- Frank`s Hospital Workshop
Contents
1. Pressure compensating reservoir Silencer intake Exhaust valve for condensate water 12 STAXEL 2 and AIR Service Manual 7 3 Switching attitude of the valve unit Switching position A Medicinal compressed air of 1 7 bar from the pressure compensation reservoir is available at the valve unit In switching position A the valves 1 4 are open Through valve 1 flows compressed air through the adsorber container A The molecular sieve adsorbs the nitrogen part of the compressed air The residual gas atmosphere consisting of oxgen and portions of inert gases is conducted into the O2 reservoir via the back pressure valve 8 small part of the produced oxygen is conducted through a nozzle 6 to the adsorber B The oxygen whose speed of flow is accelerated by the nozzle now flows through the adsorber scavenges the adsorbed nitrogen and flows to the outlet via the open valve 4 One second ahead of the changeover from adsorber A to adsorber B the savenging valve 5 opens for the duration of two seconds and provides for the adsorber B to be scavenged once again with a large portion of oxygen After a cycle of 13 seconds the changeover from adsorber A to adsorber B takes place Switching position B Medicinal compressed air of 1 7 bar from the pressure compensation reservoir is available at the valve unit In switching position B the valves 2 3 are o2. The front panel of the appliance contains the displays of operating pressure for O2 AIR and VAC as well as a hours run meter to indicate the scheduled intervals for maintenance and servicing exchange of filters etc The entire module is mounted onto a sturdy undercarriage with an appropriate holding rail so that all STEPHAN respirators as well as reanimators pediatrics respirator F 150 and HF 300 SIMV can be used The respirators can easily be detached from the unit and attached to a wall rail system or to the incubator Attention The unit must not be operated without micro filter STAXEL 2 and AIR Service Manual 4 Installation and startup 41 Environmental conditions The STEPHAN STA XE L is intended for installation in dry rooms without risk of splash water or water drops Humid or wet environment can seriously impair the reliability of the unit Special care has to be taken to avoid placing containers filled with water or similar objects in the near vicinity The ambient temperature should in no case exceed 40 C With a prevailing relative air humidity it is recommended to operate the unit only in air conditioned rooms The air intake grids at the rear of the unit must not be covered or obstructed with any objects Distance from the rear of the unit to the wall should be at least 10 cm The STAXEL must not be operated in rooms where an explosion hazard exists The STAXEL must not be operated in the vic
3. is cleaned using a portion of the produced oxygen and can continue with the enrichment with oxygen when the second container is saturated with nitrogen This process is cyclic and continuous 3 2 Production of compressed air Compressed air is produced by means of the two compressors which also compress the ambient air required for the production of oxygen The compressed air is collected in a compressed air reservoir and is now available for the production of oxygen as well as for use as medicinal compressed air The ambient air is hereby conducted through an intake filter and a bacteria filter and then compressed in the compressors which both operate free of oil Thus the production of compressed air always runs in parallel with the production of oxygen The moment the STAXEL is switched it produces compressed air as well as oxygen STAXEL 2 and AIR Service Manual 3 3 Generation of vacuum Vacuum is generated by means of a vacuum pump which is additionally installed in the STAXEL In parallel to the production of O2 and AIR this vacuum pump can be switched on and off separately Vacuum pressure is infinitely adjustable from 0 1 to 0 6 bar by means of a rotary knob 3 4 Construction The entire supply module is mounted in a sound insulated twofold steel housing all rotating components like compressor or fans are mounted oscillation attenuated The escaping exhaust air is evacuated via a noise reducing filter
