Q50 Technical Service Manual
Contents
1. VAPOTHERM Q50 Compressor Technical Service Manual 3100792 Revision A This document contains proprietary information to Vapotherm Corporation and its receipt or possession does not convey any rights to reproduce its content or to manufacture or sell any product described Reproduction disclosure or use other than for the intended purpose without specific written authorization of Vapotherm Corporation is strictly forbidden This Technical Service Manual is subject to change without notification Revision Change Record REVISION ECO Important Safety Information This manual is subject to periodic review update and revision Always obtain and consult the latest revision before undertaking any service of the equipment Before performing any service on the Q50 Compressor read and review this entire manual After performing any service or repair always perform the operational checkout in Section 8 of this manual All tests must pass before unit can be put back in service Always disconnect the electrical power before performing service or maintenance procedures detailed in this manual Genuine replacement parts manufactured or sold by Vapotherm must be used for all repairs Technical Competence The procedures described in this service manual should only be performed by competent individuals who have a general knowledge of and experience with devices of this nature No repairs should ever be undertaken or attempted by anyone not h2. 3 4 3 Environmental Requirements cccccscccccsssecccseseeeceesececceseeeseuseeessaeeeeseuseeessuseeessageeessaeeesseuseessseseneess 4 4 4 4 Life Expectancy Of COMPSeSSOM cceeccecccececeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeaeeaeeeeeeeeeeseaaadeeeeeesesseaaseeeeeeeeesaaaaeees 4 5 5 Preyentative Maintenant C wincsteiacncaadtiedeiameneccuvamiodeannenaaa a a a 5 1 51 4000 Four PM Procedure ecenin iE ERR AEn EEEa AEREN AEAEE 5 1 5 1 1 Replace the Air Intake Muffler IFU refers this as Suction filter 00000nnnnnnnnnnnnnnnnssennnnnnnnnnnneeeeees 5 1 5 1 2 Replace the filter in the Auto draining Air Filter cccccccsesecccseeeeeseeseeeceeseeeeeeeeeeseeseesseaneeessaeees 5 2 5 2 8000 Hour PM Procedure cccccccccsseeccceceeeeeeeeeceeeseeeeeeeeeeeeeeeseeeeeeeeseeeeeeeeesseeeeeeeeeseeeeeeessaaeeeeessageeeesenas 5 3 5 2 1 Servicing the Compressor Molol eissira E E N EE 5 4 B22 FAC AS SOTO e E E E E E E A E E 5 15 5 2 3 Electrical Analyzer Testing scmcvenastiuiaceccbudasieeinaadunsnenastsimertcusde lt dasiuasnadhientaanasiubibonedendtotesuueandadensbecaeees 5 15 5 2 4 Hi Pot Safety Testing tensa avercuinnenncasunsmtend inet essa desumtadeneneaoncnnmendinseauinenncatmmanassanintaadiouaaratnunteciannsted 5 15 9 2 9 Replacing the Air MARS FINE isre nr EE E AEE E R 5 15 52 Os Se Repa omeni senenin E abyibincrmissnal minced uimanesesns 5 17 Os ORCS TING N Ue E E EE N E E E E E E E E E E E 5 18 F Eang AnaS ANC NO iceri E EEE I
3. E E E 7 1 VETOO e E E E E E ER 7 1 T2 Ar Wet FNE en EE E EEEE 7 1 Or Troupleshooung GUJE sissen a EEE E E EEE ESE EEE 8 1 9 Operational CHECKIStassicccsssederdtasiasiotesaesdiersatedeattedsibbasdus intasessinnensdateadiebstbbaddus fatabanetitasudiietdiatetbiniddsiadataneinaals 9 1 LTE ANG UII CIN eee en ehecdeus freak cuce late waequcaunctatsqen code E E E seam 10 1 For further information contact Vapotherm Inc 22 Industrial Drive Exeter NH 03833 USA Phone 603 658 0011 Fax 603 658 0181 www vtherm com May be patented www vtherm com patents Q50 Technical Service Manual 3100792 RevA Section 1 Introduction 1 Introduction The Vapotherm Q50 air compressor supplies air up to 35L min in order to support use of the Vapotherm Precision Flow system in the absence of wall or tank supplied air The compressor was designed to be mounted on a Precision Flow Roll Stand or placed directly on a flat level floor The low profile footprint light weight and pole mounting capability allow for multiple use configurations and modes of transport The Vapotherm Q50 Air Compressor is designed for use only with the Vapotherm Precision Flow system The compressor is intended to supplement the air needs of the Precision Flow in the event that wall or tank air is not available It is for institutional use only It is not intended for home use GENERAL WARNING Federal law US restricts the sales of this device to or on the order of any ph
