Weinmann Oxyway Pressure Reducer Service manual
OXYWAY
Single-stage pressure reducer, fixed:
Fix I; Fix I side outlet; Fix II; Fix III; Fix III left
Single-stage pressure reducer, variable:
Fine I; Fine II; Fine III
Single-stage pressure reducer, indexed:
Fast I; Fast II; Fast II High Flow; Fast III
Indexed flowmeter OXYWAY Click
Two-stage pressure reducer, fixed:
OXYTRON
Service and Repair Instructions
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Explanation of Numbers . . . . . . . . . . . .6
1.2 Information about conformity with
standards . . . . . . . . . . . . . . . . . . . . . .6
2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General. . . . . . . . . . . . . . . . . . . . . . .7
2.2 Fixed pressure reducer FIX
(WM 30050; 30100; 30200;
30300; 30350) . . . . . . . . . . . . . . . . .7
2.3 Variable pressure reducer FINE
(WM 30500; 30700; 30750). . . . . . .8
2.4 Indexed pressure reducer FAST
(WM 30600; 30800; 30850). . . . . . .8
2.5 Multistep pressure reducer Fast II High
Flow (WM 31899) . . . . . . . . . . . . . . .8
2.6 Two-stage pressure reducer OXYTRON
(WM 30150). . . . . . . . . . . . . . . . . . .9
2.7 Indexed flowmeter OXYWAY Click . . . . .9
2.8 Oxygen outlets pressure reducer
OXYWAY . . . . . . . . . . . . . . . . . . . . 10
3. Final Check . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 General. . . . . . . . . . . . . . . . . . . . . .11
3.2 Intervals . . . . . . . . . . . . . . . . . . . . . .11
3.3 Performing check . . . . . . . . . . . . . . . .12
3.4 Checking the adjustable output (flow)
on the OXYWAY Click . . . . . . . . . . . .15
4. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 General. . . . . . . . . . . . . . . . . . . . . .16
4.2 Intervals and scope for OXYWAY and
OXYTRON pressure reducers . . . . . . . . 16
4.3 Intervals and scope for OXYWAY Click
flowmeter . . . . . . . . . . . . . . . . . . . . .16
4.4 Storage . . . . . . . . . . . . . . . . . . . . . .17
4.5 Disposal . . . . . . . . . . . . . . . . . . . . .17
5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . 18
5.1 Pressure reducer OXYWAY and
OXYTRON . . . . . . . . . . . . . . . . . . . . 18
5.2 Flowmeter OXYWAY Click . . . . . . . . .19
6. Repair Information and Repair Instructions
for pressure reducer OXYWAY and
OXYTRON . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 General. . . . . . . . . . . . . . . . . . . . . .20
6.2 Replacing sealing ring in connector. . . . 20
6.3 Replacing filter screw . . . . . . . . . . . . .21
6.4 Replacing oxygen outlet . . . . . . . . . . .21
6.5 Replacing gage . . . . . . . . . . . . . . . .27
6.6 Replacing piston in pressure reducer
FIX (WM 30050, 30100, 30200,
30300, 30350) . . . . . . . . . . . . . . . .28
6.7 Replacing piston in pressure reducer
FINE (WM 30500, 30700, 30750) . .30
6.8 Replacing piston in pressure reducer
FAST (WM 30600, 30800, 30850) . .33
6.9 Replacing piston in pressure reducer
Fast II High Flow (WM 31899) . . . . . .36
6.10 Replacing index head / cover . . . . . . .39
6.11 Replacing index head/cover on Fast II
High Flow pressure reducer . . . . . . . . .45
6.12 Replacing Connector and Sinter Filter . . 50
6.13 Changing connector and sinter filter in
OXYTRON pressure reducer . . . . . . . .52
6.14 Replacing second stage of OXYTRON
pressure reducer (WM 30150) . . . . . .54
6.15 Replacing first-stage piston in OXYTRON
pressure reducer (WM 30150) . . . . . .55
6.16 Replacing second-stage piston in
OXYTRON pressure reducer
(WM 30150). . . . . . . . . . . . . . . . . . 56
7. Repair Information and Repair Instructions for
flowmeter OXYWAY Click . . . . . . . . . . . . . . 58
7.1 General. . . . . . . . . . . . . . . . . . . . . .58
7.2 Replacing index head / cover . . . . . . .58
7.3 Changing filter screw . . . . . . . . . . . . .63
7.4 Replace central gas supply system plug
connection . . . . . . . . . . . . . . . . . . . .63
8. Replacement Parts . . . . . . . . . . . . . . . . . . . 64
8.1 Information about conformity with
standards. . . . . . . . . . . . . . . . . . . . .64
8.2 Replacement parts list for all
pressure reducers. . . . . . . . . . . . . . . .65
8.3 Additional replacement parts for
WM 30050 . . . . . . . . . . . . . . . . . .66
8.4 Additional replacement parts for
WM 30100, 30150, 30200, 30300 67
8.5 Additional replacement parts for
WM 30500, 30700, 30750 . . . . . .68
8.6 Additional replacement parts for
WM 30800, 30850 . . . . . . . . . . . .69
8.7 Additional replacement parts for
WM 31899 . . . . . . . . . . . . . . . . . .70
8.8 Additional replacement parts for
