Maquet Compressor Mini User manual
Compressor Mini
Service Manual
CRITICAL CARE
Compressor Mini Service Manual
Notes
2 Revision 02
Compressor Mini Service Manual
Contents
1. Important ............................................................................................................................. 4
2. Introduction ......................................................................................................................... 8
2.1 General description...................................................................................................... 8
2.2 Main units..................................................................................................................... 8
2.3 Functional principles .................................................................................................... 9
3. Description of functions ....................................................................................................10
3.1 Compressed air production ....................................................................................... 10
3.2 Compressor cooling .................................................................................................. 12
3.3 Electric functions .......................................................................................................12
4. Disassembling and assembling ......................................................................................... 16
4.1 General ....................................................................................................................... 16
4.2 Handling PC boards .................................................................................................. 16
4.3 Tools ..........................................................................................................................16
4.4 Compressor cover ..................................................................................................... 17
4.5 Internal tubing ............................................................................................................ 17
4.6 Compressor with motor ............................................................................................. 18
4.7 Compressor maintenance ......................................................................................... 19
4.8 Water separator .........................................................................................................20
4.9 Thermoelectric cooler ................................................................................................ 21
4.10 Axial fan ..................................................................................................................... 22
4.11 Radial fan ...................................................................................................................22
4.12 Standby valve ............................................................................................................ 23
4.13 Drainage valve ........................................................................................................... 23
4.14 PC board ....................................................................................................................24
5. Service procedures ........................................................................................................... 25
5.1 Transport safety lock .................................................................................................25
5.2 Replacing / resetting fuses ........................................................................................26
5.3 Setting the DIP switch ...............................................................................................27
6. Troubleshooting ................................................................................................................. 28
7. Preventive maintenance .................................................................................................... 31
7.1 General ....................................................................................................................... 31
7.2 5.000 hour overhaul ...................................................................................................31
7.3 10.000 hour overhaul .................................................................................................33
8. Index ..................................................................................................................................34
9. Diagrams............................................................................................................................ 36
9.2 Wiring diagram ........................................................................................................... 36
9.2 Functional block diagram ..........................................................................................37
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Compressor Mini Service Manual
1. Important
1
General
• This Service Manual is intended to give service
personnel sufficient knowledge about the
Compressor Mini to be able to diagnose any
possible problem or failure and to identify which
part or component that causes the problem or
failure. The description is limited to a level, which
allows the service personnel to track problems
down to parts that are found in the spare part list.
• This Service Manual is also intended to give
information how to perform preventive
maintenance.
• Documentation for Compressor Mini consists of:
– Compressor Mini – User's Manual
– Compressor Mini – Service Manual
– Compressor Mini – Installation Instructions
– Compressor Mini, Alternative connections –
Installation Instructions
• The Compressor Mini – User's Manual is an
indispensable complements to the Service
Manual for proper servicing.
Text inside a box is used to highlight important
information.
• In addition to the Important information given
here and in the related documents, always pay
attention to applicable local and national
regulations.
• Responsibility for the safe functioning of the
equipment reverts to the owner or user in all
cases in which service or repair has been done
by a non-professional or by persons who are not
employed by or authorized by MAQUET, and
when the equipment is used for other than its
intended purpose.
• Data on internal pressures are given in Pa (psi).
Airway pressures are given in cm H
1 hPa = 1 mbar 1 mbar = 1 hPa
1 kPa = 10 mbar 1 mbar = 0.1 kPa
1 kPa = 0.01 bar 1 bar = 100 kPa
1 kPa ≈ 10 cm H
≈ 0.01 at 1 at ≈ 100 kPa
1 kPa
1 kPa
≈ 0.01 kgf/cm
1 kPa
≈ 0.01 kp/cm
≈ 0.145 psi 1 psi ≈ 6.9 kPa
1 kPa
O 1 cm H
2
2
2
1 kgf/cm
1 kp/cm
O (Pa).
2
O ≈ 0.1 kPa
2
2
≈ 100 kPa
2
≈ 100 kPa
Symbols used in this manual
• ESD sensitive components. When
handling ESD-sensitive devices,
established procedures must be
observed to prevent damage.
• Technical training. Refers to the
Technical training supplied by
MAQUET.
• Service contract. Refers to the
Service contract supplied by
MAQUET.
