AirSep | NewLife | Service manual | AirSep NewLife Service manual

AirSep NewLife Service manual
NewLife® Intensity 10
Oxygen Concentrator
Service Manual
AirSep Corporation • 401 Creekside Drive • Buffalo, NY 14228-2085 USA
Telephone: (716) 691-0202 • 24-Hour Fax: (716) 691-4141 • www.airsep.com
Expedited Product Warranty Check service is always at your fingertips with AirSep:
Type: http://www.airsep.com/medical/equipmentproviders.html
OR
In the US or Canada,
dial 866-873-9277
AirSep® is a registered trademark of AirSep Corporation.

NewLife® is a trademark of AirSep Corporation.
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Table of Contents
Section 1.0
Introduction
1.1
Equipment Provider Responsibility
1
1.2
Important Notice and Symbol Explanations
2
1.3
NewLife® Intensity 10 Product Warranty
4
1.4
Functional Specifications
5
2.1
Description of Operation
6
2.2
Operation Check
6
2.3
Alarm System
6
2.3.1 Start Up/Battery Test
2.3.2 Power Failure Alarm Test
7
7
2.4
Oxygen Concentration Test and Specification
7
3.1
Instructions
8
3.2
Routine Maintenance by the Patient
8
3.2.1 Cleaning the Air Intake
Gross Particle Filter
3.2.2 Checking the Alarm System Battery
8
8
Instructions
9
4.1.1 Air Intake Gross Particle Filter/GPF
4.1.2 Felt Filter Replacement
4.1.3 Product Filter
4.1.4 Battery Replacement
4.1.5 Recording Maintenance
9
9
9
9
10
Preparing for New Patient Use/Method of
Cleaning and Infection Control
10
Section 2.0
Operation Check and
Oxygen Concentration Test
Section 3.0
Patient Instructions
Section 4.0
Provider Instructions
4.1
4.2
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Section 5.0
Main Components
5.1
Components
11
5.2
Cabinet Removal
11
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
11
11
11
11
11
11
5.3
5.4
5.5
5.6
5.7
Removing Side Panel(s)
Removing Back Panel
Removing Lower Front Panel
Removing Control Panel
Superstructure
Caster Replacement
Compressor
12
5.3.1
5.3.2
12
13
Compressor Replacement
Capacitor Replacement
Solenoid Valves
13
5.4.1 Feed/Waste Valve Replacement
5.4.2 Solenoid Valve Coil Replacement
13
13
Sieve Beds
14
5.5.1
14
Sieve Bed Replacement
Cabinet Fan
15
5.6.1
15
Cabinet Fan Replacement
Circuit Board
15
5.7.1
16
Circuit Board Replacement
5.8
Product Tank Replacement
16
5.9
Product Regulator Check and Setting
17
5.9.1 Setting Product Regulator for Normal Operation
5.9.2 Product Regulator Cleaning or
Rebuilding
17
18
5.10
Circuit Breaker Replacement
18
5.11
I/0 Power Switch Replacement
18
5.12
Buzzer Replacement
19
5.13
Hour Meter Replacement
19
5.14
Flowmeter Replacement
19
5.15
Power Cord Replacement
19
5.16
Oxygen Monitor Circuit Board Replacement
20
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Section 6.0
Troubleshooting
6.1
Operating Pressure Test
21
6.1.1 High Operating Pressure
6.1.2 Low Operating Pressure
21
21
6.2
General Troubleshooting
22
6.3
Troubleshooting Chart
23
6.4
Tool Kit and Pressure Test Gauge
26
Appendix
Exploded Drawings
Wiring Diagram – Intensity 10 120V
A
Wiring Diagram – Intensity 10 220/240V
B
Control Panel Assembly
C
Main Structure Assembly
D
Base and Cabinet Components
E
Product Tank/Regulator Assembly
F
Valve Block Assembly
G
Compressor Assembly
H
Sieve Bed Assembly
I
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1.0 Introduction
1.1 Equipment Provider Responsibility
All Equipment Providers of the NewLife® Intensity 10 Oxygen Concentrator must assume
responsibilities for handling, operational check-out, patient instruction, and oxygen
concentration checks. These responsibilities are outlined below and throughout this
manual.
As an Equipment Provider, you must do all of the following:
 Inspect the condition of each NewLife Intensity 10 unit immediately upon delivery
to your business location. Note any sign of damage on the delivery receipt, and
report it directly to both the freight company and AirSep Corporation immediately.
 Check the operation of each NewLife Intensity 10 before delivery to a patient.
Confirm the oxygen concentration level is within specifications, 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 Intensity 10 units only to patients authorized by a licensed health
care provider or physician’s prescription. The NewLife Intensity 10 must not be
used as a life-supporting device. A backup supply of oxygen must be available.
 Instruct patients how to use the NewLife Intensity 10 in conjunction with the Patient
Manual.
 Instruct patients to notify their licensed health care provider/physician if they
experience any signs of discomfort.
 Instruct each patient how to perform routine maintenance of the air intake gross
particle filter and how to check the alarm system battery. (Refer to Section 3.2.)
 Be available to provide service to each patient at any time.
 Maintain the NewLife Intensity 10 in accordance with Section 4.0.
 Establish and implement a protocol to check oxygen concentration.
 Repair components and replace parts only as outlined in this manual. Use only
AirSep parts for replacement in NewLife Intensity 10 Oxygen Concentrators.
 Refer to the NewLife Intensity 10 Product Warranty if parts replacement is required
within the warranty period.
This unit is not a life-support device. Geriatric, pediatric, or any other
patient unable to communicate discomfort while using this oxygen
concentrator may require additional monitoring. Patients with hearing
and/or sight impairments may need assistance with monitoring the
alarms.
This device supplies high-concentration oxygen that promotes rapid
burning. Do not allow smoking or open flames within the same room of
(1) this device, or (2) any oxygen-carrying accessory. Failure to observe
this warning can result in severe fire, property damage, and/or cause
physical injury or death.
Use no oil, grease, or petroleum-based or other flammable products on
or near nasal end of cannula or on the Intensity 10 unit. Oxygen
accelerates the combustion of flammable substances.
1/
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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:
Describes a hazard or unsafe practice that can result in severe bodily injury or
death.
Describes a hazard or unsafe practice that can result in minor bodily injury or
property damage.
Provides information important enough to emphasize or repeat.
Symbols are frequently used on equipment in preference to words with the intention of
lessening any 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 that may be used with the NewLife
Intensity 10 Oxygen Concentrator. These symbols are referenced from the appropriate
International Electrotechnical Commission (IEC) standards:
Symbol
Description
Symbol
Description
On (power switched on)
Do not disassemble
Off (power switched off)
Consult instructions for use
Type B device
Keep in vertical position
Class II device
Fragile – handle with care
Do not smoke
Oxygen concentration warning
LED
Complies with the 93/42/EEC
directive drawn up by the
approved organization n˚ 0459
Caution: US federal law restricts
this device for sale or rental by or
on order of a licensed healthcare
provider
Do not expose to open flames
Gas outlet, connection to the
circuit
Do not grease
WEEE Directive
Consult the accompanying
documents
Keep unit and accessories dry
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Method for disposing of waste: All waste from the NewLife Intensity 10 (patient circuit,
etc.) must be disposed of using appropriate methods.