WM 30600 . . . . . . . . . . . . . . . . . .71
8.9 Additional replacement parts for
OXYWAY Click . . . . . . . . . . . . . . . .72
8.10 Additional replacement parts 2nd stage
OXYTRON WM 30150. . . . . . . . . . .73
8.11 Connections for pressure reducer . . . . .74
9. Tools, Inspection/Measuring/Test Equipment 76
9.1 General tools and resources . . . . . . . .76
9.2 Special tools. . . . . . . . . . . . . . . . . . . 76
9.3 Inspection, measuring and test
equipment . . . . . . . . . . . . . . . . . . . .77
10. Technical Data . . . . . . . . . . . . . . . . . . . . . . 79
10.1 Pressure reducer OXYWAY up to
SN 0849999 and OXYTRON . . . . . .79
10.2 Pressure reducer OXYWAY from
SN 0850000 . . . . . . . . . . . . . . . . .80
10.3 Technical Data for flowmeter
OXYWAY Click . . . . . . . . . . . . . . . .81
11. Technical amendments . . . . . . . . . . . . . . . . 82
© Copyright WEINMANN GmbH & Co. KG.
The content and presentation are copyright protected and may only be used by authorised WEINMANN Service Partners in
the course of their service operations. The content must not be reproduced or passed on to third parties. The complete documents
must be returned on termination of the cooperation with WEINMANN.
2
Introduction
For many decades WEINMANN has developed,
produced and marketed appliances for oxygen
therapy, inhalation therapy and emergency
medicine.
In 1957 WEINMANN put the first diaphragm
pressure reducer on the market.
Pressure reducers are used in medical oxygen
inhalation. They reduce the pressure delivered by
oxygen bottles from 200 bar to the specified
operating pressure.
The flowmeter is used during the inhalation of medical oxygen via the central gas supply system of a
hospital, for example.
Pressure reducers are a functional component of a
wide range of appliance combinations such as
stationary oxygen appliances and portable oxygen devices. They are therefore an important
component in the treatment of chronic respiratory
diseases and/or disorders of the cardiovascular
system.
The aim of these Service and Repair Instructions is to
familiarize you, a
the function, technology, servicing and repair of
pressure reducers and flowmeters. In conjunction
with a training course that you have already been
trained and competent expert,
with
given by WEINMANN, you now belong to that
group of “trained and competent experts”, which
means you can give your customers proper instruction, rectify faults yourself and perform the prescribed functional check and any repairs in
accordance with these Service and Repair Instructions.
In the event of any warranty claim the device must be
sent to WEINMANN
So that we can process any warranty claims or
requests for favorable treatment, please send us
the customer’s purchase slip (invoice) with the
appliance.
Repairs and/or repair work may only be performed by WEINMANN or by trained and competent experts.
You are responsible for any repairs you carry out
yourself and the relevant guarantees!
Only genuine WEINMANN replacement parts
used for repairs.
Please remember:
Your customers put their trust in you and rely on
your efficiency, just as you rely on WEINMANN.
.
may be
Note:
You will find the following information in the operating instructions for the devices:
• Safety information
• Assembly
• Operation
• Hygienic preparation
• Functional Check
• Warranty.
Introduction
3
1. Overview
1 Contents gage
2 Connector
(oxygen bottle)
3 Rating plate
4 Body
22 Cover
Oxygen outlet
(to consumer)
6 Index head
Fixed pressure reducer FIX
WM 30050; 30100; 30200;
30300; 30350
2 Connector (oxygen
bottle)
Multistep pressure reducer Fast II High Flow
WM 31899
8 Flow gage
Indexed pressure reducer FAST
WM 30600; 30800; 30850
1 Contents gage
6 Index head
Oxygen outlet
(to consumer)
1 Contents gage
15 Connection nut
2 Connector (oxygen
bottle)
4 Body
22 Cover
Oxygen outlet
(to consumer)
9 Adjuster knob
Variable pressure reducer FINE
WM 30500; 30700; 30750
4
Overview
1 Contents gage
15 Connection nut
2 Connector (oxygen
bottle)
4 Body
22 Cover
52 Body stage 2
Oxygen outlet
(to consumer)
Two-stage pressure reducer
OXYTRON WM 30150
2 Connector
22 Cover
3 Rating plate
6 Index head
13 Service plate
20 Plate for changing
filter screw
14 Sealing ring
Oxygen outlet
(to consumer)
Indexed flowmeter
OXYWAY Click WM 31030
12 Filter screw
10 Appliance number
11 Safety valve
Rear view of pressure reducer
Overview
5
1.1 Explanation of Numbers
Type: 30800
The type row indicates the basic design of the
pressure reducer, e.g. “30800” for indexed
pressure reducers (Fast I).
