Impulse Elite Service Manual Rev 12-01

MN094-1

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TABLE OF CONTENTS SERVICING THE IMPULSE ELITE UNIT Section 1.0 1.0 Introduction ... 1 Section 2.0 2.0 Removal of Unit Housing ... 2 2.1 Removing Upper Housing ... 2 2.2 Removing Lower Housing ... 2 Section 3.0 3.0 Circuit Board Replacement ... 4 3.1 Removing the Pressure Sensor Tubing ... 4 3.2 Removing the Circuit Board and Electrical Connections ... 5 3.3 Circuit Board Installation... 6 Section 4.0 4.0 Solenoid Valve Replacement ... 7 4.1 Solenoid Valve Removal ... 7 4.2 Solenoid Valve Installation ... 7 Section 5.0 5.0 Battery Holder Replacement ... 8 5.1 Battery Holder Removal ... 8 5.2 Battery Holder Installation ... 8 Section 6.0 6.0 Manual Bypass Valve Replacement ... 9 6.1 Bypass Valve Removal... 9 6.2 Bypass Valve Installation ... 9 SPECIFICATIONS ... 11 TROUBLESHOOTING ... 12 SPARE PARTS ...14 WARRANTY

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SERVICING THE IMPULSE ELITE UNIT

1.0 Introduction To service and replace any of the following ImPulse Elite components, you need to begin with the removal of the unit’s upper and lower housing (Section 2.0): • • • •

Circuit board – Section 3.0 Solenoid valve – Section 4.0 Battery holder – Section 5.0 Manual bypass valve – Section 6.0

Retain all screws removed from the unit’s housing for later re-installation. Tools required: • • • • •

Phillips screwdriver Flathead screwdriver 3/32-inch hex wrench 7/64-inch hex driver Bend-tip, needle-nose pliers

Safety guidelines To ensure safe operation and proper unit maintenance, AirSep Corporation recommends that you keep this service manual readily available for reference. As you read the manual, pay attention to any warning, caution, and note messages, such as the important warning below, which applies specifically to performing service on this product. This ImPulse Elite unit and its self-contained regulator is used for high pressure applications. Oilbased products introduced into an oxygen environment create an extremely volatile and explosive reaction. Use extreme caution at all times when working with regulators and high pressure oxygen. Serious bodily injury and/or death can occur under these circumstances.

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2.0 Removal of Unit Housing Refer to Figure 1 for the following procedures:

2.1 Removing Upper Housing 1.

To remove the upper housing, pull off the gray, plastic flow selector knob.

2.

Turn the unit over, and remove the four (4) outer Phillips screws. Do not remove the center screw at this time.

3.

Turn the unit back to its normal upright position.

4.

Rotate the regulator securing knob counterclockwise until it is stopped by the E-clip. Do not force the regulator securing knob beyond this point, as it will damage the E-clip. The upper housing can be removed to expose the circuit board.

5.

Gently lift the upper housing from the unit.

2.2 Removing Lower Housing 1.

Turn the unit over and remove the four (4) outer Phillips screws.

2.

Locate and remove the center Phillips screw on the underside of the unit.

3.

Lift the regulator and circuit board assemblies from the lower housing. If the regulator and circuit board assemblies do not lift out easily, ensure that the PULSE FLOW/CONTINUOUS FLOW SWITCH is set to PULSE FLOW and the battery has been removed from inside the battery compartment.

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Flow Selector Knob

Upper Housing Securing Knob (Yoke)

Circuit Board Assembly

E-Clip Regulator Block Assembly

(CGA) Sealing Washer

Lower Housing

Battery Compartment

(Center) Phillips Screw

Phillips Screws

Figure 1 ImPulse™ Elite Service Manual 12/01

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3.0 Circuit Board Replacement 3.1 Removing the Pressure Sensor Tubing 1.

Locate the clear, plastic tubing connected to the pressure sensor on the circuit board. (See Figure 2.)

2.

Using bend-tip, needle-nose pliers, place the jaws of the pliers around the tubing at the port in which the tubing enters the aluminum regulator block assembly. The side of the pliers should rest flush against the block with the handle extending out 90O from this surface.

3.

Squeeze the tubing with the pliers, and gently move the tubing back and forth with the pliers to loosen and remove it from the port. This action protects the pressure sensor from damage as you disconnect the tubing. Do not attempt to disconnect the tubing by any other method, or it can stress and destroy the sensor.

Pressure Sensor Port

Pressure Sensor Tubing

Pressure Sensor Regulator Block Assembly

Solenoid Valve

Bypass Valve

Figure 2

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3.2 Removing the Circuit Board and Electrical Connections A portion of the circuit board lies under the regulator pressure gauge. After removal of the tubing from the regulator block assembly, perform the following steps: 1.

