Weinmann Oxymat 3 Service manual

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Page 1

Servicing and

repair instructions

OXYMAT 3

Oxygen Concentrator

from Appliance No. 8000

Page 2

Contents

Introduction

Overview

Functional description

Servicing

3.1

3.2

3.3

Hygienic Preparation

4.1

4.2

Functional check

5.1

5.2

5.3

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

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

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

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

. .

. . . 39

. . . . . . 54

. . . . . . . 66

© 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.

Page 3

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

Page 4

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

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/I

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)

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

Page 5

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

Page 6

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

Pressure sensor

Pressure reducer

6 Functional description

Page 7

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

Page 8

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.

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.

8 Servicing

Page 9

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

Page 10

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).

Page 11

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.

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.

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

Page 12

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

O/I

Oxygen appliance!

Increased fire risk!

O/ I

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.

12 Functional check

Page 13

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!

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;

– 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.

Functional check 13

Page 14

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;

– 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.

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.

20 18

O/I

Oxygen appliance!

Increased fire risk!

– The green power indicator 20 should be

on.

– The appliance should start up.

O/ I

14 Functional check

4. Switch off the appliance at the On/Off knob 2.

Page 15

5.3.11 Checking the indirect status indicator (yellow LED) with appliance closed

1. Switch on the OXYMAT 3 at the On/Off switch 2. An internal leak test will run for about 1 minute.

The green operating indicator 20 flashes while this is in progress.

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

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

Page 16

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.

The green operating indicator 20 flashes while this is in progress.

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/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

O/ I

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

Page 17

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.

I / O

0000 0

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).

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

Page 18

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

Page 19

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

Page 20

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

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

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

Page 21

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

Power supply for power failure alarm deactivated.

Buzzer deactivated. Buzzer activated.

Alarm suppression during warming-up

phase deactivated (i.e. alarm function activated).

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

Page 22

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

Page 23

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.

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

Page 24

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.

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).

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

Page 25

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

Page 26

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

Page 27

6.3 O2 concentration outside tolerance range

If the check described in “5.3.9 Checking the O2 concentration” on page 13 indicates an oxygen concentration of less than 91% at a flow of 4 l/min after 15 minutes operating time, proceed as follows:

1. Check the system pressures as described in “5.3.13 System pressure test” on page 17.

2. If the test described in “5.3.13 System pressure test” reveals that the pressures are outside the tolerance range, proceed as described in “6.4 System pressure fault” .

If the system pressures are within the tolerance range, continue with test step “5.3.14 Checking the O2 system for leaks”. If this check reveals leaks or faulty valves, repair them.

– Then check the O2 concentration again as

described in “5.3.9 Checking the O2 concentration”.

– If the new check on O2 concentration still re-

sults in unsatisfactory values, perform another system pressure test as described in

5.3.13. Then change the adsorption containers as described in section 7.11.

3. If the check on the oxygen system in accordance with 5.3.14 reveals that there are no leaks or faulty valves, continue as described in “7.11 Replace adsorption containers (Mac valves)”.

4. Perform a functional check (see "5. Functional check" on page 10).

6.4 System pressure fault

Note: The pressure values listed below refer to sea level. If the measurements are conducted at different altitudes, corresponding correction factors must be taken into account.

Pressure measurement Setpoint Fault Cause/remedy

Pressure too high

Pressure measurement at oxygen outlet 5

Pressure measurement at O2 tank (or at outlet of O2 system)

* Water uptake by the ADS container increases the flow resistance of the molecular sieve. As a result,

pressure equalization during the flushing phase is disturbed and the pressure increases.

Pressure

0.6 bar ± 0.1 bar

Measurement at 4 l/ min Pressure range: – Min. 1.2 bar

+ 0.3 /– 0.2 bar

– Max. 1.65 bar

+ 0.3 /– 0.2 bar

Pressure too low

Pressure too high

Pressure too low

Pressure-reducer defective, replace (7.15, page 54)

Leak at the connection points between the pressure-reducer and the oxygen outlet 5. Repair leak.

Pressure-reducer defective, replace (7.15, page 54)

ADS container has absorbed water.* Replace the ADS container (7.11, 7.12 and 7.13)

Leak at the connection points between the suction filter and the O2 tank. Remedy the leak.

Troubleshooting 27

Page 28

7. Repair information and repair instructions

7.1 General

Repairs to OXYMAT 3 must always be carried out at an ESD workplace!

• Please follow the safety instructions on page 4 of the operating instructions for OXYMAT 3.

• Caution! Do not use liquids or foaming agents to check for leaks in the region of the solenoid valve 54, as moisture could penetrate into the solenoid valve, thereby causing corrosion which could prevent it functioning properly.

• Any handling of the appliance requires a precise knowledge of and compliance with the operating instructions and the service and repair instructions.

• Please carry out only the repairs described in these service and repair instructions. This is the only way to guarantee perfect functioning of OXYMAT 3.

• Please ensure that your hands and workplace are clean when carrying out repairs.

• Conduct a functional check after every repair job (see "5. Functional check" on page 10).

• When you replace components or individual parts, please use only genuine Weinmann parts.

• When ordering a frame 57 or 58 , please also quote the model, year of construction and appliance number.

• Many parts have to be screwed in using a torque wrench. To ensure that the quoted torque is maintained, check regularly that

your torque wrench adheres to the torque (monitor testing equipment).

• Note: The item numbers quoted in the following text match the item numbers in the parts list on page 69 and the overview on page 4.

7.2 Replacing the castors

1. Position the appliance with the housing lying on its back.

2. Pull off the defective castors and replace them with new ones.

28 Repair information and repair instructions

Page 29

7.3 Opening the appliance

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

Caution ! If the appliance is standing on a table, lock the castors.

1. Disconnect the plug from the socket and pull the power cord 10 from the appliance.

3. Remove the stoppers 32:

– Using the disk on the spanner set, rotate the

stopper 32 through 90° to the left.

– Lever it out downwards .

4. Unscrew the two screws 33 and remove them together with the spring washer 34 .

To make it easier to remove the screws, set the spanner in the hexagon and pull out the screw.

5. Remove the handle 1 upwards, or leave it lying in the appliance.

6. Pull off the housing 35 upwards.

2. Remove the connecting nipple with union nut 6 or the flowmeter 16 from the oxygen outlet 5.

321

34 33

O/I

0 00 0

Note: If the housing cannot be pulled off, it may be caught on the service flap. In such cases, release the lock at the service flap 38, and remove the flap from the appliance.

Repair information and repair instructions 29

Page 30

7.4 Closing the appliance

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

Caution ! If the appliance is standing on a table, please lock the castors.

1. Carefully slide the housing 35 over the foam sections.

2. Position the housing 35 on the frame in such a way that the enclosure wall engages with the groove all the way round.

3. Insert the handle 1 and secure it with the screws 33 (not forgetting the spring washers 34).

4. Insert the two stoppers 32.

5. Using the disk on the spanner set, rotate the stoppers 32 through 90° to the right.

6. Secure the connecting nipple 6 or the flowmeter 16 at the oxygen outlet 5.

34 33 32

O/I

7.5 Replacing the compressor (up to appliance no. 13350)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

1. Open the housing (see "7.3 Opening the appliance" on page 29).

I /

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

3. Remove the front plate 46:

– Tilt the front plate forwards and – pull it out upwards.

0000 0

30 Repair information and repair instructions

Page 31

The illustration opposite shows the installation position of the compressor with its electrical and pneumatic connections.

4. Disconnect the electrical connection.

5. Pull off the tubes 51 and 70 :

– Take the appropriate spanner from the

spanner set and position it between the coupling 69 and the inlet/outlet of the compressor.

– Now pull off the tube.

6. To remove the defective compressor, always take hold of it at the cylinder head.

Caution ! The cylinder head may still be hot!

Tilt the defective compressor 48 forwards and lift it out.

7. Pull the capacitor 49 out of the foam section 43.

50 67

69 51

000000

cylinder head

43 49

Before fitting the new compressor, check the condition of the vibration dampers 60.

They must be soft, elastic and must not be deformed. If the vibration dampers are hard and inelastic, they must be changed.

Then install the new compressor 48:

8. If the capacitor is faulty, disconnect both spade connectors from the capacitor 49.

9. Connect the spade connectors of the compressor to the capacitor.

Caution ! Do not short-circuit the capacitor! The connectors must be on the left and right of the central bar (see illustration).

