Weinmann Oxymat 3 Service manual
Servicing and
repair instructions
OXYMAT 3
Oxygen Concentrator
from Appliance No. 8000
Contents
Introduction
1.
Overview
2.
Functional description
3.
Servicing
3.1
3.2
3.3
4.
Hygienic Preparation
4.1
4.2
5.
Functional check
5.1
5.2
5.3
6.
Troubleshooting
6.1
6.2
6.3
6.4
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
Implementation
Disposal
No change of patient
Change of patient or reuse
General
Intervals
Implementation
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.10
5.3.11
5.3.12
5.3.13
5.3.14
Visual and acoustic signals
from
6.1.1
6.1.2
6.1.3
Remedies
O2 concentration outside
tolerance range . . . . . . . . . . . . . . . . .
System pressure fault
. . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . 10
Checking the housing
Checking the coarse dust filter
Checking the power cord
Checking the fuse
Checking the main switch and
LED displays
Checking the dosage monitor for
leaks
Checking the flowmeter for leaks
Checking the operating hours
meter
Checking the O2 concentration
Checking the mains failure alarm
Checking the indirect
cator (yellow LED) with appliance
closed
Checking the indirect status
indicator (yellow LED) with the
appliance
System pressure test
Checking the O2 system for leaks
OXYMAT 3 . . . . . . . . . . . . . . . .
Alarms
Signal patterns
Deactivating the signal functions
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 9
. . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 10
status indi
open
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . 27
10
-
19
19
27
3
4
5
8
9
7.
Repair information and repair instructions
7.1
General
7.2
Replacing the castors
7.3
Opening the appliance
7.4
Closing the
7.5
Replacing the compressor
(up to appliance no. 13350) . . . . . . . .
7.6
Replacing the compressor
(from appliance no. 13351 to 14999) .
7.7
Replacing the compressor
(from appliance no. 15000) . . . . . . . .
7.8
Replacing the operating hours meter
7.9
Replacing the circuit board
7.10
Replacing the fan
7.11
Replace adsorption containers
(Mac valves) . . . . . . . . . . . . . . . . . . .
7.12
Replace adsorption container
(plastic magnetic valve block) . . . . . . . .
7.13
Replace adsorption containers
(aluminum magnetic valve block) . . . . . .
7.14
Replace cover
7.15
Replacing the pressure reducer
7.16
Replacing the frame
(up to appliance no. 19999) . . . . . . . .
7.17
Replacing the frame
(from appliance no. 20000) . . . . . . . .
7.18
Replacing magnetic valves with valve block
(up to appliance no. 34999) . . . . . . . .
7.19
Replace magnetic valve block
8.
Spare parts
8.1 List of spare parts . . . . . . . . . . . . . . . 69
8.2 Maintenance set. . . . . . . . . . . . . . . . 72
9. Tools, testing equipment, disinfectants . . . . . 73
9.1 General tools and test equipment. . . . . 73
9.2 Special tools and test equipment . . . . . 73
9.3 Disinfectants . . . . . . . . . . . . . . . . . . 74
10. Technical Data. . . . . . . . . . . . . . . . . . . . . . . 75
10.1 Arrangement of the PCBs . . . . . . . . . . 76
11. Technical Changes . . . . . . . . . . . . . . . . . . . . 77
12. Repair and inspection log . . . . . . . . . . . . . . 78
13. Test report. . . . . . . . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . 28
. . . . . . . . . . . 29
appliance
. . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 30
. . . . . . . . . 40
. . . . . . . . . . . . . . . 42
. .
28
30
33
36
. . . 39
43
46
49
. . . . . . 54
57
59
60
. . . . . . . 66
69
© Copyright Weinmann GmbH & Co. KG.
The content and presentation are copyright protected and may only be used by authorised Weinmann Service Partners in the
course of their service operations. The content must not be reproduced or passed on to third parties. The complete documents
must be returned on termination of the cooperation with Weinmann.
2
Introduction
For decades, Weinmann has developed, manufactured and distributed equipment for oxygen therapy, inhalation therapy, sleep apnea therapy and
emergency medicine.
In 1982, Weinmann introduced the first oxygen
concentrator to the market.
Long-term oxygen therapy with an oxygen concentrator now has a firm place in the treatment of
chronic obstructive diseases of the respiratory
tracts. Many studies have proven that long-term
oxygen therapy can bring about a tangible improvement in life expectancy and quality of life.
The OXYMAT 3 oxygen concentrator from Weinmann is part of this therapy concept.
The aim of these service and repair instructions is
to familiarise you, as a knowledgeable expert, with
the OXYMAT 3 with regard to function, technology, servicing and repairs. In conjunction with the
training you have already received from Weinmann, you are now a "trained, qualified expert"
and are able to instruct your clients correctly, rectify
faults yourself, and carry out the functional checks
described in the instructions, as well as conduct
any repairs which may be necessary, as outlined
in these service and repair instructions.
In the event of a guarantee claim, OXYMAT 3 should
be returned to Weinmann.
In order to enable us to process any guarantee or
goodwill claims, please return the consumer's
proof of purchase (invoice) together with the appliance.
Repair and maintenance work must be carried out
only by Weinmann or by knowledgeable expert
staff.
You are responsible for any repairs performed by
yourself and for guaranteeing them!
Only original Weinmann spare parts should be used
for repair purposes.
Please remember:
Your customer trusts you and relies on your expertise, just as you rely on Weinmann.
Note:
The following information can be found in the description and operating instructions for OXYMAT 3:
• Safety instructions
• Installation
• Operation
• Hygienic preparation
• Warranty
3
1. Overview
Front
(with dosage monitor)
12 Nasal cannula
11 Connecting tube
(3 m) for nasal
cannula
1 Handle for lifting or
moving
2 On/Off knob
3 Warning notices
4 Operating hours meter
5 Oxygen outlet
10 Power cord
Dosage monitor
9
Back
up to appliance no. 19999 from appliance no. 20000
13 Coarse dust filter
14 Power cord socket
15 Fuse holder
Front
(with Flowmeter)
16 Flowmeter
17 Connecting tube
(10 m)
Indicators
19 Oxygen concentration status
indicator (yellow)
20 Power indicator (green)
6 Connecting nipple
with union nut (fitted)
7 Connecting tube
(20 m)
8 Castors with brake
18 Fault indicator (red)
O
O/I
2
Oxygen appliance!
