Siemens Compressor Compact, Service Manual

Page 1: ...Compressor Compact Service Manual E382 EH81E 061 01 03 02 ...

Page 2: ...ssed air at a pressure of 400 kPa 4 0 bar Do not attempt to connect or disconnect the compressed air line or service the compressor section while compressed air is being supplied Do not direct the compressed air line toward the eyes or directly onto unprotected skin surfaces Classification Class I equipment according to IEC 601 1 Type B Functional check After any service intervention in the Compre...

Page 3: ...nsport safety locks 24 Internal tubing 25 Compressor motor unit 26 Drive belt 27 Belt pulleys 28 Compressor 29 Thermoelectric cooler 32 Water separator 2 33 Filter solenoid valves 34 Pressure regulator 35 Fan 36 Compressed air reservoir 37 Control section 38 Page Adjustments 39 Pressure regulator 39 Maintenance 40 General 40 Performing the 2000 hour overhaul 41 Performing the 8000 hour overhaul 42...

Page 4: ...turbance when used during operations The Compressor Compact is fitted with two alarms a temperature alarm that is activated if the compressor should overheat and a pressure alarm that is activated if the air pressure in the compressed air reservoir drops The Compressor Compact is available in a number of versions each adapted to different mains power supply and frequence With the exception of the ...

Page 5: ...a AB 5 Main units The Compressor Compact comprises five main units Compressor section Cooling section Dryer section Air outlet section Control section Introduction Dryer section Cooling section Compressor section Control section Air outlet section COMP001E ...

Page 6: ... two stroke compressor The compressor is powered by the electric motor via the drive unit The tension of the drive belt is automatically adjusted The action of the compressor imparts heat to the compressed air To provide preliminary cooling the air flow is passed through the heat convector before it enters the cooling section The motor compressor and heat convector are cooled by the air stream for...

Page 7: ...eliminary cooling of the compressed air The compres sed air flow suppliedfrom 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 This air stream is then routed to the compressor section Cooling coil COMP003E Introduction ...

Page 8: ... the air temperature is further lowered Moisture that remains in the compressed air is then partly transformed into water by condensation This water is separated from the air in water separator 2 The dried compressed air from the air outlet of water separator 2 is collected in the compressed air reservoir A pressure regulator is connected to the compressed air tubing Air pressure in excess of the ...

Page 9: ...the hospital central gas supply fails the pressure in the reservoir drops This air pressure drop is then detected by the standby pressure switch and the compressor starts to deliver compressed air to the reservoir The electric power supply functions trans former rectifier capacitors etc are located in the dryer section Internal power supply is distributed from the electrical interconnection block ...

Page 10: ...ompressed air reservoir is displayed by the pressure manometer If water for some reason is collected in the compressed air reservoir this water can be removed by pressing the valve pin of the moisture relief valve Compressors equipped with the standby function include a compressed air inlet where the hospital central gas supply medical grade air is connected The cooling air stream that has been fo...

Page 11: ...unning Electrical control functions are located on a PC board in the control section This PC board also contains the timing circuit for the solenoid valves There are three indicator lamps four if the compressor is equipped with the standby function The test button is used to check that the indicator lamps for temperature alarm and pressure alarm light up The audible alarm buzzer is activated toget...

Page 12: ... The temperature alarm is deactivated when the compressor is switched off or when the temperature at the sensor drops below 55 C 6 C 131 F 11 F The temperature alarm function is further described in section 5 6 TEMPERATURE ALARM LAMP 1 4 Motor The Compressor Compact is equipped with a single phase electric MOTOR The motor is designed according to IEC 34 standards There are several different versio...

Page 13: ...mission ratio is approx 1 2 7 for the 60 Hz motor and 1 2 3 for the 50 Hz motor The tension of the drive belt is automatically adjusted by the belt tightener The drive belt must be replaced at the 8000 hour overhaul 1 6 Compressor The COMPRESSOR is an oil free twin cylinder assembly in which the filtered air is compressed by the action of the twin pistons A manifold pipe is connected between the t...