Order number:
In the order number the first three numbers are a
short indication of the type, and the last two digits
indicate the specific version (e.g. the connection
variants).
Appliance number:
The first two digits of the appliance number show
the year of manufacture. The next five digits are the
consecutive appliance serial number within each
type. The appliance number is stamped on the
back of the pressure reducer.
1.2 Information about conformity with standards
Up to serial number 0849999, OXYWAY
pressure reducers meet standard EN 738-1.
From serial number 0850000, OXYWAY
pressure reducers meet standard EN ISO 105241:2006.
In the course of adapting the products to standard
EN ISO 10524-1:2006, it was not possible to
design all components to be downward-compatible. Parts which are not downward-compatible are
available for both device statuses separately and
are marked accordingly in the replacement parts
lists (see “8. Replacement Parts” on page 64) of
these instructions.
• Fit replacement parts which are not downward-compatible only
pressure reducer serial numbers quoted.
• Do not convert pressure reducers up to
SN 0849999 “to suit the new standard”.
in accordance
with the
Caution!
Malfunction as a result of unclear device status.
If replacement parts which are not downward-compatible are used in the wrong pressure reducers,
connected devices will malfunction.
6
Overview
2. Function
2.1 General
During operation, the oxygen coming from the
oxygen bottle passes through the bottle valve and
the connector 2 into the body 4 of the pressure
reducer. You can read off the bottle pressure (delivery pressure) at the contents gage 1.
WEINMANN piston pressure reducers are of
modular design. This makes it possible to keep the
number of replacement parts to a minimum.
A filter screw with integrated sinter filter (see explanation on right) traps any impurities. A further sinter
filter absorbs pressure surges in the oxygen flow.
The filter screw 12 is located at the entrance to the
connector 2. The second sinter filter is fitted between
the connector 2 and the body 4.
In the reduction stage the bottle pressure is reduced
to the required nominal outlet pressure, depending
on type. The principle used, with crater drill hole
and spring-loaded piston, ensures especially constant pressure in spite of variations in flow.
All pressure reducers are protected against excess
pressure by a safety valve 11.
Explanations:
Sinter filter: Small spherical bronze particles are
pressed together under heat, creating a filter with a
particularly fine pore structure (50 - 75 µm).
Flow: Outlet volume; expressed in liters per minute.
2.2 Fixed pressure reducer FIX
(WM 30050; 30100; 30200; 30300; 30350)
A fixed orifice in oxygen outlet 7 creates a constant
flow.
The pressure reducers in this series differ in the
length and position of the connector 2 and the
oxygen outlet 7.
2
7
Function
7
2.3 Variable pressure reducer FINE (WM 30500; 30700; 30750)
The piston is acted upon by a second spring which
can be adjusted via a spindle system and thereby
creates different outlet pressures. In conjunction
with the fixed orifice in the oxygen outlet 7 you can
therefore make continuously variable adjustments
to the flow. You can read off the flow setting at the
flow gage 8.
8
2
The pressure reducers in this series differ in the
length and position of the connector 2.
7
2.4 Indexed pressure reducer FAST (WM 30600; 30800; 30850)
As in the fixed pressure reducers, this creates a
constant operating pressure (outlet pressure).
The index head 6 contains an orifice disc with
various orifice diameters which are aligned by an
index (click-in) system with the oxygen outlet 35.
This enables you to set various flow rates.
The pressure reducers in this series differ in the
length and position of the connector 2. A pressure
reducer of type WM 30850 has two oxygen
outlets.
7
35
2
6
2.5 Multistep pressure reducer Fast II High Flow (WM 31899)
As in the Fast multistep pressure reducers, there is an
orifice disk with a variety of orifice diameters in adjuster 6 which is brought into line with oxygen outlet 35
by means of a locating system.
35
In addition to the flow outlet, there is a pressure outlet
for medical devices with an oxygen requirement in excess of 90 l/min. The pressure outlet and the flow outlet may not be in operation simultaneously.
7
6
8
Function
2.6 Two-stage pressure reducer OXYTRON (WM 30150)
The two-stage pressure reducer has a first stage in
the form of a fixed pressure reducer WM 30100,
and a second reduction stage 52 to permit optimal
adjustment of pressure and flow to suit the
OXYTRON oxygen device.
In the second stage the pressure of 4.5 bar from
the first stage is similarly reduced by a system of
crater drill hole and spring-loaded pistion to
1.6 bar.
A fixed orifice in the oxygen outlet 7 generates a
constant flow of 12 l/min.
2.7 Indexed flowmeter OXYWAY Click
During operation, the oxygen supplied by the central
gas system at a pressure of 4.5 bar passes through the
inlet connector 2 into the body 22 of the OXYWAY
Click.