• Special waste. Discard disposable,
replaced and left-over parts in
accordance with appropriate
industrial and environmental
standards.
Abbreviations used in this manual
If not stated otherwise:
• The 115 V AC / 60 Hz version is referred to as the
115 V version.
• The 220 V AC / 50 Hz – 240 V AC / 50 Hz version
is referred to as the 230 V version.
Software versions
• There are three different software versions
released for the Compressor Mini:
– SW version V1.1.0
– SW version V1.2.0
– SW version V2.1
The information in this Service Manual is valid for
all SW versions unless otherwise stated. The SW
version list above is valid as from October 2004.
For further information regarding the SW
versions, refer to chapter 3. 'Description of
functions' section 28. 'PC board'.
Installation
• Only personnel trained and
authorized by MAQUET shall be
permitted to install the Compressor
Mini. The installation and handingover procedures are described in the
Compressor Mini – Installation Instructions.
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Compressor Mini Service Manual
1. Important
Functional check
• After any installation, maintenance or service
intervention in the Compressor Mini, perform a
'Function check'. Refer to the User's Manual.
Hazard notices
• Before disassembling or assembling the
Compressor Mini, make sure that the:
– Power switch is set to Off.
– Mains power cable is disconnected.
– Gas supply is disconnected.
– The system is cleaned according to instructions
in the Compressor Mini – User's Manual,
chapter 'Cleaning'.
• With mains power supply connected to
the Compressor Mini, there are
energized electrical components as
well as moving mechanical parts inside
the equipment. All personnel must
exercise extreme caution when in the
vicinity of this equipment if fault tracing
or adjustments are performed with
mains power supply connected and
with the compressor cover removed.
• The Compressor Mini generates compressed air
at a pressure of 450 kPa (64 psi). Do not attempt
to connect or disconnect the compressed air line
or service the compressor section while
compressed air is being supplied. Do not direct
the compressed air line toward the eyes or
directly onto unprotected skin surfaces.
To the responsible service personnel
• The contents of this document are not binding.
If any significant difference is found between the
product and this document, please contact
MAQUET for further information.
• We reserve the right to modify products without
amending this document or advising the user.
• Only personnel trained and authorized
by MAQUET shall be permitted to
perform installation, service or maintenance. Only MAQUET genuine spare
parts must be used. PC boards (spare
parts) must always be kept in a package for
sensitive electronic devices. MAQUET will not
otherwise assume responsibility for the materials
used, the work performed or any possible
consequences of same.
• The device complies to standards and
requirements as stated in the 'Compressor Mini –
User's Manual'.
Service
• The Compressor Mini must be
serviced at regular intervals by
personnel trained and authorized by
MAQUET. Any maintenance or service
must be noted in a log book.
• It is recommended that maintenance
and service is done as a part of a
service contract with MAQUET.
• Preventive maintenance must be performed at
regular intervals as follows:
– At 5.000 hours of operation as described in this
Service Manual, chapter 'Preventive
maintenance'.
– At 10.000 hours of operation as described in
this Service Manual, chapter 'Preventive
maintenance'.
• When working with ESD sensitive
components, always use a grounded
wrist band and a grounded work
surface. Adequate service tools must
always be used.
• The Compressor Mini is oil free, and
oil must not be used when servicing
the compressor.
• Discard all disposable, replaced and
left-over parts in accordance with
appropriate industrial and
environmental standards.
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Compressor Mini Service Manual
1. Important
1
Environmental declaration
Purpose
This environmental declaration is for a
Compressor Mini unit.
Number codes within brackets refers to the
position number on each component in the
Functional Block Diagram in chapter Diagrams.
Components with special environmental
concern
Components listed below shall be disposed of in
accordance with appropriate industrial and
environmental standards.
Printed circuit boards
• Control board (28)
Other electronics
• Compressor with motor (2)
• Thermoelectric cooler with Peltier element (4)
• Standby valve (9)
• Drainage valve (12)
• Radial fan (16)
• Axial fan (18)
• Mains power inlet with fuses and
On/Off switch (20-22)
• Mains power terminal (23)
• Transformer (24)
• Rectifier (25)
• DC Capacitor (26)
• Autofuse (27)
• Motor relay (29)
• Radial fan capacitor (30)
• Motor capacitor (31)
• Thermostat (32)
• Buzzer (33)
• Internal cabling
Construction materials
The construction materials used in Compressor
Mini in % of the total weight.