Shift the circuit board until the gauge aligns with the through-hole on the circuit board. (See Figure 3.)

2.

Carefully lift the circuit board off of the regulator block assembly. There are two electrical connections that remain attached to the board. Be careful not to damage the connections while lifting the board.

Circuit Board Assembly

Oxygen Outlet Regulator Pressure Gauge (Cylinder Contents Gauge)

Regulator Block Assembly

Figure 3 ImPulse™ Elite Service Manual 12/01

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3.

When the circuit board is clear of the regulator pressure gauge, turn the board over to expose the underside of the board where the electrical connections are located.

4.

Using the bend-tip, needle-nose pliers, gently grasp and disconnect the white electrical connectors from their mating sockets. The circuit board can now lift easily off the regulator block assembly.

Circuit Board Bottom View Mating Socket for (Red/Green) Wire Harness

Mating Socket for (Red/Black) Wire Harness

J3

J2

Figure 4

3.3 Circuit Board Installation 1.

Remove a new circuit board, part number CB055-2, from its protective bag, and make sure that the clear, plastic tubing is installed on the pressure sensor. (See Figure 2.)

2.

Connect the solenoid wire harness (red/green) to J3 on the circuit board. (See Figure 4.)

3.

Connect the battery holder wire harness (red/black) to J2 on the circuit board.

4.

Position the through-holes of the circuit board over the oxygen outlet and the regulator pressure gauge. For easier installation, position the valve wires around the oxygen outlet to keep them out of the way during final assembly.

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5.

Apply isopropyl alcohol to the outer diameter of the 1/4-inch tubing on the circuit board assembly to lubricate the tubing.

6.

Using bend-tip, needle-nose pliers, press the tube into the port of the regulator block.

4.0 Solenoid Valve Replacement 4.1 Solenoid Valve Removal 1.

Remove the circuit board from the regulator block assembly. (Refer to Section 3.2: Removing the Circuit Board and Electrical Connections.)

2.

Locate the solenoid valve. (See Figure 5.)

3.

Rotate the valve counterclockwise to remove the solenoid valve for replacement.

4.2 Solenoid Valve Installation 1.

Locate the solenoid valve assembly, part number VA218-1.

2.

Make sure the two (2) o-rings are present on the manifold side of the replacement solenoid valve.

3.

Rotate the solenoid valve into the regulator block assembly.

4.

Reinstall the circuit board according to the instructions in Section 3.3: Circuit Board Installation.

Solenoid Valve

Figure 5 ImPulse™ Elite Service Manual 12/01

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5.0 Battery Holder Replacement 5.1 Battery Holder Removal 1.

Remove the circuit board from the regulator block. (Refer to Section 3.2: Removing the Circuit Board and Electrical Connections.)

2.

Locate the battery holder. Remove the three (3) Phillips screws and retain for reinstallation.

5.2 Battery Holder Installation 1.

Locate a new battery holder, part number MI119-1. (See Figure 6.)

2.

Inspect the holder for proper electrical solder connections.

3.

Use 4-40 x 1/ 4-inch machine screws to attach the battery holder to the regulator block assembly.

4.

Re-install the circuit board according to the instructions in Section 3.3: Circuit Board Installation.

Battery Holder

1/4” Phillips screws

Figure 6

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6.0 Manual Bypass Valve Replacement 6.1 Bypass Valve Removal 1.

Remove the upper and lower housing of the unit. (Refer to Section 2.0.)

2.

Remove the circuit board. (Refer to Section 3.0.)

3.

Remove the battery holder. (Refer to Section 5.0.)

4.

Using a 7/64-inch hex driver, remove the two (2) socket cap screws securing the manifold to the regulator block.

5.

Push the tip of the bypass valve to remove it from the manifold.

6.2 Bypass Valve Installation 1.

Locate a replacement bypass valve, part number VA212-1.

Cap Screw

Manifold

Bypass Valve Regulator Block

Cap Screw

Figure 7 ImPulse™ Elite Service Manual 12/01

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2.

Ensure that the two (2) o-rings are present. Improper insertion will cut the o-rings and result in a leak. If the valve does not slide easily, USE ONLY A SMALL AMOUNT OF A TEFLON-BASED LUBRICANT. (Refer to the Caution message below.) Do not use oil-based lubricants. AirSep recommends DuPont Krytox lubricant for this application.

3.

Gently insert the valve into the manifold, ensuring that an o-ring is not cut inadvertently.

4.

Using a 7/64-inch hex driver, install the two (2) socket cap screws to secure the manifold to the regulator block.

5.

Perform procedures from Sections 5.2, 3.3, and the reverse of Section 2.0 to re-assemble the unit.