Method for disposing of the device: In order to preserve the environment, the
concentrator must only be disposed of using the appropriate methods.
Conformity with EN 60-601 (§ 6.8.2 b):
“The manufacturer, assembler, installer or importer are not considered to be responsible
themselves for the consequences on the safety, reliability and characteristics of a device
unless:
- The assembly, fitting, extensions, adjustments, modifications, or repairs have been
performed by persons authorized by the party in question.
- The electrical installation of the corresponding premises complies with IEC regulations.
- The device is used in accordance with the instructions for use.” If the replacement parts
used for the periodic servicing by an approved technician do not comply with the
manufacturer’s specifications, the latter is absolved from all responsibility in the event of
an accident. Do not open the device while in operation: risk of electrical shock. This
device complies with the requirements of the 93/42/EEC European directive but its
operation may be affected by other devices being used close by, such as diathermy and
high frequency electro-surgical equipment, defibrillators, short wave therapy equipment,
mobile telephones, CB and other portable devices, microwave ovens, induction plates or
even remote control toys, and more generally electromagnetic interferences, which exceed
the levels specified by the EN 60601-1-2 standard.
Classification
Type of protection against electric shock:
Class II Protection from electric shock is achieved by DOUBLE INSULATION.
Protective earthing or reliance upon installation conditions are not required.
Degree of protection against electric shock:
Type B
Equipment providing a particular degree of protection against electric
shock, particularly regarding:
1) allowable leakage current;
2) reliability of protective earth connection (if present).
Not intended for direct cardiac application.
Degree of protection against harmful ingress of water:
Drip-proof equipment – IPX1.
Equipment provided with an enclosure preventing entry of such an amount
of falling liquid as might interfere with the satisfactory and safe operation
of the equipment.
Method of cleaning and infection control allowed:
Please refer to the Maintenance section in the NewLife Intensity 10 Service
Manual.
Degree of safety of application in the presence of flammable anesthetic gases:
Equipment not suitable for such application.
Mode of operation: Continuous duty.
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1.3 NewLife Intensity 10 Product Warranty
AirSep Corporation warrants the NewLife Intensity 10 Oxygen Concentrator to be free
from defect in parts and workmanship for one, three, or five years (as specified on the
original invoice provided) from the date of delivery to the original purchaser, under normal
use and operation. AirSep Corporation’s obligations under this warranty are limited to the
repair or replacement of any such item of equipment (or part thereof) shown to be
defective or, at AirSep Corporation’s option, to refunding the purchase price of any such
defective item of equipment.
Each item of equipment for which a warranty claim is asserted shall, at the request of
AirSep Corporation, be returned on a prepaid basis with proof of purchase date to the
AirSep factory at the expense of the purchaser. The purchaser will be responsible for
freight charges. Replacement parts shall be warranted as stated above for the unexpired
portion of the original one-, three-, or five-year parts warranty. This warranty does not
extend to any item or part subjected to misuse, accident, improper application, or which
has been repaired or altered outside of the AirSep Corporation Factory without the express
prior written authorization of AirSep Corporation.
THE FOREGOING WARRANTY IS IN LIEU OF ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED, IN FACT OR IN LAW, INCLUDING WITHOUT
LIMITATION THE WARRANTY OF MERCHANTABILITY OR THE WARRANTY
OF FITNESS FOR PARTICULAR PURPOSE. IT IS EXPRESSLY UNDERSTOOD
THAT PURCHASER’S SOLE AND EXCLUSIVE REMEDY FOR DEFECT IN PARTS
IS LIMITED TO ENFORCEMENT OF AIRSEP CORPORATION’S OBLIGATION AS
SET FORTH ABOVE, AND AIRSEP CORPORATION SHALL NOT BE LIABLE TO
PURCHASER OR OTHERS FOR LOSS OF USE OF THE EQUIPMENT OR FOR
OTHER SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
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1.4 Functional Specifications
Oxygen Concentration:
2-9 LPM: 92% +3.5/-3%
10 LPM: 90% +5.5/-3%
(Based on 70°F [21°C] at sea level)
Accuracy:
Flowmeter ± 10% or ± 200ml of indicated flow, whichever is
greater.
Response Time:
Allow 5 minutes to attain maximum oxygen concentration.
Positioning:
Operate the unit in an upright position, maintaining at least
12 inches (30.5cm) of open space on all sides for ventilation.
Dimensions:
27.5 in. high x 16.5 in. wide x 14.5 in. deep
(69.9 cm high x 41.9 cm wide x 36.8 cm deep)
Weight:
58 lb; shipping weight – 65 lb
(26.3 kg; shipping weight – 29.5 kg)
Electrical:
120 VAC, 60 Hz, 6.0 amps, 590 watts
220-240 VAC, 50 Hz, 3.0 amps, 590 watts
Two-prong polarized plug
Double-insulated cabinet
Alarms:
Power Failure
Low Oxygen Concentration (with optional Oxygen Monitor)
Low Pressure
High Pressure
High Temperature
Battery Test
Operating Temperature
Range:
41°F to 104°F (5°C to 40°C) for 120 VAC 60 Hz models
41°F to 95°F (5°C to 35°C) for 220-240 VAC 50 Hz models
Storage Temperature
Range:
-4°F to 140°F (-20°C to 60°C)
Humidity:
Up to 95% (non-condensing)
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2.0 Operational Check and Oxygen Concentration Test
2.1 Description of Operation
Air is drawn into the NewLife Intensity 10 Oxygen Concentrator through an external air
intake gross particulate filter. Before this air enters the compressor, it passes through the
unit’s 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 concentrated oxygen.
There are two sieve beds: while one produces high concentration oxygen, the other is
purged of the nitrogen it adsorbed (collected) during this pressure swing adsorption (PSA)
cycle. Each adsorber produces oxygen and delivers it to the product tank. Oxygen exits
the product tank through a pressure regulator, flow control valve, and flowmeter. The
NewLife Intensity 10 unit delivers up to 95.5% oxygen at flow rates from 2-10 lpm.
2.2 Operation Check
AirSep tests every NewLife Intensity 10 Oxygen Concentrator thoroughly after
manufacture. You must perform the following test to ensure that no damage occurred in
shipping or handling.
Do not use extension cords with this unit or connect too many plugs
into the same electrical outlet. The use of extension cords could
adversely affect the performance of the device. Too many plugs into
one outlet can result in an overload to the electrical panel, causing the
breaker/fuse to activate or fire if the breaker or fuse fails to operate.
2.3
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.