Increased
Dosage monitor
26 Connection,
3 m hose to
nasal cannula
25 Humidifier
glass of
bubble
humidifier
4 Overview
21 Dosage unit (flowmeter)
0
,
5
0
,
4
0
,
3
0
,
2
0
,
1
5
,
0
24 Flow control knob
22 Ball, indicates
flow
23 Connection, long
tube to
OXYMAT 3 (20 m)
Flowmeter
16 Flowmeter
22 Ball, indicates
flow
28 Connection,
OXYMAT 3
29 Connection for
tubes
(3 m or 10 m)
27 Flow control knob
2. Functional description
OXYMAT 3 is a time-controlled appliance, i.e. the changeover time remains constant; only the pressure is
monitored.
Layout
The appliance essentially consists of three components:
• the compressor,
• the O2 system,
• the electronic/pneumatic control.
During operation, the compressor draws in ambient air via a coarse dust filter and a suction filter,
and passes the compressed air (approx. 1.7 bar
overpressure) into containers with molecular sieves
where the actual oxygen enrichment takes place.
The functional principle of molecular sieves is
based on their property of absorbing the nitrogen
contained in the air. The oxygen contained in the
air is then collected in the oxygen tank (further details can be found in the chapter “ The O2 enrichment process” on page 6).
The outlet pressure is regulated by a pressurereducer set to 0.6 bar.
The required quantity (flow) of oxygen is set on the
oxygen dosage control knob 24. Where a flowmeter is used, the flow is controlled via the flow
control knob 27. The flow is read at the top edge
of the flowmeter ball 22.
Every time it is switched on, the appliance control
system performs an internal self-test of the entire O2
system. This test takes about a minute. If the test detects an error in the O2 system that results in a drop
in the oxygen concentration, it activates the yellow
status indicator 19.
After the self-test, OXYMAT 3 switches to normal
operation. During normal operation the sequence
control constantly monitors the electrical and pneumatic circuits of the oxygen system.
Dosage monitor
Pressure-reducer
Oxygen tank
Container with
molecular sieve
Noise suppressor
Cooler
Compressor
Suction filter
Coarse dust
filter
5,0
4,0
3,0
2,0
1,0
0,5
Ambient air
In order to allow the process to run continuously, the containers operate alternately, i.e. before one container
is saturated with nitrogen, the system switches to the second container, which then continues with oxygen
enrichment. During this period, the first container is regenerated by a brief reduction in pressure, and at the
same time is flushed by a partial flow of enriched oxygen. This procedure is implemented cyclically at 7second intervals, thereby ensuring continuous oxygen enrichment of the inspiratory air.
Functional description 5
The level of oxygen concentration depends on the
set flow and is available within a few minutes.
The waste air is expelled to the rear via a noise
suppressor on the underside of the appliance.
The electronic control with microprocessor consists
of one circuit board. It is housed separately from
the oxygen system on the front panel.
The O2 enrichment process
The compressor draws the ambient air into the
housing via a coarse dust filter. Part of this air is
used to cool the compressor assembly. The other
part enters the compressor via the suction filter,
where it is compressed. A cooler reduces the temperature of the air. The compessed and cooled air
is then passed to the O2 system to enrich the oxygen.
Oxygen concentration
Flow [ l/min ]
Ambient air
The adsorption containers (ADS containers) are
alternately filled with compressed air in fixed
cycles, then regenerated by expanding the
compressed air and flushing with oxygen.
At the end of each enrichment, a pressure of
around 1.7 bar will have built up in the currently
active container.
After 7 seconds, the magnetic valves are alternately triggered by the electronic control and
switch between the two ADS containers.
Of the valves in the two ADS containers, one is
open and the other closed during operation.
Once the changeover time has been reached,
pressure compensation is implemented between
the two ADS containers. During pressure compensation, both valves are open for approximately
1 second.
The actual process of oxygen enrichment takes
place in the ADS containers. A molecular sieve
adsorbs the nitrogen from the air, thereby increasing the proportion of oxygen by volume.
As soon as the pressure in the ADS container has
risen sufficiently, air enriched with oxygen flows
into the oxygen tank at the other end of this container via the non-return valve.
Noise suppressor
Magnetic valves
Non-return valves
Suction filter
Compressor
Cooler
ADS container
Oxygen tank
Coarse dust filter
ADS container
Flushing nozzle
Throttle
Shutoff valve
outlet
2
O
Pressure sensor
Pressure reducer
6 Functional description
Part of the oxygen flows via the flushing nozzle into
the other ADS container for flushing.
During the oxygen enrichment process, the area
where adsorption of the nitrogen occurs will shift
from the beginning of the ADS container towards
the end. Before reaching the end of the container,
the pressure between the two ADS containers is
compensated via the pressure compensating
valve. Parallel to this, the pressure escapes via the
noise suppressor and the other ADS container is
opened. The same procedure then takes place
there.
Via pressure compensation, the remaining oxygen
passes to the other ADS container, compression
energy is saved, and blow-off noise is reduced.
The nitrogen adsorbed in the first ADS container is
desorbed as a result of the pressure drop when the
valve is opened and is expelled via the noise
suppressor.
Displays and alarms
In order to attain adequate desorption of the molecular sieve, part of the oxygen extracted in one
ADS container is continuously passed to the other
ADS container via the flushing nozzle.
The oxygen stored in the oxygen tank at an overpressure of up to 1.7 bar is reduced to 0.6 bar via
the pressure-reducer.