4. foam insert while feeding the three hoses up through their appropriate openings d Ensure the capacitor is aligned with the capacitor opening and the fan is aligned with the fan slot Ensure the elbow and tubing for the water drain are also in their channels Pull the blue water drain tube through the foam insert opening where the heat exchange coil is visible The two sides should now fit together with minimal gap Reconnect hoses Connect the blue water drain hose to the Auto Drain Filter Reinsert the straight gray fitting into the push to connect fitting on the cooling coil Pull gently on the braided tube to ensure a good connection Reconnect the other end of the 3 8 rigid tubing to the Auto Drain filter and pull gently to ensure a good connection Insert the 3 8 tubing into the foam tubing constraints Insert the barbed T into the 3 8 braided tube at the compressor inlet Replacing the Housing Bottom 6 5 13 Gather the compressor and fan wires and tuck them into the Wago terminal block space on the foam insert to prevent from damaging them while sliding the housing back on While the foam insert is elevated on the supports carefully slide the housing bottom back onto the foam insert Q50 Technical Service Manual 3100792 Rev A Section 5 Preventative Maintenance 8 Reconnect the Ground Wire a Reinstall the star washer on the ground stud then install the compressor ground wire and t
5. intake filter in the back of the unit should be removed weekly and cleaned Brush gross dust particles off the surface of the filter Submerge filter in warm soapy water and gently squeeze and massage the filter to flush any dust particles from the interior Air dry Replace the filter making sure that it is completely tucked into the opening and there are no gaps around the filter This procedure will help to assure the product s performance and service life by allowing the maximum amount of clean dust free air to be available for cooling the compressor motor Q50 Technical Service Manual 3100792 RevA Section 8 Operational Checklist Check V if VAPOTHERM Q50 COMPRESSOR complete amp Pre Use Operational Checklist performance is acceptable Unit Serial If performing the pre operational checkout with access to a Precision Flow unit and Disposable Patient Circuit 1 1 Affix a Precision Flow unit to an IV pole or test rack Install a High Flow Disposable Patient Circuit DPC in the Precision Flow See the Precision Flow Instructions for Use Manual Section 7 5 for additional information 1 2 Attach a sterile water bag to the spiked tube of the DPC and unclamp the spike tube clamp to allow the DPC to fill with water The Water Out Icon may blink until the DPC has completely illed with water 1 3 Ensure that the air inlet gas filter assembly with hose attached is installed in the air inlet port on the rear of the
6. 92 Rev A 5 1 Section 5 Preventative Maintenance 5 Preventative Maintenance 5 1 4000 Hour PM Procedure The 4000 hours preventive maintenance procedure includes the following e Replacing the air intake muffler e Replacing the filter in the auto draining air filter e Replacing the air intake filter Note Before you begin read these instructions thoroughly and assemble the necessary tools Tools required e 1 8 Allen wrench e 3 16 Allen wrench to remove the pole clamp if needed a manual set of Allen wrenches is recommended to prevent the threads from stripping A WARNING Unplug the compressor before beginning disassembly 1 Remove 18 screws from the housing top with 1 8 Allen wrench 9 per side If you are unable to access the screw under the pole mount remove the pole mount with a 3 16 Allen wrench first 2 Remove the housing top 5 1 1 Replace the Air Intake Muffler 3 Locate the Air Intake Muffler on the intake side of the compressor 4 Grasp the tubing near the Air Intake Muffler and the Air Intake Muffler and pull the tubing away from the foam insert Tubing Constraints Q50 Technical Service Manual 3100792 RevA 5 6 7 5 1 2 Replace the filter in the Auto draining Air Filter 8 10 Ti 12 13 14 15 5 2 Section 5 Preventative Maintenance Remove the Air Intake Muffler from the tubing Replace with a new Air Intake Muffler Reseat the tubing in the tubing c
7. CAUTION Place capacitor off to side leaving it connected to lead wires Q50 Technical Service Manual 3100792 Rev A 12 13 14 15 Section 5 Preventative Maintenance Carefully remove the valve plates 4 from the bottom of the head or cylinder sleeves Note orientation with respect to the tab on valve plate for reassembly See Figure 1 Remove the head gasket O rings 3 and discard them Turn the valve plates over Remove the valve plate O rings 5 and discard them See Figure 2 plate indicates Note Number 4 Valve plate orientation is a exhaust side representation note which valve flapper orientation you have Remove the intake valve flapper 1 restraint 2 keeper 3 if assembled and screw from the bottom of the valve plate and discard Clean the bottom of the plate with a clean soft cloth Install the new intake valve flapper and restraint if one was removed The valve keeper should be placed on top of the flapper so that the word UP is visible See Figure 2 Note Pay close attention to valve assembly Some parts in kit may not be for your model Note Torque new flapper screw to 18 inch pounds Install the new O ring seating it firmly into the groove with your finger or blunt object See Figure 2 O Ring Groove Q50 Technical Service Manual 3100792 RevA 16 17 18 19 Insert the 5 32 Hex wrench into the access hole in the 5 10 Section 5 Preventati
