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 *HQHUDOLQWURGXFWLRQ ,WHP &RPSRQHQW


3 Mixer block
4 A-cone valve
5 Mixed gas tank
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6 MIXER PCB

)LJ Mixer without cover, for legend see Table 1

7DEOH Legend to Fig. 1


,WHP &RPSRQHQW
1 PRIMUS CPU PCB
2 Gas inlet block

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1HZ &RPSRQHQW $FWLRQ
X &6SUHVVXUHUHGXFHUV 35312353$,5 1. Follow the safety instructions (see Safety precautions
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3532 document ).
Replacing see Maintenance work 2. Remove the rear panel (see document: Removing rear
panel).
X PRIMUS CPU PCB lithium battery
3. Remove the compressed gas supply tubing as
Replacing see Maintenance work
necessary.
4. Remove the three central gas supply tubes (see Fig.
2).

)LJ Central gas supply tubing

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5HSDLU,QVWUXFWLRQV 0L[HU FRPSOHWHPRGXOH

5. Use a hexagonal spanner to remove the fixing screw 6. Remove the centre fixing screw from the gas inlet block
from the gas inlet block (see Fig. 3). (see Fig. 4).
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)LJ Centre fixing screw

7. Withdraw the mixer block about half-way out of the


housing and unplug the electrical connection to the
mixer (see Fig. 5).

)LJ Fixing screw on gas inlet block

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1. Before fitting the mixer, check that the six terminal


block O-rings are fitted in the housing (see Fig. 6).
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)LJ Unplugging electrical connection

8. Take the mixer block fully out of the housing and place
it on a suitable surface.

)LJ Six O-rings on terminal block

2. Refit the mixer in the reverse order of its removal (see


section 3.2 Mixer fitting).

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5HSDLU,QVWUXFWLRQV 0L[HUFRYHU

3. Check integrity, gas type and mixer function as per Test  0L[HUFRYHU
Certificate.
 5HPRYLQJPL[HUFRYHU

1. Follow the safety instructions (see Safety precautions


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document ).
2. Remove the compressed gas supply tubing as
necessary.
3. Remove the three mixer cover fixing screws (see Fig.
7).

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 &RQQHFWRUDVVLJQPHQWDQGFDEOHOD\RXW
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)LJ Mixer cover fixing screws

4. Remove the mixer cover.

)LJ Connector assignment, sensors and valves

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5HSDLU,QVWUXFWLRQV 0L[HUFRYHU

To avoid interference, the cables are laid in three


groups.

Follow the specified cable layout (see Fig. 9).


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)LJ Specified cable layout )LJ Mixer, example of cable layout

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1. Follow the specified cable layout (see mixer cover or


 5HSODFLQJ&6SUHVVXUHVHQVRUV
Fig. 9).
The following steps can be carried out with the mixer
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

fitted.
Damage to cables by trapping!
1. Take off the housing cover as necessary (see
Make sure no cables are trapped when refitting
document: Removing housing cover).
the mixer cover.
2. Remove the mixer cover (see section 4.1 Removing
2. Refit the mixer cover in the reverse order of its mixer cover.
removal.
3. Remove the mixer tank (see Fig. 11).
3. Fit the mixer (see section 3.2 Mixer fitting).

)LJ Removing mixer tank

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4. Unplug the connector of the CS pressure sensor from


the mixer PCB (see Fig. 8 or connection diagram on
mixer cover).
In the following, the CS pressure sensor PPN2O is
removed by way of an example. The steps also apply
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correspondingly to the PPAIR and PPO2 pressure


sensors.
5. Hold the connecting cable perpendicular to the sensor
and unscrew the sensor by hand (see Fig. 12).

)LJ Removing CS pressure sensor PPN2O

6. Check that the O-ring is fitted on the new CS pressure


sensor.

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7. Hold the connecting cable perpendicular to the new CS  &6SUHVVXUHUHGXFHUV35312353$,5


pressure sensor. Screw in the new CS pressure sensor 3532
hand-tight.
After mounting, the pressure sensor can still be moved  5HPRYLQJUHILWWLQJ&6SUHVVXUHUHGXFHUV
slightly (at its topmost point) horizontally. This is
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The following steps can be carried out with the mixer


normal. The O-ring ensures leak-tightness.
fitted.