The pressure sensor monitors this system pressure.
If the pressure falls below 0.5 bar or rises above
2.5 bar, the system activates visual and acoustic
alerts.
At an overpressure of around 0.6 bar, the oxygen
flows towards the outlet of the appliance.
The prescribed flow is set on the dosage monitor
or on the flowmeter. It then flows to the patient via
the nasal cannula.
• If a leak that is likely to cause a drop in the oxy-
gen concentration occurs after the internal self-
test, this situation is indicated immediately by a
visual warning signal (yellow lamp).
• If the compressor output falls off, a visual alarm
signal is displayed (red lamp flashes) and an
acoustic warning (intermittent tone) sounds.
Further information on displays and alarms can be found in Chapter “6.1 Visual and acoustic signals from
OXYMAT 3” on page 19“.
• The green lamp indicates that the system is operational.
• In the event of a power failure, an intermittent
warning signal will sound and the red lamp
will flash. The green lamp is not illuminated.
Functional description 7
3. Servicing
3.1 General
• Important!
Enter the operating hours of OXYMAT 3 and the
oxygen concentration in your service record
(see page 78).
• The number of operating hours can be read
from the operating hours meter 4 on the front of
the device.
• As a precautionary measure, we recommend
that the OXYMAT 3 be serviced once a year
or every 5,000 operating hours.
• After each servicing, a functional check should
be carried out (see "5. Functional check" on
page 10).
Note: Dark discoloration of the intake filter 30 does
not mean that its flow characteristics are impaired,
provided its operating hours do not exceed
5,000 h; an exception applies if the device is operated in a very dusty environment.
3.2 Implementation
Servicing the OXYMAT 3 involves changing the coarse dust filter and the suction filter and performing a final
check (see "5. Functional check" on page 10).
The filters are located on the back of the appliance.
1. Detach the coarse dust filter 13 from the
service flap 38.
13
2. Release the lock on the service flap 38 and
remove the latter from the appliance.
When removing the suction filter, please proceed
with caution, since the connector and tube may be
torn off if the suction filter is handled carelessly.
3. You will find a black clip in the recess to the
left of the suction filter. Use your fingers or an
object to press against this clip to prevent it
from being pulled out as well.
4. Pull the suction filter 30 off the connector 71
without twisting. The suction filter must not be
twisted, as the connector could become
detached from the tube.
5. Connect the new filter 30 to the connector.
6. Clean the service flap 38 and insert it.
7. Clip a new coarse dust filter 13 into the service
flap 38.
38
71
30
8 Servicing
3.3 Disposal
Do not dispose of the unit with domestic waste. For proper disposal of the device and its components, please contact a certified waste disposal site for electronic goods. Ask your Environmental
Officer or local council for the address. Appliance packaging (cardboard and inserts) may be disposed of in the paper recycling bin.
4. Hygienic Preparation
4.1 No change of patient
Proceed as described in the operating instructions
for the OXYMAT 3.
4.2 Change of patient or reuse
• Dispose of extension tubes and nasal cannulas, and replace with new parts.
• Dispose of coarse dust filter and suction filter,
and replace with new parts.
• For the bubble humidifier, please observe the
separate operating instructions.
• Wipe housing and power cord with TERRALIN
disinfectant.
• Clean inside of housing with vacuum cleaner,
clean any particularly dirty parts with household cleaner (to open and close the appliance, see sections 7.3 and 7.4 on page 29
and page 30).
Hygienic Preparation 9
5. Functional check
5.1 General
• Should you discover any faults or deviations
from the set values during your functional
check, OXYMAT 3 must not be used again until the faults have been rectified.
• The possible causes underlying the fault and
how to rectify them are outlined in Chapter “6.
Troubleshooting” on page 19.
Please use the following equipment to carry out the functional check:
• Oxygen measuring device,
• Filled oxygen cylinder with adjustable pressure reducer (e.g. HIT,WM 33100),
• Respiratory tubes WM 5726 and WM 5772.
• For environmental reasons a capacitor backup unit has been installed instead of a battery
to serve the power failure alarm function.
As soon as OXYMAT 3 is operational, the capacitor is recharged. Charging takes approximately 5 minutes.
If the device has been out of service for some
time, an alarm cannot be triggered until the device has been operational for at least 5 minutes.
5.2 Intervals
A final check must be performed on the appliance:
• after every service;
• after every repair.
5.3 Implementation
5.3.1 Checking the housing
Check the housing to determine its general
condition.
• Dirt can be wiped off with a damp cloth. The
all-purpose cleaner WM 14937 is also very
suitable.
• If you want to use a disinfectant, we recommend TERRALIN.
10 Functional check
• If the housing is defective, replace it (see "7.3
Opening the appliance" on page 29) and
„7.4 Closing the appliance“ auf Seite 30.
• If the frame is defective, please replace it (see
"7.16 Replacing the frame (up to appliance
no. 19999)" on page 57).
5.3.2 Checking the coarse dust filter
Check the coarse dust filter 13 to determine its general condition:
1. Unclip the coarse dust filter from the back of
OXYMAT 3.
2. If the filter is dirty, clean it. As a general rule,
the filter should be freed from dust once a
week (either by tapping or vacuuming).
3. If the filter is defective, replace it.
13
5.3.3 Checking the power cord
1. Check the power cord 10.
Make sure that
– the insulation is undamaged,
– the cable is undamaged,
– none of the contacts are wobbly.
2. If any of these requirements are not satisfied,
replace the power cord 10.
5.3.4 Checking the fuse
The fuse holder 15 can be found on the rear of the appliance beneath the power socket 14.
1. Pull the power cord 10 from the socket and
from the device.
2. Press the side tabs on the fuse holder 15 together and pull out the fuse holder.
3. Check that the correct fuses are installed.
There should always be two fuses installed:
A mains fuse and a spare fuse.
The fuses 39 should carry the following label:
DIN EN 60127-T 2.5 A H 250 V.