Repair information and repair instructions 31

Page 32

10. Place the two tubes 51 and 70 sideways across the frame.

11. Then insert the compressor:

– Grasp the compressor in such a way that

you are able to read the letters on the cylinder head the right way round.

– Insert the front screws of the compressor into

the vibration damper 60.

– Tilt the compressor into the appliance.

Make sure that the compressor is securely and safely positioned.

12. Slide the capacitor 49 into the opening of the foam section 43 and lay the cables neatly into the groove.

000000

43 49

13. Connect tube 70 to the inlet and tube 51 to the outlet of the compressor.

14. Attach the connector of the compressor to the power supply socket and lay the cables neatly into the groove.

15. Check that the compressor is positioned in the appliance the right way round, i.e. with the inlet pointing to the right:

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Feel from which side of the compressor air

is being drawn in. This side is the inlet. It

must be on the right.

16. Check that all cables are laid correctly in the groove.

00000

– Switch off the appliance and pull the power

cord 10 from the socket and from the appliance.

– If the inlet of the compressor is on the left-

hand side, re-install the compressor.

17. Place the lower edge of the front plate 46 into the frame and tilt it against the foam section 45.

18. Place the straps 42 over the foam sections and tighten them.

32 Repair information and repair instructions

Page 33

19. Before assembling the housing, subject the compressor to a test run:

– Connect the power cord 10 to the

appliance and to a socket.

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).

– Switch on the appliance.

If no rattling or slipping is audible, the compressor is correctly installed.

– Switch off the appliance and pull the power

cord 10 from the socket and from the appliance.

7.6 Replacing the compressor (from appliance no. 13351 to 14999)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Water-pump pliers.

1. Open the housing (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

0000 0 0

3. Remove the front plate 46:

– Tilt the front plate forwards and – pull it out upwards.

The illustration opposite shows the installation position of the compressor with its electrical and pneumatic connections.

50 67

Repair information and repair instructions 33

Page 34

4. Disconnect the electrical connection.

000

5. Pull off the tubes 51 and 70 :

– Loosen clip 89 on tube 51 with the water-

pump pliers.

– Now pull off the tube.

6. To remove the defective compressor, always take hold of it at the cylinder head.

Caution ! The cylinder head may still be hot!

Tilt the defective compressor 48 forwards and lift it out.

7. Pull the capacitor 49 out of the foam section 43.

Before fitting the new compressor, check the condition of the vibration dampers 60.

They must be soft, elastic and must not be deformed. If the vibration dampers are hard and inelastic, they must be changed.

89 51

000000

cylinder head

43 49

Then install the new compressor 48:

8. If the capacitor is faulty, disconnect both spade connectors from the capacitor 49.

9. Connect the spade connectors of the compressor to the capacitor.

Caution ! Do not short-circuit the capacitor! The connectors must be on the left and right of the central bar (see illustration).

10. Place the two tubes 51 and 70 sideways across the frame.

11. Then insert the compressor:

– Grasp the compressor in such a way that

you are able to read the letters on the cylinder head the right way round.

– Insert the front screws of the compressor into

the vibration damper 60.

– Tilt the compressor into the appliance.

Make sure that the compressor is securely and safely positioned.

12. Slide the capacitor 49 into the opening of the foam section 43 and lay the cables neatly into the groove.

000000

43 49

34 Repair information and repair instructions

Page 35

13. Push clip 89 onto tube 51. Then connect tube

70 to the compressor inlet and tube 51 to the

compressor outlet. Now attach tube 51 to the compressor outlet with the aid of clip 89 and the water-pump pliers.

14. Attach the connector of the compressor to the power supply socket and lay the cables neatly into the groove.

15. Check that the compressor is positioned in the appliance the right way round, i.e. with the inlet pointing to the right:

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Feel from which side of the compressor air

is being drawn in. This side is the inlet. It

must be on the right. – Switch off the appliance and pull the power

cord 10 from the socket and from the

appliance. – If the inlet of the compressor is on the left-

hand side, re-install the compressor.

000000

16. Check that all cables are laid correctly in the groove.

17. Place the lower edge of the front plate 46 into the frame and tilt it against the foam section 45.

18. Place the straps 42 over the foam sections and tighten them.

19. Before assembling the housing, subject the compressor to a test run:

– Connect the power cord 10 to the

appliance and to a socket.

– Switch on the appliance.

If no rattling or slipping is audible, the compressor is correctly installed.

– Switch off the appliance and pull the power

cord 10 from the socket and from the appliance.

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).

Repair information and repair instructions 35

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7.7 Replacing the compressor (from appliance no. 15000)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

• Hexagon socket wrench 8 mm,

• Water-pump pliers.

1. Open the housing (see "7.3 Opening the appliance" on page 29).

2. Detach the compressor:

– Place the appliance on its back; – Detach the compressor by using the socket

wrench to remove the 4 hexagonal nuts 92 with washer 90 and spring washer 91 from the underside of the chassis.

– Then stand the appliance upright again.

3. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

90 91 92

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4. Remove the front plate 46:

– Tilt the front plate forwards and – pull it out upwards.

The illustration opposite shows the installation position of the compressor with its electrical and pneumatic connections.

50 67

36 Repair information and repair instructions

Page 37

5. Disconnect the electrical connection.

6. Pull off the tubes 51 and 70 :

– Loosen clip 89 on tube 51 with the water-

pump pliers.

– Now pull off the tube.

7. To remove the defective compressor, always take hold of it at the cylinder head.

Caution ! The cylinder head may still be hot!

Tilt the defective compressor 48 forwards and lift it out.

8. Pull the capacitor 49 out of the foam section 43.

Before fitting the new compressor, check the condition of the vibration dampers 60.

They must be soft, elastic and must not be deformed. If the vibration dampers are hard and inelastic, they must be changed.

000000

89 51

cylinder head

43 49

Then install the new compressor 48:

9. If the capacitor is faulty, disconnect both spade connectors from the capacitor 49.

10. Connect the spade connectors of the compressor to the capacitor.

Caution ! Do not short-circuit the capacitor! The connectors must be on the left and right of the central bar (see illustration).

11. Place the two tubes 51 and 70 sideways across the frame.

12. Then insert the compressor:

– Grasp the compressor in such a way that

you are able to read the letters on the cylinder head the right way round.

– Insert the bolts of the vibration dampers 60

in the holes provided in the chassis.

– Tilt the compressor into the appliance,

making sure that the bolts of the rear vibration dampers are also inserted in the holes.

Make sure that the compressor is securely and safely positioned.

13. Slide the capacitor 49 into the opening of the foam section 43 and lay the cables neatly into the groove.

000000

43 49

Repair information and repair instructions 37

Page 38

14. Push clip 89 onto tube 51. Then connect tube

70 to the compressor inlet and tube 51 to the

compressor outlet. Now attach tube 51 to the compressor outlet with the aid of clip 89 and the water-pump pliers.

15. Attach the connector of the compressor to the power supply socket and lay the cables neatly into the groove.

16. Check that the compressor is positioned in the appliance the right way round, i.e. with the inlet pointing to the right:

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Feel from which side of the compressor air

is being drawn in. This side is the inlet. It

must be on the right. – Switch off the appliance and pull the power

cord 10 from the socket and from the

appliance. – If the inlet of the compressor is on the left-

hand side, re-install the compressor.

000000

17. Check that all cables are laid correctly in the groove.

18. Place the lower edge of the front plate 46 into the frame and tilt it against the foam section 45.

19. Place the straps 42 over the foam sections and tighten them.

20. Attach the compressor to the chassis:

– Place the appliance on its back. – Place a washer 90 and then a spring

washer 91 on the threaded bolt.

– Now use the socket wrench to tighten the

hexagonal nuts 92 hand tight.

21. Before assembling the housing, subject the compressor to a test run:

– Connect the power cord 10 to the

appliance and to a socket.

– Switch on the appliance.

If no rattling or slipping is audible, the compressor is correctly installed.

– Switch off the appliance and pull the power

cord 10 from the socket and from the appliance.

22. Close the appliance (see "7.4 Closing the appliance" on page 30).

23. Perform a functional check (see "5. Functional check" on page 10).

38 Repair information and repair instructions

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7.8 Replacing the operating hours meter

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Carefully lift the operating panel out of the foam section.

45 47

3. Pull the connector X9 of the operating hours meter 4 from the circuit board.

4. Press the lock of the operating hours meter 4 together and pull the meter through the operating panel.

5. Make a note of the meter reading in the service log on page 78. This will enable you to calculate the actual operating hours when a new meter is installed.