8. Intake Filter and water bottle Replace the housing top a Extend the black foam side while replacing to prevent damage to the internal components b Ensure the insulated foam is facing the exhaust side of the compressor the side with no components c Ensure the top edges of the housing extend over the front and back ends of the compressor housing base this will prevent water ingress to the unit and also facilitate alignment of the screws 20 Reattach the screws with Allen wrenches power driver not recommended due to potential damage to the threads 5 2 3 Electrical Analyzer Testing 21 22 23 24 5 15 On your electrical safety analyzer press the Omega Q button to prepare for the Ground Wire Resistance Measurement Attach the plug end of the Red test lead to V Q A jack Connect the red probe to the Null jack Press the F4 softkey labeled Zero Leads This zeroes out the measurement to cancel the test lead resistance Connect a power cord between the Electrical Safety Analyzer and the Q50 compressor Toggle the Q50 power switch to the On position Q50 Technical Service Manual 3100792 RevA 25 26 27 28 29 30 31 Section 5 Preventative Maintenance With the test lead still plugged into the V Q A jack firmly hold the test lead tip to the housing screw closest to the power inlet To ensure proper electrical contact apply considerable pressure to the probe Co
9. Precision Flow unit 1 12 Turn off the Q50 compressor by toggling the power inlet switch above the power cable on the back of the Q50 If performing the pre operational checklist without access to a Precision Flow 2 3 Turn on the Q50 compressor by toggling the power inlet switch above the power cable on the back of the Q50 8 1 Q50 Technical Service Manual 3100792 RevA Section 8 Operational Checklist 2 4 Verify that compressed air is output from the DISS fitting on the back of the Q50 compressor 2 5 Turn off the Q50 compressor by toggling the power inlet switch above the power cable on the back of the Q50 2 6 Disconnect the power cord from AC power 2 7 Disconnect the power cord from the rear of the Q50 compressor 8 2 Q50 Technical Service Manual 3100792 RevA 9 Troubleshooting Guide Section 9 Troubleshooting Possible Cause No air output Power inlet switch is on but there is no audible noise Power cord is connected to a functioning power outlet but there is no audible noise The fuse failed repeatedly after being replaced Power cord is connected to a functioning power outlet and there is an audible click inside the compressor but no other noise The cooling fan is running but not the compressor The cooling fan is running but not the compressor even when the compressor is cool Power cord is not connected or connected to a faulty outlet The fuse is blown The soft start
10. aving such qualifications y Use a static strap and or a static control work station to ensure that static charges are safely conducted to ground and not through static sensitive devices Whenever this Electrostatic Aviad Discharge ESD symbol appears beside a procedure follow appropriate static control precautions Q50 Technical Service Manual 3100792 RevA Limited Warranty Vapotherm expressly warrants for a period of one 1 year from the date of shipment by Vapotherm to the initial purchaser of the Q50 device Customer that the Q50 device shall meet the specifications set forth in the applicable official operating instructions for use provided with each Q50 device the Instructions The sole remedy for this warranty is that Vapotherm shall at its sole option either refund repair or replace any part or all of any Q50 device that is defective at no cost to the Customer Vapotherm shall pay any shipping charges required in repairing or replacing any part or all of a Q50 device provided that such Q50 device is shipped back to Vapotherm within three 3 months of the date the Q50 device was originally shipped to the Customer Thereafter shipping charges shall be paid by the Customer Customer shall also be responsible for the cost of labor for repairs The warranty set forth herein shall become null and void if 1 the Q50 device is not used or serviced in accordance with the applicable Instructions or any related preventative