Page 14: ...rmed into water by condensation when passing through the cooling section The water separator is automatically drained at regular intervals by one of the two 3 4 FILTER SOLENOID VALVES and the water is collected in the 3 5 DRAINAGE BOTTLE WATER SEPARATOR 1 in compressors with standby function has a different design see the chapter Introduction Dryer section The function and purpose of this water se...

Page 15: ...een installed in the 115 V 60 Hz version of Compressor Compact with Serial No 20498 20530 The PC board RCD must not be installed in these units as long as the spark arrestor with components mounted onto the cables is installed 3 3 Water separator 2 WATER SEPARATOR 2 is a standard compressed air filter provided to filter the air as well as to separate water from the air This water separator is conn...

Page 16: ...the 4 1 COMPRESSED AIR RESERVOIR The compressor starts to supply compressed air to the reservoir The standby solenoid valve is controlled by the 3 8 STANDBY PRESSURE SWITCH via the 5 3 ELECTRICAL CONTROL FUNCTIONS The standby function is further described in section 5 7 STANDBY LAMP 3 7 Low pressure switch The LOW PRESSURE SWITCH is connected to the 4 1 COMPRESSED AIR RESERVOIR This switch will ac...

Page 17: ...sformer Rectifier with capacitor Start relay compressors with standby function The transformer used in the compressor is a toroid transformer There are two different versions of the transformer one for 115 V mains power supply and one for 230 V mains power supply The output is 12 V and max power consumption is 100 VA for both transformers Transformers with serial number extention 0017 are fitted w...

Page 18: ...s live voltage at the mains power fuses even when the on off switch is in OFF 0 position 3 13 Dust filters There are two DUST FILTERS mounted on the compressor housing These two identical filters are made of a synthetic material They must be regularly inspected and cleaned as described in the Operating Manual chapter Cleaning The filters must be replaced at the 2000 hour overhaul as well as at the...

Page 19: ...sor Compact It provides a simulated load that permits rapid easy checks of the output pressure When testing the Compressor Compact the test nozzle should be connected to this outlet so that compressed air flows through the nozzle Output pressure can then be read off from the pressure manometer The test nozzle permits an air flow that is higher than 40 l min For this reason the air pressure in the ...

Page 20: ...ts for the solenoid valves 1 and 2 including RL2 Standby functions including RL1 and RL3 The test button the indicator lamps and the buzzer are mounted on this PC board 5 4 Test button The purpose of the TEST BUTTON is to make it possible to check the alarm indicator lamps and the audible alarm When this button is held depressed the indicator lamps for temperature alarm and pressure alarm will lig...

Page 21: ... STANDBY PRESSURE SWITCH detects that the pressure in the reservoir drops and stays below approx 300 kPa 3 0 bar for a few seconds The start relay RL4 connects mains power to the compressor motor The compressor starts to work i e the compressor supplies compressed air The 3 6 STANDBY SOLENOID VALVE is automatically set to supply compressed air from the compressor to the 4 1 COM PRESSED AIR RESERVO...

Page 22: ...ds are used on many of the screwed connections Detailed information can be found in the Spare Parts List Old locking and sealing compound must be removed and the threads must be cleaned before any new compound is applied 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 Wi...

Page 23: ...ns 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 The front cover 1 is secured with two screws 2 Rear cover The rear cover 3 is secured with four screws 4 Casing The casing 5 is secured with four screws 6 COMP009X 3 4 5 6 2 ...

Page 24: ...o remove the transport safety locks Open the front cover and remove the rear cover as described in the section Compressor covers Remove the two screws 1 and the screw 2 and lift off the front transport safety lock 3 Remove the two screws 4 and lift off the rear transport safety lock 5 Refit the front and rear covers Do not discard the transport safety locks They must be mounted on the compressor m...