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SPECIFICATIONS Dimensions: 4.39 in. x 5.58 in. x 2.55 in. 11.15 cm x 14.17 cm x 6.48 cm Weight:

24 oz (with “D” size battery) 682 g

Power:

(1) 1.5 V “D” alkaline battery

Indicators:

Alarm/No inspiration - Audible/Visual (red) Low Battery - Audible/Visual (yellow) Pulse Flow - Visual (green); indicates good battery

Continuous Flow: Contents Gauge: Maximum Cylinder Pressure:

2 lpm oxygen; manual switch Red/Refill Zone: 0–500 psi Green Shaded Zone: 500–2,200 psi Green Outlined Zone: 2,200–3,000 psi

3,000 psi

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TROUBLESHOOTING If your unit fails to operate as described in this manual, first review the following chart for possible causes and solutions. If necessary, contact your Equipment Provider.

Problem

Possible Cause

Possible Solution

ON/OFF p o we r switch se t to ON p o sitio n, b ut no lig hts are illuminate d o n unit.

No b atte ry o r d ischarg e d b atte ry in unit.

Che ck and re p lace b atte ry as ne ce ssary.

ImPulse Elite d o e s no t d e live r o xyg e n.

Cannula tub ing is kinke d o r no t p ro p e rly ad juste d .

Che ck o r re p lace tub ing as ne ce ssary.

ON/OFF p o we r switch se t to OFF p o sitio n.

Se t ON/OFF p o we r switch to ON p o sitio n.

Oxyg e n cylind e r is e mp ty.

Che ck cylind e r, and re p lace if e mp ty.

Oxyg e n cylind e r valve is shut o ff.

Make sure cylind e r valve is o p e n o ne full turn co unte rclo ckwise .

Unit se nsitivity re q uire s ad justme nt.

Co ntact yo ur Eq uip me nt Pro vid e r.

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Problem

Possible Cause

Possible Solution

De vice d o e s no t turn o n with p o we r switch in ON p o sitio n (no lig hts, no alarm afte r 30 se co nd s, no initial p ulse o f o xyg e n).

No p o we r to unit.

Che ck b atte ry. Che ck p o we r sup p ly (if no t using b atte ry). Che ck wall o utle t (if using p o we r sup p ly).

Faulty e le ctrical co nne ctio n fro m b atte ry.

Che ck e le ctrical co nne ctio ns.

Faulty b atte ry ho ld e r.

Che ck b atte ry ho ld e r (so ld e r jo ints, wiring , co ntacts). Re p lace b atte ry ho ld e r if ne ce ssary.

De fe ctive circuit b o ard .

Re p lace circuit b o ard .

Initially, unit functio ns with p o we r switch in ON p o sitio n (lig hts and alarm functio n, p ulse o f o xyg e n). The n d e vice d o e s no t lig ht o r p ulse o xyg e n.

Bro ke n circuit to so le no id valve o r faulty transd uce r.

Re p lace circuit b o ard .

De vice d o e s no t p ulse o xyg e n (Lig hts flash whe n p atie nt b re athe s into unit).

Faulty e le ctrical co nne ctio n to so le no id valve .

Che ck e le ctrical co nne ctio n.

Faulty so le no id valve .

Re p lace so le no id valve .

Le ak in so le no id valve .

Re p lace so le no id valve .

Le ak in manual b yp ass valve .

Re p lace b yp ass valve .

Transd uce r o ut o f calib ratio n.

Re p lace circuit b o ard .

Oxyg e n le aking at cannula co nne ctio n.

Erratic p ulse - p ulse o n e xhale , d o ub le p ulse s, e tc.

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SPARE PARTS LIST Part No.

Description

Unit Cost USD*

CA144-1 (LA161-1)

Battery Door Label, Grip Strip

5.00 1.00

CA145-2

Upper Housing Assembly, with Labels

10.00

CA146-1

Lower Housing Assembly with Labels

10.00

CB055-2

Circuit Board

165.00

CB055-2R

Circuit Board, Re-manufactured

99.00

FA011-1

E-Clip

1.00

MI108-1 (LA162-1)

Securing Knob (Yoke) Label, Regulator Knob

5.00 1.00

MI187-1

Flow Selector Knob

1.00

MI119-1

Battery Holder

5.00

OR005-1 VA212-1

(CGA) Sealing Washer Bypass Valve

1.25 15.00

VA218-1

Solenoid Valve

50.00

* Prices subject to change without notice.

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LIMITED WARRANTY AirSep Corporation warrants the ImPulse Elite Oxygen Conserver to be free from defect in parts for three 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 return freight charges. Replacement parts shall be warranted as stated above for the unexpired portion of the original three-year parts warranty (as specified on the original invoice provided). This warranty does not extend to any item or part subjected to misuse, accident, improper maintenance, or 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, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.

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