11. edge of the sleeve locates in the O ring groove in the bottom of the valve plate l CAUTION Make sure gasket is not twisted when seated in groove 28 Place head on the valve plates making sure that the same letter orientation is as was before disassembly Torque the head screws to 55 Inch pounds in a crisscross pattern CAUTION To avoid property damage or personal injury always try rotating the fan by HAND prior to connecting the unit to the power source Check for suction at the air inlet port by placing your finger over the port as you turn the fan You should feel a slight suction with each rotation of the fan If you don t feel suction or if you feel or hear a thump as you turn the fan DO NOT CONNECT THE UNIT TO A POWER SOURCE review the assembly procedure for possible error Numbers indicate tightening sequence for Head Assembly KO ld ay E aly Power Leads 5 2 2 Reassembly Cooling Fan Installation 1 Make sure the Air Flow arrow is pointing up away from the compressor motor a Reconnect blue water drain hose leading to water bottle if it becomes detached from the connectors 2 Place the compressor motor in the bottom foam insert with the tubes and wires facing up 5 12 Q50 Technical Service Manual 3100792 RevA 5 Section 5 Preventative Maintenance Ensure the wires are inserted into the wire channels of the foam insert using a spline insertion tool or similar blunt tool Replace the top
12. he other star washer on the ground stud b Reattach the nut onto the ground stud c Tighten with 11 32 socket wrench 9 Reconnect the brown compressor wire and white shrink wrapped fan wire to the appropriate Wago Terminal Block Set the orange tabs to the closed position and gently pull on the wires to ensure a firm connection 10 Reconnect the blue compressor wire and black fan wire to the other Wago Terminal Block Set the orange tabs to the closed position and gently pull on the wires to ensure a firm connection 11 Insert the Wago Terminal Blocks back into the space in the foam insert one over the other 12 Slide the foam inserts completely into the housing bottom and stand up the compressor Reconnect the through wall connector 5 14 Q50 Technical Service Manual 3100792 RevA 13 14 15 16 17 18 19 Section 5 Preventative Maintenance Wrap Teflon tape twice around the threads of the exposed metal pipe Install the nut and washer onto the exposed metal pipe Insert the through wall connector through the hole in the housing bottom and thread onto the exposed metal pipe Tighten the through wall connector with a 7 8 wrench while holding the regulator to prevent rotation until the through wall connector has contact with the housing base Slide the tooth washer over the threads on the inside of the housing base and tighten the nut using a 7 8 wrench Reinstall the Air
13. ied The red light on the tester flashes to indicate that high voltage is being applied The test will proceed automatically Hold the high voltage probe in the LINE socket until the tester completes the test sequence the red light will stop flashing 38 When the test is complete record the current and the Pass Fail status from the Hi Pot tester display Press the red Stop button to reset the display 39 Connect the high voltage connector to the power cord neutral terminal 40 Press the green start button to start the test AN warnine High Voltage is now being applied The red light on the tester flashes to indicate that high voltage is being applied The test will proceed automatically Hold the high voltage probe in the LINE socket until the tester completes the test sequence the red light will stop flashing 41 When the test is complete record the current and the Pass Fail status from the Hi Pot tester display 42 Press the red Stop button to reset the display 43 This concludes the Hi Pot testing and the Q50 compressor power cord can be disconnected and the power switch toggled off 5 2 5 Replacing the Air Intake Filter The air intake filter can be removed easily When replacing with a A new filter ensure all corners are tucked in and there are no gaps around the filter 5 2 6 Fuse Replacement 5 17 Q50 Technical Service Manual 3100792 Rev A Section 5 Preventative Maintenance Fuses need to be replaced
14. ion 1 Output Pressure The output pressure is 35 40 psi 2 Flow 0 35 L min 3 Safety Pressure The compressor will recirculate pressures in excess 75 psi through of Air Path a feedback loop 4 Air Tightness The compressor shall not bleed any quantity of air that would otherwise impact full therapy at 35 L min 5 Pressure Rise A pressure of 35 psi will be reached within 30 seconds of the Time compressor being turned on 6 Noise The noise level is 54 dBA on average 7 Electrical Safety Electrical Safety Meets requirements as defined by IEC 60601 1 medical electrical equipment Part 1 general safety requirement Results obtained as follows The average sound level measure 1m from the front of the unit at height of 1m in an anechoic chamber is 54 dB A 4 3 Environmental Requirements Temperature Relative Humidity Operation 18 30 C 10 90 Storage 10 50 C 20 90 f CAUTION If the storage conditions are outside of the stated operating range the Q50 Compressor must be acclimated to the operating environment for a minimum of 8 hours prior to use 41 Q50 Technical Service Manual 3100792 RV Section 4 Specifications 4 4 Life Expectancy of Compressor 4 2 The average life expectancy will be 20 000 hours based upon operating conditions and with maintenance being performed as outlined on page 5 1 Dimensions and Weight Dimensions 20 5in L X19in H X9in W Weight 44lbs Q50 Technical Service Manual 31007