6. Guide the connector and cable of the new operating hours meter 4 through the opening in the operating panel.

7. Push the operating hours meter into the opening the right way round until it locks home.

8. Attach the connector X9 to the contacts on the circuit board. The precise location on the circuit board can be found in Chapter “10.1 Arrangement of the PCBs” on page 76.

9. Carefully re-insert the operating panel, inserting the pins on the operating panel into the holes in the foam section 45.

10. Close the appliance (see "7.4 Closing the appliance" on page 30).

11. Perform a functional check (see "5. Functional check" on page 10).

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Repair information and repair instructions 39

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7.9 Replacing the circuit board

This repair must always be carried out at an ESD workplace.

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Cross-head screwdriver size1,

• Flat nose pliers.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Carefully lift the operating panel out of the foam section.

3. Detach the connectors X1 and X2 from the circuit board by pressing the lock together and pulling off the connector.

4. Detach tube 63 from pressure sensor B1.

Caution! Do not damage pressure sensor when detaching the tube .

5. The operating panel can now be folded away upwards.

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X10X11X13 X1 X2842B1

X1 X2

6. Next, pull connectors X13, X11 and X10 from the circuit board.

7. Release the tube 84:

– Press the lock back using an appropriate

spanner from the set.

– Pull out the tube.

8. Using flat nose pliers, carefully pull off the On/ Off knob 2.

Caution ! Do not let the pliers slip!

9. To allow you to work more easily, place the operating panel into the foam section 44.

How to remove the foam section 44:

– Loosen the straps 42, without pulling the

strap out of the fastener, and place them next to the appliance.

– Remove the foam section 44.

40 Repair information and repair instructions

Page 41

10. Disconnect the connector X9 for the meter from the printed circuit board.

11. Unscrew the four screws 41.

12. Place the circuit board on your ESD workplace.

13. Carefully place the new circuit board 40 on the operating panel and secure with the four screws 41.

14. Attach the connector X9 to the contacts of the circuit board. The precise location on the circuit board can be found in Chapter “10.1 Arrangement of the PCBs” on page 76.

15. Next, push the long tube 84 (from the pressure reducer) into the Y-connector.

16. Securely attach the connectors X1, X13, X10 and X11 to the circuit board. The location of the corresponding contacts on the circuit board can be found in Chapter “10.1 Arrangement of the PCBs” on page 76.

Connectors X10 and X11 may be swapped without causing any problems.

17. Tilt the operating panel forwards and secure the connector X2 on the circuit board.

18. Push tube 63 onto the pressure sensor B1.

X10X11X13 X1 X2

19. Carefully re-insert the operating panel, inserting the pins on the operating panel into the holes in the foam section 45.

20. Insert the foam section 45.

21. Place the straps 42 over the foam sections and tighten them.

22. Press the On/Off knob 2 onto its switching axis.

After installing, actuate the switch several times to ensure it is not jammed.

23. Close the appliance (see "7.4 Closing the appliance" on page 30).

24. Perform a functional check (see "5. Functional check" on page 10).

Repair information and repair instructions 41

Page 42

7.10 Replacing the fan

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

3. Remove the front plate 46:

– Tilt the front plate forwards and – pull it out upwards.

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4. Lift up the foam section 45 together with the operating panel and pull out the defective fan

52.

5. Pull the connector off the fan.

6. Take a new fan 52 and push the connector onto the contacts.

7. There are two arrows on the edge of the fan showing the direction of air flow. As you want the air to be drawn in and expelled to the compressor, it is important to hold the fan so that the arrow is pointing downwards.

8. Lift up the foam section 45 together with the operating panel and insert the fan (with the

arrow pointing downwards) .

9. Place the cable into the groove in the foam section 43.

10. Before assembling the appliance, please subject the fan to a test run:

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Check the function of the fan:

Never reach into the fan!

With your hand held flat, place it between

the fan and the compressor and feel the air

flow.

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42 Repair information and repair instructions

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Caution ! If you do not feel any air flow, remember to disconnect the appliance from the power before taking any further action!

11. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

12. Place the lower edge of the front plate 46 into the frame and tilt it against the foam section 45.

13. Place the straps 42 over the foam sections and tighten them.

14. Align the operating panel.

15. Close the appliance (see "7.4 Closing the appliance" on page 30).

16. Perform a functional check (see "5. Functional check" on page 10).

7.11 Replace adsorption containers (Mac valves)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Open-ended spanner SW 17.

Dismantle

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

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Repair information and repair instructions 43

Page 44

3. Remove the foam section 44.

Replace both ADS containers 53 as follows:

4. Loosen the Y-connector 73 by pushing back the sleeve (e.g. using a spanner from the set) and pull out the angular bush.

5. Pull the ADS container 53 out of the foam section.

6. The ADS container 53 and magnetic valve 54 are connected by a double nipple. Use an open-ended spanner to hold the double nipple firm on the ADS container 53 and unscrew the magnetic valve 54 from the double nipple by hand.

7. Lay the open-ended spanner aside and hold the magnetic valve firmly with your hand.

8. Next, unscrew the ADS container by hand, including the double nipple.

Test

1. In order to ascertain whether the ADS container really needs changing, you should weigh it.

The container needs changing when it has absorbed approximately 50 g of moisture, i.e. when it is approximately 50 g heavier.

Expiry weight = Original weight + 50 g.

The two containers should always be changed at the same time.

black

73 75 72 76 75 73

75 74

72 74 93

blackwhitewhite

44 Repair information and repair instructions

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Fit

1. Take a new ADS container 53 and ensure that there is a pressure seal 55 on the thread of the double nipple.

Caution ! The pressure seal has a profile on one side, known as the sealing lip. This sealing lip must be pointing towards the magnetic valve !

2. Screw the double nipple into the magnetic valve.

Note: Make sure that the cables on the magnetic valve are not twisted.

3. Secure the double nipple onto the magnetic valve using the open-ended spanner.

Caution ! Once the pressure seal between the double nipple and the magnetic valve is squashed, never turn the magnetic valve back; otherwise, the pressure seal will no longer seal effectively and a new seal will be required.

4. Check that the screw of the clip on the ADS container and the narrow side of the magnetic valve are flush.

If this is not the case, loosen the screw of the clip slightly, align the clip and re-tighten it.

5. Connect the Y-connector 73 to the upper angular bush on the ADS container.

6. Place the ADS container into the foam section.

Note: Take care to ensure that there are no cables or tubes between the ADS container and the foam section.

7. Loose cables and/or tubes should be laid in the side groove of the foam section.

8. Replace the second ADS container in the same way.

9. Then check whether the cables and tubes are correctly laid in the groove on the foam section.

Important! The cable for the 230 V voltage supply must be routed in the left-hand side of the foam section.

94 95

Repair information and repair instructions 45

Page 46

10. Before assembling the OXYMAT 3, check it for leaks:

– Connect the dosage unit 21 or flowmeter 16

to the oxygen outlet 5.

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Set a flow of 4 l/min. – Check for leaks by soaping all connection

points to the ADS containers with a foaming

agent (e.g. Snoop).

Caution! Do not use liquids or foaming agents to check for leaks in the region of the solenoid valve 54, as moisture could penetrate into the solenoid valve, thereby causing corrosion which could prevent it functioning properly.

11. If you discover a leak, rectify it.

12. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

13. Remove the dosage unit 21 or the flowmeter 16.

14. Place the foam section 44 in position.

Note: Check that both foam pads 88 are in place.

15. Place the straps 42 over the foam sections and tighten them.

16. Close the appliance (see "7.4 Closing the

appliance" on page 30).

17. Perform a functional check (see "5. Functional check" on page 10).

7.12 Replace adsorption container (plastic magnetic valve block)

Tools required

• Spanner set WM 14249

• Allen key 6 mm

• Open-ended spanner SW 17

• Open-ended spanner SW 19

Dismantle

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

46 Repair information and repair instructions

Page 47

2. Loosen the straps 42 without pulling the strap out of the fastener and place them next to the appliance.

3. Take off the foam section 44.

Replace both ADS containers 53 as follows:

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4. Undo the Y-connector 73 by pushing back the sleeve (e.g. using a spanner from the set) and pull out the angular bush.

5. Tilt the right-hand ADS container 53 out of the foam section.

6. The ADS container and the magnetic valve block are connected to one another via an adapter 104. Hold the adapter steady with an open-ended spanner SW19 and unscrew the ADS container by hand.