4. If necessary, replace the defective or missing
fuses.
5. Push the fuse holder 15 into the housing until it
locks home.
15
5.3.5 Checking the main switch and LED displays
1. Connect the power cord 10 to OXYMAT 3
and to a wall socket.
2. Connect the dosage monitor or the flowmeter
to the oxygen outlet 5.
Functional check 11
3. Switch on the OXYMAT 3 at the On/Off
knob 2. The following LED displays will appear:
– The power indicator (green LED) 20 lights
up.
– The fault indicator (red LED) 18 and status
indicator (yellow LED) 19 light up briefly.
Important
The program then makes an internal check for
leaks:
– Pressure is built up within 20 seconds. The
green operating indicator 20 flashes light/
dark.
– Then the compressor is switched off and the
existing pressure is monitored for about 20
seconds. If there is a fault and the pressure
drops, the yellow status indicator 19 lights
up.
– Finally the system is vented so that the com-
pressor can start up again without any
back-pressure.
5.3.6 Checking the dosage monitor for leaks
19
20
O/I
Oxygen appliance!
Increased
fire risk!
O/ I
2
O
2
18
1. Check the screw connections between the humidifier glass/cap and humidifier/dosage
monitor to verify that they are firmly seated. If
necessary, re-tighten the connections by hand.
2. Set a flow of 4 l/min on the flow control
knob 24 for oxygen dosage.
3. To check the dosage monitor 9 for leaks,
– bend the 3 m tube 11
– or pull the 3 m tube 11 from the connection
of the bubble humidifier 25 and hold the
connection 26 closed.
If the ball 22 sinks all the way to the bottom,
there are no leaks in the dosage monitor system.
4. In the event of leaks, change the sealing rings
on the humidifer.
5.3.7 Checking the flowmeter for leaks
1. Set a flow of 4 l/min on the knob 27.
2. To check the flowmeter 16 for leaks:
– Bend the connection tube 17
– or pull the tube 17 from the connection of
the flowmeter and hold the connection 29
closed.
If the ball 22 sinks all the way to the bottom,
there are no leaks in the flowmeter.
3. In the event of leaks, change the sealing rings
on the flowmeter.
26
25
0
,
5
0
,
4
0
,
3
0
,
2
0
,
1
5
,
0
22
9
24
16
22
27
29
17
12 Functional check
5.3.8 Checking the operating hours meter
Check that the red minute counter on the operating
hours meter 4 is incremented every 6 minutes.
5.3.9 Checking the O2 concentration
Leave the OXYMAT 3 to run for at least 10 minutes
before starting the measurement.
Before you check the oxygen concentration on the
OXYMAT 3, you must first calibrate the oxygen
measuring device (e.g. OXYcontrol WM 13550).
For this purpose, you will need the respiratory tube
WM 5726 and an oxygen cylinder with an adjustable pressure reducer (e.g. WM 33100).
Caution !
Please observe the instructions for handling oxygen!
Important!
Before calibrating the oxygen sensor for the first
time, the sensor must be stored in ambient air for
at least 15 minutes (refer to instructions for use of
the sensor).
Observe instructions
for use!
4
000000
How to calibrate the oxygen sensor:
1. Connect the oxygen measuring device to the
pressure reducer of the oxygen cylinder using
the respiratory tube WM 5726.
2. Slowly open the cylinder valve. One revolution
is sufficient!
3. Set a flow of 4 l/min at the pressure reducer.
4. Leave the oxygen measuring device (e.g.
OXYcontrol) flowing for approximately 2 minutes,
until the displayed oxygen level remains steady.
5. Set a value of "100" using the calibration
knob.
6. Close the cylinder valve again.
The oxygen measuring device is now calibrated
and you can check the oxygen concentration on
OXYMAT 3.
Please remember that OXYMAT 3 must have already
been operational for at least 10 minutes.
When operating with a dosage monitor:
Important!
It is vital that you empty the humidifier glass 25 of the
bubble humidifier; otherwise, the oxygen sensor of
the oxygen measuring device will be damaged.
7. Connect the oxygen measuring device:
– To do so, remove connecting tube 11 from
connection 26 of the dosage monitor and
use breathing tube WM 5772 to make a
connection between connection 26 and the
oxygen measuring device;
or
– Unscrew the bubble humidifer (sterile water
system) from the dosage monitor and attach
the connecting tube to the OXYcontrol at
this point with the union nut.
8. Using the flow control knob 24, set a flow of
4 l/min.
11
26
24
Functional check 13
9. After waiting for a short while, read the oxygen concentration from the oxygen measuring
device.
It should be between 90 and 95 % by volume.
10. Re-connect the connecting tube 11.
11. If the O2 concentration is outside the tolerance
range, proceed as described in “6.3 O2 concentration outside tolerance range” on
page 27.
When operating with a flowmeter:
7. Connect the oxygen measuring device:
– To do this, remove connecting tube 17 from
connection 29 of the flowmeter and use
breathing tube WM 5772 to make a connection between connection 29 and the
oxygen measuring device;
or
– Unscrew the union nut from the flowmeter
and attach the connecting tube to the
OXYcontrol at this point with the union nut.
8. Using the flow control knob 27 set a flow of
4 l/min.
9. After waiting for a short while, read the oxygen concentration from the oxygen measuring
device.
27
29
17
It should be between 90 and 95 % by volume.
10. Re-connect the connecting tube 17.
11. If the O2 concentration is outside the tolerance
range, proceed as described in “6.3 O2 concentration outside tolerance range” on
page 27.
5.3.10 Checking the mains failure alarm
Note:
As power is supplied to the alarm function via a capacitor, the OXYMAT 3 should first be operated for 5 minutes
to allow the capacitor to charge.
1. Pull the power cord from the socket or from the
device.
2. Check whether the following displays and
alarms occur:
– Acoustic: The device emits a continuous
tone.