15. ir inlets are not blocked Call for service 3100792 RevA Section 10 Tools amp Equipment 10 Tools amp Equipment Tools include the following e Torx Drivers T 20 T 15 T 10 e Small blade flat head screw driver set e Small Philips screw driver set e Diagonal Cutters e Socket for encoder 11mm e 7 8 wrench e Flat head screwdriver e 11 32 socket e nut driver e Teflon tape e Spline insertion tool e 1 4 Hex Socket attachment for torque wrench e Torx T 20 attachment for torque wrench for retainer screws e Torx T 25 attachment for torque wrench for head screws e 5 32 Hex wrench for torque wrench eccentric screw e Clean Cloths e Allen wrench set a manual set of Allen wrenches is recommended to prevent the threads from stripping Equipment e Electrical Safety Analyzer e Hi Pot tester 10 1 Q50 Technical Service Manual 3100792 RevA For Questions and Further Assistance Please Contact Vapotherm Technical Support Phone 1 855 557 8276 Email ts vtherm com Q50 Technical Service Manual 3100792 RevA
16. itch and Fuse Drawer mo Figure 2 3 1 Q50 Technical Service Manual 3100792 Rev A Section 3 Functional Description Power Inlet Switch The Vapotherm Q50 compressor makes use of a medical grade power inlet switch The power inlet switch contains two 2 fuses e 5ET8 R 5mm X 20mm 8A SLOW BLOW GLASS FUSE 250V A WARNING To avoid risk of electric shock this equipment must only be connected to supply mains with protective earth Air Intake The compressor utilizes air from its surrounding environment It passes through multiple stages of filtration prior to delivery to the Precision Flow The first filtration stage is accessible from the outside and should be cleaned one per week according to maintenance procedures below A WARNING Never restrict or block the air intake This could result in failure to deliver therapy as intended Air Outlet The air exiting the Q50 compressor is to be used only in conjunction with the Vapotherm Precision Flow system The compressor output is designed to match the performance needs of the Precision Flow and as such has no user adjustable settings or gauges AN WARNING The Q50 Compressor is only to be used with the Vapotherm Precision Flow system 3 2 Q50 Technical Service Manual 3100792 Rev A Section 4 Specifications 4 Specifications 4 1 Main Specifications e Power Supply 115V 10 60Hz e Continuous Flow 0 35 e Input Power lt 600VA 4 2 Performance No Item Descript
17. maintenance instructions provided with the Q50 device or 2 repairs or service are performed or attempted on the Q50 device by anyone other than Vapotherm or a Vapotherm certified service center EXCEPT AS EXPRESSLY SET FORTH ABOVE VAPOTHERM MAKES NO WARRANTY EXPRESS IMPLIED STATUTORY OR OTHERWISE WITH RESPECT TO THE PRODUCTS OR ANY OTHER ITEMS PROVIDED BY VAPOTHERM OR OTHERWISE IN CONNECTION WITH THIS AGREEMENT AND HEREBY EXPRESSLY DISCLAIMS ANY OTHER FORM OF WARRANTY INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THIS STATED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES PROVIDED BY LAW ii Q50 Technical Service Manual 3100792 RevA TABLE OF CONTENTS Important Safety Information ccccccccsscececccssseseecesssuseeessaueuseeessaaeeeeeessaaeeeeessaaeseeesssauuaeeesssaaaaeeessaauaaeeessaaaensesssaaaass i Toennicar Compo ONGO creeren a na E E nian cidsetbatachndonuadsuca i PMV Wamran spree eae cestterrasettrecn ea ni a EEEE EEEE ENEE EEA EEEE ENE EE EEEE ENEE EA EEEE EA EEE EIEEE E A EENE EEA ii Te AOOO aieea EE E E EEEE eee EE E EEE E E ee es 1 1 2 Principles Ol OPEraON cussies E aE 1 1 3 Functional Description cece ceeecccceeeeeeeceeseeecaeeeeeaaeeeeeseaeeeessaeeesseeeeeessaseeeseaaeeesseeeeeseaeeeessadeeessaueeeesaaeesessags 1 1 A SOC CMO ANOS a a E E E E E O E 4 1 A MANMODE CAO NS resa EEEE E oes EE A EENE 4 2 EO FN ANG E eroras EE rE aR EE a E EEE E as 4
18. nfirm that the Ground Wire Resistance measurement is less than 0 20 Ohms Remove the red E oo probe from the housing top screw This concludes the Ground Cord Resistance Measurement test Press the microAmp uA button to select the units to be used for the Ground Leakage Current test Press the F1 softkey labeled Earth on the screen above the softkey Press the Polarity button until Normal appears on the screen Press the Neutral button until Open appears on the screen Confirm that the Ground Leakage Current Normal Open measurement is less than 500 pA 5 2 4 Hi Pot Safety Testing 32 33 34 35 36 37 5 16 Confirm that the Hi Pot Tester is plugged in and turned on Confirm that the tester is set to the following AC test Voltage 1 800 kV High Current 10 00 mA Test Time 5 seconds Low Current OFF ARC 10 00 mA Ramp Time 5 0 seconds Fall Time 5 0 seconds Verify that the black ground lead and the red high voltage probe are connected to the Hi Pot tester Plug the power cord into the Q50 compressor Toggle the Q50 power switch to the On position Connect the Hi Pot ground wire to the power cord Ground and connect the high voltage connector to the power cord line terminal Press the green start button to start the test Q50 Technical Service Manual 3100792 RevA Section 5 Preventative Maintenance N warnine High Voltage is now being appl