Metal – total 43%
• Aluminum
• Steel
• Stainless steel
• Brass
• Copper
• Bronze
• Zinc (surface treatment)
• Chromium (surface treatment)
• Nickel (surface treatment)
Polymeric material – total 13%
• ABS (Acrylonitrile-butadiene-styrene plastic)
• PA (Polyamide)
• PE (Polyethylene)
• PET (Polyethylene terephtalate)
• PMMA (Polymethyl methacrylate)
• POM (Polyoxymethylene)
• PTFE (Polytetrafluoroethylene)
• PUR (Polyurethane)
• PVC (Polyvinyl chloride)
• CR (Chloroprene Rubber)
• EPDM (Ethylene Propylenendienmonomer)
• FPM (Fluoro Rubber)
• IR (Isoprene Rubber, Synthetic)
• NBR (Nitrile rubber)
• VMQ (Silicone)
Electronics – total 44%
• Printed circuit boards, cables etc.
Others – very small amounts
• Threadlocking adhesives
• Tape
• Corrugated cardboard
• Label
• Marking ink
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Compressor Mini Service Manual
1. Important
Articles of consumption
1. Compressor dust filter
2. Thermoelectric coolers dust filter
3. Air inlet filter
4. Water separator filter incl. O-ring
5. Compressor shock absorbers
6. Compressor maintenance kit incl:
– Cylinder liners
– Piston rings
– Valve plates
– Gaskets
– O-rings
– Misc. screws.
Items 1 – 4: Changed approx. every 5.000 hours.
Items 5 – 6: Changed approx. every 10.000 hours.
1
Power consumption
550 W at nominal voltage.
Noise level
Approximately 50 dB(A) at a distance of 1 m.
Packing materials
•Plywood
• Steel
• PE (Polyethyelene)
• PA (Polyamide)
• Corrugated cardboard
• Desiccator
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Compressor Mini Service Manual
2. Introduction
2.1 General description
The Compressor Mini is designed to supply medicalgrade compressed air. The compressor has a
capacity of approx. 30 l/min at a pressure of 350 –
450 kPa (50 – 64 psi).
The Compressor Mini can be placed on the ventilator
cart to form a compact unit which is easy to move.
It can also be used as a stand-alone unit.
2
The Compressor Mini is well insulated against noise
and therefore does not cause disturbance when used
during operations.
The Compressor Mini is equipped with a standby
function. In the standby mode, the compressor will
start to deliver compressed air if the hospital central
gas supply fails.
The Compressor Mini is fitted with temperature and
pressure alarms. The temperature alarm is activated
if the compressor should overheat or if there is a
malfunction in the thermoelectric cooler.
The pressure alarm is activated if the air pressure in
the compressed air tank is too high or too low.
The Compressor Mini is available in two different
versions; 115 V/60 Hz and 230 V/50Hz. With the
exception of air connections and ratings of various
electrical components, these versions are identical.
2.2 Main units
The Compressor Mini comprises the following main
units:
• Compressor with motor
• Cooling coil
• Water separator
• Thermoelectric cooler including axial fan
• Tank
• Radial fan for compressor cooling
• PC board including display.
Compressor
with motor
Tank
PC board
including display
Radial fan for
compressor cooling
Thermoelectric
cooler
Thermoelectric
cooler
Water
separator
Cooling
coil
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Compressor Mini Service Manual
2.3 Functional principles
This description refers to the Functional block
diagram, see chapter 9. 'Diagrams'.
Compressed air production
The dry and clean compressed air is produced as
follows:
• Ambient air from the inside of the Compressor Mini
is supplied to the Compressor with motor via the
Air inlet with filter.
• The action of the compressor imparts heat to the
compressed air. To provide preliminary cooling, the
air flow is passed through the Cooling coil before it
enters the Thermoelectric cooler. The cooling coil
is cooled by the air stream forced through the unit
by the Radial fan.
• In the Thermoelectric cooler, the air temperature is
further lowered. Moisture that remains in the
compressed air is then partly transformed into
water by condensation. This water is separated
from the air in the Water separator and routed to
the Drainage bottle via the Drainage valve.
