Compressor Compact Service Manual E382 EH81E 061 01 03 02
Important Compressor Compact Important General information Classification The documentation for the Compressor Compact consists of: • Class I equipment. • Operating Manual • according to IEC 601-1. Type B • Service Manual • Spare Parts List For proper servicing, the Operating Manual and the Spare Parts List are indispensable complements to this Service Manual. Data on pressures in the Compressor Compact are given in Pa (bar): 1 kPa = 10 mbar 1 kPa = 0.01 bar 1 kPa ≈ 10 cm H2O 1 kPa ≈ 0.
Contents Compressor Compact Page Page Important ................................................. 2 Adjustments ............................................. 39 Introduction .............................................. 4 Pressure regulator .............................. 39 General .............................................. 4 Maintenance ............................................ 40 Main units ........................................... 5 General ...........................................
Introduction Compressor Compact Introduction General The Compressor Compact is designed to supply medical-grade compressed air. The compressor has a capacity of approx. 40 l/min at a pressure of 400 kPa (4.0 bar). The Compressor Compact can be placed on the ventilator cart to form a compact unit which is easy to move. The Compressor Compact is well insulated against noise and therefore does not cause disturbance when used during operations.
Introduction Compressor Compact Main units The Compressor Compact comprises five main units: • Compressor section • Cooling section • Dryer section • Air outlet section • Control section.
Introduction Compressor Compact Basic principles This text also refers to the Block diagram on page 53. Compressor section The compressor section contains the following main parts: Temperature sensor Air inlet silencer • Air inlet with filter Motor Air inlet with filter • Air inlet silencer • Temperature sensor • Motor • Drive unit • Compressor COMP002E • Heat convector. Heat convector Compressor Drive unit The air inlet is supplied with ambient air from the inside of the dryer section, i.e.
Introduction Compressor Compact Cooling section COMP003E Cooling coil E382 EH81E 061 01 03 02 The main part of the cooling section is the cooling coil which provides further preliminary cooling of the compressed air. The compressed air flow, supplied from the compressor section, passes through the cooling section via this cooling coil. The cooling coil is cooled by the air stream forced through the cooling section by the fan in the dryer section.
Introduction Compressor Compact Dryer section Fuses Filter / Solenoid valves Electric power supply The dryer section contains the following main parts: • Water separator 1 • Thermoelectric cooler • Water separator 2 • Filter/solenoid valves • Drainage bottle • Standby solenoid valve Fan • Low pressure switch Pressure regulator • Standby pressure switch COMP004E • Pressure regulator Electrical interconnection • Electric power supply Dust filter • Electrical interconnection • Fuses • Dust filters
Introduction Compressor Compact Water separators 1 and 2 are automatically drained at regular intervals by the two filter/ solenoid valves. The water is collected in the drainage bottle. A low pressure switch is connected to the compressed air reservoir. This switch (sensor) detects the air pressure inside the compressed air reservoir and activates the pressure alarm if the air pressure in the reservoir drops.
Compressor Compact Introduction Air outlet section The air outlet section contains the following main parts: • Compressed air reservoir • Pressure manometer • Moisture relief valve • Compressed air outlet • Compressed air inlet • Cooling air outlet. COMP006E The dried air is supplied via water separator 1 in the dryer section to the compressed air reservoir. The compressed air is available at the compressed air outlet.
Compressor Compact Introduction Control section Electrical control function Indicator lamps The control section contains the following main parts: • On/off switch Buzzer • Operating time meter • Electrical control functions COMP008E • Test button ON/OFF switch • Indicator lamps Operating time meter Test button • Buzzer. Mains power to the compressor is connected via and controlled by the on/off switch. The operating time meter indicates how many hours the compressor has been running.
Description of functions Compressor Compact Description of functions 1.4 Motor The Compressor Compact is equipped with a single phase electric MOTOR. The motor is designed according to IEC 34 standards. The text in this chapter Description of functions refers to the: • Circuit and connection diagrams and Block diagram on pages 48 – 51. There are several different versions of the motor each adapted to different mains power supply and frequence. 1.
Compressor Compact Description of functions 1.6 As motors fitted with a self-resetting termal switch can restart automatically, all personnel must exercise extreme caution when in the vicinity of this equipment if fault tracing is performed with mains power supply connected and with the compressor cover opened or removed. The motion of the motor is transmitted to the compressor by the 1.5 DRIVE UNIT.