7. Now pull the left-hand ADS container out of the foam section.

8. Release the screwed connection 102 incl. the angle connector 98 from the double nipple.

Test

1. In order to ascertain whether the ADS containers really need changing, you should weigh them.

A container needs changing when it has absorbed approximately 50 g of moisture, i.e. when it is 50 g heavier.

Expiry weight = original weight + 50 g.

Please always replace both containers at the same time.

112

104

107

102

75 74

72 74 93

106

105

Repair information and repair instructions 47

Page 48

Fit

1. Take up a new ADS container and ensure that there is a pressure seal 55 on the thread of the double nipple.

2. Screw the screwed connector onto the double nipple.

3. Take up the second ADS container and unscrew the double nipple using the openended spanner SW17.

4. Screw the ADS container onto the adapter of the magnetic valve block. Hold the adapter steady with an open-ended spanner SW19 to do so.

5. Check that the side with the magnetic valve block coils and the screws for the clip are flush. If this is not the case, align the ADS container accordingly, the adapter has a rotating bearing.

6. Push the Y-connector 73 into the top angular bush on the ADS container.

7. Insert the ADS container in the foam section.

Note

Please ensure that there are no cables or tubes between the ADS container and the foam section.

8. Route cables and/or the tube in the lateral groove in the foam section.

9. Insert the second ADS container in the foam section and restore the tube connections.

10. Finally, please check whether the cables and tubes are correctly routed in the groove in the foam section.

Important! The cable for the 230 V voltage supply must be routed in the left-hand side of the foam section.

11. Before you assemble the OXYMAT 3, check it for leaks:

– Connect the dosage unit 21 or the

flowmeter 16 to the oxygen outlet 5.

– Connect the power cord 10 to the

appliance and to a power socket. – Switch on the appliance. – Set a flow of 4 l/min. – Check for leaks by soaping all connection

points to the ADS containers with a foaming

agent (e.g. Gaspruf).

48 Repair information and repair instructions

Page 49

Warning! Do not use liquids or foaming agents to check for leaks in the region of the solenoid valve, as moisture could penetrate into the solenoid valve, thereby causing corrosion which could prevent it functioning properly.

12. If you discover a leak, rectify it.

13. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

14. Remove the dosage unit 21 or the flowmeter

16.

15. Put the foam section 44 in position.

16. Place the straps 42 over the foam sections and tighten them.

17. Close the appliance (see "7.4 Closing the appliance" on page 30).

18. Perform a final check (see "5. Functional check" on page 10).

7.13 Replace adsorption containers

(aluminum magnetic valve block)

Tools required:

• Spanner set WM 14249

• Allen key 6 mm

• Open-ended spanner SW17

• Water pump pliers

Dismantle

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42 without pulling the strap out of the fastener and place next to the appliance.

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Repair information and repair instructions 49

Page 50

3. Take off the foam section 44 .

Replace both ADS containers 53 as follows:

4. Undo the Y-connector 73 by pushing back the sleeve (e.g. using a spanner from the set) and pull out the angular bush.

5. Take the right-hand ADS container 53 out of the foam section.

6. The ADS container and the magnetic valve block are connected to one another via a double nipple. Release the double nipple from the magnetic valve block using an open-ended spanner SW17. Hold the magnetic valve block steady with water pump pliers as you do so.

7. Put down the open-ended spanner and the water pump pliers and hold the magnetic valve block steady with your hand.

8. Use the other hand to unscrew the ADS container and the double nipple from the magnetic valve block.

9. Now take the left-hand ADS container out of the foam section.

10. Undo the screwed connection incl. angle connector from the double nipple.

75 74

72 74 93

Double nipple Pressure seal

Aluminum valve block

50 Repair information and repair instructions

112

102

Page 51

Test

1. In order to ascertain whether the ADS container really needs changing, you should weigh it.

A container needs changing when it has absorbed approximately 50 g of moisture, i.e. when it is approximately 50 g heavier.

Expiry weight = original weight + 50 g.

The two containers should always be changed at the same time.

Fitting

1. Take a new ADS container and ensure that there is a pressure seal 55 on the thread of the double nipple.

2. Screw the screwed connector onto the double nipple.

3. Take the second ADS container and ensure that there is a pressure seal 55 on the thread of the double nipple.

4. Screw the double nipple into the magnetic valve block.

5. Tighten up the double nipple on the magnetic valve block with the open-ended spanner.

Warning! Once the pressure seal between the double nipple and the magnetic valve is squashed, never screw the magnetic valve back, otherwise the pressure seal will no longer seal effectively and a new seal will be required.

6. Check whether the side with the magnetic valve block coils and the screws for the clip are flush. If this is not the case, undo the screw for the clip a little, align the clip and screw up tightly.

7. Push the Y-connector 73 into the upper angular bush on the ADS container.

8. Insert the ADS container in the foam section.

Note

Please ensure that there are no cables or tubes between the ADS container and the foam section.

9. Route cables and/or the tube in the lateral groove in the foam section.

10. Restore the tube connections.

11. Insert the second ADS container in the foam section and restore the tube connections.

Repair information and repair instructions 51

Page 52

12. Finally, please check whether the cables and tubes are correctly routed in the groove in the foam section.

Important! The cable for the 230 V voltage supply must be routed in the left-hand side of the foam section.

13. Before you assemble the OXYMAT 3, please check for leaks:

– connect the dosage unit 21 or the flowmeter

16 to the oxygen outlet 5.

– Connect the power cord 10 to the

appliance and to a power socket. – Switch on the appliance. – Set a flow of 4 l/min. – Check for leaks by soaping all connection

points to the ADS containers with a foaming

agent (e.g. Gaspruf).

Caution! Do not use liquids or foaming agents to check for leaks in the region of the solenoid valve, as moisture could penetrate into the solenoid valve, thereby causing corrosion which could prevent it functioning properly.

14. If you discover a leak, rectify it.

15. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

16. Remove the dosage unit 21 or the flowmeter 16.

17. Place the foam section 44 in position.

18. Place the straps 42 over the foam sections and tighten them.

19. Close the appliance (see "7.4 Closing the appliance" on page 30).

20. Perform a final check (see "5. Functional check" on page 10).

52 Repair information and repair instructions

Page 53

7.14 Replace cover

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Open-ended spanner SW 17.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Remove the adsorption container (see Section

7.11, 7.12 or 7.13 depending on model).

3. Unscrew the screw 109 and remove the clip 110.

4. Take the cover off the adsorption container.

5. Take the spring off the cover.

Double nipple

6. Take a new cover 108 and attach the spring.

Note If the plastic valve block is used, replace the double nipple from the new cover with the adapter 104 from the old cover.

7. Moisten the O-ring 111 slightly, e.g. with “Snoop” leak detector.

8. Insert the cover in the adsorption container.

109 110

108 111

Spring

9. Put on the clip so that the screw is at the nameplate. This allows the nameplate to be read easily when fitted.

10. Apply some thread locker (e.g. Loctite 245, WM 14920) to the thread of the screw.

11. Tighten the screw, max. torque

1.2 Nm ± 0.1 Nm.

12. Fit the adsorption container (see Section 7.11,

7.12 or 7.13 depending on model).

13. Close the appliance (see "7.4 Closing the appliance" on page 30).

14. Perform a final check (see "5. Functional check" on page 10).

Repair information and repair instructions 53

Page 54

7.15 Replacing the pressure reducer

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Open-ended spanner SW 17.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

3. Remove the foam section 44.

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4. Carefully raise the operating panel and detach the connector X13 for the shutoff valve.

5. Carefully pull out the right-hand ADS container.

6. Pull out the wiring harness for the shutoff valve.

7. Press the ADS container back into the foam section.

X13

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54 Repair information and repair instructions

Page 55

8. Carefully pull the oxygen tank out of the foam section 43.

9. Remove the tube 56 from the inlet to the oxygen tank by pushing back the sleeve of the angular bush (e.g. using a spanner from the set) and pulling out the tube.

10. Detach tube 84 from the shutoff valve in the same way.

11. Using an open-ended spanner, take hold of the double nipple between the oxygen tank and the pressure reducer 82 and unscrew the pressure reducer.

X13

84 43

12. Place a new pressure seal 55 onto the double nipple.

Caution ! The pressure seal has a profile on one side, known as the sealing lip. This sealing lip must be pointing towards the pressure reducer !

13. Screw the new pressure reducer 82 into place.

Caution ! Once the pressure seal between the double nipple and the pressure reducer is squashed, under no circumstances should you turn the pressure reducer back; otherwise, the pressure seal will no longer seal effectively.