Connect unit to power, and set the I/0 power switch to the “I” position. Check to
see that the following occurs:
a. A continuous alarm sounds for approximately five seconds. See the
troubleshooting chart in Section 6.3 of this manual if the unit’s
alarm does anything other than sound for five seconds.
b. The compressor runs and flow is indicated in flowmeter.
c. OPTIONAL: The Oxygen Monitor’s amber light remains on until
the oxygen concentration reaches 85% ±3% (approximately two
minutes). Perform an oxygen concentration test, as described in
Section 2.4.
Alarm System
The NewLife Intensity 10 Oxygen Concentrator is equipped with a battery-powered alarm
system, which sounds a continuous and loud alarm when a power failure occurs. It sounds
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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 I/0 power switch to the “0”
position. Refer to Section 6.0 for a list of probable alarm causes.
2.3.1 Start Up/Battery Test
Each time the NewLife Intensity 10 unit is turned on, an alarm should sound for
approximately five seconds.
The audio alarm must sound for approximately five seconds each time
the unit is turned to the “I” position to indicate the battery is in good
condition.
2.3.2 Power Failure Alarm Test
To test the power failure alarm, disconnect the unit from power, set the l/0 power
switch to the “I” position. This should activate the audio alarm. If it does not, refer
to the troubleshooting chart in Section 6.3 of this 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 the oxygen concentration. Test the unit upon delivery to a patient and at periodic
intervals. Equipment Providers need to establish and implement a protocol to check
oxygen concentration.
1.
If a humidifier bottle is used, disconnect it.
2.
Connect a calibrated oxygen concentration analyzer to the oxygen outlet.
3.
Verify that the product flow rate delivered by the unit matches the patient’s
prescription and does not exceed the capacity of the unit.
4.
Set the unit’s l/0 power switch to the “I” position. Allow approximately five
minutes for the oxygen concentration to stabilize. Take oxygen concentration
readings and verify levels are within specification at the liter flow being tested.
5.
Disconnect the oxygen analyzer, and reconnect the humidifier bottle (if used).
Do not measure oxygen concentration output after the product stream
passes through a humidifier bottle, or erroneous readings will result.
AirSep NewLife Intensity 10 Concentration Specifications
Liter
Flow
Oxygen Concentration
2-9 lpm
10 lpm
92% +3.5/-3%
90% +5.5/-3%
7
In Spec
89% or higher
87% or higher
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3.0 Patient Instructions
3.1 Instructions
It is important that patients thoroughly understand how to operate the AirSep NewLife
Intensity 10 unit. This enables proper treatment, as prescribed by a licensed health care
provider/physician. If patients experience any discomfort or the unit alarms, they must
notify their licensed health care provider/physician immediately.
You, as the Equipment Provider, are responsible to see that each patient receives the
Patient Manual. Explain each step in the operation of the unit to the patient in reference to
this manual.
This device supplies high-concentration oxygen that promotes rapid
burning. Do not allow smoking or open flames within the same room of
(1) this device, or (2) any oxygen-carrying accessory. Failure to observe
this warning can result in severe fire, property damage, and /or cause
physical injury or death.
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:
 Clean the air intake gross particle filter
 Check the alarm system battery
3.2.1 Cleaning the Air Intake Gross Particle Filter
The patient must clean this filter weekly, as described below. The
filter may require daily cleaning if the NewLife Intensity 10 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 filter from the back of the NewLife
Intensity 10 unit, and install a clean filter, as described above.
2. Wash the dirty filter in warm soapy water, and rinse.
3. Use a soft absorbent towel to remove excess water.
4. Keep the clean, dry filter readily available for next use.
3.2.2 Checking the Alarm System Battery
The alarm system battery is tested each time the l/0 power switch is set to the “l”
position. A continuous alarm sounds for approximately five seconds to indicate a
good battery. If the alarm does anything other than sound for five seconds, instruct
the patient to call the Equipment Provider immediately.
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4.0 Provider Instructions
4.1 Instructions
To ensure that the unit’s output of oxygen is within specification, you must perform a test
of the oxygen concentration. Test the unit upon delivery to a patient and at periodic
intervals. Equipment Providers need to establish and implement a protocol to check
oxygen concentration. (Refer to Section 2.4.)
AirSep does not require preventative maintenance on the concentrator. You do not need to
perform any maintenance as long as the NewLife Intensity 10 unit remains within
specifications at the desired flow rate.
4.1.1 Air Intake Gross Particle Filter/GPF
The external air intake gross particle filter is located on the back of the unit. You
can easily remove it by hand. Instruct the patient to clean this filter weekly. (Refer
to Section 3.2.1.)
4.1.2 Felt Filter Replacement
The internal felt filter requires changing every 5,000 hours of use. See below on
instructions for changing the filter:
1.
Set the unit’s l/0 power switch to the “0” position, and disconnect the
power cord.
2.
Remove right side panel to locate the felt intake filter.
3.
Remove filter in the unit, and replace with a new filter.
4.
Remove left side panel and record information about the filter
replacement on the History Record Label.
5.
Reconnect both side panels.
4.1.3 Product Filter
The product filter, which may be located within the unit’s product tank, is designed
to last for the life of the unit. Whether inside the product tank or an external
component to this tank, there is no required or scheduled replacement needed for
this part.
4.1.4 Battery Replacement
Each time the NewLife Intensity 10 unit is turned on, the alarm must sound for
approximately five seconds to indicate a good battery. An alarm that does anything
other than sound for five seconds indicates a weak battery and requires
replacement.
To replace the battery, take the following steps:
1. Set the unit’s l/0 power switch to the “0” position, and disconnect the power
cord.
2. Remove the left side panel.
3. Lift the battery out of the battery holder.
4. Install the new battery, maintaining proper polarity.
5. Set the l/0 power switch to the “l” position to test the alarm.
6. Record the battery replacement information on the History Record Label.
7. Reconnect the side panel.
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4.1.5 Recording Maintenance
As the Equipment Provider, you can record all routine maintenance and repairs
performed on the NewLife Intensity 10 unit, including hours and dates of service.
A History Record label is located on the side panel inside the unit. Keep this record
current to avoid unnecessary replacement of parts (i.e., intake filter and battery).
Electrical shock hazard. Disconnect the power cord from the electric
outlet before you clean the unit to prevent accidental electrical shock and
burn hazard. Only your Equipment Provider or a qualified service
technician should remove the covers or service the unit.
Care should be taken to prevent the NewLife Intensity 10 from getting wet
or allowing water to enter the unit. This can cause the unit to malfunction
or shut down, and cause an increased risk for electrical shock or burns.
Do not use liquid directly on the unit. Clean the exterior of unit and power
cord only with a mild household cleaner applied with a damp cloth or
sponge, and then wipe all surfaces dry.
4.2 Preparing for New Patient Use/Method of Cleaning and
Infection Control
When you remove NewLife Intensity 10 from a patient’s home or a facility, always
dispose of the used nasal cannula and humidifier bottle. Clean the exterior of the NewLife
Intensity 10 unit with a soapy water solution or mild household cleaner applied with a
damp cloth or sponge to remove any gross debris. Do not use liquid directly on unit, and be
careful not to get liquid into the interior of the unit.