Description of functions Compressor Compact 2. Cooling section 3. Dryer section 2.1 3.1 Cooling coil Water separator 1 A further preliminary cooling of the compressed air is provided by the COOLING COIL assembly, which is made of metal tubing. The compressed air to this cooling coil is supplied from the 1.7 HEAT CONVECTOR, and the output is connected to 3.1 WATER SEPARATOR 1. WATER SEPARATOR 1 is a “water trap” made of a Y-piece connector. This water separator is connected to the outlet of the 2.
Compressor Compact Description of functions A cooler temperature switch (thermostat) is connected to the Peltier element. The switch detects the temperature at the cool side of the element. To avoid formation of ice in the thermoelectric cooler, this switch will cut the power supply to the Peltier element if the temperature drops below approx. +2°C (+36°F). This thermostat is factory calibrated and must not be adjusted. The PC board RCD connected to the thermostat is a spark arrestor.
Description of functions 3.5 Compressor Compact Drainage bottle 3.7 The DRAINAGE BOTTLE collects the water that is extracted from the compressed air by 3.1 WATER SEPARATOR 1 and 3.3 WATER SEPARATOR 2. It is a plastic container with a screw cap into which the water hose from the water separators is connected. There is a ventilation hole in the cap. 3.6 Standby solenoid valve Compressors with standby function are equipped with a STANDBY SOLENOID VALVE.
Compressor Compact 3.9 Description of functions Pressure regulator The compressed air supply is tapped off at a three-port coupling at the thermoelectric cooler-inlet and applied to the PRESSURE REGULATOR. This device is actually a relief valve. Pressure in excess of the set level, normally approx. 400 kPa (4.0 bar), opens this relief valve. The excess compressed air flow is returned to the inlet of the 1.6 COMPRESSOR via the 1.2 SILENCER.
Description of functions Compressor Compact 3.12 Fuses 3.13 Dust filters The compressor is equipped with three FUSES: two mains power fuses (F1 and F2) and one fuse for the 12 V power supply (F3). The fuses are located in the 3.11 ELECTRICAL INTERCONNECTION block. There are two DUST FILTERS mounted on the compressor housing. These two identical filters are made of a synthetic material. F1 / F2 F3 They must be regularly inspected and cleaned as described in the Operating Manual, chapter Cleaning.
Compressor Compact Description of functions 4. Air outlet section 4.1 Compressed air reservoir The COMPRESSED AIR RESERVOIR is a plastic container with a volume of approx. 1.8 liters. 4.2 Pressure manometer A PRESSURE MANOMETER is connected to the 4.1 COMPRESSED AIR RESERVOIR. This manometer shows the air pressure in the reservoir. The manometer has the range: • 0 – 6 bar in older versions of the Compressor Compact. • 0 – 10 bar in newer versions of the Compressor Compact. 4.
Description of functions Compressor Compact 5. Control section 5.4 5.1 The purpose of the TEST BUTTON is to make it possible to check the alarm indicator lamps and the audible alarm. On/off switch The ON/OFF SWITCH is the switch for mains power supply to the compressor. Mains power is connected to the mains power fuses in the 3.11 ELECTRICAL INTERCONNECTION terminal and then routed, via internal cabling, to the on/off switch. 5.
Compressor Compact 5.7 Description of functions Standby lamp The yellow STANDBY LAMP will be on only when the compressor is in standby mode, i. e. when the 4.1 COMPRESSED AIR RESERVOIR is supplied with compressed air from the hospital central gas supply. The standby function can be described as follows: 1.With the compressor switched off, connect compressed medical grade air from the hospital central gas supply to the 4.5 COMPRESSED AIR INLET. The gas pressure must be above approx. 300 kPa (3.0 bar).
Disassembling and assembling Compressor Compact Before any compressor cover or the front panel is opened or removed, make sure that the mains power supply is disconnected and that the compressed air reservoir is depressurized. With mains power supply connected to the unit, there are energized electrical components as well as moving mechanical parts inside the equipment.