14. Should screwed connector 93 or angle connector 96 be broken, please replace them.

15. Check that the screw of the clip on the oxygen tank and the button on the pressure reducer form an angle of approximately 45°.

If this is not the case, loosen the screw of the clip slightly, align the clip and re-tighten it.

Note: If the tightening screw to the pressure reducer is not in the correct position, you will be unable to place the foam sections on top of one another properly later.

Top view

Screw

about 45°

Button on the pressure-reducer

Repair information and repair instructions 55

Page 56

16. Connect the wiring harness of the shutoff valve 83 on X13 of the printed circuit board. To do so:

– pull out the right-hand ADS container, – lay the wiring harness behind the ADS

container. The spiral insulating tube must be

gripped in the upper groove of the foam section 43.

– push the ADS container back into the foam

section.

17. Slide the tube 56 into the inlet of the oxygen tank as far as it will go.

18. Slide the tube 84 into the shutoff valve 83 as

far as it will go.

19. Before assembling the OXYMAT 3, check all connection points for leaks:

– Connect the dosage unit 21 or flowmeter 16

to the oxygen outlet 5.

– Connect the power cord 10 to the

appliance and to a socket.

– Switch the appliance on. This starts the

internal leak test. – Set a flow of 4/min. – Check for leaks by soaping the connection

points to the ADS containers with a foaming

agent (e.g. Snoop). – If you discover a leak, rectify it.

20. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

21. Remove the dosage unit 21 or the flowmeter 16.

22. Place the foam section 44 in position.

Note: Check that both foam pads 88 are in place.

23. Place the straps 42 over the foam sections and tighten them.

24. Close the appliance (see "7.4 Closing the

appliance" on page 30).

25. Perform a functional check (see "5. Functional check" on page 10).

56 Repair information and repair instructions

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7.16 Replacing the frame (up to appliance no. 19999)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Side nippers.

Note: It is easier to change the frame if you have another person to help you.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Remove the compressor (see “7.5 Replacing the compressor (up to appliance no. 13350)” on page 30, steps 3. to 7.).

3. Separate the two cable ties 65, which fix the exhaust damper in position.

4. Remove the foam section 44.

5. Pull the two appliance connectors 59 upwards out of the frame.

Repair information and repair instructions 57

Page 58

6. Place one arm around the entire foam sections.

7. With the other arm, support yourself against the frame and lift up the foam sections (including ADS containers, oxygen tank, cooler, fan and operating panel).

Note: If two people are working together, one of you can lift up the foam sections with both arms whilst the other holds the frame steady.

8. Position the new frame 58 (with appliance label) on the castors.

9. Insert the foam sections into the frame.

10. Place the appliance connector 59 into the groove of the frame.

11. Push the exhaust damper 66 backwards as far as possible and secure it to the frame with two cable ties 65.

12. Align all parts, such as ADS containers and oxygen tank.

13. Check that the cables and tubes are laid in the groove on the foam section. If necessary, press them in.

14. Place the foam section 44 in position.

Note: Check that both foam pads 88 are in place.

15. Install the compressor (see “7.5 Replacing the compressor (up to appliance no. 13350)” on page 30, steps 10. to 16.).

000000

65 66

16. Place the lower edge of the front plates 46 into the frame and tilt it against the foam section 45.

17. Place the straps 42 over the foam sections and tighten them.

18. Before assembling the housing, subject the appliance to a test run:

– Connect the power cord 10 to the

appliance and to a socket.

– Switch on the appliance.

You should not hear any unusual noises, such as rattling and slipping.

– Switch off the appliance and pull the power

cord 10 from the socket and from the appliance.

19. Close the appliance (see "7.4 Closing the appliance" on page 30).

20. Perform a functional check (see "5. Functional check" on page 10).

58 Repair information and repair instructions

Page 59

7.17 Replacing the frame (from appliance no. 20000)

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Hexagon socket wrench 8 mm,

• Water-pump pliers.

Note: It is easier to change the frame if you have another person to help you.

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Remove the compressor (see “7.7 Replacing the compressor (from appliance no. 15000)” on page 36, steps 4. to 8.).

3. Remove the foam section 44.

4. Pull the two appliance connectors 59 upwards out of the frame.

5. Place one arm around the entire foam sections.

6. With the other arm, support yourself against the frame and lift up the foam sections (including ADS containers, oxygen tank, cooler, fan and operating panel).

Note: If two people are working together, one of you can lift up the foam sections with both arms whilst the other holds the frame steady.

7. Position the new frame 57 (with appliance label) on the castors.

8. Insert the foam sections into the frame.

9. Place the appliance connector 59 into the groove of the frame.

10. Align all parts, such as ADS containers and oxygen tank.

11. Check that the cables and tubes are laid in the groove on the foam section. If necessary, press them in.

Repair information and repair instructions 59

Page 60

12. Place the foam section 44 in position.

Note: Check that both foam pads 88 are in place.

13. Install the compressor (see “7.7 Replacing the compressor (from appliance no. 15000)” on page 36, steps 11. to 17.).

14. Close the appliance (see "7.4 Closing the appliance" on page 30).

15. Perform a functional check (see "5. Functional check" on page 10).

7.18 Replacing magnetic valves with valve block

(up to appliance no. 34999)

This section describes conversion of the appliances from two separate magnetic valves WM 13151 to valve block WM 13179 (conversion set WM 15461).

Valve block WM 13179 is fitted as standard on OXYMAT 3 oxygen concentrators from appliance number 40000. Old appliances can be converted in accordance with this section if the

Tools required:

• Spanner set WM 14249,

• Allen key 6 mm,

• Hexagon socket wrench 17 mm,

• Hexagon socket wrench 19 mm,

Removing magnetic valves

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

2. Loosen the straps 42, without pulling the strap out of the fastener, and place them next to the appliance.

magnetic valves are damaged and need to be replaced.

Note

The valve block was fitted in a variant with aluminum housing (WM 13177) in concentrators with appliance numbers from 35000 to 39999. This variant is no longer available. The

• Hexagon socket wrench 20 mm,

• Side nippers,

• Conversion set WM 15461.

I / O

0000 0

60 Repair information and repair instructions

Page 61

3. Remove the foam section 44.

4. Loosen the Y-connector 73 by pushing back the sleeve (e.g. using a spanner from the set) and pull out the angular bush. Remove the outlet piping system WM 13265 from the appliance.

5. Disconnect plugs X10 and X11 from the board.

6. Pull the right ADS container 53 out of the foam section.

7. The ADS container 53 and magnetic valve 54 are connected by a double nipple. Use a 17mm open-ended spanner to hold the double nipple firm on the ADS container 53, and use a second open-ended spanner (20 mm) to unscrew the magnetic valve 54 from the double nipple.

Caution!

Be sure to use the 20-mm open-ended spanner only in the position shown. Otherwise parts of the magnetic valve could break off.

SW 17

SW 20

8. Next, unscrew the ADS container by hand, including the double nipple.

9. Repeat points 6. to 8. for the left ADS container.

10. Use spanner set WM 14249 to detach the connecting tube, short 80 and hose, PA, 8 x 1, 115 long 79 of the inlet piping system, then remove the right magnetic valve.

11. Use spanner set WM 14249 to detach the connecting tube, long 81 and hose, PA, 8 x

1.65 long 78 and the T and push-in connectors of the inlet piping system. Remove the left magnetic valve.

78 81

Repair information and repair instructions 61

Page 62

Unscrew the piping systems

1. Unscrew the connections to the air inlet and exhaust hoses and remove the parts. These are:

– Connecting tube, long 81 WM 13277 – Connecting tube, short 80 WM 13276 – Push-in connector WM 13146 – Piping system, inlet WM 13270

For concentrators up to appliance no. 19999:

Also remove the exhaust hose and place it ready for refitting (see point 5. onwards on page 64).

2. For concentrators from appliance No. 8000 onwards: To remove the pressure measurement tube, first turn the appliance so that the compressor is facing you, then pull container 67 out of the foam section.

Exhaust hose (up to appliance no.19999

To ensure safe refitting, note the route followed by pressure measurement tube 63.

Carefully remove the pressure measurement tube

from the pressure sensor on the board.

Use a diagonal cutter to cut through the cable binders, then remove the pressure measurement tube from the appliance.