– Optical: The red fault indicator 18 lights up;
the green power indicator 20 is off.
3. Re-make the connection to the mains.
Now:
– The acoustic alarm should be silenced.
– The red fault indicator 18 should go out.
O
20 18
O/I
Oxygen appliance!
Increased
fire risk!
– The green power indicator 20 should be
on.
– The appliance should start up.
O/ I
2
14 Functional check
4. Switch off the appliance at the On/Off knob 2.
5.3.11 Checking the indirect status indicator (yellow LED) with appliance closed
The purpose of this check is to establish whether the status indicator that warns if a leak that is likely to cause
a drop in the oxygen concentration is working properly. This is done by an internal program that creates an
artificial leak which results in the alarm being triggered.
1. Switch on the OXYMAT 3 at the On/Off
switch 2.
An internal leak test will run for about 1 minute.
19
The green operating indicator 20 flashes while
this is in progress.
20
2. With the appliance running, set a flow of
4 l/min at the top of the ball.
To start the test program, proceed as follows:
3. Remove power cord 10 from the wall socket or
the appliance.
4. Wait for the acoustic power failure alarm to
sound (two groups of five tones – – – – –).
5. Switch off the OXYMAT 3 at the On/Off
switch 2. Do not connect the power cord
again.
6. Switch OXYMAT 3 on again at On/Off
switch 2.
11. Check that the yellow status indicator 19 is on
while this is happening.
If the status indicator does not light up, either:
– you have not set the flow to exactly 4 l/min
or
– the status indicator is faulty.
12. Switch off the OXYMAT 3 at the On/Off
switch 2, then switch it on again.
The test program is now deactivated and the
OXYMAT 3 is in normal operating mode.
7. Wait for the acoustic power failure alarm to
sound again (two groups of five tones
– – – – –).
8. Switch off the OXYMAT 3 at the On/Off
switch 2.
The yellow status indicator 19 must now light
up. If it does not, repeat the procedure.
9. Connect the power cord again.
10. Switch on the OXYMAT 3 at the On/Off
switch 2.
The following LED indicators appear:
– green operating indicator 20 lights up
– red fault indicator 18 lights up briefly
– yellow status indicator 19 lights up briefly.
O/I
Oxygen appliance!
Increased
fire risk!
O/ I
2
O
2
18
The program then runs an internal leak check
routine:
– pressure is built up within 20 s. The green
operating indicator 20 flashes.
– the pressure is checked for about 20 s with
the compressor switched off.
An artificial leak is created in the OXYMAT 3, and
this results in the oxygen concentration falling below 82 %.
Functional check 15
5.3.12 Checking the indirect status indicator (yellow LED) with the appliance open
Note:
Not necessary as part of a normal functional check or service.
The purpose of this check is to establish whether the status indicator that warns if a leak that is likely to cause
a drop in the oxygen concentration is working properly. This is done by an internal program that creates an
artificial leak which results in the alarm being triggered. If the appliance is open (e.g. for repair work) you
can start this test program with switch S5 on the printed circuit board.
1. Switch on the OXYMAT 3 at the On/Off
switch 2.
An internal leak test will run for about 1 minute.
19
The green operating indicator 20 flashes while
this is in progress.
20
2. With the appliance running, set a flow of
4 l/min at the top of the ball.
To start the test program, proceed as follows:
3. Switch off the OXYMAT 3 at the On/Off
switch 2.
4. Open coding switch S5 on the printed circuit
board.
5. Switch on the OXYMAT 3 at the On/Off
switch 2.
The following LED indicators appear:
– green operating indicator 20 lights up
– red fault indicator 18 lights up briefly
O
O/I
– yellow status indicator 19 lights up briefly.
The program then runs an internal leak check
routine:
– pressure is built up within 20 s. The green
operating indicator 20 flashes.
– the pressure is checked for about 20 s with
the compressor switched off.
O/I
Oxygen appliance!
Increased
fire risk!
O/I
2
O/ I
2
O
2
18
S5
An artificial leak is created in the OXYMAT 3, and
this results in the oxygen concentration falling below 82 %.
6. Check that the yellow status indicator 19 is on
while this is happening.
If the status indicator does not light up, either:
– you have not set the flow to exactly 4 l/min
or
– the status indicator is faulty.
7. Switch off the OXYMAT 3 at the On/Off
switch 2.
8. Close coding switch S5 on the printed circuit
board.
The test program is now deactivated and the
OXYMAT 3 is in normal operating mode.
9. Close the appliance (see "7.4 Closing the
appliance" on page 30).
16 Functional check
5.3.13 System pressure test
General
The system pressure should only be tested if there is a fault in the appliance.
Fitting the test pressure gauge
1. Connect the test pressure gauge inlet directly
to the oxygen outlet 5.
If your pressure gauge also has an outlet, close
it (e.g. with your thumb).
2. Open the appliance housing (see "7.3 Opening the appliance" on page 29).
3. Open the strap system 42 without pulling the
strap out of its buckle.
4. Carefully remove foam section 44.
5. To prevent the ADS containers from slipping
out, lay the strap system 42 over the remaining
foam sections and gently tighten it.
44
I
/
O
2
O
/I
O
O
2
0000
0
0
5
To make fitting easier, the test pressure gauge is
not fitted directly to the inlet of the O2 tank, but
before the 6 mm diameter tube 56 which leads
directly to the O2 tank.
6. At the T-connector 74, push back the sleeve of
the elbow connector and remove the tube 56.
7. Push the tube of the test pressure gauge firmly
into the elbow connector.
8. Push the tube 56 into the free inlet of the test
pressure gauge.
Pressure test
Oxygen outlet
1. Plug the power cord 10 into the appliance and
insert the mains plug in a wall socket.
2. Switch the OXYMAT 3 on.
3. After 10 minutes, attach the pressure gauge to
the oxygen outlet 5.
4. Read off the pressure.
The reading must be in the range
0.6 bar ± 0.1 bar (at sea level).