Page 25: ...t 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 To connect a tube Push the tube 2 into the coupling Push the tube forcefully toward the stop inside the coupling Pull the tube to make sure that it is secured to the coupling Mains power cable If the mains power cable is replaced the three conductors must b...

Page 26: ...nnect the tube 2 at the cooling coil 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 Note On older versions of the Compressor Compact disconnect the cable connector 3 Remove the four nuts 6 and lift off the compressor motor unit To refit the compressor motor unit The procedure for ref...

Page 27: ...replace the drive belt To remove the drive belt Open the front cover and remove the rear cover and the casing as described in the section Compressor covers Remove the screw 1 and loosen the screw 2 This will release the torsion spring in the belt tightener Remove roll off the drive belt 3 To refit the drive belt The procedure for refitting the drive belt is the reverse of the removal procedure pre...

Page 28: ...cribed 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 Fit the belt pulley on the shaft and tighten the screws 1 loosely Use a straight edge ruler 3 to check that the two belt pulleys align Tighten the screws 1 gradually and alternately Refit the drive belt and the compressor...

Page 29: ...emove the rubber seals 4 Disconnect the heat convector 5 Using a 3 16 hexagonal wrench remove the four cylinder head screws 6 Remove the Cylinder head 7 Head gasket 8 Outlet valve 9 Valve plate 10 Inlet valve 11 Cylinder gasket 12 Using a 3 16 hexagonal wrench remove the two cylinder screws 13 and lift off the cylinder 14 From the piston remove the Piston rings 15 and 17 Piston seals 16 and 18 Rid...

Page 30: ...s Do not use oil or grease in the compressor When fitting the piston seals piston rings and rider ring make sure that the gaps in these seals and rings are distributed around the piston The gaps must not be in line with each other Check that the piston aligns with the outer edge of the cylinder Refit the cylinder and the cylinder screws 13 Do not tighten the screws Place a straight edge rule 20 ve...

Page 31: ...s 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 Tighten the cylinder head screws 6 to a torque of approx 10 5 Nm 0 5 Nm 95 lbf in 5 lbf in Retighten the screws to the above setting after the compressor has been in operation for about ten minutes 11 9 6 COMP024X ...

Page 32: ...perature switch 4 Lift the thermoelectric cooler 5 carefully until the connector 6 is accessible Note This connector is not included in older versions of the Compressor Compact The thermoelectric cooler cables must then be disconnected at the electrical interconnection block see Connection diagram Disconnect the two cables at connector 6 Lift off the thermoelectric cooler 5 To refit the thermoelec...

Page 33: ...ect the water tube 1 from the metal bowl Unscrew the metal bowl 2 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 Use a 14 mm open end wrench to unscrew the water separator housing 7 To refit water separator 2 The procedure for refitting water separator 2 is the reverse of the removal...

Page 34: ... 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 Note The restriction washers 4 the mesh nets 5 and the plastic rings 6 must be replaced at the 8000 hour overhaul To refit the filter solenoid valves The procedure for refitting the filter solenoid valves is the reverse of the removal p...

Page 35: ...uple of turns Turn the control knob 1 counter clockwise until it stops Unscrew the holder ring 3 Push the regulator 4 backward out through its mounting hole Hold the regulator 4 while unscrewing the complete upper part 5 of the regulator Remove the washer 6 the plastic ring 7 and the diaphragm 8 from the regulator housing Note The diaphragm 8 must be replaced at the 8000 hour overhaul To refit the...

Page 36: ...ivets Remove the three screws 4 Note On older versions of the Compressor Compact there is also a screw 5 that must be removed Loosen the transformer to make this screw accessible Disconnect the fan cables at the electrical interconnection block see Connection diagram Withdraw the cables Lift off the complete fan 6 To refit the fan The procedure for refitting the fan is the reverse of the removal p...