Compressor Compact Disassembling and assembling Compressor covers Before any compressor cover or the front panel is opened or removed, make sure that the mains power supply is disconnected and that the compressed air reservoir is depressurized. The covers and the casing are secured with hexagonal screws. Use a 5 mm hexagonal wrench when removing or tightening the screws. Front cover 4 • The front cover (1) is secured with two screws (2).
Disassembling and assembling Compressor Compact Transport safety locks To secure the compressor/motor unit and thereby prevent damage during transit of the Compressor Compact or when the Compressor Compact is turned upside down, the unit must be fixed to the base with two transport safety locks. When the transport safety locks are removed, the tension in the vibration dampers is released.
Compressor Compact Disassembling and assembling Internal tubing 1 The couplings used for the internal tubing (nylon tubes) are quick-action couplings. These couplings are used for compressed air tubes as well as for drain water tubes. The tubes must be cut at a right angle and the ends of the tubes must be without burrs. To disconnect a tube • Push in and hold the ring (1). • Pull out the tube (2). COMP037X To connect a tube 2 • Push the tube (2) into the coupling.
Disassembling and assembling Compressor Compact Compressor/motor unit To remove the compressor/motor unit • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. • Disconnect the two tubes (1) at the compressor inlets. • Disconnect the tube (2) at the cooling coil. 3 • Disconnect the motor cables at the electrical interconnection block (4) in the dryer section (see Connection diagram). Loosen the cable sleeve (5) and withdraw the cable.
Compressor Compact Disassembling and assembling Drive belt A drive belt is included in the 8000 hour maintenance kit. When this overhaul is performed, the compressor/motor unit is removed from its mountings and it is therefore suitable to replace the drive belt when the compressor/motor unit has been removed. However, the compressor/motor unit does not have to be removed only to replace the drive belt.
Disassembling and assembling Compressor Compact Belt pulleys To remove the belt pulleys • Remove the compressor/motor unit as described in the section Compressor/motor unit. 1 • Remove the drive belt as described in the section Drive belt. • Remove the two screws (1). • Put one of the screws in the hole (2) and tighten it until the belt pulley loosens from the shaft. To refit the belt pulleys COMP017X • Fit the belt pulley on the shaft and tighten the screws (1) loosely.
Compressor Compact Disassembling and assembling Compressor To disassemble the compressor 8 9 10 11 • Remove the compressor/motor unit as described in the section Compressor/motor unit. 12 • Loosen the four screws (1) and lift off the fan shroud (2). 13 • Disconnect the manifold pipe (3) and remove the rubber seals (4)*. • Disconnect the heat convector (5). 6 14 7 • Using a 3/16" hexagonal wrench, remove the four cylinder head screws (6).
Disassembling and assembling Compressor Compact To assemble the compressor • The procedure for assembling the compressor is the reverse of the disassembling procedure previously described. The following points must be noted during assembling: • Inspect the cylinder, the cylinder head and the piston. If necessary they can be cleaned by using an industrial, non-flammable, nontoxic solvent. Do not use a chlorinated solvent to clean the unit, and do not attempt to flush the unit with liquids.
Compressor Compact 9 11 Disassembling and assembling • There are guide holes in the cylinder head as well as in the gaskets and valve plates. These guide holes show how the various parts must be assembled: – The outlet valve (9) has a diagonal cavity and one guide hole. – The inlet valve (11) has two guide holes. 6 COMP024X E382 EH81E 061 01 03 02 • Tighten the cylinder head screws (6) to a torque of approx. 10.5 Nm ±0.5 Nm (95 lbf in ±5 lbf in).
Disassembling and assembling Compressor Compact Thermoelectric cooler To remove the thermoelectric cooler 3 4 • Disconnect the tubes at the inlet connector (1) and remove the inlet connector. Use a 14 mm open-end wrench. 1 5 2 • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. • Remove the water separator (2) as described in the section Water separator 2. • Remove the two screws (3).
Compressor Compact Disassembling and assembling Water separator 2 To remove water separator 2 6 • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. • Disconnect the water tube (1) from the metal bowl. • Unscrew the metal bowl (2). 7 • Remove the plastic shield (3) and the filter insert (4). Note – The filter insert (4) and the O-ring (5) must be replaced at the 8000 hour overhaul. • Disconnect the air tube (6).