5. Rectify any discrepancies you find (see "6.2
Remedies" on page 22).
42
56
74
6. Switch the appliance off, then remove the
mains plug from the wall socket and the power
cord from the appliance.
7. Remove the pressure gauge.
8. Perform a functional check (see "5. Functional
check" on page 10).
Functional check 17
O2 tank inlet
9. Attach the dosage unit 21 or the flowmeter 16.
10. Plug the power cord 10 into the appliance and
insert the mains plug in a wall socket.
11. Switch the OXYMAT 3 on.
Caution!
Risk of injury or death!
Beware of live or moving components.
12. Set the flow to 4 l/min.
13. After 10 minutes, read off the pressure on the
pressure gauge.
The reading must be in the following range:
At the O2 tank inlet:
min. 1.2 + 0.3/- 0.2 bar to
max. 1.65 bar + 0.3/- 0.2 bar
at 4 l/min (at sea level).
Rectify any discrepancies you find(siehe „6.2
Remedies“ auf Seite 22).
5.3.14 Checking the O2 system for leaks
14. Switch the appliance off, then remove the
mains plug from the wall socket and the power
cord from the appliance.
15. Remove the dosage unit 21 or flowmeter 16
from the appliance.
16. Remove the pressure gauge.
17. Attach the tube 56.
18. Slacken the strap system.
19. Carefully insert the foam section 44 and tighten the straps again.
20. Close the appliance (see "7.4 Closing the
appliance" on page 30).
21. Perform a functional check (see "5. Functional
check" on page 10).
General
A check for leaks should only be made if there is a
problem with the appliance.
Method
Soap all connections between the compressor exit,
the pressure equalization system (tubes, exit) and
the shutoff valve after the pressure reducer.
18 Functional check
6. Troubleshooting
6.1 Visual and acoustic signals from OXYMAT 3
6.1.1 Alarms
The following appliance states trigger an alarm:
1. Power failure
2. Overheating
3. Memory error
4. Under-pressure
5. Over-pressure
6. Implausible pressure measurement
7. Leak in O2 system
1. Power failure
The energy for a power failure alarm is supplied by
a capacitor back-up unit. If the capacitor back-up
unit is fully discharged, the power failure alarm is
not available for the first minute after switching on
the OXYMAT 3 until the back-up unit has charged
up again.
2. Overheating
A temperature sensor is mounted on the printed circuit board. If the temperature rises above 60 °C
(± 2.5 °C), an alarm is given and at the same time
the compressor is switched off. The compressor remains switched off as long as the temperature
alarm is activated. The cause may for example be
a malfunction of the fan.
3. Memory error
Every time the appliance is switched on, the
EEPROM is first read out. Among other things, this
contains the operating cycles for the valves and the
calibration data for the temperature sensor. A plausibility check is performed on the data read out.
If a memory error occurs:
– default values (basic settings) are read from
the program memory and used to start the
control program;
– the memory error alarm is activated;
– after every alarm cycle a fresh attempt is
made to read the EEPROM;
– after a successful read attempt the alarm is
terminated.
4. Under-pressure
This alarm is activated if the pressure sensor at the
inlet to the O2 system measures a pressure lower
than the required operating pressure.
5. Over-pressure
This alarm is activated if the pressure sensor at the
inlet to the O2 system measures a pressure higher
than the required operating pressure.
6. Implausible pressure measurement
Since the OXYMAT 3 has a time control, there
must be a defined pressure pattern over time. This
pressure pattern is measured by the pressure
sensor and analyzed by the appliance software. If
necessary an alarm is activated.
7. Leak in O2 system
Every time the appliance is switched on, the control system runs a leak test on the entire O2 system.
If a leak is found, the yellow status indicator 19 is
switched on, as sooner or later this leak in the O2
system may result in the oxygen concentration at
the outlet falling below 82 %.
During the leak test the green power indicator 20
flashes.After the leak test the OXYMAT 3 switches to
normal operating mode.
If the leak test is not successfully completed within
one minute, the control system stops the test cycle
and switches on the yellow status indicator 19 to
indicate an operating fault. The cause of the leak
must now be identified.
No further test for leaks is performed during normal
operation.
Troubleshooting 19
6.1.2 Signal patterns
The alarm signal patterns are in accordance with EN 475 (see Table of Signal Patterns). To make it possible
to distinguish the alarm sources, this standard assigns specific signal patterns to individual error situations
(see Table of Error Situations).
Since it is possible that two or more errors may occur at the same time, the alarms are weighted by the
software and the appropriate alarm pattern is output. For example: if under-pressure and overheating occur
simultaneously, the alarm pattern for overheating is output (see Table of Alarm Situations).
Table of Alarm Situations:
Appliance Status
Power failure
Overheating
Implausible
pressure reading
Memory error
Under-pressure
Over-pressure
O2 status
Release after
x minutes
1 minute after
cold start
Immediately after
switching on
1 minute after
end of leak test
Immediately after
switching on
1 minute after
end of leak test
1 minute after
end of leak test
Test immediately
after switching on
Pattern of alarm
signal indicators
Buzzer: A
Red LED: A
Yellow LED: off
Green LED: off
Buzzer: A
Red LED: A
Yellow LED: off
Green LED: on
Buzzer: A
Red LED: C
Yellow LED: off
Green LED: on
Buzzer: B
Red LED: B
Yellow LED: off
Green LED: on
Buzzer: C
Red LED: C
Yellow LED: off
Green LED: on
Buzzer: C
Red LED: D
Yellow LED: off
Green LED: on
Buzzer: off
Red LED: off
Yellow LED: on
Green LED: on
Classification of
Weighting
1 High priority
1 High priority
2 High priority
3 High priority
4 High priority
5 High priority
Is indicated
independently by
the yellow LED
signal patterns
under EN 475
Low priority
Note:
The green power indicator 20 is not an alarm signal indicator. Its status is only given here for completeness’
sake.