Connector diagram - see mixer cover or Fig. 8. 1. Follow the safety instructions (see Safety precautions
Follow the specified cable layout - see mixer document ).
cover or Fig. 9. 2. Remove the compressed gas supply tubing.
8. Plug the sensor connector into the mixer PCB. 3. Take off the housing cover as necessary (see
9. Screw in the mixer tank hand-tight. document: Removing housing cover).
10. Check integrity, gas type and mixer function as per Test 4. Remove the mixer cover (see section 4.1 Removing
Certificate. mixer cover.
5. For details on how to remove and refit the CS pressure
reducers see Maintenance work Removing CS
pressure reducers)

 &DOLEUDWLQJ&6SUHVVXUHUHGXFHUV

1. Switch on the Primus.


2. Connect the central supply tubes.
3. Activate service mode.

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5HSDLU,QVWUXFWLRQV 'LIIHUHQWLDOSUHVVXUHVHQVRUV 3'0,;3'0*6/23'0*6+,

4. From the mixer menu select 'Service test“ and then test  'LIIHUHQWLDOSUHVVXUHVHQVRUV 3'0,;
42, 43 or 44, depending on the replaced CS pressure 3'0*6/23'0*6+,
reducer.
5. Set the pressure value to ambient pressure + 2.1 bar  5HPRYLQJGLIIHUHQWLDOSUHVVXUHVHQVRUV
0.1 bar.
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The following steps can be carried out with the mixer


6. Fix the locking cap of the CS pressure reducer in place. fitted.
7. Fit the mixer cover (see section 4.3 Fitting mixer
cover). 1. Follow the safety instructions (see Safety precautions
document ).
2. Remove the compressed gas supply tubing as
necessary.
3. Take off the housing cover as necessary (see
document: Removing housing cover).
4. Remove the mixer cover (see section 4.1 Removing
mixer cover.
5. Remove the mixer tank (see Fig. 11).
In the following, the differential pressure sensor PDMIX
is removed by way of an example. The steps also apply
correspondingly to PDMGSLO and PDMGSHI.

For the connector assignment and the positions


of the differential pressure sensors see the mixer
cover or Fig. 8.
6. Unplug the differential pressure sensor connector from
the mixer PCB.

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5HSDLU,QVWUXFWLRQV 'LIIHUHQWLDOSUHVVXUHVHQVRUV 3'0,;3'0*6/23'0*6+,

7. Release the differential pressure sensor holder just a 1. Check that the O-rings are fitted on the new differential
quarter of a turn and take out the sensor (see Fig. 13). pressure sensor.
2. Plug in the new differential pressure sensor and fix it in
place in the holder by turning it a quarter turn.
After mounting, the sensor can still be moved slightly.
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This is normal. The O-rings ensure leak-tightness.

Connector assignment - see mixer cover or Fig.


8. Follow the specified cable layout - see mixer
cover or Fig. 9.
3. Plug the differential pressure sensor connector into the
mixer PCB.
4. Screw in the mixer tank hand-tight.
5. Check integrity, gas type and mixer function as per Test
Certificate.

)LJ Differential pressure sensor PDMIX

 )LWWLQJGLIIHUHQWLDOSUHVVXUHVHQVRUV

To avoid possible faults arising from open circuits


and contact resistance, each differential pressure
sensor is replaced with the cable.

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Connector assignment - see mixer cover or Fig.


8.

The following steps can be carried out with the mixer


fitted.

1. Follow the safety instructions (see Safety precautions


document ).
2. Remove the compressed gas supply tubing.
3. Remove the unit cover (see Housing cover repairs,
'Removing the housing cover“ section.
4. Remove the mixer cover (see section 4.1 Removing
mixer cover).
)LJ Pressure sensor PTANK
5. Remove the mixer tank (see Fig. 11).
In the following, the pressure sensor PTANK is
removed by way of an example. The steps also apply
correspondingly to PSYS.
6. Unplug the sensor connector from the mixer PCB.
7. Hold the connecting cable perpendicular to the sensor
and unscrew the sensor by hand (see Fig. 14).