The dial head 6 contains an orifice disk with orifices of different diameters which are lined up with
the oxygen outlet 35 by means of a click dial system. You can set the following flow rates: 1, 2, 3,
4, 5, 6, 9, 12, 15 l/min..
52
7
2 35
6
22
Function
9
2.8 Oxygen outlets pressure reducer OXYWAY
Oxyway pressure reducers are available with different oxygen outlets: the pressure outlet and the
flow outlet are different (see also “10. Technical
Data” on page 79).
Flow outlets are intended for the direct supply of
the patient, e.g. via nasal cannula, mask or
Flow outlet
(Fix I, Lateral outlet Fix I)
9/16 UNF thread
Pressure and flow outlet
(Fast II)
(Fine I up to III)
9/16 UNF thread
Pressure and flow outlet
(Fast II High Flow)
intermediate humidifier. Flow outlets have a 9/16
UNF thread.
Pressure outlets are intended to supply ventilators
such as the Medumat, modules or distributor bars.
Pressure outlets have a G 3/8" thread.
Flow outlet
Flow outlet
(Fast I and III)
9/16 UNF thread
Pressure outlet
(Fix III, Fix III left)
G 3/8"
thread
9/16 UNF
thread
Flow outlet
(Oxytron)
18 x 11 thread
G 3/8"
thread
G 3/8" thread
9/16 UNF
thread
Flow outlet
(Oxyway Click)
9/16 UNF thread
10
Function
3. Final Check
3.1 General
Test conditions:
• Ambient temperature: 15 °C
• Ambient pressure: 1013 hPa
• Connection to oxygen supply. For flow tests, a
constant pressure* of 100 bar or 200 bar is
required.
* 100 bar up to SN 0849999
200 bar from SN 0850000
All the tolerances listed in these instructions (see
“10. Technical Data” on page 79) relate to these
conditions. Note that if different ambient conditions prevail, deviating measuring results may be
obtained.
For the check you will need:
• shutoff valve (max. 6 bar) after oxygen outlet
• test pressure gage 0 - 10 bar
• test pressure gage 0 - 2.5 bar
and three flow meters:
• 0 - 50 ml/min
• 0 - 20 l/min
• 0 - 220 l/min.
If the final check reveals faults, the device must not
be used until the defect has been rectified. For possible causes of the defect and how to remedy
them, see Chapter “5. Troubleshooting” on
page 18.
A complete check of the OXYWAY Fix, Fast and
Fine pressure reducer includes:
• Visual inspection for mechanical damage,
• “3.3.1 Testing system for leaks” on page 12,
• “3.3.2 Testing safety valve for leaks” on
page 13,
• “3.3.3 Checking “0” position of contents
gage” on page 13,
• “3.3.4 Checking “0” position of flow gage on
pressure reducer FINE” on page 13
• “3.3.5 Checking for leaks with valve closed
on pressure reducer FINE” on page 14,
• “3.3.6 Checking adjustable flow rate on pressure reducer FINE” on page 14,
• “3.3.7 Checking adjustable flow rate on pressure reducer FAST” on page 14.
• “3.3.8 Checking constant flow rate in pressure reducers FIX, FAST and
FAST II high Flow” on page 15
• “3.3.9 Checking static outlet pressure p4 for
all pressure reducers” on page 15.
A complete check of the OXYWAY Click flowmeter includes:
• “3.4 Checking the adjustable output (flow)
on the OXYWAY Click” on page 15.
We recommend that you always keep in stock:
• Replacement seal set WM 1148,
• Filter screw WM 30905.
3.2 Intervals
After any servicing or repair work
• Perform a final check.
Final Check
11
3.3 Performing check
3.3.1 Testing system for leaks
1. Close system after pressure reducer, e.g. by
closing a valve after the pressure reducer.
2. Check that all screwed joints and hoses are
firmly seated. If necessary tighten joints by
hand.
3. Slowly open valve of oxygen bottle. Contents
gage 1 of pressure reducer now shows bottle
pressure, e.g. 200 bar.
4. To detect leaks, wet screwed connections with
a soap-and-water solution. Use Lanosan
for this purpose.
Warning!
Risk of explosion from soap penetration.
Leaks can cause soap to penetrate the system
and combine with the oxygen to form an explosive mixture.
• Open the O2 valve before wetting parts of the
system with a soap-and-water solution. The
system is then pressurized. No soap can penetrate the system.
• Remove the soap-and-water solution without
leaving any residues after the test is complete.
5. Close bottle valve again.
6. Observe needle of contents gage 1 for about
1 minute. If needle stays in same position, the
system is gas-tight. If the needle falls steadily,
there is a leak.
®
med
1
Eliminating leaks
We recommend that you keep a stock of replacement seals for the connections.
1. Prepare solution of soapy water, using perfume-free soap.
2. Wet all screwed joints with solution. If bubbles
form, this indicates a leak.
3. Release pressure in system:
– Close oxygen bottle valve.