20 Troubleshooting
The signal patterns for the buzzer consist of 2 identical pulse sequences, repeated every 10 seconds. Each
pulse sequence consists of 5 individual pulses (see Table of Signal Patterns).
Table of Signal Patterns:
Buzzer pattern
for one pulse
sequence
Pulse duration / ms
(= buzzer on)
Pulse interval/ ms
(= buzzer off)
Pulse interval
between 3rd and
4th pulse / ms
Graphic representation
A 150 100 500 — — — — —
B 150 10 320 — — — — —
C 150 0 300 ——— ——
Flashing pattern
for
red LED
Flashing
frequency / Hz
On time / ms Off time / ms Graphic representation
A 1.43 200 500 — —
B 1.43 400 300 —— ——
C 2.5 80 320 – –
D 2.5 240 160 — —
6.1.3 Deactivating the signal functions
The signal functions can be deactivated by means of the switches S2, S3, S4 and S5 on the printed circuit
board. To see where the switches are located on the PCB, consult the illustrations in Section “10.1 Arrangement of the PCBs” on page 76.
Coding switch Open Closed
S2
S3
Power supply for power failure alarm
deactivated.
Buzzer deactivated. Buzzer activated.
Alarm suppression during warming-up
S4
phase deactivated
(i.e. alarm function activated).
S5
Tip:
Activates program for checking status
indicator
Power supply for power failure alarm
activated.
Alarm suppression during warming-up
phase activated
(i.e. alarm function deactivated).
Normal operation
For fault-finding purposes it can be useful to open coding switch S4. This enables the alarms immediately on
completion of the leak test.
Troubleshooting 21
6.2 Remedies
Fault Cause Localisation Remedy
No motor noises,
power indicator does
not light up, mains
failure alarm sounds.
No power.
Faulty fuse.
Check mains lead for
secure connection.
If applicable, check
whether power is available
at the mains (e.g. with a
lamp).
Replace fuse 39 (see "5.3.4
Checking the fuse" on
page 11).
A spare fuse can be found
in the fuse box.
Power indicator fails to
illuminate, no acoustic
alarm.
No flow at nasal
cannula, although
there is flow at the
appliance outlet. In
such cases, the
appliance does not
emit an alarm.
After running for a
long period,
appliance emits
intermittent acoustic
warnings and red fault
indicator flashes;
no flow.
After running for a
long period,
appliance emits
intermittent acoustic
warnings and red fault
indicator flashes.
Power cord damaged. Replace power cord.
Capacitor for mains
failure alarm is
completely
discharged.
Tube connections
interrupted.
Oxygen distributor in
bubble humidifier
blocked.
Motor compressor not
rotating.
Crank mechanism stiff,
motor circuit-breaker of
compressor is
activated.
Appliance too hot,
coarse dust filter
blocked.
Leak at compressor
outlet port elbow
connector
Suction filter blocked.
Overtemperature of
60 °C ± 2.5 °C.
Disconnect tube from inlet of
dosage monitor; check
whether flow is escaping
from the tube.
Loosen union nut of bubble
humidifier; the ball should
then rise.
Leave the appliance to run
for 5 minutes.
Seal all connection and
sealing points from the
appliance outlet to the inlet
of the dosage monitor.
Clean or replace the
oxygen distributor.
Capacitor incorrectly
connected or not connected
at all. Connect the
capacitor correctly
(7.5, page 30).
Check the voltage supply at
the motor. Motor defective:
Replace the compressor
(7.5, page 30).
Compressor defective:
Replace compressor
(7.5, page 30).
Clean or replace coarse
dust filter.
(3.2, page 8).
Replace parts (7.5,
page 30)
Replace suction filter.
(3.2, page 8).
Check fan
(7.10, page 42).
22 Troubleshooting
The following faults are based on a defective circuit. They occur with the compressor and fan running.
Caution !
Always pull out the mains plug before working on electrical components.
Remember that all coding switches on the circuit board must be closed during normal operation.
Fault Cause Localisation Remedy
After switching on, first of all
After running for a
long period,
appliance emits
intermittent acoustic
warnings and red
fault indicator
flashes.
Memory failure.
the EEPROM is read. In the
event of a memory failure,
an alarm is issued and it is
then re-read. If this readout
attempt is successful, the
fault will be cleared. If not,
the circuit board should be
replaced.
(7.9, page 40).
Blow-off noises on
compressor
(overpressure valve
activated).
Connectors X10 and/
or X11 have worked
loose.
Inadequate voltage
supply to magnetic
valves.
No voltage supply to
magnetic valves.
Fuse F1 tripped.
Green LED is illuminated and
an acoustic pressure alarm
sounds.
See above.
See above.
Green LED not illuminated,
mains failure alarm.
Re-make the connection
(7.9, page 40).
Ensure that the mains
voltage is at least 207 V.
Replace fuse F2
(7.9, page 40).
Replace fuse F1
(7.9, page 40).
Overpressure
alarm
(acoustic alarm,
red LED 18 flashing
2.5 times per
second).
No overpressure
alarm, even though
overpressure exists.
Underpressure
alarm
(acoustic alarm,
red LED 18 flashes
briefly 2.5 times
per second).
Thermal release in
transformer tripped.
Overpressure exists.
Valves of O2 system
jamming
Circuit board
defective.
Warm-up phase not
yet complete.
Pressure measurement
tube faulty.
Circuit board
defective.
Underpressure exists.
Circuit board
defective.
Pressure measurement
tube has come loose.
Green LED not illuminated,
mains failure alarm.
Check pneumatic system for
blockages.
Perform a system pressure test
(5.3.13, page 17)
Each time the device is
switched on, the overpressure
alarm is blocked for one
minute.
Visual check on tube for:
properly seated connection;
not blocked.
Check pneumatic system for
leaks.
Perform a system pressure test
(5.3.13, page 17)
Visual check for proper seating
of pressure measurement tube.