• A Pressure regulator is connected to the
compressed air tubing. Air pressure in excess of
the preset level on this pressure regulator, normally
approx. 450 kPa (64 psi), will cause a flow which is
fed back to the inlet of the compressor.
• The dried, compressed air is collected in the Tank
and routed to the Compressed air outlet. The Tank
is equipped with a Safety valve. If water, for some
reason, is collected in the Tank, this water can be
removed by manually pressing the Drain valve pin.
• Compressed air from the hospital central gas
supply can be connected to the Compressed air
inlet and the Compressor Mini can then be started
in stand-by mode. The air pressure in the
Compressed air inlet is monitored by a pressure
sensor in Compressor Mini. If the hospital central
gas supply fails, the compressor automatically
starts to deliver compressed air. The Standby valve
will switch between the Compressed air inlet and
the Tank as compressed air source.
Compressor cooling
Efficient cooling is required to keep the specified
working temperature inside the unit, but also to
condensate water from the compressed air.
• The Compressor with motor is cooled by the air
stream forced through the unit by the Radial fan
and the two fans in the compressor. The cooling air
is cleaned by a Dust filter mounted on the rear
panel.
• The Thermoelectric cooler is cooled by the air
stream forced through its Cooling flanges by the
Axial fan. The cooling air is cleaned by a Dust filter
mounted on the underside of Compressor Mini.
Electric functions
Mains power to the compressor is connected via and
controlled by the On/Off switch which also includes
mains fuses. A number of electric power supply
functions (transformer, rectifier, capacitors, etc.) are
mounted inside the unit. Internal mains power supply
is distributed from the Mains power terminal.
Electrical control functions, the display and the
indicator LEDs are located on the PC board.
Three Temperature sensors and two pressure
sensors monitor the unit. The Buzzer (audible alarm)
and the red alarm indicator LED is activated during
temperature alarm and/or pressure alarm. The alarm
will be silenced if the Compressor Mini is switched off.
Transport safety lock
The Transport safety lock, mounted into the rear
panel, secures the Compressor with motor to the
rear panel. This will relieve the load from the shock
absorbers.
The Transport safety lock must be removed before
starting the Compressor Mini.
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Compressor Mini Service Manual
3. Description of functions
The text in this chapter refers to the Circuit and
connection diagrams and the Functional block
diagram, see chapter 9. 'Diagrams'.
The number in each sub-heading refers to the
position number on each component in the
Functional block diagram.
3.1 Compressed air production
1. Air inlet with filter
The Air inlet with filter supplies ambient air from the
inside of the unit to the Compressor with motor.
The filter is made of a felt, and must be replaced at
3
the 5.000 hour overhaul as well as at the 10.000 hour
overhaul. The filter must not be cleaned in any liquid.
2. Compressor with motor
The Compressor Mini is equipped with an integrated
compressor and electric motor unit.
The electric motor is a single phase motor supplied
with mains power. There are two different versions of
the motor, one for 115 V and one for 230 V.
The motor is fitted with a self-resetting thermal
switch that will cut the power supply to the motor
if the temperature at the switch exceeds approx.
130°C (266°F). When the motor cools down, the
thermal switch will automatically restart the motor.
As motors fitted with a self-resetting termal
switch can restart automatically, all personnel
must exercise extreme caution when in the
vicinity of this equipment if fault tracing is
performed with mains power supply connected
and with the compressor cover opened or
removed.
The compressor is an oil free twin-cylinder assembly
in which the filtered air is compressed by the action
of the twin pistons. A manifold pipe is connected
between the two cylinder heads so that the
compressed air generated collectively by both
pistons is available at a single outlet on one of the
cylinder heads.
The compressor’s capacity is at least a flow rate of
30 l/min at a pressure of 350 kPa (50 psi).
An overhaul of the compressor must be performed at
the 10.000 hour overhaul.
3. Cooling coil
A preliminary cooling of the compressed air is
provided by the Cooling coil assembly, which is
made of metal tubing. The compressed air to this
cooling coil is supplied from the compressor and the
output is connected to the Thermoelectric cooler.
The Cooling coil is cooled by the air stream forced
through the unit by the Radial fan. This air stream is
then routed to the Compressor with motor.