– Open valve after pressure reducer until
contents gage 1 reads “0”.
12 Final Check
4. Replace faulty seal responsible for leak (see
“6.2 Replacing sealing ring in connector” on
page 20).
Important!
Screwed joints of oxygen line must only be hand
tightened.
5. Check for leaks again.
6. If leak cannot be eliminated, unit must be
repaired.
3.3.2 Testing safety valve for leaks
1. Test must be performed at maximum flow. In
the Fine and Fast series this is set accordingly.
2. Slowly open oxygen bottle valve.
3. Test with finger whether oxygen is escaping
from safety valve 11.
If oxygen is escaping, have pressure reducer
repaired by manufacturer (WEINMANN).
Alternatively, you can also wet the safety valve
with soap-and-water solution to find leaks. Use
Lanosan® med.
Warning!
Risk of explosion from soap penetration.
Leaks can cause soap to penetrate the system
and combine with the oxygen to form an explosive mixture.
• Open the O2 valve before wetting parts of the
system with a soap-and-water solution. The
system is then pressurized. No soap can
penetrate the system.
• Remove the soap-and-water solution without
leaving any residues after the test is complete.
11
3.3.3 Checking “0” position of contents gage
1. Slowly open oxygen bottle valve.
Contents gage
1 now shows bottle pressure.
2. To release pressure in system:
– Close oxygen bottle valve
– Switch on connected appliance
– Open shutoff valve after oxygen outlet.
3. Needle of contents gage
“0”. Wait until needle stops moving. Now
switch appliance off.
4. Check whether needle points exactly to “0”.
If not, fit replacement contents gage (see “6.5
Replacing gage” on page 27).
3.3.4 Checking “0” position of flow gage on pressure reducer FINE
1. Slowly open oxygen bottle valve.
2. Set flow rate (e.g. 7 l/min) at adjuster knob
You can read the set value at the flow gage 8.
3. To release pressure in system:
– Close oxygen bottle valve
– Open shutoff valve after oxygen outlet
– Switch on connected appliance.
4. Needle of flow gage 8 now falls toward “0”.
Wait until needle stops moving. Now switch
appliance off.
9.
1
8
1 now falls toward
9
5. Check whether needle points exactly to “0”.
If not, fit replacement gage (see “6.5 Replacing gage” on page 27).
Final Check 13
3.3.5 Checking for leaks with valve closed on pressure reducer FINE
You need a flow meter with a range of 0 – 50 ml/min.
Perform measurement at an inlet pressure of 200 bar.
1. Slowly open oxygen bottle valve.
Contents gage 1 now shows bottle pressure.
2. Check whether flow gage 8 shows a flow rate
of “0”.
If not, use adjuster knob 9 to set flow rate to
“0”.
3. Connect flow meter (0 - 50 ml/min) to oxygen
outlet 7.
4. Wait until flow meter shows constant reading.
5. Read off value.
If value is greater than 30 ml/min, fit replacement piston (see “6.7 Replacing piston in pressure reducer FINE (WM 30500, 30700,
30750)” on page 30).
3.3.6 Checking adjustable flow rate on pressure reducer FINE
You need a flow meter with a range of 0 – 20 l/min.
Perform measurement at an inlet pressure of 100 bar ± 10 bar.
1. Slowly open oxygen bottle valve.
Contents gage 1 now shows bottle pressure.
2. Turn adjuster knob 9 to the left as far as it will
go, until flow gage 8 shows a flow rate of “0”.
3. Connect flow meter to oxygen outlet 7.
4. Set any desired flow rate at adjuster knob 9.
Note: Checking the flow of the second oxygen outlet is described in a later section (3.3.8, page 15).
5. Check on flow meter whether actual value
agrees with set value.
Note tolerances of pressure reducer:
1 to 5 l/min: ± 0.5 liters,
6 to 15 l/min: ± 10 %.
6. If any value does not agree, have pressure reducer repaired by manufacturer
(WEINMANN).
3.3.7 Checking adjustable flow rate on pressure reducer FAST
You need a flow meter with a range of 0 – 20 l/min.
Perform measurement at an inlet pressure of 100 bar ± 10 bar.
1. Slowly open oxygen bottle valve.
Contents gage 1 now shows bottle pressure.
2. Set flow of “0” at index head 6.
3. Connect flow meter to oxygen outlet 7.
4. Set any desired flow rate at index head 6.
Note: Checking the flow of the second oxygen outlet is described in a later section (3.3.8, page 15).
5. Check on flow meter whether actual value
agrees with set value.
Note tolerances of pressure reducer:
1 to 5 l/min: ± 0.5 liters,
6 to 15 l/min: ± 10 %.
6. If any value does not agree, have pressure
reducer repaired by manufacturer
(WEINMANN).
14 Final Check
3.3.8 Checking constant flow rate in pressure reducers FIX, FAST and
FAST II high Flow
You need a flow meter as follows:
• For WM 30050, 30100, 30150: flow meter 0 – 20 l/min
• For WM 30200, 30300, 30350, 30850, 31899: flow meter 0 – 220 l/min.