4. After 10 000 hours run a general overhaul has to be carried out by the service department 13 1 Power supply The mains supply takes place by means of a connection cable which is led into the strip of sockets on the rear of the STAXEL The terminal block 230 V is connected with the strip of sockets by means of an interconnecting cable The mains supply L 1 N and PE is led from the terminal strip to the mains switch O2 AIR in the STAXEL housing lid Designation of terminals 1 2 3 The mains switch switches the mains supply bipolar on resp off From the mains switch O2 AIR the switched mains supply is led back to the terminal block Designation of terminals 7 9 The terminal block 230 V supplies the two compressors 1 2 the fan as well as the control board with the switched mains supply On the control board the 230 V mains supply is transformed and converted to 5 V DC and 24 V DC The valves are activated with 24 V DC The pressure switches and the wind switch are supplied with 5 V DC A 9 V battery is connected in parallel to the 5 V supply This battery takes over the voltage supply of the monitoring components pressure switch and horn in case of failure of mains supply The 5 V supply is switched on and off by means of the mains switch O2 AIR designation of terminals10 12 and then supplies the pressure switch In case of failure the pressure LED in the lid of the STAXEL is activat
5. STEPHAN STEPHAN O2 AIR ENERGY SUPPLY MODULE STAXEL 1 5 3 5 ros a E Ltt SERVICE MANUAL F STEPHAN GmbH Medizintechnik D 56412 Gackenbach Kirchstr 19 Tel 06439 9125 0 Fax 06439 9125 111 info stephan gmbh com www stephan gmbh com STAXEL 2 and AIR Service Manual Table of contents 2 TECHNICAL DIMENSIONS 4 3 1 Production of oxygen 5 3 2 Production of compressed air 5 3 3 Generation of vacuum 6 3 4 Construction 6 4 INSTALLATION AND STARTUP 7 41 Environmental conditions 7 4 2 Startup 8 5 CONTROL AND DISPLAY ELEMENTS 9 6 CONNECTIONS FOR OXYGEN COMPRESSED AIR AND VACUUM10 7 TECHNICAL DESCRIPTION 11 7 1 Description of system 11 7 2 Schematic representation 12 7 3 Switching attitude of the valve unit 13 8 TECHNICAL DETAILS 15 9 PERFORMANCE DATA OF STAXEL 16 10 ERROR DETECTION SYSTEM 17 11 MAINTENANCE 18 12 GUARANTEE 18 13 SERVICE 19 STAXEL 2 and AIR Service Manual 13 1 Power supply 19 13 2 Wiring diagram STAXEL bottom part 20 133 Wiring diagram V2A cover of STAXEL 21 13 4 Adjustment of the adsorber containers 22 13 5 Technical details 25 13 5 1 Exchanging the bacteria filter and the intake filter mat ambient air filter 25 13 5 2 Removing the top the rear panel and the side covers 26 13 5 3 Removing the adsorber containers 27 13 5 4 Removing the compressed air reservo
6. ation in 1 95 2 95 3 95 4 95 5 94 6 91 The values apply with a temperature of 25 C and a relative air humidity of 60 Furthermore concentration of O2 fluctuates for 2 96 Specifications Supply voltage 230V 50Hz Current consumption 5A Changeover cycle 13 sec Duration of one scavenging 2 sec Noise level 48 dB A Dimensions Lx WxH 500 x 510 1550 Weight ca 65 kg Compressor Number of revolutions 1380 R min Power consumption 2 x 250 watt Capacitor 2x 8 uF 400 V Fan Number of revolutions 930 R min Power consumption 1 x 80 watt Capacitor 2 uF 400 V 15 STAXEL 2 and AIR Service Manual 9 Performance data of STAXEL 100 90 R 85 80 1 2 3 4 5 6 7 8 l min Production of oxygen dependent on consumed quantity 100 p 80 ch 60 40 20 1 2 3 4 5 6 7 8 9 10 t min Produktion of oxygen dependent on time with consumption of ca 6 litres min STAXEL 2 and AIR Service Manual 10 Error detection system Error No pressure at O2 and compressed air audible alarm Initial pressure of O2 or compressed air falls below 0 7 Consumption of gas is too high bar audible alarm Red LED 1 4 illuminates Staxel is overheated unit ceases to operate Red LED 1 5 illuminates Concentration of O2 falls below minimum value Cause Failure of supply voltage fuse defective Microfilter is obstructed Compressor defective Leak in line Airflow is too weak va