Disassembling and assembling Compressor Compact Filter/solenoid valves To remove the filter/solenoid valves • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. COMP019X 1 2 • Loosen the screw (1) and slide out the filter/solenoid valve unit (2). • Hold the filter/solenoid valve unit while unscrewing the couplings (3). Use a 21 mm open-end wrench.
Compressor Compact Disassembling and assembling Pressure regulator To remove the pressure regulator • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. • At the pressure regulator, pull the control knob (1) out until the snap lock on the knob is released and the control knob can be turned. Note – If the regulator is equipped with a screw (2), first release the screw a couple of turns.
Disassembling and assembling Compressor Compact Fan To remove the fan • Open the front cover and remove the rear cover and the casing as described in the section Compressor covers. 1 COMP031X 3 4 2 • Remove the four screws (1) and (2). Lift off the mounting plate (3). Note – On older versions of the Compressor Compact, the mounting plate is mounted with rivets instead of the screws (2). Use a drill to remove these rivets. • Remove the three screws (4).
Compressor Compact Disassembling and assembling Compressed air reservoir To remove the air reservoir • Refit the transport safety locks as described in section the Transport safety locks. 4 • Turn the Compressor Compact upside down. Note – The compressor must not be turned upside down if the compressor casing is removed. COMP033X • Remove the compressed air outlet nipple (1). • Compressors equipped with standby function: remove the compressed air inlet nipple (2).
Disassembling and assembling Compressor Compact Control section Before any compressor cover or the front panel is opened or removed, make sure that the mains power supply is disconnected and that the compressed air reservoir is depressurized. To disassemble the control section • Remove the six screws (1). 2 1 3 • Lift off the complete front panel (2). 4 • Pull off the test button knob (3) and remove the nut (4).
Compressor Compact Adjustments This adjustment is performed with mains power connected and energized electrical components as well as moving mechanical parts in the Compressor Compact. All personnel must exercise extreme caution when in the vicinity of the unit. Adjustments Pressure regulator • Open the compressor’s front cover to make the pressure regulator accessible. • Connect the test nozzle to the compressed air outlet. • Start the compressor with the on/off switch.
Maintenance Compressor Compact Maintenance General The Compressor Compact must be serviced at regular intervals as follows: • 2000 hour overhaul when replacing filters according to this chapter. • 8000 hour overhaul according to this chapter. The filters that must be replaced during the 2000 hour overhaul are supplied in the Set of filters for Compressor Compact. The 8000 hour overhaul requires disassembly of the Compressor Compact.
Compressor Compact Maintenance Performing the 2000 hour overhaul COMP065X 1. Replace the two dust filters. COMP066X 2. Using a 5 mm hexagonal wrench, unscrew the two screws holding the front cover and open the cover to access the inlet filter. COMP067X 3. Replace the filter located in the compressor inlet filter housing. 4. Close and secure the compressor's front cover. 5. Perform a functional check. See instructions in the Operating Manual, chapter Functional check.
Maintenance Compressor Compact Performing the 8000 hour overhaul 1. Replace inlet and outlet valves, cylinder and head gaskets, piston rings, piston seals and rider rings in the compressor. Also replace the rubber seals in the manifold pipe. See instructions in the chapter Disassembling and assembling, section Compressor. 2. Replace the drive belt. See instructions in the chapter Disassembling and assembling, section Drive belt. 3. Replace the O-ring and filter insert in water separator 2.
Compressor Compact Troubleshooting Troubleshooting Before you start any troubleshooting, begin if possible by questioning the person reporting the fault. Ask how the fault appeared. Make sure that there has been no operating error. For this purpose, see also the chapter Troubleshooting in the Operating Manual. There should be a logical trend to your troubleshooting. First try to trace the faulty function.
Troubleshooting Compressor Compact Malfunction Action The compressor stops; the mains power lamp stays on: • The thermal switch inside the motor may have tripped. 115 V version: The thermal switch on the motor must be reset manually. 230 V version: The thermal switch will reset automatically and the motor will restart. Operating pressure (shown on the manometer) is correct during functional check but drops when a ventilator is connected: • Too high air consumption.
Compressor Compact Troubleshooting Malfunction Action The temperature alarm is activated: • Ambient air temperature is too high. • The compressor’s ventilation holes are blocked. Check cooling air inlets as well as cooling air outlet. • The dust filters are clogged. Clean or replace the filters if necessary. • Check the operation of the fan. Replace it if necessary. • Temperature alarm function faulty. Replace temperature sensor and/or control section PC board if necessary.