Next, following the same guidelines above, clean the exterior with either a common
chemical disinfectant or a bleach solution*, while wearing eye and skin protection. After
using the disinfecting solution, wipe entire unit with a cloth or sponge applied with water
only, then wipe dry. Make sure unit is completely dry and then retest it before you return
it to inventory.
Clean the air intake gross particle filter with warm soapy water between each patient’s use.
Clean this filter at least once per week, depending on the environment, during normal
operation.
_________________________________________________________________________
* The manufacturers of sodium hypochlorite products recommend various strengths of a bleach
solution for killing bacteria, etc., based on the type of germ to disinfect; however, a generally
recommended solution is ¾ cups (177mL) of household bleach per gallon (3.79 liters) of water.
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5.0 Main Components
5.1 Components
The design of the AirSep NewLife Intensity 10 Oxygen Concentrator allows for easy
access and removal of most components. This allows you to perform repair and
replacement of parts with minimal time and effort.
To prevent accidental electrical shock or burn, be sure to set the unit’s I/0
power switch to the “0” position and disconnect the power cord of the unit
from the electrical outlet before you service the NewLife Intensity 10
Oxygen Concentrator.
Record all scheduled maintenance. (Refer to Section 4.0.)
Before reattaching tubing connections using a tie-wrap, remove 1/8 inch
(0.32 cm) from end of tubing to assure a proper seal. Tubing should be
cut evenly across width.
5.2 Cabinet Removal
5.2.1 Removing Side Panel(s)
To remove one or both side panels, unscrew the ¼ 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 Panel
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.
5.2.6 Caster Replacement
1.
2.
3.
4.
Remove the cabinet panels to expose the caster nut.
Remove the caster nut with a 9/16-inch socket. Use an extension for the two
front caster nut removals.
Install the new caster with original washer and securing nut.
Reconnect the cabinet panels.
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5.3 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 of the sieve
beds in the NewLife Intensity 10 unit.
Two different aspects of the compressor cause concern: the output and the sound level.
Output
Compressor output refers to how much compressed air the compressor can produce. This
depends upon the model of the compressor, stroke size, bore size, and cup seal condition.
The cup seals form the seal between the piston and the cylinder wall. As the cup seals
wear, the compressor’s output begins to gradually decrease. This reduction in compressor
output results in less air for the sieve beds. Therefore, the production of oxygen decreases.
Since this drop in oxygen production occurs over a long period of time, preventative
maintenance on the compressor is not required. You can continue a patient’s therapy on
the NewLife Intensity 10 unit as long as that unit’s oxygen concentration level at the
prescribed liter flow rate is within AirSep’s specifications.
Sound Level
The condition of the compressor’s cup seals, bearings, and other components can result in
an increased sound level. If the compressor’s cup seals or bearings wear to the point that
they become noisy, the concentrator may become noticeably louder; therefore, compressor
service or exchange may be required.
5.3.1 Compressor Replacement
Compressor Assembly Removal
To remove the compressor assembly, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side and lower front panels of unit.
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.
6. Disconnect the compression fitting for the heat exchanger located at the
bottom center of the compressor.
7. Remove the two screws that connect the compressor plate to the base of the
unit, and slide the compressor assembly up and out.
Compressor Assembly Installation
To install compressor assembly, follow the steps below:
1. Perform the compressor removal procedure in reverse order.
2. Make sure to position the compressor’s blue and brown lead wires behind
the braided suction tube.
3. Leak test all connections.
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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, follow the
steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect 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 tiewrap holding it in place.
4. To install the new capacitor, connect the leads and slide the capacitor into
the tie-wrap holding it in place.
5.4 Solenoid Valves
The NewLife Intensity 10 uses five two-way solenoid valves: two feed, two waste, and one
equalization. Each valve has an open (energized) and closed (de-energized) position. As
the NewLife Intensity 10 operates, two or three valves are always energized.
The solenoid valves of the NewLife Intensity 10 unit require no scheduled maintenance. If
a valve becomes noisy, you can easily replace the internal valve parts. To identify the
noisy valve, observe which green circuit board light (115 VAC units only) illuminates at
the time of the noise. The lighting matrix on the circuit board corresponds to the valve
location.
5.4.1 Feed/Waste Valve Replacement
Feed/Waste Valve Removal
To remove the feed or waste valves, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side and back panels.
3. Remove the red cap from the appropriate valve with a slotted-head
screwdriver.
4. Lift off the solenoid coil.
Correct direction of spring is required for proper valve function.
5. Loosen and remove the valve using a one-inch deep well socket. Be sure to
also remove and discard valve o-ring.
Feed/Waste Valve Installation
To install a feed or waste valve, follow the feed/waste valve removal procedure in
reverse order. Make sure to install new o-ring and test for leaks.
5.4.2 Solenoid Valve Coil Replacement
An ohmmeter can be a useful tool in determining the condition of a valve coil.
When using and ohmmeter in the NewLife Intensity 10 unit, valve coil readings
should be as indicated below:
1. 120VAC units
a. EQ coil = 1,000ohms +/- 10%
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b. Feed/waste coil = 850ohms +/- 10%
2. 220-240VAC units
a. EQ coil = 4,300ohms +/- 10%
b. Feed/waste coil = 3,100ohms +/- 10%
You can also determine which coil is not operating by checking each valve to see if
it becomes energized (magnetized) during unit operation.
To check for coil operation, follow the steps below:
1. Remove plastic cap securing the valve coil to the valve stem. (Do not
remove coil).
2. With unit operating, hold a paperclip or the metal tip of a screwdriver
slightly over the top of the valve stem located in the center of the coil.
3. When the coil becomes energized (magnetized) the paperclip or tip of the
screwdriver will be pulled down onto valve stem, indicating the valve coil is
operating.
4. If a coil is faulty, it will not become energized and require replacement.
(In 115 VAC units, if a solenoid valve coil does not operate, its corresponding green light on
the circuit board does not illuminate).
To replace a solenoid valve coil, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side and back panels.
3. Remove the red cap with a slotted-head screwdriver.
4. Disconnect the solenoid leads, and lift off the solenoid coil.
5. Replace with the new coil.
6. Press the red cap back on top of the coil, and reconnect the solenoid leads.
7. Reconnect the back and side panels.
5.5 Sieve Beds
The NewLife Intensity 10 unit utilizes two sieve beds, each containing molecular sieve.
The unique property of molecular sieve enables it to physically attract nitrogen when air
passes through this material, thus producing highly concentrated oxygen.
While one sieve bed produces high concentration oxygen, the other is purged of the
nitrogen it adsorbed (collected) while it concentrates oxygen. Each adsorber (sieve bed)
produces oxygen and delivers it to the product tank
5.5.1 Sieve Bed Replacement
Temporarily seal sieve bed openings with tape to prevent the sieve
material from being exposed to the moisture in room air. Prolonged
exposure to room air results in contamination and permanent damage
to the sieve material.
Leaks can be so small in air loss that oxygen concentration is not
affected immediately. The sieve material can become contaminated
gradually. Careful leak testing is important as the sieve material can
become contaminated gradually with very small leaks.