7. bes and copper tubes must be checked for leaks coarse filters and microfilters must be exchanged if necessary faultless performance of the solenoid valves must be checked the filter mat at the intake grid of the blower must be exchanged if necessary Pressure controller of O2 reservoir The two pressure controllers for minimum and maximum pressure on the O2 reservoir must release an alarm with the following values limit for minimum pressure 0 6 bar limit for maximum pressure 2 bar J HCH E 22 STAXEL 2 and AIR Service Manual Adsorber container To guarantee maximum concentration of O2 calibration must be carried out as follows pressure gauges must be installed as shown in figure 1 hereafter the STAXEL must run for 10 minutes under operating conditions a flow of 6 l min 15 set on tbe O2 connection a flow of 5 l min is set on the compressed air connection pressure displayed by the pressure gauges should be 0 1 bar on the exhausted adsorber and must rise to approximately 1 5 bar when the adsorber is filled again Attention If pressure with exhausted adsorber does not fall below 0 2 bar the outlet filter must be exchanged see 13 5 6 deflections of the pressure gauges on both adsorber containers must take place simultaneously and in contrary direction concentration of O2 should now have a value of not below 90 23 STAXEL 2 and AIR Service Manual Supplement for the adjust
8. ed designation of terminals 11 5 In addition the horn sounds The wind switch is supplied with a second 5 V voltage which is tapped directly from the control board In case of failure the fan LED in the Staxel lid is activated designation of terminal 4 6 Voltage supply 230 V for the vacuum pump is tapped in parallel from the terminals 1 3 in the STAXEL lid The vacuum pump is switched on respectively off directly by means of the mains switch VAC 19 STAXEL 2 and AIR Service Manual 13 2 Wiring diagram STAXEL bottom part 20 STAXEL 2 and AIR Service Manual 13 3 Wiring diagram V2A cover of STAXEL 21 STAXEL 2 and AIR Service Manual 13 4 Adjustment of the adsorber containers To guarantee a faultless performance of the STAXEL a check and in case a renewed calibration of the pressure controllers on the O2 reservoir should be carried out with each servicing In addition the adsorber containers must be checked Checks all tu
9. inity of open fire or red hot objects because of the increased explosion hazard which exists on account of the ambient air being enriched with oxygen of high purity STAXEL 2 and AIR Service Manual 4 2 Startup First the STAXEL is connected to the mains supply socket The STAXEL has two mains switches one mains switch for the production of O2 and AIR and a second one for the generation of vacuum By means of the mains switch 2 and AIR the unit is switched and OFF for the production of oxygen and compressed air Immediately after switching it on the STAXEL starts to produce oxygen and compressed air The respective pressure gauges on the front panel blue for oxygen and yellow for compressed air indicate the pressure at the respective outlets The typical values for oxygen and compressed air are 1 bar By means of the mains switch VAC the unit is switched ON and OFF for the generation of vacuum Immediately after switching it on the Staxel starts to generate vacuum The pressure gauge at the front panel white for vacuum indicates the pressure at the respective outlet The typical value for vacuum is 0 5 bar On both sides of the unit one connection each for oxygen and compressed air is provided An additional connection for vacuum is provided on the right side of the unit During normal operation always one pair of connections O2 and AIR is used If necessary the spare pair of connec
10. ir complete HI 33 STAXEL 2 and AIR Service Manual 15 3 O2 pressure reducer STAXEL complete 34 STAXEL 2 and AIR Service Manual 15 4 Terminal block STAXEL bottom part 35 STAXEL 2 and AIR Service Manual 15 5 Cover STAXEL bottom part Kabeldurchf hrung 15 6 mA L tnippel d 12 6 mm innen d 10 mm Luftk hler Staxel Gebl se doppelflutig D mm Matte Kompr raum Vent 36 STAXEL 2 and AIR Service Manual 15 6 Housing lid STAXEL H j 37 STAXEL 2 and AIR Service Manual 15 7 Adsorber unit complete 38 STAXEL 2 and AIR Service Manual 15 8 Adsorber manifold complete 39 STAXEL 2 and AIR Service Manual 15 9 Compressor unit pre assembled 40