19. only when blown The mains fuses 5ET 8 R 5mm X 20mm 8A SLOW BLOW GLASS FUSE 250V are located next to the power cord inlet Use two small flat blade screwdrivers to push the release clips on either end of the fuse block toward each other and release the fuse block to access the fuses 6 Ordering PM parts Parts are availiable by contacting Vapotherm Total Customer Care Phone 603 658 4899 Email cs vtherm com 5 18 Q50 Technical Service Manual 3100792 RevA Section 7 Cleaning and Disinfection 7 Cleaning and disinfection 7 1 Exterior and Water Bottle 1 Use a warm water and soap solution to wipe the exterior if needed Use clean warm water to remove residual residue Do not allow liquids to infiltrate beyond the exterior surfaces of the compressor or into any electrical interfaces or components Rince the water bottle reservoir with warm soapy water after emptying the water bottle reservoir and between patient uses Confirm rinsing of the water bottle reservoir to remove soap residue Disinfect according to institution policy only with chemicals that do not contain or produce volatile organic compounds VOCs and are non corrosive The following agents were tested and confirmed to have no adverse effects on the compressor e Solution of 6 Chlorine Solution of 15 hydrogen peroxide Solution of 90 isopropyl alcohol Water Dry Kim Wipes SaniCloth AF3 Germicidal Wipes Cavi Wipes 7 2 Air Intake Filter 7 1 The air
20. onstraints Disconnect the blue water drain tubing push in on the connector to release the tubing Disconnect the clear tubes push in on the connector to release the tubing on either side of the Auto draining Air Filter Grasp the Auto draining Air Filter by the bowl and pull away from the constraints Unscrew the polycarbonate bowl 1 4 turn to the left Note the lock and unlock markings on the bowl Slide the bowl off the filter assembly Unscrew the white plastic wheel and remove the filter from the assembly Replace the white filter ensuring the larger diameter end is inserted on to the post first filter will not seat firmly if the smaller diameter end is installed first Screw on the white plastic wheel on to the filter assembly Q50 Technical Service Manual 3100792 Rev A Section 5 Preventative Maintenance 16 Reattach the polycarbonate bowl to the assembly 17 Reattach the tubing coming from the Relief Valve to the filter assembly 18 Reseat the filter assembly into the foam constraints 19 Reattach the remaining tubing Ensure all tubing is firmly connected to prevent air leakage and potential loss of air pressure Filter 20 Replace the housing top a Extend the black foam side while replacing to prevent damage to the internal components b Ensure the insulated foam is facing the exhaust side of the compressor the side with no components c Ensure the top edges of the housing e
21. rew Clean Cloths Electrical Safety Analyzer Hi Pot tester Allen wrench set a manual set of Allen wrenches is recommended to prevent the threads from stripping A WARNING Unplug the compressor before beginning disassembly 5 2 1 Servicing the Compressor Motor 5 4 Remove 18 screws from the housing top with 1 8 Allen wrench 9 per side If unable to access the screw under the pole mount remove the pole mount with a 3 16 Allen wrench first Save these screws Remove the housing top Q50 Technical Service Manual 3100792 Rev A Section 5 Preventative Maintenance 3 Remove the through wall connector bulkhead fitting from the air outlet port a Loosen and then completely removing the nut on the inside of the housing by the regulator using two 7 8 wrenches one on the inside of the housing and one to hold the nut on the exterior e b Slide the nut and washer off the fitting and onto the exposed metal pipe c Loosen and remove the through wall connector by unscrewing the exterior nut This will disconnect the exposed metal pipe from either the regulator side or the through wall connector side 4 Remove the compressor from the base housing a Lay the compressor on its side with the components facing up Place foam or other equivalent supports to elevate the housing bottom from the bench b Using a flathead screwdriver pry out the two Wago Terminal Blocks from the foam insert one is underneath