14
MN134-1 rev A
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If replacement is necessary, you must replace both sieve beds at the
same time.
Sieve Bed Removal
To remove sieve beds, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side and back panels.
3. Cut the tie-wrap and disconnect green tubing at each elbow fitting located
on the top of the sieve beds.
4. Remove the 9/16-inch compression fitting from the bottom of each sieve
bed.
5. Cut the tie-wraps securing the sieve beds to the superstructure and remove
the sieve beds.
Sieve Bed Installation
To install the sieve beds, follow the sieve bed removal procedure in reverse order.
Do not over tighten fittings.
To check for leaks, take the following steps:
1. Connect the unit to power, and set the unit’s I/0 switch to the “I” position.
2. Allow unit to run for three minutes.
3. Apply soapy water solution around tubing connections on both sieve beds,
and check for leaks.
5.6 Cabinet Fan
The cabinet fan pulls ambient air into the NewLife Intensity 10 unit. As this air is drawn
in, the air cools internal components (including the compressor) and exits out the bottom of
the unit.
The cabinet fan for NewLife Intensity 10 is located in the back of the unit. Refer to the
troubleshooting chart in Section 6.0 of this manual for instances where replacement of the
fan may be required.
5.6.1 Cabinet Fan Replacement
To replace the cabinet fan, follow the steps below
1.
Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2.
Remove the side and back panels.
3.
Remove the two screws that hold the fan to the superstructure, and remove the fan.
4.
Disconnect the fan leads.
5.
Position the new cabinet fan so that the air flow arrow points toward the
compressor and the electrical connections are in the bottom right corner.
6.
Connect the fan leads, and install the cabinet fan screws.
7.
Reconnect the back and side panels.
5.7 Circuit Board
The solid-state printed circuit board controls the timing operation of the five solenoid
valves and the alarm system functions. The five-green-light matrix (115 VAC units only)
corresponds to the valve configuration of the NewLife Intensity 10 unit. Two or three
green lights should always illuminate and rotate (cycle) during normal operation.
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A green light that fails to illuminate indicates a disconnected or faulty solenoid coil or an
electrical malfunction in that valve circuit. The two vertical red lights indicate high and
low pressure.
Consult the troubleshooting chart in Section 6.0 to determine when to replace the printed
circuit board.
The Printed Circuit Boards (PCBs) contain components that are sensitive
to electrostatic discharge (ESD) and can damage the board if not handled
properly. As when handling any ESD-sensitive PCB, observe standard
ESD safety procedures.
5.7.1 Circuit Board Replacement
Circuit Board Removal
To remove the circuit board, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side and back panels.
3. Disconnect the main power 10-pin connector from the circuit board.
4. Disconnect the alarm 6-pin connector from the circuit board.
5. Cut the tie-wrap at the circuit board pressure transducer and disconnect the
green tube from transducer.
Care must be taken when removing and installing tubing to circuit
board sensor to prevent damaging sensor.
6. Push in on the circuit board support tabs while you lift each area of the
circuit board to remove circuit board from the control panel.
Circuit Board Installation
To install the circuit board, follow the steps below:
1. Push the circuit board on to the support tabs.
2. Install green tubing to the top barb of transducer located on the circuit
board. Secure with the tie-wrap.
3. Carefully align and firmly install the 6-pin connector and the 10-pin
connector to the circuit board so that the connector’s tab locks securely into
place.
4. Reconnect the back and side panels.
5.8 Product Tank Replacement
Product Tank Removal
To remove the product tank, follow the steps below:
1.
Set the unit’s I/0 power switch to the “0” position, and disconnect the power
cord.
2.
Remove the sides, lower front, and back panels.
3.
Remove the compressor. (Refer to Section 5.3.)
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4.
5.
6.
7.
8.
9.
10.
Remove the 2nd stage intake resonator, which is held in place by Velcro.
Remove the securing nut that holds the product tank to the superstructure.
(This securing nut is located in the top right area of the compressor
compartment).
Remove the screws that hold the control panel to the superstructure. It is not
necessary to fully remove the control panel. It is only necessary to create
enough room to allow the product tank to be removed from the unit.
Remove the green tubing located at the regulator outlet and at the bottom of
the product tank assembly.
Cut the tie wrap securing the product tank to the superstructure.
Lift the product tank with regulator attached from the mounting hole and
remove from the unit.
Carefully remove regulator from product tank.
Product Tank Installation
To install the product tank assembly, follow the steps below:
1. Perform the product tank removal procedure in reverse order.
2. Apply sealant or sealant tape to threads of product tank fitting before
reinstalling regulator onto product tank.
3. Perform the procedure from Section 5.9.1 to set the regulator to 20 psig
(138 kPa). Leak test all connections.
5.9 Product Regulator Check and Setting
The product regulator is factory-set at 20 psig (138 kPa) and should not require adjustment.
To check for proper adjustment of the product regulator, take the following steps:
1.
Install outlet pressure test kit (AirSep p/n: TU131-2) to the outlet
of the NewLife Intensity 10 unit.
2.
Set the unit’s I/0 power switch to the “I” position.
3.
Turn the flowmeter adjustment knob counter-clockwise until it stops (wide
open).
4.
Allow the unit to run for five minutes.
5.
The outlet pressure should be 20 psig (138 kPa). If the outlet pressure is not
at 20 psig (138 kPa), the product regulator needs to be reset.
5.9.1 Setting Product Regulator for Normal Operation
Use the following procedure to set the product regulator to 20 psig (138 kPa):
1.
Disconnect the humidifier bottle, if used, and the tubing from oxygen outlet.
2.
Remove the side panels and back panel.
3.
Connect unit to power.
4.
Install outlet pressure test kit (TU131-2) to the outlet of the NewLife
Intensity 10.
5.
Set the unit’s I/0 power switch to the “I” position, and allow unit to run at
least five minutes to build up pressure.
6.
Turn the flowmeter adjustment knob counter-clockwise until it stops (wide
open).
7.
Pull outward on the regulator knob to unlock it.
8.
Turn the regulator knob until the outlet pressure is 20 psig (138 kPa) on the
gauge of the pressure test kit.
9.
Push in the regulator knob to lock it.
10.
Reconnect the back and side panels.
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MN134-1 rev A
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5.9.2 Product Regulator Cleaning or Rebuilding
Clean or rebuild the product regulator if the regulator cannot be adjusted for
lockout.
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the right side panels and back panels.
3. Use large pliers to unscrew the bonnet of the product regulator, which
contains a large spring.
Adjust the product regulator fully counter-clockwise to unload the
spring. This makes disassembly and reassembly easier.
4. Remove the diaphragm. (Clean or replace it.)
5. Using a Phillips-head screwdriver, 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.
8. With the spring behind the seat, screw the diaphragm stem guide back into
the body of the regulator. (Do not over tighten.)
9. Install a clean or replacement diaphragm.
10. Put the large spring and slip ring into the bonnet, and screw the bonnet onto
the regulator body.