1. Connect flow meter to oxygen outlet.
2. Close
– on pressure reducers WM 30850 and
WM 31899: oxygen outlet for adjustable
flow,
– on pressure reducer WM 30200: second
oxygen outlet (on the side).
3. Slowly open oxygen bottle valve.
– Contents gage 1 now shows bottle pressure
– Flow meter shows flow rate.
4. Check flow rate reading against set value.
Pressure reducers must maintain the following
flow rates:
WM 30050, 30100: 4 l/min ± 0.5 l/min
WM 30150: 12 l/min ± 1.2 l/min
WM (30200), 30300,
30350: 120 l/min ± 15 l/min
WM 30850: 90 l/min ± 10 l/min
WM 31899: min. 160 l/min
5. In the event of discrepancies, have pressure reducer repaired by manufacturer
(WEINMANN).
6. There is a second oxygen outlet on pressure
reducer WM 30200. This is a free pressure
outlet.
3.3.9 Checking static outlet pressure p4 for all pressure reducers
1. Connect appropriate test gage to oxygen
outlet 7.
2. Check closing pressures p4 (see “10. Technical Data” on page 79). They are valid for a
delivery pressure of p
* = 100 bar or
1
200 bar and must be reached within 1 minute
at most. After this they must not show any further increase.
* 100 bar up to SN 0849999
200 bar from SN 0850000
3.4 Checking the adjustable output (flow) on the OXYWAY Click
You need a flow meter with a range of 0 – 20 l/min.
Perform the measurement at an inlet pressure of 4.5 bar ±0.2 bar.
1. Set the flow "0" at index head 6.
2. Plug the flowmeter into a suitable compressed
gas supply (e.g. a central gas supply system).
3. Connect the flow meter to the oxygen outlet.
4. Set any flow value at index head 6.
5. Check on the flow meter whether the set value
corresponds to the actual value.
Please observe the tolerances of the flowmeter in
the process.
Rising test:
1 to 5 l/min: ±0.5 liter,
6 to 15 l/min: ±10 %.
Falling test:
6 ±10 % and 0/min: ±0.15 l/min
Final Check 15
4. Servicing
4.1 General
We recommend that all maintenance work, such
as inspections and repairs, be carried out by the
manufacturer (WEINMANN) or by expert technical personnel trained by WEINMANN.
When carrying our repairs, be sure to observe the
directions in these Service and Repair Instructions.
4.2 Intervals and scope for OXYWAY and OXYTRON pressure
reducers
In cases of dirt accumulation, or at least every 2 years:
1. Fit replacement filter screw 12 (see “6.3 Re-
placing filter screw” on page 21).
Every 4 years
1. Fit replacement filter screw 12 (see “6.3 Re-
placing filter screw” on page 21);
2. Completely replace piston 16.
– For pressure reducers WM 30050,
30100, 30200, 30300 and 30350:
see Section 6.6, page 28,
– For pressure reducers WM 30500,
30700, 30300 and 30750:
see Section 6.7, page 30,
– For pressure reducers WM 30600;
30800, 30850:
see Section 6.8, page 33;
2. Perform a functional check (see “6. Functional
Check“ on page 12 of the Operating Instructions”).
– For pressure reducers WM 31899;
30800, 30850:
see Section 6.9, page 36;
3. Fit replacement sinter filter 19 (see “6.12 Replacing Connector and Sinter Filter” on
page 50);
4. Fit replacement sealing ring 14 (see “6.2 Replacing sealing ring in connector” on
page 20)
5. Perform a final check (see “3. Final Check” on
page 11). If you find any faults, rectify them.
6. Replace service plate 13 with a new one with
the new data from “8. Replacement Parts” on
page 64.
4.3 Intervals and scope for OXYWAY Click flowmeter
Check metering accuracy by having a check measurement performed every 4 years.
We recommend that repair work be performed
only by the manufacturer, WEINMANN, or by
trained qualified experts expressly authorized by
WEINMANN.
16 Servicing
4.4 Storage
If the pressure reducer is to remain unused for long periods, we recommend the following procedure:
1. Clean pressure reducer (see “Hygienic
preparation” in the Operating Instructions).
2. Store pressure reducer in a dry place.
4.5 Disposal
Do not dispose of the unit with domestic
waste. To dispose of the unit properly,
please contact a licensed, certified
electronic scrap disposal merchant. This
address is available from your Environment Officer or from your local authority.
Important:
Be sure to observe the servicing intervals for stored appliances as well. Otherwise the appliance is no longer
fit for use on removal from storage.
Servicing 17
5. Troubleshooting
5.1 Pressure reducer OXYWAY and OXYTRON
Fault Cause Remedy
Replace sealing ring
(Section 6.2, page 20).
Replace connector
(Section 6.12, page 50).