22. the other c Carefully pull the base housing away from the compressor insert until there is approximately a 2 3 gap 5 5 Q50 Technical Service Manual 3100792 RevA Section 5 Preventative Maintenance d Using an 11 32 socket remove the top nut and star washer a N from the ground post to disconnect the compressor ground wire from the housing bottom e Disconnect the brown wire from compressor and the black wire with white shrink wrap from fan from one of the Wago Terminal Blocks by lifting the corresponding orange tabs to an upright position f From the second Wago Terminal Block disconnect the blue wire from compressor and the black wire from fan by lifting the corresponding orange tabs to an upright position g At this point the compressor insert is no longer connected to the housing bottom and the Wago Terminal Blocks should still have two connections each power inlet and hour meter h Slide the housing bottom away from the compressor insert 5 Set the Air Intake Filter and water bottle aside 6 Disconnect the hose connections a Disconnect the tubing from the right side of the Auto Drain Filter b Disconnect the other end of this same tubing from the outlet side of the cooling coil c Disconnect the braided hose from the barbed T junction 5 6 Q50 Technical Service Manual 3100792 RevA Section 5 Preventative Maintenance d Using a flathead screwdriver disconnect the s
23. top of the connecting rod and retainer with a clean damp cloth Carefully place new cylinder sleeve 1 over connecting rod top with the machine rabbit up Carefully pull the cylinder sleeve up forming the cup Rotate the rotor shaft so that flat faces up 12 00 Position piston cup at bottom dead center of cylinder sleeve Slide the connecting rod assembly onto the shaft until the eccentric face positively stops against the bearing Align the eccentric setscrew with the flat of the shaft Rotate the eccentric and shaft 90 degrees so the set screw is visible through the access hole in the housing and tighten set screw to 125 Inch pounds Align the flat on the fan with the flat on the motor shaft and slide the fan back onto the motor shaft making sure you position the fan clip in the same orientation as it was before you removed it Incorrect orientation of the fan will not provide adequate cooling of the compressor Q50 Technical Service Manual 3100792 Rev A Section 5 Preventative Maintenance 26 Hold the sleeve down against the housing with one hand and slowly rotate the fan with the other hand to ensure all components are lined up properly As the piston travels up and down it will also rock from side to side This is a feature of the WOB L Piston Repeat steps on the other side of compressor 27 With the sleeves firmly seated on the housing replace the valve plates in same manner as they were Make sure the top
24. traight gray fitting attached to the braided hose from the push to connect fitting on the heat exchange coil e Pull the straight gray fitting from the push to connect fitting f Disconnect the blue water drain hose from the Auto Drain filter 7 Carefully lift the top half of the foam insert away from the compressor a If necessary remove the capacitor and the fan from the top foam insert and place them in their locations on the bottom insert 8 Remove the compressor motor from the insert l CAUTION Improper assembly or use of damaged parts may lead to premature failure To avoid frequent repairs follow the recommended assembly procedures 5 7 Q50 Technical Service Manual 3100792 Rev A 5 8 Section 5 Preventative Maintenance 9 Open the Compressor Service Kit SK2668 10 11 This kit includes the following parts LSD 1 tead Screw 8 Head Gasket 2 _ O Ring 2 Flapper Screw 4 9 C gt 7 Piston Cup 2 vane Keeper 4 e o l Tapered up or tapered D NN down note which style Valve Backer 4 _ you have in disassembly instructions Valve Flapper 4 f __ Cylinder Sleeve 2 Screw Piston Cup 2 Note To avoid confusion service one end of the compressor at a time Clean loose dirt from the outside of the compressor Loosen the 8 head screws 1 and remove the compressor head 2 Note orientation of head for reassembly very important Discard head screws
25. valve has failed The cooling fan has failed possibly causing the compressor to overheat or fail Compressor has overheated The compressor has failed Connect power cord and ensure that the outlet is functioning Replace fuse with 250V 8A slow blow fuse Part number 3100727 Call for service Call for service Ensure that the air intake filter is clean and not obstructed Allow compressor to cool for 20 30 minutes and attempt to restart Call for service The compressor and The air pipeline is not Tighten the fittings cooling fan are running tightened properly The air pipeline hose is OK and the exhaust noise can be heard inside the machine Air output is low causing PF to alarm There is condensation in the PF water trap 9 1 Insufficient pressure Insufficient pressure Pipeline inside has disconnected Internal pressure regulator below recommended operating levels Internal pressure gauge below recommended operating levels Q50 Technical Service Manual Call for service Call for service Call for service 3100792 RevA 9 2 There is condensation in the PF water trap cont Airflow is blocked Air inlet or exhaust are blocked or air filter needs cleaning Cooling fan is not The fan has failed operating no airflow from exhaust port on bottom of compressor Q50 Technical Service Manual Section 9 Troubleshooting Clean air filter and ensure that the a