Troubleshooting Compressor Compact Malfunction Action Water appears to be leaking from the Compressor Compact: • Inspect all water tubes and connectors. Tighten loose connectors and/or replace damaged components. • Inspect the drainage bottle for leaks or a loose connection. Replace the bottle if necessary. • Inspect filter/water separators and replace them if necessary. • Inspect solenoid valves and replace them if necessary. Water does not accumulate in the drainage bottle at regular intervals.
Compressor Compact Indicator lamps Internal tubing 6 6 12 10 19 Low pressure switch 28 11 21 C Compressed air inlet Compressed air outlet Compressed air reservoir Compressor Compressor covers Compressor section Compressor/motor unit Control section Cooling air outlet Cooling coil Cooling section 10 10 10 6 19 19 19 37 13 29 23 6 12 26 11 20 38 10 19 7 14 7 14 D Drainage bottle Drive belt Drive unit Dryer section Dust filters 8 16 6 8 8 13 14 18 27 8 17 11 20 8 17 E382 EH81E 061 01 03 02 Adjus
ELECTRICAL CONTROL FUNCTIONS RL2 10 11 12 13 14 8 2 3 1 4 9 F3 ON / OFF SWITCH L1 COOLER TEMP. SWITCH (THERMOSTAT) F1 1 2 3 + MAINS POWER INLET N F2 12 V TEMP.
Compressor Compact E382 EH81E 061 01 03 02 ON / OFF SWITCH ELECTRICAL CONTROL FUNCTIONS 1 BNGN 9 BK 4 RDBK GNBK RD 3 - VT WH BU BN BNBK 8 10 2 WHBK CONTROL SECTION N N 10 + + + - - - 12 13 14 1 2 3 5 5 6 - - - THERMOEL. COOLER FILTER / SOLENOID V. FILTER / SOLENOID V. LOW PRESS. SWITCH TEMP. SENSOR P1 COOLER TEMP.
RL1 RL2 10 11 12 13 RL3 14 8 2 3 5 1 9 4 6 7 F3 ON / OFF SWITCH L1 COOLER TEMP. SWITCH (THERMOSTAT) F1 – MAINS POWER INLET N 1 2 3 4 + Circuit and connection diagrams RL4 10 ELECTRICAL CONTROL FUNCTIONS With standby function 50 + 12 V F2 TEMP.
Compressor Compact E382 EH81E 061 01 03 02 ON / OFF SWITCH CONTROL SECTION ELECTRICAL CONTROL FUNCTIONS RL4 10 WHPK BNGN WHBK BK WHGN RDBK GNBK 7 6 BK N N + + + + - - - - - 12 13 14 1 2 3 4 5 5 6 7 7 - - STANDBY SOLENOID V. START RELAY RL4 THERMOEL. COOLER FILTER / SOLENOID V. FILTER / SOLENOID V. STANDBY PRESS. SW. LOW PRESS. SWITCH TEMP. SENSOR P1 COOLER TEMP.
Compressor Compact Block diagram Compressor Compact 5. CONTROL SECTION 5.5 MAINS POWER 5.2 OPERATING TIME METER 0 5.7 STANDBY 5.9 BUZZER 5.4 TEST 5.6 TEMP. 5.8 PRESS. ALARM ALARM l l 5.1 ON/OFF SWITCH 5.3 ELECTRICAL CONTROL FUNCTIONS 2.1 COOLING COIL 2. COOLING SECTION 3.3 3.2 THERMO- WATER ELECTRIC SEPACOOLER RATOR 2 1.1 AIR INLET WITH FILTER 3.1 WATER SEPARATOR 1 1. COMPRESSOR SECTION 1.2 SILENCER 1.3 TEMP. SENSOR FILTER 3.4 SOLENOID VALVE 3.14 FAN FILTER 3.4 SOLENOID VALVE 3.
Compressor Compact – Service Manual Order No.: 60 27 044 EH81E E382 EH81E 061 01 03 02 © Siemens-Elema AB, Electromedical Systems Division, 1993-1999. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior permission of the copyright owner in writing. Subject to alterations without prior notice.