11. ir 29 13 5 5 Removing the compressors 30 13 5 6 Exchanging the outlet filter 30 14 STAXEL SET OF SPARE PARTS FOR AN OPERATING PERIOD OF 2 YEARS 31 15 MODULES WITH PRODUCT NUMBERS 32 15 1 Pressure reservoir complete 32 15 1 O2 reservoir complete 33 15 3 02 pressure reducer STAXEL complete 34 15 4 Terminal block STAXEL bottom part 35 15 5 Cover STAXEL bottom part 36 15 6 Housing lid STAXEL 37 15 7 Adsorber unit complete 38 15 8 Adsorber manifold complete 39 159 Compressor unit pre assembled 40 STAXEL 2 and AIR Service Manual 1 General notice The STEPHAN STAXEL unit serves for the production of oxygen and compressed air as well as for the production of vacuum and is primarily designed for the operation of appliances for pediatrics and anaesthesia It continuously produces oxygen from the ambient atmosphere and thus offers an economocal alternative to the supply of oxygen from cylinders or the supply with liquid oxygen The STAXEL basic unit is available for diverse applications STEPHAN STAXEL PEDIATRICS for 2 respirators STEPHAN STAXEL ANAESTHESIA WITH RESPIRATOR Note Upon request or order also other combinations are available The STAXEL can be mounted on a service carriage and thus offers the greatest possible mobility and flexibility It is made from stainless steel and therefore extremely resistant against weathering and easy to keep in hygienic condition The STAXEL is available wi
12. lves do not switch properly Electronics defective Compressors defective Supply hose torn off Pressure between the two adsorber containers is no longer balanced obsolete adsorber containers 17 Elimination Check supply voltage Exchange fuse Exchange microfilter Reduce consumption of gas notify service agency Exchange filter mat check fan for sufficient performance exchange if necessary Notify service agency Adsorbers must be adjusted anew adsorber containers must be exchanged STAXEL 2 and AIR Service Manual 11 Maintenance Maintenance The Stephan STAXEL requires only little maintenance For hygienic reasons the unit should be cleaned periodically by wiping it using customary household cleansing agents or disinfectants e g Sagrotan diluted The microfilter and the filter mat must be exchanged every 10 days or after each 240 hours run 12 Guarantee If used according to instructions the product is guaranteed for 12 months from the date of sale The guarantee applies to replacement and repair of parts for which a fault in material and manufacturing can be acknowledged 18 STAXEL 2 and AIR Service Manual 13 Service To warrant faultless performance the units must be checked after each approximate 1000 hours run at least however once a year by an authorized specialist firm Eventually occurring disorders or failures must only be eliminated by the service department
13. ment of the adsorber containers Figure 1 24 STAXEL 2 and AIR Service Manual 13 5 Technical details 13 5 1 Exchanging the bacteria filter and the intake filter mat ambient air filter Bacteria filter The bacteria filter is located at the rear of the STAXEL The retaining clip is pulled upward and out the old filter set is removed and the new set is inserted Hereafter the retainig clip is replaced Intake filter mat The intake filter mat ambient air filter is located at the rear of the STAXEL The old filter mat is pulled out of the fixture and the new filter mat is inserted 25 STAXEL 2 and AIR Service Manual 13 5 2 Removing the top part the rear panel and the side covers Top part unscrew the holding screws lift the top part disconnect the electrical connections on the plug pull off tubes from the pressure gauges Rear panel unscrew the holding screw detach rear panel until the intake tube slides out of its mounting disconnect the electrical connection at the terminal block Side cover remove top part and rear panel unscrew and remove the square tubes of the assembly elements unscrew the remaining screws at the lower rim detach side covers so far that the connections with the outlets for O2 and AIR can be disconnected pull the complete side cover forward and out and remove it 26 STAXEL 2 and AIR Service Manual 13 5 3 Removing the adsorber containers remove top par
14. nd remove hose clamp of fabric tube on the cooler remove socket strip from the control board disconnect all electrical connections on the terminal block note allocation of terminals lift off cover of compressor housing complete with fan loosen fabric tubes on the compressors and remove them unscrew mounting rails of compressor 4 X nut 5 take compressors out 13 5 6 Exchanging the outlet filter remove top part rear panel and side covers unscrew screws of the cover on compressor housing disconnect the copper tube from compressed air reservoir undo and remove hose clamp of fabric tube on the cooler remove socket strip from the control board disconnect all electrical connections on the terminal block note allocation of terminals lift off cover of compressor housing complete with fan unscrew and remove the old outlet filter from rear panel of compressor housing screw in new outlet filter 30 STAXEL 2 and AIR Service Manual 14 STAXEL set of spare parts for an operating period of 2 years 1 mmer 5 0 3 3 Microfilter bacteria filter article no 701 60 250 exchange after maximum 500 h Intake filter mat article no 701 60 205 clean weekly respectively exchange 31 STAXEL 2 and AIR Service Manual 15 Modules with product numbers 15 1 Pressure reservoir complete L TOPITE 944 bond with LOCTITE 245 32 STAXEL 2 and AIR Service Manual 15 1 O2 reservo