Fit valve block to ADS container

1. Place one angle connector 98 in each of the openings on the underside of the valve block 97.

2. On one of the ADS containers, replace the double nipple with the adapter for valve block 104.

3. Moisten the O-ring 107 with oxygen lubricant WM 14902.

4. Put the ADS container on the valve block and secure the connection with the spring clip 105.

104

107



106

105

62 Repair information and repair instructions

Page 63

Prepare second ADS container

1. Replace the pressure seal of the double nipple with the sealing ring 112 and place the sealing ring in the screwed connector 102.

2. Screw screwed connector 102 onto the double nipple of the ADS container using a torque wrench SW 17. Tighten up the screwed connector 102, torque 2.5 Nm. Ensure that it is

not damaged in the process.

3. Put an angle connector 98 in the screwed connector.

Refitting

Note: Steps 1. to 3. are not necessary for concentrators up to appliance no. 7999. For these appliances, start with step 4..

1. Carefully push the new pressure measurement tube

99 (WM 13268, pressure sensor piping system)

from the back of the appliance (ADS container) through the central foam section to the front of the appliance (compressor).

Take care that the pressure measurement tube is the right way round. After installation in the appliance, the end with the T connector and push-in connector must be at the back of the appliance.

112

102

)



)







2. At the front of the appliance, lead the pressure measurement tube 99 along behind container 67 and carefully fit the end of the pressure measurement tube onto the pressure sensor on the board.

3. Place two new cable binders 65 around the new pressure measurement tube 99, and around the exhaust and inlet hoses. Pull the cable binders tight. Push container 67 back into the corresponding recess in the central foam section.

4. Place the ADS container with valve block in the right-hand recess in the central foam section.

Repair information and repair instructions 63

Page 64

5. Connect up the piping system. To do so, proceed as follows:

– For all concentrators:

Push the piping system 101 (ADS container) firmly into the connection on the side of the valve block.

– For concentrators from appliance No. 20000

onwards:

Connect the exhaust hose to the rear angle connector of the valve block. For this purpose use exhaust piping system 100.

101

100

– For concentrators up to appliance no. 19999:

Fit an angle connector 95 and a connecting tube, short 80 onto the push-in connector of the exhaust hose.

– Wet the rear end of the exhaust hose with

Gaspruf. Push the exhaust hose through the central foam section onto the exhaust damper. May sure that the exhaust hose is pushed onto the damper as far as it will go. While doing so, hold the exhaust damper in position from the front of the appliance.

– Push the connecting tube, short 105 of the

exhaust hose into the rear angle connector of the valve block.

Exhaust hose

– For all concentrators:

Push the connecting tube 105 of the pressure sensor piping system 99 firmly into the front angle connector of the valve block.

– For concentrators up to appliance no. 7999:

Replace the pressure measurement tube of the pressure sensor piping system 99 with the blanking plug 106.

From appliance no. 8000 onwards:

– For all concentrators:

Connect the inlet hose to the remaining angle connector of the pressure sensor piping system 99.

64 Repair information and repair instructions

inlet hose

remaining angle connector

Page 65

6. Push plugs X10 and X11 (cables for valve block) onto the appropriate connection points on the board. Carefully locate the cable in the groove to the side of the right ADS container.

X10, X11

) /



/ ) 





7. Fit the outlet piping system WM 13265 (non-return valves) to both ADS containers.

8. Now place the ADS container with angle connector in the left recess of the central foam section and push the free end of the ADS container piping system

101 onto the angle connector of the left

ADS container.

9. Before assembling the OXYMAT 3, check it for leaks:

– Connect the dosage unit 21 or

flowmeter 16 to the oxygen outlet 5.

– Connect the power cord 10 to the

appliance and to a socket. – Switch on the appliance. – Set a flow of 4/min. – Check for leaks by soaping all

connection points to the ADS

containers with a foaming agent (e.g.

Snoop).

Tubing for outlet

Cable guide groove

Air supply hose

Exhaust air hose

Tubing, exhaust

Valve block 97

air 100

Tubing for ADS

Tubing for pressure

containers 101

sensor 99

Conversion to valve block – view complete

Repair information and repair instructions 65

Page 66

10. If you discover a leak, rectify it.

11. Switch off the appliance and pull the power cord 10 from the socket and from the appliance.

12. Remove the dosage unit 21 or the flowmeter 16.

13. Place the foam section 44 in position.

Note Check whether the two foam pads are present in the rear part of the EPP foam.

14. Place the straps 42 over the foam sections and tighten them.

15. Close the appliance (see "7.4 Closing the appliance" on page 30).

16. Perform a functional check (see "5. Functional check" on page 10).

7.19 Replace magnetic valve block

This section describes the following processes:

• for concentrators with appliance numbers from

35000 to 39999: converting the valve block

with aluminum housing (WM 13177) to valve block with plastic housing (WM 13179)

Tools required

• Spanner set WM 14249

• Allen key 6 mm

• Open-ended spanner SW 17

• Open-ended spanner SW 19

• for concentrators with appliance numbers from

40000: replacing the valve block with plastic

housing (WM 13179)

• Open-ended spanner SW 20

• Side nippers

• Conversion set WM 15461

Dismantle magnetic valve block

1. Open the appliance (see "7.3 Opening the appliance" on page 29).

66 Repair information and repair instructions

Page 67

2. Loosen the straps 42 without pulling the strap out of the fastener and put next to the appliance.

3. Take off the foam section 44.

I / O

0000 0 0

4. Undo the Y-connector 73 by pushing back the sleeve (e.g. using a spanner from the set) and pull out the angular bush. Tilt one container slightly out of the foam section to do so. Remove the outlet piping system WM 13265 from the appliance.

5. Pull connectors X10 and X11 off the circuit board.

6. Pull the right-hand ADS container 53 out of the foam section.

Note Steps 7. to 9. do not apply to concentrators which already have a plastic valve block.

7. The ADS container 53 and the magnetic valve block are connected to one another by a double nipple. Use an open-ended spanner SW17 to hold the double nipple steady at the ADS container. Hold the magnetic valve block steady with water pump pliers and remove the ADS container from the magneticvalve block.

8. Now unscrew the ADS container incl. double nipple by hand.

9. Replace the double nipple of the ADS container with the connecting adapter 104.

10. Remove the tubing from the valve block (see “Unscrew the piping systems” on page 62).

11. Remove the two push-fit angle connectors from the magnetic valve block and plug them into the same connectors of the new magnetic valve block.

Double nipple Pressure seal

Aluminum

Note Steps 12. to 13. do not apply to concentrators with an aluminum magnetic valve block.

Repair information and repair instructions 67

Page 68

12. Release the connection between the ADS container and the magnetic valve by taking the spring clip 105 out of the adapter for the valve block.

13. Take the ADS container off the magnetic valve.

14. Moisten the O-ring 107 with oxygen lubricant WM 14902

15. Put the ADS container on the new valve block and secure the connection with the spring clip 105.

Fit magnetic valve block

1. Put the ADS container and valve block into the right-hand location in the central foam.

2. Prepare the tubing. Proceed as follows to do so.

– Push the tubing 101 (ADS container) firmly in

the side connection on the magnetic valve block.

– Connect the exhaust air hose or on

appliances up to appliance no. 19.999 the connecting pipe for the exhaust air hose, to the rear angle connector of the valve block.

– Push the connecting pipe firmly into the front

angle connector of the valve block.

104

107

106

105

3. Push connectors X10 and X11 (cabling for valve block) onto the relevant connections of the circuit board. Guide the cables carefully into the groove to the side of the right-hand ADS container.

4. Fit the outlet piping system WM 13265 (nonreturn valves) to both ADS containers.

5. Put foam section 44 in position.

6. Close the appliance (see "7.4 Closing the appliance" on page 30).

7. Perform a final check (see "5. Functional check" on page 10).

68 Repair information and repair instructions

Page 69

8. Spare parts

8.1 List of spare parts

Note:

The item numbers in the following table match the numbers in the text of these service and repair instructions.

Item no. Description Order No.

1 Handle for lifting or moving WM 13610

2 Push-button for On/Off knob WM 13515

4 Operating hours meter WM 13517

8 Twin castor with brake WM 1733

10 Power cord WM 13421

13 Set of coarse dust filters WM 15360

30 Suction filter WM 13190

31 Twin castor WM 1732

32 Stopper WM 13613

33 Cheese head screw M8 x 40 WM 50604

34 Spring washer WM 50395

35 Housing with label WM 13605

36 Plastic board WM 13521

37 Warning notice WM 13520

38 Service flap WM 13630

39 Fuse insert, DIN EN 660127-2 T, 2.5 H 250V WM 13422

41 Fillister-head screw KB 30 x 10 WM 13518

42 Strap system WM 13115

44 EPP foam section 2, rear section WM 13117

45 EPP foam section 3, top front section WM 13118

46 Front plate, assembled WM 13625

47 Retaining bracket WM 13111

48 Compressor, repair set WM 13365

49 Capacitor WM 13356

Circuit board, replacement Circuit board, new

EPP foam section 1, centre section (up to appliance no. 19999) EPP foam section 1, centre section (from appliance no. 20000)

Cooler, fitted, consisting of: – Finned cooler – Stopper

– Tube, silicone, woven, 8 x 3.5, 530 long – Clip – Coupling.