4. Thermoelectric cooler
The Compressor Mini is equipped with a Thermoelectric cooler. The thermoelectric cooler is a selfcontained unit including a 12 V Peltier element which
has one cool side and one warm side.
The compressed air is supplied to the cool side of
the Peltier element. When the temperature of the
compressed air is lowered, moisture that remains in
the air is partly transformed into water by
condensation. This water is then collected in the
Water separator connected to the outlet of the
Thermoelectric cooler.
The temperature at the Peltier element is controlled
by the PC board. The temperature sensor TS3,
connected to the Peltier element monitors the
temperature at the cool side of the element. To avoid
formation of ice in the thermoelectric cooler, power
supply to the Peltier element will be cut if the
temperature drops below a specified limit.
The warm side of the Peltier element is equipped
with Cooling flanges and is cooled by the air stream
provided by the Axial fan. A thermostat mounted at
the cooling flanges will cut the power to the Peltier
element if the warm side is overheated, refer to
section 32. 'Thermostat' below.
5. Water separator
The Water separator is a standard compressed air
filter (5 microns) provided to filter the air as well as to
separate water from the air. This water separator is
connected to the outlet of the Thermoelectric cooler,
and it supplies compressed air to the Tank (via a
one-way valve).
Water separated from the air is collected in the metal
bowl. The water separator is automatically drained at
regular intervals by the Drainage valve, and the water
is collected in the Drainage bottle.
The Water separator must be overhauled at the
5.000 hour overhaul as well as at the 10.000 hour
overhaul.
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Compressor Mini Service Manual
6. Pressure regulator
The compressed air supply is tapped off at the Water
separator and applied to the Pressure regulator. This
device is actually a pressure relief valve.
Pressure in excess of the set level, normally approx.
450 kPa (64 psi), opens this relief valve. The excess
compressed air flow is returned to the inlet of the
compressor. This arrangement effectively silences
the outlet of this relief valve.
7. Tank
The compressed air Tank is a metal container with a
volume of approx. 1.25 liters. A Safety valve and a
manual Drain valve is connected to the Tank.
8. Safety valve
A spring-loaded Safety valve is connected to the
Tank. The valve will open if the pressure inside the
tank exceeds approx. 700 kPa (102 psi).
9. Standby valve
The Standby valve is powered with 6 V and
electrically controlled by the PC board. The standby
pressure levels differ between the SW versions.
The Standby valve is a three-port valve with the
following function:
1. If the air pressure in the hospital central gas
supply, connected to the Compressed air inlet,
is above approx.:
• 300 kPa (44 psi) for SW version V1.1.0
• 250 kPa (36 psi) for SW version V1.2.0 and V2.1
the Standby valve connects this inlet with the
Compressed air outlet. The compressor is in
standby mode.
2. If the air pressure in the hospital central gas
supply, connected to the Compressed air inlet,
drops and stays below approx.:
• 300 kPa (44 psi) for SW version V1.1.0
• 250 kPa (36 psi) for SW version V1.2.0 and V2.1
for more than 2 seconds, the compressor starts
to supply compressed air to the Tank. At the
same time, the Standby valve will switch to
connect the Tank with the Compressed air outlet.
The compressor runs in active mode.
3. If the air pressure in the hospital central gas
supply, connected to the Compressed air inlet,
rises and stays above approx.:
• 350 kPa (50 psi) for SW version V1.1.0
• 300 kPa (44 psi) for SW version V1.2.0 and V2.1
for more than 30 seconds, the compressor stops.
At the same time, the Standby valve will switch
to connect the Compressed air inlet with the
Compressed air outlet. The compressor returns
to standby mode.
10. Compressed air inlet
Compressor Mini is equipped with a Compressed air
inlet. The purpose of this air inlet is to provide
compressed air from the hospital central gas supply
via Compressor Mini when used as a standby unit.
The inlet nipple can be adapted to local standards.
The inlet air connection nipple is provided with a
M12 x 1 thread.
The standby function is further described in section
9. 'Standby valve' above and in the User's Manual.
11. Compressed air outlet
The Compressed air outlet is connected to the Tank
via the Standby valve. The outlet nipple can be
adapted to local standards. The outlet air connection
nipple is provided with a M12 x 1 thread.
A test nozzle, provided as a service tool, can be used
when performing functional checks or troubleshooting on the Compressor Mini. It provides a
simulated load that permits rapid, easy checks of the
output pressure.