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1. Check that the O-ring is fitted on the new pressure


 5HPRYLQJWHPSHUDWXUHVHQVRUV
sensor.
2. Hold the cable of the new sensor perpendicular to the
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

sensor and screw the sensor in hand-tight. After Connector assignment - see mixer cover or Fig.
mounting, the sensor can still be moved slightly (at its 8.
topmost point) horizontally. This is normal. The O-ring
ensures leak-tightness. The following steps can be carried out with the mixer
fitted.
Connector assignment - see mixer cover or Fig.
1. Follow the safety instructions (see Safety precautions
8. Follow the specified cable layout - see mixer
document ).
cover or Fig. 9.
2. Remove the compressed gas supply tubing as
3. Plug the sensor connector into the mixer PCB. necessary.
4. Screw in the mixer tank hand-tight. 3. Take off the housing cover as necessary (see
5. Check integrity, gas type and mixer function as per Test document: Removing housing cover).
Certificate. 4. Remove the mixer cover (see section 4.1 Removing
mixer cover.
5. Remove the mixer tank (see Fig. 11).
6. Unplug the sensor connectors from the mixer PCB.
7. Remove the temperature sensor fixing screws.

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5HSDLU,QVWUXFWLRQV 7HPSHUDWXUHVHQVRUV7$1.7(030*67(03

 )LWWLQJWHPSHUDWXUHVHQVRUV 1. Fit the new temperature sensors in the reverse order of
their removal.

The temperature sensors are fitted one above the


other. Connector assignment - see mixer cover or Fig.
8. Follow the specified cable layout - see mixer
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

Fit TANKTEMP (Fig. 15/1) on the top and cover or Fig. 9.


MGSTEMP on the bottom (Fig. 15/2). 2. Check integrity, gas type and mixer function as per Test
Certificate.

)LJ Positions of TANKTEMP (1) and MGSTEMP


(2)

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5HSDLU,QVWUXFWLRQV 9DOYHV90,;1290,;$,590,;297$1.96:$.

 9DOYHV90,;1290,;$,590,;297$1. 1. Unplug the valve connector from the mixer PCB.


96:$. 2. Remove the two fixing screws (see Fig. 16).
The following steps can be carried out with the mixer
fitted.
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

 5HPRYLQJ90,;1290,;$,590,;2
97$1.

1. Follow the safety instructions (see Safety precautions


document ).
2. Remove the compressed gas supply tubing as
necessary.
3. Take off the housing cover as necessary (see
document: Removing housing cover).
4. Remove the mixer cover (see section 4.1 Removing
mixer cover.
5. Remove the mixer tank (see Fig. 11).

 5HPRYLQJ90,;1290,;$,590,;297$1. )LJ Valve VMIXN2O fixing screws


In the following, valve VMIXN2O is removed by way of
an example. The steps also apply correspondingly to  )LWWLQJ90,;1290,;$,590,;297$1.
the other valves.
1. Check that the sealing ring shaped like an 8 is fitted on
the valve.
Connector assignment - see mixer cover or Fig.
2. Refit the valves in the reverse order of their removal.
8.

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5HSDLU,QVWUXFWLRQV 9DOYHV90,;1290,;$,590,;297$1.96:$.

Connector assignment - see mixer cover or Fig.


8. Follow the specified cable layout - see mixer
cover or Fig. 9.
3. Screw in the mixer tank hand-tight.
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4. Check integrity, gas type and mixer function as per Test


Certificate.

 5HPRYLQJ96:$.

Connector assignment - see mixer cover or Fig.


8.
)LJ Valve VSWAK fixing screws

1. Unplug the valve connector from the mixer PCB.  )LWWLQJ96:$.
2. Remove the two fixing screws (see Fig. 17).
1. Check that the three sealing rings are fitted on the
valve.
2. Refit the valve in the reverse order of its removal.

Connector assignment - see mixer cover or Fig.


8. Follow the specified cable layout - see mixer
cover or Fig. 9.
3. Screw in the mixer tank hand-tight.
4. Check integrity, gas type and mixer function as per Test
Certificate.

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5HSDLU,QVWUXFWLRQV )DQ

 )DQ

 5HPRYLQJIDQ

1. Follow the safety instructions (see Safety precautions


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document ).

Connector assignment - see mixer cover or Fig.


8.

2. Take off the housing cover as necessary (see


document: Removing housing cover).
3. Remove the mixer (see section 3.1 Removing mixer).
4. Remove the mixer cover (see section 4.1 Removing
mixer cover).
5. Unplug the fan connector from the mixer PCB.
6. Remove the two fixing screws (Fig. 18 /1) from the )LJ Fixing screw positions
holder.
7. Slacken the three holder fixing screws (Fig. 18/2/3). 8. Remove the two fan fixing screws.