11. Reset the product regulator as described in Section 5.9.1.
5.10 Circuit Breaker Replacement
Circuit Breaker Removal
To remove the circuit breaker, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect 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.
Circuit Breaker Installation
Follow the removal procedure for the circuit breaker in reverse order to install the
new circuit breaker. Wire connections on circuit breaker can be made to either
terminal.
5.11 I/0 Power Switch Replacement
I/0 Power Switch Removal
To remove the I/0 power switch, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove both side panels and back panel.
3. Disconnect wire connections from the I/0 power switch.
4. Push on the back of the power switch, while holding in its upper and lower
retaining tabs, and remove the switch through the front panel.
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I/0 Power Switch Installation
Follow the removal procedure for the I/0 power switch in reverse order to install a
new power switch.
1. Be sure to reinstall the new switch properly with the orientation of the “0”
on the switch located on the bottom when finished.
2. Same side wire connections of power switch can be made to either terminal.
5.12 Buzzer Replacement
1.
2.
3.
4.
5.
Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
Remove the left side panel.
Unscrew the two Phillips-head screws that hold the buzzer to the superstructure,
and solder to disconnect the buzzer leads.
Solder the leads to the new buzzer, and screw the buzzer to the superstructure.
Reconnect the side panel.
5.13 Hour Meter Replacement
HM009-2 is a dual function hour meter. It has a selection switch accessible by a pinhole in
the upper right corner of the hour meter.
To toggle between display modes - press in the switch once using a small paperclip.
1. ‘TMR1’ mode displays accumulated hours, which can be reset to zero hours by pressing
and holding the switch in until 0.0 is displayed (approximately 3 seconds).
2. If ‘TMR1’ is not displayed, then total operating hours of unit is displayed.
1.
2.
3.
4.
5.
6.
7.
8.
Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
Remove the left side panel.
Disconnect the hour meter leads.
Push hour meter mounting tabs inward from the hour meter.
Remove the hour meter through the control panel.
Install the new hour meter into the control panel, making sure the hours are
displayed on top. (Hour glass icon should be located on bottom of hour meter when
properly installed).
Reconnect the hour meter leads.
Reconnect the side panel.
5.14 Flowmeter Replacement
Flowmeter Removal
To remove the flowmeter, follow the steps below:
1. Set the unit’s I/0 switch to the “0” position and disconnect the power cord.
2. Remove the side panel.
3. Cut the tie-wraps, and remove the ¼-inch green oxygen tubing from the
flowmeter fittings.
4. Unscrew the flowmeter nuts with a wrench.
5. Remove the flowmeter through the control panel.
Flowmeter Installation
To install a new flowmeter, follow the flowmeter removal procedure in reverse
order. Leak test the tubing connections.
5.15 Power Cord Replacement
1. Set the unit’s I/0 switch to the “0” position, and disconnect the power cord.
2. Remove the side and back panels.
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MN134-1 rev A
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3.
4.
5.
6.
Open the plastic twist clamps.
Cut the tie-wraps (located near the power cord push-on connectors).
Disconnect the white power cord lead from the I/0 switch lead.
Disconnect the black power cord lead from the top terminal on the circuit
breaker.
7. Locate strain relief inside power cord receptacle. Press both ends together
with pliers while pushing power cord from the back to remove power cord.
Pull the power cord through the opening on the power cord receptacle.
8. Using the same length of installation for the strain relief from the original
power cord, slide the strain relief onto the new power cord so that the larger
lip of the strain relief faces the power cord plug end.
9. Insert and install the new power cord through the opening of the receptacle
squeezing the strain relief together with pliers to secure in place.
10. Reconnect the power cord leads, close the plastic twist clamps, and reattach
the tie-wraps.
11. Reconnect the side and back panels.
5.16 Oxygen Monitor Circuit Board Replacement (In Equipped Units)
Oxygen Monitor Circuit Board Removal
To remove the circuit board, follow the steps below:
Care must be taken when removing and installing tubing to circuit
board sensor to prevent damaging sensor.
1. Set the unit’s I/0 switch to the “0” position, and disconnect the power cord.
2. Remove the side and back panels.
3. Locate oxygen monitor circuit board and carefully disconnect the 4-pin wire
harness from circuit board.
4. Using Phillips-head screwdriver, remove screws and spacers securing
circuit board to superstructure.
5. Disconnect tubing connections from circuit board sensor. (Note: depending
on unit, there may be one or two tubing connections on the sensor). Review
of tubing connection position(s) should be made prior to disconnecting.
Oxygen Monitor Circuit Board Installation
To install a new circuit board, follow the circuit board removal procedure in reverse
order.
1. Be sure to reinstall tubing connection(s) to correct position on sensor of
new circuit board.
2. Spacers are installed between circuit board and superstructure.
If unit is installed with a ceramic-style O2 monitor circuit board and the
circuit board requires replacement, you will need to retrofit the unit to
the ultrasonic-style O2 monitor circuit board. (Retrofit kit part number:
KI366-2)
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6.0 Troubleshooting
6.1 Operating Pressure Test
Testing the operating pressure is a useful diagnostic tool when a concentrator produces low
oxygen concentration and requires servicing. Units functioning normally do not require
operating pressure tests.
Use the following procedure to test the operating pressure of the unit:
1.
Set the unit’s I/0 power switch to the “0” position, and disconnect the power cord.
2.
Remove the right side panel.
3.
Locate the pressure test port location (black tube with plug in the end). Remove
plug, and using a pressure test port adapter (AirSep p/n KI257-1), connect the
pressure gauge to the test port.
4.
Connect the unit to power, and set the unit’s I/0 power switch to the “I” position.
Set the flowmeter to 10 lpm, and allow the unit to run five minutes.
5.
Observe the maximum and minimum readings on the pressure test gauge.
The maximum reading should not exceed 36 psig (248 kPa).
The minimum reading should not be less than 20 psig (138 kPa).
When you turn the unit on, the system pressure always registers
higher than normal for the first few minutes of operation.
6.1.1 High Operating Pressure
Higher than normal operating pressure may indicate any of the following:
 A restrictive exhaust muffler, which does not allow the waste (purge) gas to
exit the system freely.
Operate the unit with the exhaust muffler disconnected to see if the operating
pressure returns to normal.
 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
If the oxygen concentration level at the desired liter flow is within AirSep’s
specifications, no service is required, even if operating pressure is low. If
concentration is below specifications at the desired liter flow rate with low
operating pressure, this may indicate any of the following:
 A restriction in the intake resonator, which limits the amount of room air
available to the compressor.
Disconnect the braided tube at the compressor, and allow the unit to operate
without the intake resonator to see if normal operating pressure returns.
 A compressor with reduced output.
If it is below specifications, replace or repair the compressor.
 An improperly operating circuit board or solenoid valve.
Confirm that the circuit board and solenoid valves function properly.
 A leak in the unit, which allows system pressure to escape.
Leak test unit.
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6.2 General Troubleshooting
Before reviewing the troubleshooting chart, the following steps may be useful to isolate
any malfunctions:
1.