When testing the Compressor Mini, the test nozzle
should be connected to this outlet so that
compressed air flows through the nozzle. Output
pressure can then be read on the display.
The test nozzle permits an air flow of approx. 30 l/min
at 350 kPa (50 psi). An air pressure of 350 – 400 kPa
(50 – 58 psi) indicated on the display shows that the
compressor is operating correctly.
12. Drainage valve
The Drainage valve is powered with 12 V and
electrically controlled by the PC board.
The purpose of the Drainage valve is to remove
water collected in the Water separator at regular
intervals.
The valve is closed in non-activated condition.
During operation, the valve will be activated (open)
for approx. 0.5 seconds twice every minute by the
timing circuit on the PC board.
When the valve opens, the water collected in the
water separator will be transported to the Drainage
bottle.
13. Drainage bottle
The Drainage bottle collects the water that is
extracted from the compressed air by the Water
separator. It is a plastic container with a screw cap
into which the water hose from the water separator is
connected. There are ventilation holes in the cap.
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Compressor Mini Service Manual
14. Drain valve
The manual Drain valve is connected to the bottom
of the Tank with a plastic tube. This valve is a springloaded valve that is provided to drain the tank if
water, for some reason, collects in the tank. The
valve pin must be pushed manually.
The Drain valve can also be used to decrease the
internal air pressure e.g. during Function check or
during troubleshooting of the unit.
3.2 Compressor cooling
15. Dust filter – compressor
This Dust filter, made of a synthetic material, is
mounted on the rear panel of the unit. The purpose
3
of this filter is to clean the cooling air forced through
the unit by the Radial fan and the two fans in the
compressor.
The filter must be inspected and cleaned regularly as
described in the User's Manual, chapter 'Cleaning'.
The filter must be replaced at the 5.000 hour
overhaul as well as at the 10.000 hour overhaul.
16. Radial fan
The Compressor Mini is equipped with a Radial fan.
The fan is supplied with mains power as long as the
29. 'Motor relay' is activated. There are two different
versions of the fan, one for 115 V and one for 230 V.
The purpose of this Radial fan is to provide forced air
cooling for the Cooling coil and for the Compressor
with motor.
The forced cooling air stream provided by the Radial
fan enters the unit via the 15. 'Dust filter' and exits
via the outlet on the underside of the unit.
17. Dust filter – thermoelectric cooler
This Dust filter, made of a synthetic material, is
mounted on the underside of the unit. The purpose
of this filter is to clean the cooling air forced through
the Cooling flanges of the Thermoelectric cooler.
The filter must be inspected and cleaned regularly as
described in the User's Manual, chapter 'Cleaning'.
The filter must be replaced at the 5.000 hour
overhaul as well as at the 10.000 hour overhaul.
18. Axial fan
The Compressor Mini is equipped with an Axial fan.
The fan is supplied with 12 V power supplied by the
PC board.
The purpose of this Axial fan is to provide forced air
cooling for the 19. 'Cooling flanges' of the
Thermoelectric cooler.
The forced cooling air stream provided by the Axial
fan enters the unit via the 17. 'Dust filter' and exits
via the outlet on the underside of the unit.
19. Cooling flanges
The warm side of the Peltier element in the Thermoelectric cooler is equipped with Cooling flanges.
The purpose of these Cooling flanges is to lower the
temperature in the Thermoelectric cooler and thus
make the cooler work more efficient.
3.3 Electric functions
20. Mains power inlet
The mains power cable is connected to the Mains
power inlet, a male connector mounted on the rear
panel of the unit.
The Mains power inlet, the holder for the Mains fuses
F3/F4 and the On/Off switch is one complete unit.
On the 115 V-version, the mains power cable must
have a hospital grade plug.
21. Mains fuses F3/F4
There are two mains power fuses, F3 and F4.
The value for the mains fuses is as follows:
• 115 V version .....................................8.0 AT, 250 V
• 230 V version .....................................4.0 AT, 250 V
22. On/Off switch
The On/Off switch is the circuit breaker between the
mains power fuses F3/F4 and the power supply to
the rest of the unit.
23. Mains power terminal
Mains power from the On/Off switch is connected to
the Mains power terminal and, from this terminal,
distributed to the rest of the unit.
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