allow the unit to run at least three minutes to build up pressure. 3 Connect the humidifier bottle, oxygen tubing, and cannula to the oxygen outlet. 4 Remove the right side panel. 5 Turn the flowmeter adjustment knob counterclockwise until it stops (wide open). 6 Pull outward on the regulator knob to unlock it. 7 Turn the regulator knob clockwise until the flowmeter ball centers on the 5.5 lpm line.
NewLife® Elite Service Manual NOTE Adjust the product regulator fully counterclockwise to unload the spring. This makes disassembly and reassembly easier. 5.9 4 Remove the diaphragm. (Clean or replace it.) 5 Use a Phillips-head screwdriver to unscrew the diaphragm stem guide located in the center of the regulator body to gain access to the seat. 6 Remove the seat. Be careful not to lose the spring located behind the seat. 7 Clean or replace the seat.
NewLife® Elite Service Manual 5 Install the new pressure switch, connect the leads, and leak test. 6 Reconnect the side panel. 5.10 Circuit Breaker Replacement 5.10.1 Circuit Breaker Removal 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the left side panel. 3 Disconnect the circuit breaker leads. 4 Unscrew the circuit breaker while you apply pressure to the circuit breaker retaining ring. 5.10.
NewLife® Elite Service Manual 5.11.2 ON/OFF Power Switch Installation Follow the removal procedure for the ON/OFF power switch in reverse order to install a new power switch. Make sure to reinstall the switch properly by having the “O” on the switch located on the bottom when finished. 5.12 Buzzer Replacement 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the left side panel.
NewLife® Elite Service Manual 5.14 Flowmeter Replacement 5.14.1 Flowmeter Removal 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the left side panel. 3 Cut the tie-wraps, and remove the 3/8-inch green oxygen tubing from the flowmeter fittings. 4 Unscrew the flowmeter nuts with a wrench. 5 Remove the flowmeter through the control panel. 5.14.2 Flowmeter Installation To install a new flowmeter, follow the flowmeter removal procedure in reverse order.
NewLife® Elite Service Manual 5-17 10 Pull the power cord through the opening on the power cord receptacle. 11 Using same distance located on old power cord, slide the strain relief onto the new power cord with the lip of the strain relief facing the ends of the power cord leads. 12 Insert the new power cord through the opening on the receptacle by squeezing the strain relief together with pliers.
NewLife® Elite Service Manual 6.0 Troubleshooting 6.1 Operating Pressure Test Testing the operating pressure is a useful diagnostic tool when a concentrator has low oxygen concentration and requires servicing. Units functioning normally do not require operating tests. Use the following procedure to test the operating pressure of the unit. 1 Set the unit’s ON/OFF switch to the OFF position, and unplug the power cord. 2 Remove the right side panel.
NewLife® Elite Service Manual An improperly operating circuit board or solenoid valve. Confirm that the circuit board and solenoid valves function properly. Contaminated sieve beds. Change the sieve beds. 6.1.2 Low Operating Pressure Lower than normal operating pressure may indicate any of the following: A restriction in the suction resonator or optional air intake filter, which limits the amount of room air available to the compressor.
NewLife® Elite Service Manual AirSep® Corporation 2 Make sure all filters are clean. 3 Turn flowmeter completely open, up to the highest setting. The ball should rest at 5.5 lpm. If setting is not 5.5 lpm, adjust regulator so that the ball is set at 5.5 lpm with the flowmeter completely open. 4 Make sure the unit is cycling properly by following the green valve lights on the circuit board. The lights should follow the label below the circuit board and two lights should be activated at all times.
NewLife® Elite Service Manual 6.3 Troubleshooting Chart Problem Compressor does not run. Constant audio alarm with ON/OFF power switch in ON position. Probable Cause Solution No power to unit. Check wall outlet for power. Unit circuit breaker tripped or faulty. Reset or replace circuit breaker. Faulty electrical connections. Check electrical connections. Defective circuit board. Check circuit board for two-light rotation/replace circuit board. Defective ON/OFF power switch.
NewLife® Elite Service Manual Problem Probable Cause Solution Compressor runs with intermittent low pressure alarm and low oxygen concentration. Leak. Leak test and repair leak. Defective circuit board. Check circuit board for two-light rotation/replace circuit board. Compressor runs with intermittent high pressure alarm and low oxygen concentration. Defective sieve beds. Replace sieve beds. Faulty solenoid valve. Repair or replace solenoid valve. Restriction in exhaust muffler.
NewLife® Elite Service Manual Problem Flowmeter fluctuates. Cabinet fan does not turn. Limited or low flow. Low oxygen concentration. 6-6 Probable Cause Solution Improperly set or faulty product regulator. Check regulator setting/clean, repair, or replace regulator. Leak. Leak test and repair leak. Worn compressor. Replace compressor. Defective circuit board. Check circuit board for two-light rotation/replace circuit board. Defective flowmeter. Replace flowmeter. Defective solenoid valve.
NewLife® Elite Service Manual 6.4 Tool Kit and Pressure Test Gauge The tools needed for you to properly service the NewLife unit are listed below: Large pliers, wire cutters, needle-nose pliers, slotted-head screwdriver, Phillipshead screwdriver, ratchet, 8-inch adjustable wrench, 1-inch deep well socket, 9/16-inch socket, 2-inch extension, 7/16-inch combination wrench, 9/16-inch combination wrench, and 5/8-inch combination wrench.
NewLife® Elite Service Manual Appendix Exploded Drawings Control Panel Assembly A-1 Main Structure Assembly A-2 Base and Cabinet Components A-3 Test Block Assembly A-4 Valve Block Assembly A-5 Compressor Assembly A-6 Adsorption Bed Assembly A-7 AirSep® Corporation
NewLife® Elite Service Manual Figure A.
NewLife® Elite Service Manual Figure A.
NewLife® Elite Service Manual Figure A.
NewLife® Elite Service Manual Figure A.
NewLife® Elite Service Manual Figure A.
NewLife® Elite Service Manual Ref No. 1 2 3 4 5A 5B 6 7 8 9 10 11A 11B 11C 11D Part No. KI070-1 SC003-2 WA002-8 CL007-1 HX002-1 HX002-2 F0104-1 VA005-1 F0045-2 VA008-1 F0006-4 CO006-1R(T/N) CO006-4R(T/N) CO006-9R(T/N) CO006-10R(T/N) Description Kit, Vibration, Spring Mount includes bumpers/capacitor bracket (not shown) #6 Phillips 3/8” Long #6 Washer Clamp, Hose 3/8” Heat exchanger, Medserv Heat exchanger (Elite) Fitting, brass, Comp. Align.
NewLife® Elite Service Manual Figure A.