Replace the circuit board
(7.9, page 40).
Rectify blockage
(7.9, page 40).
(see " Blow-off noises on
compressor (overpressure
valve activated)." on
page 23)
Replace the circuit board
(7.9, page 40).
Wait for one minute.
Replace pressure measurement tube if necessary.
Replace the circuit board
(7.9, page 40).
Remedy the leak.
Replace circuit board
Establish trouble-free
pneumatic connection.
Troubleshooting 23
Fault Cause Localisation Remedy
Each time the appliance is
No underpressure
alarm.
Warm-up phase not
yet complete.
Circuit board
defective.
Miniature fuse in nonheating appliance
connector has tripped.
switched on, the overpressure
alarm is blocked for one
minute.
Compressor and fan not
running and green LED is
extinguished.
Wait for one minute.
Replace the circuit board
(7.9, page 40).
Check fuse 39 and replace
if necessary (5.3.4,
page 11).
Internal connection has
worked loose at nonheating appliance
See above.
Check connection and remake if necessary.
connector.
Mains failure alarm
Connector X1 has
worked loose.
Cable harness
defective.
Fuse F1 has tripped.
See above.
See above.
Compressor and fan not
running and green LED is
extinguished.
Check connection and remake if necessary.
Replace the cable harness
(item no. 86 in the spare
parts list).
Check fuse F1 and replace
if necessary
(7.9, page 40)
(10.1, page 76).
Device fails to emit
correct mains
failure alarm.
Thermal release in transformer has tripped.
Circuit board
defective.
Coding switch S3 is
open.
Coding switch S2 is
open.
Voltage supply for
mains failure alarm
discharged.
Mains failure alarm is
shorter than 1 minute.
See above.
Green LED illuminated,
compressor and fan running.
Valves are switching.
Green LED is extinguished.
Buzzer off. Red LED is flashing.
Green LED is extinguished.
Buzzer off. Red LED is
extinguished.
See above.
Operate the appliance for 30
minutes. If the alarm duration is
then shorter than 1 minute, the
circuit board is defective.
Replace the circuit board
(7.9, page 40).
Replace the circuit board
(7.9, page 40).
Close coding switch S3
(7.9, page 40).
Close coding switch S2
(7.9, page 40).
Operate the device for one
minute to recharge the
voltage supply.
Replace the circuit board
(7.9, page 40).
24 Troubleshooting
Fault Cause Localisation Remedy
Leak in O2 system
Switch S5 for checking
status indicator was not
closed again (5.3.12,
page 16)
Examine pneumatic system for
leaks.
Switch off OXYMAT 3.
Close switch S5.
Switch on OXYMAT 3.
Eliminate leaks.
Close switch S5.
During a power failure
O2 alarm
alarm the OXYMAT 3
was switched off and on
twice, thereby starting a
status indicator check
(5.3.11, page 15)
Check plug-in connection X13.
Connect OXYMAT 3 to
mains.
Then switch OXYMAT 3 off
and on again.
Ensure trouble-free plug-in
connection.
No voltage at shutoff
valve.
Check fuse F3.
Change fuse F3
(7.9, page 40),
(10.1, page 76).
Shutoff valve 83 faulty.
Pressure measurement
tube 63 blocked.
Flow starts immediately after
switching on.
Self-test is stopped after 60 s
without stopping compressor.
Change shutoff valve 83.
Re-route tube 63, replace if
necessary.
No O2 alarm,
even though
concentration is
< 82 % by
volume.
Compressor not
running
Temperature alarm,
fan not running.
Pressure sensor B1
faulty.
Leak occurred since
last switching on.
Pressure sensor faulty.
Compressor overpressure
valves activate after 30 s.
Switch OXYMAT 3 off then on
again to initiate self-test.
Check indirect status indicator
(5.3.11, page 15) (5.3.12,
page 16).
Change board
(7.9, page 40).
Eliminate leak.
If yellow LED does not light
up, change board
(7.9, page 40).
OXYMAT 3 was operated for long time at
relative humidity in
Weigh ADS container
(7.11, 7.12 and 7.13).
Change ADS container
(7.11, 7.12 and 7.13).
excess of 75 %.
Fuse F3 defective. Green LED is on. Replace fuse F3.
Suction filter blocked.
Plug-in connection X2
faulty.
Check plug-in connection
Clean or replace suction
filter (3.2, page 8).
Replace wiring harness if
necessary.
Allow OXYMAT 3 to cool
Overheating alarm.
Appliance control system
switches off compressor if
overheating alarm given.
down. After the end of the
overheating alarm the control system switches the
OXYMAT 3 on again.
Board faulty.
Change board
(7.9, page 40).
Check connection at fan. If
Fan failure.
No draught can be felt at the
coarse dust filter, compressor is
running.
necessary, replace cable
harness (item no. 86 in
spare parts list) or fan
(7.10, page 42).
Troubleshooting 25
Fault Cause Localisation Remedy
Comply with maximum
Temperature alarm
although fan is
running.
Appliance was
operated at an
ambient temperature
of > 41 °C, or was
switched off briefly
and back on.
Accumulated heat warmed the
temperature sensor after
switching off.
ambient temperature of
40 °C. After operating for
a short time, the
accumulated heat is
eliminated by the fan and
the temperature alarm must
stop.
Ambient temperature is
< 40 °C, fan and compressor
working correctly.
Visual inspection to verify
correct seating of the
connector.
Install a replacement meter as a
test. If it moves forward by
00000.1 after 6 minutes, the
old meter was defective.
If the above measures have
failed to solve the problem.
Replace the circuit board
(7.9, page 40).
Re-make the connection
(7.9, page 40).
Replace the operating hours
meter
(7.8, page 39).
Replace the circuit board
(7.9, page 40).
Operating hours
meter no longer
counting.
Circuit board
defective.
Connector at X9 has
worked loose.
Meter is defective.
Circuit board
defective.
26 Troubleshooting
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