WM 13442 WM 13460

WM 13116 WM 13157

WM 13310

WM 13312 WM 12537 WM 13321 WM 13314 WM 13122

Spare parts 69

Page 70

Item no. Description Order No.

52 Fan WM 13185

53 Adsorption container, packs of 2 WM 13225

55 Pressure seal WM 13244

56 Tube, PU 4 x 1, 740 long WM 13108

59 Appliance connector WM 13420

Magnetic valve, repair set Magnetic valve, replacement,repair set

Frame, fitted* (up to appliance no. 19999) Frame, fitted* (from appliance no. 20000)

Frame, with notices* (up to appliance no. 19999) Frame, with notices* (from appliance no. 20000)

Vibration damper (up to appliance no. 14999) “O-form” vibration damper (from appliance no. 15000)

Tube set for pressure sensor

WM 13152 WM 13159

WM 13171 WM 13197

WM 13170 WM 13196

WM 13125 WM 13104

comprising:

62 63

– nozzle, – tube, PU 4 x 1, 580 long,

Tube, silicone, 8 x 3.5, 1160 long (up to appliance no. 19999) Exhaust hose (from appliance no. 20000) comprising: – Tube, silicone, 8 x 3,0, 900 long – Coupling – Connector

WM 13206 WM 13209

WM 13132 WM 13175

WM 13176 WM 13122 WM 13167

65 Cable tie WM 13148

Exhaust damper, complete, consisting of:

– Exhaust filter housing, complete

WM 13129 – Foam cartridge – Noise suppressor

Piping, vacuum,

WM 13145 consisting of:

67 68 69 70 71

– Container – Tube, silicone, 8 x 3.5, 400 long – Coupling – Tube, silicone, 8 x 3.5, 239 long – Connector with foam cartridge

WM 13140

WM 13137

WM 13122

WM 13136

WM 13133 – Clip – Foam sheet

Piping, outlet,

WM 13265 consisting of:

72 73 74 75 76

– Nozzle tube, fitted – Y-connector – Elbow connector – Non-return valve, fitted – T-joint

WM 13290

WM 13283

WM 13282

WM 13294

WM 13284

70 Spare parts

Page 71

Item no. Description Order No.

Piping, inlet,

WM 13270

consisting of:

77 78 79

– T-joint – Hose, PA, 8 x 1. 65 long – Hose, PA, 8 x 1. 115 long – Elbow connector.

Tube set, inlet, pressure sensor

WM 13274 WM 13271 WM 13272 WM 13273

WM 13255 comprising: – T-connector,

– Connecting pipe, short, – Elbow connector,

– Connecting pipe, long, – Plug-in connector.

82 Pressure reducer, complete WM 13188

83 Shutoff valve WM 13184

84 Tube, PU, 4 x 1, 480 long WM 13107

85 Plug-in connector WM 13204

86 Cable harness, non-heating appliance circuit board WM 13431

87 Cable harness, circuit board – compr. + fan WM 13432

88 Foam plate WM 13106

89 Clip WM 13314

90 Washer WM 53536

WM 13274

WM 13276

WM 13273

WM 13277

WM 13204

91 Spring washer WM 50370

92 Hexagonal nut WM 50924

93 Screwed socket G1/8 WM 13281

94 Screwed socket G1/4 WM 13153

95 Elbow connector G1/4 WM 13273

96 Elbow connector G1/8 WM 13527

97 Magnetic valve block, plastic WM 13179

98 Push-fit angle connector WM 13146

99 Tubing for pressure sensor, conversion set WM 13268

100 Tubing for exhaust air, conversion set WM 13267

101 Tubing, ADS container WM 13212

102 Screw-in connector WM 13218

103 Blind plug for tubing, pressure sensor WM 13268 WM 13202

104 Adapter for valve block WM 13248

105 Spring clip WM 28052

106 O-ring; 10.5 – 2 WM1145/147

107 O-ring; 12 – 1 WM1145/56

108 Cover, preassembled WM 13240

109 Tapered flange clip D95 WM 13252

110 Cap screw M6x30 EN ISO 7045 WM 53115

111 O-ring; 73-3 WM1145/60

Spare parts 71

Page 72

Item no. Description Order No.

112 Sealing ring 8-11-1.5 WM 13233

F1 Fuse insert IEC 127-2-T-L 400 mA WM 13426 F2 Fuse insert IEC 127-2-T-L 400 mA WM 13426 F3 Fuse insert IEC 127-2-T-L 1.25 A WM 13427

Control panel, printed WM 13510

for dosage monitor: measuring tube, compl., 5 l measuring tube, compl., 3 l O-ring 10-1, 3

for flow meter: measuring tube, compl., 5 l measuring tube, compl., 3 l flow meter sleeve O-ring 7-1, 5 O-ring 22-1, 5

Service bag WM 13632

Service card WM 16196

Pin, chrome-plated WM 13615

Split rivet WM 13617

Label, fire WM 0957

Instructions for use WM 16641

Packaging, complete WM 14570

WM 13725 WM 13726 WM 1145/47

WM 13660 WM 13662 WM 1284 WM 1145/40 WM 1145/69

* When ordering, please specify the model, appliance number and year of construction

8.2 Maintenance set

Maintenance set, 5,000 operating hours

Set WM 15299

consisting of:

• 1 coarse dust filter WM 13631,

• 1 suction filter WM 13190,

• 1 sealing ring for connecting nipple WM 1145/31,

• 1 set of spare parts (for humidifier) WM 15038.

72 Spare parts

Page 73

9. Tools, testing equipment, disinfectants

Below is a list of all tools and test equipment used in these service and repair instructions. The particular tools and test equipment required are explained in the relevant chapters. Special tools can be purchased from the manufacturer Weinmann.

9.1 General tools and test equipment

• Cross-head screwdriver, size 1;

• Cross-head screwdriver, size 2;

• Open-ended spanner SW 17;

• Open-ended spanner SW 19;

• Open-ended spanner SW 20;

• Allen key with tee-handle SW 6, 150 mm long (WM 14250);

• Side nippers;

• Flat nose pliers;

• Hexagon socket wrench 8 mm;

• Spanner set WM 14249;

• Conversion set WM 15461;

• Balance, tolerance 1 g;

• Multimeter for testing voltage, current and resistance;

• Leak detection agent “Snoop”, available in various sizes: 2 oz = 60 ml, 8 oz = 235 ml, 1 gal = 3,8 l, from: Germany B.E.S.T. Ventil + Fitting GmbH Frankfurt Robert-Bosch-Straße 20 63477 Maintal Tel.: +49 6181 4332-0 Fax: +49 6181 4332-39 Internet: www.swagelok.com.

• Universal cleaning agent WM 14937

• Loctite 245 WM 14920

9.2 Special tools and test equipment

• Oxygen measuring device, e. g. OXYcontrol ; WM 13550

• Respiratory tube, WM 5726 4 x 7 mm, 2 m long, for connecting the oxygen measuring device to the pressure reducer of the oxygen cylinder;

• Respiratory tube, WM 5772 4 x 7 mm, 1.5 m long, for connecting the oxygen measuring device to the bubble humidifier;

• Tightening and loosening aids for metric connectors. WM 14249

• Test pressure gauge WM 13098 0 - 2.5 bar, Class 1,6, for apliance outlet pressure; for O2 tank inlet

• T-connector, WM 13284 for fitting test pressure gauge 4/1

Tools, testing equipment, disinfectants 73

Page 74

• Oxygen cylinder with adjustable WM 33100 pressure reducer HIT,

• STURTEVANT RICHMONT Torque indicator spanner measuring range: 1.2 to 6 Nm permanently set to: 2.5 ± 0 .1 Nm Hahn + Kolb order no.: 52249-200

• STURTEVANT RICHMONT Tool with T-handle open-ended spanner SW17 Hahn + Kolb order no.: 52250-200