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5HSDLU,QVWUXFWLRQV )DQ

 )LWWLQJIDQ 1. Fit the new fan with its grille such that the flow direction
points towards the outer (see Fig. 19).

Mixer failure due to incorrect fan installation!

Pay attention to the flow direction of the fan (see


All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

Fig. 19).

Fan failure due to incorrect fan installation!

Tighten the fixing screws only enough to hold the


fan frame in place without bending it.

)LJ Fan flow direction

2. Refit the holder in the reverse order of its removal.

Connector assignment - see mixer cover or Fig.


8. Follow the specified cable layout - see mixer
cover or Fig. 9.
3. Check according to Test Certificate.

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1. Remove the two fixing nuts (see Fig. 20).


 5HPRYLQJ3&%V

1. Follow the safety instructions (see Safety precautions


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document ).
2. Remove the mixer (see section 3.1 Removing mixer ).
3. Remove the mixer cover (see section 4.1 Removing
mixer cover).
4. If the mixer PCB is being removed, first remove the
mixer tank (see Fig. 11).

)LJ Fixing nut positions

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5HSDLU,QVWUXFWLRQV 3&%V

2. Disconnect the mixer CPU PCB from the mixer PCB


connector and place it on a suitable surface.

 5HSODFLQJ35,086&383&% OLWKLXPEDWWHU\

1. Replacing lithium battery see Maintenance work.


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2. Check according to Test Certificate.

 )LWWLQJ35,086&38 3&%

No jumpers are connected to the


PRIMUS CPU PCB.

If present at all, the jumpers are fitted only at their )LJ Jumper parked positions
parked positions (see Fig. 21).
1. Refit the PRIMUS CPU PCB in the reverse order of its
removal (see section 12.1.2 Replacing PRIMUS CPU
PCB lithium battery).
2. Check integrity, gas type and mixer function as per Test
Certificate.

 5HPRYLQJPL[HU3&%

1. Remove the PRIMUS CPU PCB (see section 12.1.1


Removing PRIMUS CPU PCB).
2. Remove the two fixing screws (Fig. 22 /1). Remove the
ground connection (Fig. 22/2).

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5HSDLU,QVWUXFWLRQV 3&%V

 )LWWLQJPL[HU3&%

Connector assignment - see mixer cover or Fig.


8. Follow the specified cable layout - see mixer
cover or Fig. 9.
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1. Fit the new mixer PCB in the reverse order of the old
one’s removal.
2. Check integrity, gas type and mixer function as per Test
Certificate.

)LJ Fixing screws and ground connection

3. Unplug all electrical connections from the mixer PCB.


4. Withdraw the mixer PCB from its guide and place it on
a suitable surface.

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

 *DVLQOHWEORFN

 5HPRYLQJFRPSOHWHJDVLQOHWEORFN

1. Follow the safety instructions (see Safety precautions


All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

document ).
2. Remove the mixer (see section 3.1 Removing mixer ).
3. Remove the mixer cover (see section 4.1 Removing
mixer cover).
4. Remove the two fixing screws (Fig. 23 /1) from the
holder.
5. Slacken the three fixing screws (Fig. 23/2/3).

)LJ Fixing screw positions

6. Remove CS pressure sensors (see section 5.1


Replacing CS pressure sensors).
7. Remove CS pressure reducers (see section 6.1
Removing/refitting CS pressure reducers ).
8. Remove the two fixing screws at the left (see Fig. 24).

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

)LJ Right side fixing screws

)LJ Left side fixing screws


10. Remove the gas inlet block and place it on a suitable
surface.
9. Remove the two fixing screws at the right (see Fig. 25).

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

 )LWWLQJFRPSOHWHJDVLQOHWEORFN  *DVLQOHWEORFNFRPSRQHQWV

1. Check that the four O-rings are fitted in the mixer block  5HPRYLQJUHILWWLQJQRQUHWXUQYDOYHV
(see Fig. 26). The following steps can be carried out with the mixer
fitted.
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

On the top of the gas inlet block there are five non-
return valves (see Fig. 27/1).

)LJ O-rings in mixer block

2. Refit the mixer block in the reverse order of its removal.


3. Check integrity, gas type and mixer function as per Test
Certificate.

)LJ Non-return valve positions

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

The following procedure for removal and refitting also 3. Rotate the non-return valve by hand and remove it from
applies correspondingly to the other safety valves. the hole by overcoming the slight resistance (see Fig.
29).
1. Follow the safety instructions (see Safety precautions
document ).
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

2. Unscrew the non-return valve, but do not yet remove it


fully from the hole (see Fig. 28). Hold the non-return
valve firm.