Replace sealing ring
(Section 6.2, page 20).
Replace piston
(Section 6.6, page 28 or
Section 6.7, page 30 or
Section 6.8, page 33).
Have pressure reducer repaired by
manufacturer (WEINMANN).
Replace pressure gage
(Section 6.5, page 27).
Replace oxygen outlet
(Section 6.4, page 21)
Replace index disc (Section 6.9,
page 36)
Replace index disc (Section 6.9,
page 36)
Leak at connector
(bottle connection).
Leak at oxygen outlet
(appliance connection).
Leak at relief valve.
Pressure gage does not read
“0” at zero pressure.
Outlet flow rate too low.
Damaged sealing ring.
Damaged seat for connector sealing
ring.
Damaged sealing ring.
Unacceptable pressure rise in
pressure reducer (delayed rise
effect).
Relief valve not gas-tight.
Crater in body faulty.
Pressure gage faulty.
Oxygen outlet faulty.
Index disk faulty.
Index disk incorrectly adjusted.
Outlet flow rate of OXYTRON
WM 30150 outside
tolerance of
12 l/min ± 1.2 l/min
Outlet pressure of OXYTRON
WM 30150 outside
tolerance of
1.5 bar ± 0.08 bar
Variable pressure reducer:
leak at oxygen outlet 7
> 30 ml/min
(with valve closed and
200 bar bottle pressure).
Second stage faulty
Unacceptable pressure rise in
pressure reducer.
Replace complete piston
(Section 6.16, page 56)
Replace piston
(Section 6.6, page 28 or
Section 6.7, page 30 or
Section 6.8, page 33)
or
have pressure reducer repaired by
manufacturer (WEINMANN).
18 Troubleshooting
5.2 Flowmeter OXYWAY Click
Fault Cause Remedy
Unusually high oxygen
consumption
Inadequate O2 supply during
inhalation
Flowmeter not working
Leak in system Find and eliminate leak
Leak in system Find and eliminate leak
Defect or internal soiling in
flowmeter
Flowmeter defective Have flowmeter repaired
Oxygen source defective or empty Check oxygen source
Have flowmeter repaired
Troubleshooting 19
6. Repair Information and Repair Instructions for
pressure reducer OXYWAY and OXYTRON
6.1 General
• Observe the safety information on page 4 of the
Operating Instructions for OXYWAY.
• Caution: Risk of explosion!
To prevent explosion risks, make sure your
hands, tools and workplace are absolutely
free from oil and grease during the repair
work.
For this reason you should always wash your
hands before starting work.
• Any operations on the appliance presuppose
detailed knowledge and observance of the
Operating Instructions and the Service and
Repair Instructions.
• You should only carry out repairs described in
these Service and Repair Instructions. Otherwise proper functioning of OXYWAY cannot
be guaranteed.
• Be sure to perform a final check after every
• If you replace components or individual parts,
• If there is a fault in the body or the relief valve,
• Certain parts must be screwed up using a
• Note:
6.2 Replacing sealing ring in connector
repair (see “3. Final Check” on page 11).
always use genuine WEINMANN parts only.
have OXYWAY repaired by the manufacturer
(WEINMANN).
torque wrench. To ensure compliance with the
specified torque, check your torque wrench
regularly for torque compliance (control of inspection, measuring and test equipment).
The item numbers in the following text are the
same as the item numbers in the Replacement
Parts List on page 64 and the overview on
page 4.
Tools required:
• From tool set WM 15366:
– Watchmaker’s screwdriver WM 3004130041 (cleaned with methylated spirit).
1. Using a cleaned screwdriver, ease sealing
ring 14 carefully out of its groove.
Be careful not to damage the groove in any way.
2. If necessary, clean the groove with a dry cloth
or a cloth moistened with clean water.
3. Carefully press a new sealing ring into the
groove. Do not use any tools for this.
4. Perform a final check (see “3. Final Check” on
page 11).
14
20 Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON
6.3 Replacing filter screw
Tools required:
• From tool set WM 15366:
– Allen wrench 4 mm WM 30042 (cleaned with methylated spirit).
1. If necessary, clean out the hexagonal socket of
the filter screw 12 with a small screwdriver.
2. Loosen the filter screw
12, but do not unscrew
it completely yet.
3. So that no dirt can fall into the pressure reducer,
hold it with the connector pointing down. In this
position, remove the filter screw
12.
4. Screw a new filter screw 12 into the connector
stub and tighten.
5. Perform a final check. Enter the change of filter
screw with date in the service record.
6.4 Replacing oxygen outlet
12
6.4.1 Replacing G 3/8 pressure outlet
Tools and material required:
• From tool set WM 15366:
– Counter tool with clamping handle WM 30035,
– Screwdriver bit 9 mm WM 30039 (cleaned with methylated spirit);
– Watchmaker’s screwdriver WM 30041 (cleaned with methylated spirit);
• Vise;
• Sealing ring
• Loctite 245 WM 14920 (never use other Loctite products).