Turn on the concentrator. If the unit does not turn on, refer to the troubleshooting
chart.
2.
Verify the outlet pressure is 20 psig (138 kPa). If the outlet pressure is not
at 20 psig (138 kPa), the product regulator needs to be reset. Refer to Section 5.9.
3.
Make sure the unit is cycling properly by:
a. observing the flowmeter ball is stable in flowmeter. (Flowmeter ball does not
move up and down more than ¼ of a liter.)
b. checking circuit board if high or low pressure lights are illuminated and audible
pressure alarm is sounding.
4.
Place your thumb over outlet of unit. The flowmeter ball should drop to the bottom
of the flowmeter. If the ball does not drop completely to the bottom, there is a leak
present between the top of the flowmeter and the outlet of the unit.
5.
If concentrator is not meeting specifications, make sure that the unit is leak-free by
testing all tubing connections and fittings with leak testing solution. Protect circuit
board(s) from solution and start leak test at the heat exchanger, following air flow
of unit to oxygen outlet. Repair all leaks by tightening connections and fittings.
6.
Set the concentrator at 10 lpm and connect pressure test gauge to unit. Determine
pressure parameters by observing high and low pressure points on the gauge. If
pressures are high or low, refer to Section 6.1.
7.
Review troubleshooting chart to isolate and repair any other malfunctions.
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MN134-1 rev A
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6.3 Troubleshooting Chart
Problem
Unit does not run.
Constant audio alarm with
I/0 power switch in “I” position.
Compressor runs and shuts
down periodically.
Compressor does not start.
I/0 power switch in “I” position,
intermittent alarm, and
cabinet fan turns.
Compressor runs with
intermittent low pressure alarm
and low oxygen concentration.
Probable Cause
Solution
No power to unit from electrical outlet.
Check/restore power to outlet.
Unit circuit breaker tripped/faulty.
Reset or replace circuit breaker.
Faulty electrical connections.
Check electrical connections.
Faulty I/0 power switch.
Replace I/0 power switch.
Faulty circuit board.
Replace circuit board.
Restricted air flow.
Remove obstruction.
Unit overheating due to improper location.
Compressor thermally cut off due to
excessive heat. NOTE: It will not restart until
it cools down.
Locate unit away from heating
source, providing adequate
ventilation on all sides. (Do not
run multiple units next to each
other).
Faulty high temperature switch.
Replace high temperature
switch.
Faulty cabinet fan.
Replace cabinet fan.
Extreme cold start.
Allow unit to reach room
temperature.
Faulty electrical connection for compressor.
Check electrical connections for
compressor.
Faulty capacitor.
Replace capacitor.
Faulty high temperature switch.
Replace high temperature
switch.
Faulty circuit board.
Replace circuit board.
Leak.
Leak test and repair leak.
Reduced air intake (suction).
Check compressor intake path
for obstruction. Clean/remove
obstruction.
Weak capacitor.
Replace capacitor.
Faulty circuit board.
Replace circuit board.
Weak compressor.
Replace compressor.
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MN134-1 rev A
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Problem
Compressor runs with intermittent
high pressure alarm and low
oxygen concentration.
Compressor relief valve releases
(popping sound)
Constant alarm with I/0 power
switch in “I” position. Circuit
breaker repeatedly trips.
Alarm does not sound.
Flowmeter fluctuates.
Probable Cause
Solution
Restriction in exhaust muffler.
Replace or clean muffler.
Faulty solenoid valve.
Repair or replace solenoid valve.
Faulty circuit board.
Replace circuit board.
Contaminated sieve beds.
Replace sieve beds.
Faulty electrical connection at waste
valve.
Repair electrical connection.
Faulty solenoid valve coil. (Refer to
section 5.4.2 for acceptable ohm
ratings)
Replace valve coil. (Use of an
ohmmeter can be a helpful to easily
determine a faulty coil).
Faulty relief valve.
Replace relief valve or compressor.
Faulty circuit board.
Replace circuit board.
Contaminated sieve beds.
Replace sieve beds.
Faulty electrical connection.
Repair electrical connection.
Faulty capacitor.
Replace capacitor.
Faulty circuit breaker.
Replace circuit breaker.
Faulty circuit board.
Replace circuit board.
Faulty compressor.
Replace compressor.
Incorrectly installed battery.
Reinstall battery with correct
polarity.
Faulty electrical connection.
Repair electrical connection.
Dead battery.
Replace battery.
Faulty buzzer.
Replace buzzer.
Faulty I/0 power switch.
Replace I/0 power switch.
Faulty circuit board.
Replace circuit board.
Leak.
Leak test and repair leak.
Reduced air intake (suction).
Check compressor intake path for
obstruction. Clean/remove
obstruction.
Improperly set or faulty product
regulator.
Check regulator setting. Repair or
replace regulator.
Faulty flowmeter.
Replace flowmeter.
Worn compressor.
Replace compressor.
Faulty circuit board.
Replace circuit board.
Faulty solenoid valve.
Repair or replace solenoid valve.
24
MN134-1 rev A
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Problem
Cabinet fan does not turn.
Limited or low flow
Low oxygen concentration
Probable Cause
Solution
Faulty electrical connections.
Check electrical connections.
Faulty cabinet fan.
Replace cabinet fan.
Restriction in humidifier/tubing.
Replace humidifier or tubing.
Product regulator set too low.
Adjust regulator setting.
Leak.
Leak test and repair leak.
Reduced air intake (suction).
Check compressor intake path for
obstruction. Clean/remove
obstruction.
Faulty solenoid valve.
Repair or replace solenoid valve.
Restriction in product tank.
Replace product tank.
Faulty circuit board.
Replace circuit board.
Weak compressor.
Check system pressure, and rebuild
or exchange compressor.
Outlet pressure not set to 20 psig.
Reset outlet pressure.
Leak.
Leak test and repair leak.
Ambient or unit’s temperature is too
high. Unit operating above
temperature range specifications.
Obstructed air intake or exhaust.
Locate unit away from heating
source, providing adequate
ventilation on all sides. (Do not run
multiple units next to each other).
Replace cabinet fan.
Reduced air intake (suction).
Check compressor intake path for
obstruction. Clean/remove
obstruction.
Restriction in exhaust muffler.
Replace or clean exhaust muffler.
Faulty solenoid valve.
Repair or replace solenoid valve.
Faulty circuit board.
Replace circuit board.
Contaminated sieve beds.
Replace sieve beds.
Weak compressor.
Check system pressure, and rebuild
or replace compressor.
25
MN134-1 rev A
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6.4
Tool Kit and Pressure Test Gauge
The tools needed for you to properly service the NewLife Intensity 10 unit are listed
below:
Multi-adjustable pliers, wire cutters, needle-nose pliers, slotted-head screwdriver, Phillipshead screwdriver, ratchet, adjustable wrench, 1-inch deep well socket, 9/16-inch socket, 2inch extension, 7/16-inch combination wrench, 9/16-inch combination wrench, and 5/8inch combination wrench.