15. ot adsorbed and form the residual gas atmosphere which is led into an O2 resrevoir Through a nozzle and a scavenging valve which are located at the outlet of the adsorber containers the adsorber not participating in the production of oxygen at this moment is blown through with a portion of the produced oxygen and the nitrogen is flushed into the atmosphere This procedure is periodically repeated whereby two adsorber containers are used alternatingly to increase efficiency The two adsorber containers are interlocked against one another via two back pressure valves so that in the course of changing over to the adsorber container which participates in the production of oxygen the produced oxygen is not completely blown through the adsorber container that has to be cleaned but flows into the O2 resrevoir The O2 outlets are supplied with oxygen from the reservoir via an additional microfilter Pressure at the outlet is limited to 1 bar by means of a pressure reducer 11 STAXEL 2 and AIR Service Manual 7 2 Schematic representation Microfilter Pressure reducer 02 i e reservoir i y e O2 outlet ES Back pressure valve Scavenging valve Nozzle Ger usc Sintered filter 99004 AuslaB p Absorber A Go Me d Absorber Valve unit DG 4 c AIR outlet Fan Microfilter compressor 1 compressor 2
16. pen Through valve 2 flows compressed air through the adsorber container B The molecular sieve adsorbs the nitrogen part of the compressed air The residual gas atmosphere consisting of oxygen and portions of inert gases is conducted into the O2 reservoir via the back pressure valve 7 small part of the produced oxygen is conducted through a nozzle 6 to the adsorber The oxygen whose speed of flow is accelerated by the nozzle now flows through the adsorber scavenges the adsorbed nitrogen and flows to the outlet via the open valve 3 One second ahead of the changeover from adsorber B to adsorber A the scavenging valve 5 opens for the duration of two seconds and provides for adsorber A to be scavenged once again with a large portion of oxygen After a cycle of 13 seconds the changeover from adsorber B to adsorber A takes place 13 STAXEL 2 and AIR Service Manual The changeover between adsorber A and B takes place cyclic and continuously All the switching times are a fixed program in the control electronics of the STAXEL and can not be altered Switching cycles can be checked by means of the LEDs on the control board Valve control O2 separation O2 reservoir O2 eer al A i phe mee gt o ba S Switching position A Switching position B 14 STAXEL 2 and AIR Service Manual 8 Technical details Available concentrations of oxygen with respective flow Flow 1 min O2 concentr
17. t and rear panel unscrew the two socket head screws on the adsorber manifold and remove the manifold undo the two holding straps on the adsorber containers last disconnect the quick push pull connectors at the bottom of the adsorber containers remove the adsorber containers Important Always close the removed adsorber containers airtight because otherwise the granulate molecular sieve will be destroyed ATTENTION Do not attempt to disassemble the adsorber containers The filling material of the adsorbers is compressed by means of a spring with a spring rate of 450 N Adsorber containers must always be exchanged completely 24 STAXEL 2 and AIR Service Manual Adsorber container 28 STAXEL 2 and AIR Service Manual 13 5 4 Removing the compressed air reservoir e remove STAXEL top part and rear panel e unscrew brass screw coupling on the copper tube e pull PVC tubes on top out of the quick push pull connector e undo holding straps e pull exhaust valve for condensate water and excess pressure valve on the bottom out of the quick push pull connectors e remove air reservoir 29 STAXEL 2 and AIR Service Manual 13 5 5 Removing the compressors remove top part rear panel and side covers unscrew the screws of the front panel on the compressor housing remove front panel unscrew the screws of the cover on compressor housing disconnect the copper tube from compressed air reservoir undo a