Page 37: ...ote The compressor must not be turned upside down if the compressor casing is removed Remove the compressed air outlet nipple 1 Compressors equipped with standby function remove the compressed air inlet nipple 2 Disconnect the moisture relief valve tube 3 Remove the three clamps 4 Lift off the complete air reservoir 5 To refit the air reservoir The procedure for refitting the air reservoir is the ...

Page 38: ...n Remove the six screws 1 Lift off the complete front panel 2 Pull off the test button knob 3 and remove the nut 4 Grasp the PC board 5 at the PC board connector and pull it up To assemble the control section The procedure for assembling the control section is the reverse of the disassembling procedure previously described After any service intervention in the Compressor Compact perform a Function...

Page 39: ...crease the pressure turn the knob in a clockwise direction To decrease the pressure turn the knob in a counter clockwise direction Push in the control knob until the snap lock on the knob is engaged and the control knob cannot be turned Note If the regulator is equipped with a screw 1 tighten the screw Switch off the compressor with the on off switch and remove the test nozzle Close and secure the...

Page 40: ...eplaced and new parts are supplied in the Maintenance kit for Compressor Compact Inlet and outlet valves cylinder and head gaskets piston rings piston seals and rider rings in the compressor Rubber seals in the manifold pipe Drive belt O ring and filter insert in water separator 2 Restriction washers mesh nets and plastic rings for the filter solenoid valves Pressure regulator diaphragm Air inlet ...

Page 41: ...5 mm hexagonal wrench unscrew the two screws holding the front cover and open the cover to access the inlet filter 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 COMP065X COMP066X COMP067X ...

Page 42: ...ng section Water separator 2 4 Replace the restriction washers mesh nets and plastic rings in the two filter solenoid valves See instructions in the chapter Disassembling and assembling section Filter solenoid valves 5 Replace the pressure regulator diaphragm See instructions in the chapter Disassembling and assembling section Pressure regulator 6 Replace the air inlet filter and the dust filters ...

Page 43: ...to trace the faulty function Then the most suitable procedure is to track down the exact fault by systematically replacing individual parts one at a time Malfunction Action The compressor will not start the mains power lamp does not come on Check the mains power supply and mains fuses Inspect all electrical cables and connectors Tighten loose connectors and or replace damaged components The compre...

Page 44: ... Inspect the internal compressed air tubing Clear obstructions tighten loose connec tors and or replace faulty components The dust filters or the air inlet filter are clogged Clean or replace the filters if necessary Pressure alarm function faulty Replace low pressure switch and or control section PC board if necessary Check the operation of the compressor Overhaul or replace it if necessary The t...

Page 45: ...s of water flush out through the moisture relief valve when the valve pin is depressed Check the operation of water separator 2 and filter soleniod valves Overhaul or replace them if necessary Malfunction in the thermoelectric cooler Check the function of the cooler temp switch as previously described Replace the thermoelectric cooler if necessary The manometer does not indicate the correct operat...

Page 46: ...ary Water does not accumulate in the drainage bottle at regular intervals Drainage is too frequent not frequent enough or does not occur at all Inspect all water tubes and connectors Clear obstructions and or replace faulty components Inspect filter solenoid valves and replace them if necessary Inspect water separator 2 and replace it if necessary Replace the control section PC board Malfunction i...

Page 47: ...onnection 8 17 F Fan 8 18 36 Filter solenoid valves 8 15 34 Fuses 8 18 H Heat convector 6 13 I Indicator lamps 11 Internal tubing 25 L Low pressure switch 8 16 M Mains power cable 25 Mains power lamp 20 Moisture relief valve 10 19 Motor 6 12 O On off switch 11 20 Operating time meter 11 20 P PC board RCD 15 32 Pressure alarm lamp 21 Pressure manometer 10 19 Pressure regulator 8 17 35 39 S Silencer...