Pressure test adapter (AirSep p/n: KI057-1).
Outlet pressure test kit (AirSep p/n: TU131-2).
A pressure test gauge (AirSep p/n: KI036-1) to read operating system pressures and outlet
pressures on the Intensity 10 unit should be kept available at all times.
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MN134-1 rev A
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APPENDIX
 Exploded drawings
Wiring Diagram – Intensity 10 120V
A
Wiring Diagram – Intensity 10 220/240V
B
Control Panel Assembly
C
Main Structure Assembly
D
Base and Cabinet Components
E
Product Tank/Regulator Assembly
F
Valve Block Assembly
G
Compressor Assembly
H
Sieve Bed Assembly
I
WIRING DIAGRAM
INTENSITY 10 120V
A
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WIRING DIAGRAM
INTENSITY 10 220/240V
B
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ITEM
PART
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
BK016-1
CA003-1
CB068-9
CB107-1
CR001-1
CR001-6
F0005-2
F0007-3
F0025-1
F0414-1
F0590-1
F0631-1
DESCRIPTION
BRACKET, FLOWMETER, DUAL
CABINET, CONTROL PANEL
CIRCUIT BOARD, 120V
CIRCUIT BOARD, 220V
CIRCUIT BREAKER, 120V
CIRCUIT BREAKER, 220V
FITTING, BRASS, ADAPTER
FITTING, OUTLET
FITTING, OXYGEN CONNECTOR
FITTING, PALNUT, FLOWMETER
FITTING, ADAPTER, DEMAND VALVE
FITTING, OUTLET BLOCK
ITEM
PART
NUMBER
13
14
15
16
17
18
19
20
21
22
23
FA002-1
FM056-1
HM009-2
MO002-1
SW114-1
TU201-1
TW001-4
VA006-2
VA059-3
WA021-1
WA036-1
DESCRIPTION
FASTENER, TIE WRAP MOUNT
FLOWMETER
HOUR METER
MOUNT, CIRCUIT BOARD
SWITCH, ON/OFF
TUBING, ASSY, OUTLET, DUAL, SECONDARY
TIE WRAP
VALVE, CHECK
VALVE, DEMAND
WASHER, INTERNAL, DUAL
WASHER, EXTERNAL, DUAL
CONTROL PANEL ASSEMBLY
C
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
BT001-2
BT002-1
CA214-1
FA002-1
FA003-1
FN022-1
FN022-2
FO002-1
HA001-1
MI161-2
MU089-1
NU003-1
RN020-1
RN027-1
DESCRIPTION
BATTERY, HOLDER
BATTERY
CABINET, SUPERSTRUCTURE
FASTENER, TIE-WRAP MOUNT
FASTENER, WIRE HARNESS
FAN, 120V
FAN, 220V
FOAM, EQ
SPACER, TEMP SWITCH
FELT, INTAKE
MUFFLER
NUT, TERMINAL BLOCK
RESONATOR, 1ST STAGE
RESONATOR, 2ND STAGE
ITEM
PART
NUMBER
15
16
17
18
19
20
21
22
23
24
25
26
27
28
SC002-1
SC001-2
SC002-6
SC003-1
SC004-1
SW002-3
TE040-1
VA003-1
VA003-2
VA543-1
VA496-1
VA496-2
WA002-8
WH096-2
DESCRIPTION
SCREW, TEMP SWITCH
SCREW, TERMINAL BLOCK
SCREW, FAN
SCREW, BUZZER
SCREW, BATTERY HOLDER
SWITCH, TEMPERATURE
TERMINAL BLOCK
VALVE, EQ, 120V
VALVE, EQ, 220V
VALVE, CHECK
VALVE, EQ, ASSY, 120V
VALVE, EQ, ASSY, 220V
WASHER, TEMP SWITCH
BUZZER (W/WIRE HARNESS)
MAIN STRUCTURE ASSEMBLY
D
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
3
4
5
BE186-1R
CA034-1
CA036-4
CA201-1
CA254-1
DESCRIPTION
BEDS
CABINET, BACK PANEL
CABINET, SIDE PANEL
CABINET, ROLLER BASE
CABINET, FRONT PANEL
ITEM
PART
NUMBER
6A
6B
7
8
CD011-2
CD011-4
CS001-1
FI002-1
DESCRIPTION
CORD, POWER, US-STYLE
CORD, POWER, EUROPEAN –STYLE
CASTER
FILTER, FOAM
BASE AND CABINET COMPONENTS
E
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
RG088-1
TA132-1
DESCRIPTION
REGULATOR (ONLY)
TANK, MIXING, ASSY
PRODUCT TANK/REGULATOR ASSEMBLY
F
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
3A
VA290-3
VA034-1
VA054-1
DESCRIPTION
VALVE, BLOCK (ONLY)
VALVE, FEED/WASTE REBUILT KIT
VALVE, COIL, 120V
ITEM
PART
NUMBER
3B
4A
4B
VA117-1
VA001-1
VA001-2
DESCRIPTION
VALVE, COIL, 220V
VALVE, SOLENOID, 120V
VALVE, SOLENOID, 220V
VALVE BLOCK ASSEMBLY
G
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
3
4
5
CL007-1
CO306-1R
CO306-2R
F0045-2
F0627-1
DESCRIPTION
CLAMP, HEAT EXCHANGER
COMPRESSOR, ASSY, 120V
COMPRESSOR, ASSY, 220V
FITTING, ELBOW, INTAKE
FITTING, ADAPTER, INTAKE
ITEM
PART
NUMBER
6
7
8
9
10
F0104-1
HX002-2
KI070-1
SC013-2
WA002-14
DESCRIPTION
FITTING, ELBOW, HEAT EXCHANGER
HEAT EXCHANGER
KIT, SPRING MOUNT
SCREW, CLAMP
WASHER, CLAMP
COMPRESSOR ASSEMBLY
H
MN134-1 rev A
08/11
ITEM
PART
NUMBER
1
2
3
4
5
6
7
8
BE002-4
BE005-2
BE005-3
BE006-1
BE011-4
BE058-1
BE059-1
BE071-1
DESCRIPTION
BED, TUBE
BEDS, LEFT CAP ASSY, TOP
BEDS, RIGHT CAP ASSY, TOP
BEDS, CAP ASSY, BOTTOM
BEDS, RODS
BEDS, BAFFLE
BEDS, PISTON ASSY, STATIONARY
BEDS, PISTON ASSY, MOVING
ITEM
PART
NUMBER
9
10
11
12
13
14
15
16
F0001-2
F0105-7
F0134-1
GS017-1
NU001-1
NU040-1
OR001-1
SP006-1
DESCRIPTION
FITTING, ELBOW, TOP CAP
FITTING, ADAPTER, BOTTOM CAP
FITTING, COMPRESSION NUT
GASKET
NUT, BOTTOM CAP
NUT, TOP CAP
O-RING
SPRING
SIEVE BED ASSEMBLY
I
MN134-1 rev A
08/11
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