)LJ Unscrewing non-return valve

4. Throw away the old lip seal (see Fig. 30).


5. Apply Oxygenoex S4 to the turned down part of the lip
seal.

)LJ Unscrewing non-return valves

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

7. Once the lip seal is seated, rotate it five times around


Malfunction resulting from incorrect fitting of the its own axis. This will distribute the grease evenly.
lip seal! 8. Clean away the surplus grease above and below the lip
seal with a non-fluffy cloth.
Follow the preferential direction of the lip seal
9. Check that the O-ring on the non-return valve is
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

(see Fig. 30).


undamaged and replace it as necessary (see Fig. 31).

)LJ Preferential direction of lip seal


)LJ Non-return valve O-ring
6. Fit the new lip seal.

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

Apply a little spirit or Desderman to the sealing lip


of the lip seal. This will enable the element to be
fitted more easily.
10. Insert the non-return valve and tighten it to
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

24 Nm 2 Nm.
11. Leak test and gas type test as per Test Certificate.

 5HPRYLQJUHILWWLQJVLQWHUHGPHWDOILOWHU
The following steps can be carried out with the mixer
fitted.
On the underside of the gas inlet block are the NIST )LJ Connection positions
connections (Fig. 32/1) of the central supply gases and
of the N2O/O2 compressed gas cylinders (Fig. 32/2).
1. The following procedure for removal and refitting
(based on the example of the Nist connection for O2)
applies correspondingly to all NIST connections.

'DQJHUWROLIH

3RVVLELOLW\RIFRQQHFWLRQVEHLQJVZDSSHG

Never remove all connections at the same time.


Replace the sintered-metal filter of the
connection you have just removed.

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5HSDLU,QVWUXFWLRQV *DVLQOHWEORFN

1. Follow the safety instructions (see Safety precautions 5. Check that the O-ring on the Nist connection is
document ). undamaged and replace it as necessary.
2. Remove the two fixing screws of the Nist connection 6. Screw in the two fixing screws of the Nist connection
for O2. for O2. Make sure the O-ring is not trapped.
3. Unscrew the sintered-metal filter of the O2 Nist 7. Replace the other sintered-metal filters one after the
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

connection (see Fig. 33). other.


8. Check that the marking on the gas inlet block matches
the marking on the fitted Nist connections (see Fig. 34).
The marking also applies to the cylinder connections
for N2O and O2 on the second line.

)LJ Marking of Nist connections and cylinder


connections

)LJ Unscrewing sintered-metal filter 9. Leak test and gas type test as per Test Certificate.

4. Screw in the new sintered-metal filter of the O2 Nist


connection hand-tight.

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5HSDLU,QVWUXFWLRQV 0L[HUEORFN

 0L[HUEORFN

 5HPRYLQJVLQWHUHGPHWDOILOWHU50*6
The following steps can only be carried out with the
All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

mixer removed.

1. Remove the mixer (see section 3.1 Removing mixer ).


2. Remove the threaded insert next to the A-cone valve
(VSWAK) (see Fig. 35).
)LJ Pressing out sintered-metal filter

4. Retighten the threaded insert next to the A-cone valve


(VSWAK).

)LJ Removing threaded insert

3. Use a suitable implement (such as a spherical socket


head, length approx. 13 cm) to press out the sintered-
metal filter and the brass element behind it (see Fig.
36).

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1. Insert the new sintered-metal filter (see Fig. 37).


All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

)LJ Inserting sintered-metal filter

)LJ Asymmetrical end piece on brass element


2. Check that the O-ring on the brass element is
undamaged and replace it as necessary.
4. Insert the brass element flush, in the preferential fitting
3. Owing to the internal drill holes, the brass element has direction (see Fig. 39).
a preferential direction of fitting (see Fig. 38).

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All rights reserved. Copyright reserved • R5132300T08_Mischer.fm 05.04.02 • Repair Instructions • Version 1.0 • Released

)LJ Inserting brass element

5. Fit the mixer (see section3.2 Mixer fitting).


6. Carry out the leak test according to the Test Certificate.
7. Connect up the O2 central supply.
8. In service mode, select the mixer menu and start
service test 3. Read out the MFA value and compare it
with the specified value from the Test Certificate.

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