Order from: Hahn + Kolb Werkzeuge GmbH Borsigstr. 50 D – 70469 Stuttgart Tel.: +49/711/9813 - 0 Fax: +49/711/9813 - 354 e-mail: infohahn-kolb.de Internet: www.hahn-kolb.de

9.3 Disinfectants

• TERRALIN

• MIKROZID LIQUID

Order from: Schülke & Mayr GmbH Robert-Koch-Str. 2 D–22851 Norderstedt Tel.: +49/40/52 100 - 0 Fax: +49/40/52 100 - 318 Internet: www.schuelkemayr.de

74 Tools, testing equipment, disinfectants

Page 75

10. Technical Data

OXYMAT 3

Product category according to 93/42/EEC

Dimensions W x H x D in mm 400 x 700 x 350

Weight approx. 20 kg

Temperature range: – Operation – Storage

Power supply 230 V, 50 Hz

Power output / current consumption 360 W / 1.6 A

Mains fuse DIN EN 60127-2 T 2.5 A H 250V

Classification acc. to EN 60601-1: – Protection against electric shock – Degree of protection against

electric shock

Electromagnetic compatibility: – Radio interference suppression – Radio interference resistance

Sound pressure level approx. 40 dB(A) (from appliance no. 20000)

O2 output (values after 10 min. operation at + 20 °C, 50 % relative humidity and 1013 mbar)

IIa

+ 10 to + 40 °C – 20 to + 70 °C

Class 2 Type B

EN 55011 (VDE 0875 T.11) IEC 1000-4 Parts 2-6 and 11

95 (+1/–3) Vol % O2 1 to 4 l/min 90 (± 3) Vol % O2 4 to 5 l/min

O2 output at 2000 m above msl 90 ± 3 Vol % O2 at 5 l/min

Oxygen outlet pressure 0.6 bar = 60 kPa

Flow rate (read at top of ball)

O2 status indicator OSCI according to DIN EN ISO 8359.51.9 Warning at < 82 VOL % O

Fault warning Visual and acoustic

Actuating pressure of pressure relief mechanism 3 bar = 300 kPa

Servicing After 1 year / every 5000 operating hours

Materials: – Case – Foam sections

Subject to technical change without notice.

0.5 to 5.5 l/min

0.2 to 3.0 l/min

Installed

PP PP

Technical Data 75

Page 76

10.1 Arrangement of the PCBs

S3 S5

F2 F1

X10 X11 X13

76 Technical Data

Page 77

11. Technical Changes

Technical change from Device No. Date

EPP foam section 4, bottom front, Item 47 WM 13119 replaced by front plate, assembled WM 13625.

Vibration damper Item 60 WM 13125 replaced by “Vibration damper, complete”, WM 13143.

Item 48 compressor type 2650 WM 13355 is replaced by compressor type 2660. For replacement purposes only “Compressor, repair set WM 13365” is available.

Length of Item 51 tube, silicone, woven, 8x3.5 (WM 13321) altered from 530 mm to 610 mm.

Item 50 cooler, assembled, no longer includes the coupling WM 13122.

Length of Item 68 tube, silicone, woven, 8x3.5 (WM 13137) altered from 400 mm to 450 mm.

Item 69 coupling WM 13122 no longer present.

Vibration damper, complete, Item 60 WM 13143, is replaced by “O-form” vibration damper, WM 13104.

Chassis WM 13110 replaced by Chassis WM 13156 20.000 05.11.01

13.000 13.11.00

13.350 30.11.00

15.000 03.04.01

EPP foam section 1, centre section, Item 43 WM 13116, replaced by EPP foam section 1, centre section WM 13157

Mac magnetic valves WM 13151 replaced by valve block 13177

Material of cover WM 13241 changed. 38.770 01.06.2005

20.000 05.11.01

35.000 10.05.04

Technical Changes 77

Page 78

12. Repair and inspection log

service instructions

Service performed in

accordance with OXYMAT 3

Company

Date Signature

___________ ________________

Company

Date Signature

___________ ________________

Company

Date Signature

___________ ________________

Company

Date Signature

___________ ________________

Measures / comments

tion (%)

concentra-

at 4 l/min

hours

Operating

22525 Hamburg

Device master data Maintenance and repair work carried out in accordance with service documents

Manufacturer: Weinmann GmbH + Co.

78 Repair and inspection log

Device model: OXYMAT 3

Device no.: __________________

Date commissioned: ________________

Operator :

________________________________

Page 79

13. Test report

Test report in accordance with service and repair instructions for OXYMAT

Medical retailer: IK-No.:

• Patient

Name: First name: Health insurance No.:

Address:

• Appliance

Appliance: Oxygen concentrator Oxymat

Device No.: Year of construction: Operating hours:

• Findings

Visual inspection/mechanical inspection according to service instructions

Accessories included: Power cord

Dosage monitor

Humidifier

20 m Tube

10 m Tube

3 m Tube

Nose piece

Flow meter

3 Manufacturer: Weinmann

not OK

General condition of housing checked

Coarse dust filter checked for dirt

Power cord checked for damage

Fuse set checked regarding correct or missing fuses

Functional check in accordance with service instructions

Main switch/LED displays checked

Dosage monitor checked for leaks

Flow meter checked for leaks

Operating hours counter checked

concentration checked (95 + 1/-3 vol.% at 4 l/min) Measured value: vol.%

Warning for power failure checked

Status indicator (up to appliance No. 8000) and negative pressure alarm checked

Self-test (from appliance No. 8000) checked

Test report 79

Page 80

• Maintenance

Maintenance carried out after 5,000/10,000 etc. operating hours or once every year in accordance with service instructions

Replacement of suction filter WM 13190

Replacement of coarse dust filter WM 13631

Maintenance report completed

Faults and possible causes

Repair necessary: yes no

not OK

• Final check

Visual inspection (housing and power cord intact, coarse dust filter fitted properly)

Functional test of the control and operating elements

Test of the alarms

O2 concentration at 4 l/min: 95 + 1/-3 vol.% Measured value: vol.%

If repaired: all functions of the repaired parts tested

• Comments

not OK

Findings / maintenance / repair / final repair carried out

Date: Name: Company:

WM-No. 13004

80 Test report

Page 81

Page 82

Page 83

Page 84

For decades Weinmann has been

developing, producing and marketing

medical devices for markets around

the world. In cooperation with our

partners we design economic health

systems for diagnosis and therapy in

Sleep Medicine, Home Mechanical

Ventilation, Oxygen Medicine

and Emergency Medicine.

Weinmann Geräte für Medizin GmbH + Co. KG P.O. Box 540268 · D-22502 Hamburg Phone +49/40/5 47 02-0 Fax +49/40/5 47 02-461 E-Mail int.sales@weinmann.de Internet www.weinmann.de

WM 16642e · 03/07

Weinmann Oxymat 3 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

1. Overview

2. Functional description

3. Servicing

3.1 General

3.2 Implementation

3.3 Disposal

4. Hygienic Preparation

4.1 No change of patient

4.2 Change of patient or reuse

5. Functional check

5.1 General

5.2 Intervals

5.3 Implementation

5.3.1 Checking the housing

5.3.2 Checking the coarse dust filter

5.3.3 Checking the power cord

5.3.4 Checking the fuse

5.3.5 Checking the main switch and LED displays

5.3.6 Checking the dosage monitor for leaks

5.3.7 Checking the flowmeter for leaks

5.3.8 Checking the operating hours meter

5.3.9 Checking the O2 concentration

5.3.10 Checking the mains failure alarm

5.3.11 Checking the indirect status indicator (yellow LED) with appliance closed

5.3.12 Checking the indirect status indicator (yellow LED) with the appliance open

5.3.13 System pressure test

5.3.14 Checking the O2 system for leaks

6. Troubleshooting

6.1 Visual and acoustic signals from OXYMAT 3

6.1.1 Alarms

6.1.2 Signal patterns

6.1.3 Deactivating the signal functions

6.2 Remedies

6.3 O2 concentration outside tolerance range

6.4 System pressure fault

7. Repair information and repair instructions

7.1 General

7.2 Replacing the castors

7.3 Opening the appliance

7.4 Closing the appliance

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)

7.14 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)

7.19 Replace magnetic valve block

8. Spare parts

8.1 List of spare parts

8.2 Maintenance set

9. Tools, testing equipment, disinfectants

9.1 General tools and test equipment

9.2 Special tools and test equipment

9.3 Disinfectants

10. Technical Data

10.1 Arrangement of the PCBs

11. Technical Changes

12. Repair and inspection log

13. Test report