Page 48: ...by function M M 10 RL2 8 2 3 1 9 4 1 2 3 5 5 6 F3 12 V N N N F1 F2 10 11 12 13 14 L1 N ON OFF SWITCH ELECTRICAL CONTROL FUNCTIONS LOW PRESSURE SWITCH TEMP SENSOR COOLER TEMP SWITCH THERMOSTAT FAN COMP038E MAINS POWER INLET TEC THERMO ELECTRIC COOLER FILTER SOLENOID VALVES COMPRESSOR MOTOR OPERATING TIME METER ...

Page 49: ... 6 12V L1 N N N N N N L1 N N N N N F1 F2 F3 10 11 12 13 14 8 10 2 3 4 9 10 11 12 13 14 1 2 3 5 5 6 1 RD BK BK BK BK BK YERD YERD YEBK YEBK BNWH BK BU BN BN BU BK 2 BK 1 YE GY BN BU WH VT GY RD BNBK RD GNBK RDBK WHBK BK BNGN BK TIME METER FAN CAPACITOR FAN COMPRESSOR MOTOR TRANSFORMER COOLER TEMP SWITCH THERMOSTAT TEMP SENSOR THERMOEL COOLER FILTER SOLENOID V ON OFF SWITCH CONTROL SECTION ELECTRICA...

Page 50: ...9 6 7 4 1 2 3 4 5 5 6 7 7 F3 N N N F1 F2 10 11 12 13 14 L1 N RL4 ON OFF SWITCH ELECTRICAL CONTROL FUNCTIONS TEMP SENSOR OPERATING TIME METER FAN COMO040E MAINS POWER INLET TEC COMPRESSOR MOTOR STANDBY SOLENOID VALVE FILTER SOLENOID VALVES START RELAY THERMO ELECTRIC COOLER COOLER TEMP SWITCH THERMOSTAT LOW PRESSURE SWITCH STANDBY PRESSURE SWITCH 12 V ...

Page 51: ... 13 14 8 10 2 3 5 4 1 9 6 7 RL4 10 11 12 13 14 1 2 3 4 5 5 6 7 7 BK BK RD BK RD BK BK BK BK BK PKBU PKBU YERD YERD YEBK YEBK BNWH VT WHRD WHRD BN BU WH ON OFF SWITCH CONTROL SECTION ELECTRICAL CONTROL FUNCTIONS COMP041E MAINS POWER INLET COOLER TEMP SWITCH THERMOSTAT RD or BNWH P2 P1 GY RD BNBK RD GNBK RDBK WHBK BK BNGN BK WHGN WHPK TEMP SENSOR THERMOEL COOLER FILTER SOLENOID V FILTER SOLENOID V L...

Page 52: ...RATOR 2 3 1 WATER SEPA RATOR 1 3 14 FAN 3 DRYER SECTION 3 10 ELECTRIC POWER SUPPLY 3 11 ELECTRICAL INTER CONNECTION 3 12 FUSES 3 7 LOW PRESS SWITCH 3 8 STANDBY PRESS SWITCH 3 2 THERMO ELECTRIC COOLER FILTER SOLE NOID VALVE 1 COMPRESSOR SECTION 1 2 SILENCER 1 3 TEMP SENSOR 1 6 COMPRESSOR 1 4 MOTOR 1 5 DRIVE UNIT 1 7 HEAT CONVECTOR 4 2 PRESS MANO METER 4 6 COOLING AIR OUTLET 4 5 COMPRESSED AIR INLET...

Page 53: ...s electronic mechanical photocopying recording or otherwise without the prior permission of the copyright owner in writing Subject to alterations without prior notice Issued by Siemens Elema AB Electromedical Systems Division SE 171 95 SOLNA Sweden Compressor Compact Service Manual Order No 60 27 044 EH81E E382 EH81E 061 01 03 02 Printed in Sweden TK 81 TU 0699 0 7 3rd English edition June 1999 ...