• Torque wrench 25 Nm ± 1 Nm,
Note:
The oxygen outlet must always be replaced as a complete unit, because the flow rate cannot be guaranteed if
individual parts are replaced.
1. Clamp pressure reducer firmly in counter tool.
To do this, perform the following steps:
– Using a cleaned screwdriver, carefully ease
sealing ring 14 out of groove in connector.
Be careful not to damage the groove at all.
– Clamp bottom part of counter tool firmly in
a vise.
– Place the top part of the counter tool on the
bottom part of the counter tool.
– Screw the connection nut onto the bottom
part of the counter tool.
– Tighten the connection nut using the top part
of the counter tool.
14 (WM 1145);
7
2
Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON 21
2. Using cleaned screwdriver bit, unscrew defective oxygen outlet 7 by turning to left.
3. Fit new oxygen outlet 7:
– Remove any adhesive residues from screw
threads. Use a brass wire brush for the external thread and if necessary a tap G 1/
8 for the internal thread.
Caution:
When cleaning threads, no dirt must enter
body of pressure reducer.
– Take a new oxygen outlet .
Caution:
The oxygen outlet must be clean and free
from oil and grease.
– Apply a little Loctite 245 to screw thread
with the exception of the first two turns.
The first two turns must be kept free of Loctite
to ensure that no Loctite enters the body of the
pressure reducer.
– Screw oxygen outlet 7 by hand into pres-
sure reducer.
– Tighten oxygen outlet 7 with 9 mm screw-
driver bit and a torque wrench
(25 Nm ± 1 Nm).
7
2
7
4. Release pressure reducer from counter tool.
5. If necessary, clean groove in connector
2 with
dry cloth or cloth moistened with clean water.
6. Now press
new sealing ring 14 carefully into
groove. Do not use any tools.
7. Perform a final check
(see “3. Final Check” on page 11).
6.4.2 Replacing UNF 9/16 flow outlet
Tools required:
• UNF 9/16 counter tool, consisting of:
– counter tool WM 14224
– locknut WM 14223
• special wrench SW 20/22, WM 22391
• counter tool WM 30035 (clamping handle not required)
• torque wrench with SW 22 open-end wrench insert.
Remove defective flow outlet
1. Screw locknut WM 14223 onto counter tool
WM 14224.
22 Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON
2. Screw the UNF counter tool completely onto
the flow outlet of the pressure reducer.
3. Clamp the pressure reducer in a vise so that
only counter tool WM 14224 is actually in the
vise.
4. To clamp the defective flow outlet firmly in the
counter tool, turn locknut WM 14223 clockwise with a 22 mm open-end wrench.
5. To release the pressure reducer from the flow
outlet, turn the pressure reducer anticlockwise
by hand.
Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON 23
6. Take the pressure reducer off the flow outlet.
7. To release the defective flow outlet in the
counter tool, turn locknut WM 14223 anticlockwise with the 22 mm open-end wrench.
8. Unscrew the defective flow outlet from the locknut.
Assembling new flow outlet
Caution:
When cleaning threads, no dirt must enter body
of pressure reducer.
1. Take a new oxygen outlet.
Caution:
The oxygen outlet
from oil and grease.
35 must be clean and free
2. Screw the new flow outlet fully into the counter
tool.
3. Wet about 2 threads of the new flow outlet
with Loctite 245 (WM 14920).
The first two turns must be kept free of Loctite to
ensure that no Loctite enters the body of the pressure reducer.
4. Clamp the counter tool in a vise so that only
counter tool WM 14224 is actually in the
vise.
5. To clamp the new flow outlet firmly in the
counter tool, turn the counter tool clockwise
with the 22 mm open-end wrench.
35
24 Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON
6. Screw the pressure reducer onto the new flow
outlet hand-tight.
7. Take the pressure reducer with the counter tool
screwed onto it out of the vise.
8. Clamp counter tool WM 30035 in the vise.
9. Screw the pressure reducer and oxygen inlet
hand-tight to clamped counter tool WM
30035.
10. Put a torque wrench with open-end wrench insert SW 22 on counter tool WM 14224.
11. Tighten counter tool WM 14224 and thus the
new flow outlet on the pressure reducer
(torque: 25 Nm ±1 Nm).
12. Release the pressure reducer from counter tool
WM 30035.
13. Take counter tool WM 30035 out of the vise.
14. Clamp the pressure reducer in the vise so that
only counter tool WM 14224 is actually in the
vise.
Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON 25
15. To release locknut WM 14223 from the flow
outlet, turn it anticlockwise with the 22 mm
open-end wrench.
16. Unscrew the pressure reducer and flow outlet
from locknut WM 14223.
17. Take the counter tool out of the vise.
18. Perform a final check
(see “3. Final Check” on page 11).
26 Repair Information and Repair Instructions for pressure reducer OXYWAY and OXYTRON
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