26. ve Maintenance Remove the exhaust valve flapper 1 restraint 2 and valve keeper 3 from the top of the valve plate and discard them Clean the top of the plate with a clean soft cloth Install the new exhaust valve flapper restraint and keeper The valve keeper should be placed on top of the flapper so that the word UP is visible See Figure 3 Note Torque flapper screw to 18 Inch pounds Install the new head gasket seating it firmly into the groove with your finger or blunt object See Figure 3 Set aside Repeat steps 13 through 16 to service other end of compressor Remove the fan by using two flat blade screwdrivers to pry off making sure screwdriver contact is made with hub back and not the fan blades Note fan orientation and color for reassembly Eccentric Set Screw compressor housing Loosen the set screw 1 4 turn Rotate Access connecting rod to top dead center 180 and slide the connecting rod eccentric assembly off the shaft and through the opening in the housing Q50 Technical Service Manual 3100792 RevA 20 21 22 23 24 25 Section 5 Preventative Maintenance Secure the rod assembly in a fixture Remove the sleeve 1 Discard from the connecting rod Remove the screw 2 Discard from the cup retainer 3 Retain for reassembly Note Read before proceeding with the following disassembly instructions Remove the piston cup 4 Discard and wipe debris from the
27. xtend over the front and back ends of the compressor base this will prevent water ingress to the unit and also facilitate alignment of the screws 21 Reattach the screws with Allen wrenches Power driver not recommended due to potential damage to the threads 22 Connect the compressor to a PF unit and run the PF unit at 35 at 21 FiO2 for 5 minutes to confirm the is functional and able to maintain flow 5 1 3 Replace the Air Intake Filter 23 Locate the Air Intake Filter on the back of the compressor and remove from the compressor 24 Place a new filter in the inlet opening making sure that the filter is completely tuced into the opening and that there are no gaps around the filter 5 3 Q50 Technical Service Manual 3100792 RevA Section 5 Preventative Maintenance 5 2 8000 Hour PM Procedure The 8000 hours preventive maintenance procedure includes the following Servicing the Compressor Motor Replacing the filters This procedure is recommended every 8000 hours of compressor operation Note Before you begin read these instructions thoroughly and assemble the necessary tools Tools Required 7 8 wrench Flat head screwdriver 11 32 socket nut driver Teflon tape Spline insertion tool 1 4 Hex Socket attachment for torque wrench Torx T 20 attachment for torque wrench for retainer screws Torx T 25 attachment for torque wrench for head screws 5 32 Hex wrench for torque wrench eccentric sc
28. ysician This device should be used ONLY by a trained operator For more information see the Precision Flow Operating Instruction Manual 2 Principles of Operation The air compressor starts after being plugged in and power inlet switch toggled The power inlet switch is located above the power inlet on the unit Ambient room air is pulled in through the air intake filter on the unit past the heat exchange coil and into the compressor Note Excess moisture is directed to the water bottle reservoir Here it is compressed moves through the heat exchange coil in order to reduce the air temperature through an auto draining air filter pressure relief valve and pressure regulator The air then exits the unit and is delivered to the Precision Flow via the air hose 3 Functional Description The air compressor is comprised of the following components e Air Intake Filter e Compressor e Heat Exchange Coil e Auto drain Air Filter e Air Intake Muffler e Pressure Regulator e Pressure Relief Valve e Tubing Piping e Sound Deadening Foam e Housing Top Bottom 1 1 Q50 Technical Service Manual 3100792 RevA Section 3 Functional Description The Front Panel Fig 1 contains e Water bottle reservoir Water Bottle Reservoir The Rear Panel Fig 2 contains e Air Intake Filter Power Inlet Switch and Fuse Drawer Hour Meter Serial Number Label DISS Air Fitting DISS Air Fitting Air Intake Filter f Serial Number Power Inlet Sw
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