18. th a number of different shelves brackets for appliances and appliances rails for attaching instruments holding devices or vessels Furthermore four earthed sockets Schuko 230 V are provided on the rear panel where diverse other appliances can be connected STAXEL 2 and AIR Service Manual 2 Technical dimensions VAC 02 AIR STAXEL 2 and AIR Service Manual 3 Construction and description of performance 3 1 Production of oxygen The production of oxygen is based upon the adsorption effect of molecular sieves For this purpose air which has been compressed by compressors is blown through two containers which are filled with molecular sieves Since the molecules of oxygen are smaller than these of nitrogen the oxygen can pass the sieve unimpeded whereas the nitrogen is aborbed completely by the molecular sieve Thus air enriched with oxygen is obtained at the outlet of the container Concentration of oxygen is approximately 95 with an extraction of 5 litres min The remaining 5 are inert gases contained in the normal ambient atmosphere like argon neon xenon etc Of the two containers filled with molecular sieves only one at a time takes part in the production of oxygen Prior to the first container being completely saturated with nitrogen changeover to the second container which now performs the enrichment of air with oxygen takes place While the second container is in operation the first one
19. tions can be used in parallel for connecting a second respirator or incubator STAXEL 2 and AIR Service Manual S Control and display elements MWZ Modul f r Iftensiv Therapi L FTER a NV 14 15 16 LT 2 3 2 4 1 Mains switch ON OFF for 2 and AIR 1 1 Hours run meter for the production of O2 and AIR 1 2 Pressure gauge for indication of O2 pressure 1 3 Pressure gauge for indication of AIR pressure 1 4 Visual alarm for over heating 1 5 Visual alarm for failure of electronics or switching valves 1 6 Fuse for O2 and AIR production 1 7 Fuse for O2 and AIR production 2 Mains switch ON OFF for VAC 2 1 Rotary knob for regulating the vacuum pressure 2 2 Pressure gauge for indication of vacuum pressure 22 Fuse for generation of VAC 2 4 Fuse for generation of VAC STAXEL 2 and AIR Service Manual 6 Connections for oxygen compressed air and vacuum Outlet compressed air Outlet oxygen Outlet vacuum Strip of sockets with connecting cable VAC 02 AIR Outlets for O2 and AIR are located on both sides of the STAXEL The connections are quick coupling and are are interlocked automatically after plugging in To unplug them the unlocking pin on the top of the connection must be depressed The outlet for vacuum is located at the right side The connection consists of a 1 8 female hose connector The hose leading to the suction unit is slipped on 10 STAXEL 2 and AIR Service Man
20. ual 7 Technical description 7 1 Description of system Ambient air is taken in via a microfilter led through a silencer inlet and finally compressed in the compressors 1 2 The compressed air is then conducted over a condenser and cooled before it is collected in a pressure compensation reservoir This reservoir is provided with an exhaust valve for condensate water which briefly opens every 45 minutes and blows the condensate water out The compressed air reservoir is continuously filled with compressed air from the compressors The AIR outlets are supplied with compressed air from this reservoir The output pressure is limited to 1 bar by means of a pressure reducing valve The compressors operate free of oil thus the provided air is medicinal compressed air The compressed air from the pressure compensation reservoir also supplies the two adsorber containers A B via a valve unit The valve unit consists of a 5 2 way valve which is electronically controlled The valve is constructed in such a way that only one adsorber at a time takes part in the production of oxygen while the other one is being scavenged and cleaned The compressed air is conducted through the adsorber containers The adsorber containers are filled with a special granulate which works like a molecular sieve On account of the different sizes of molecules the nitrogen contained in the air is physically adsorbed while oxygen and portions of inert gases are n
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