5384 EVAir Compressor

EVair Medical Compressor
Service Manual
Service Manual EVair
Page 2 of 87 Version 1.1

Table of Contents
1 Preface ..................................................................................................................................5
1.1 Operation Symbols ...................................................................................................................................................... 7
1.2 Symbols ...................................................................................................................................................................... 8
2 Safety Instructions ...............................................................................................................9

2.1 Symbols for Danger, Warnings and Notes .................................................................................................................. 9
2.2 Personnel .................................................................................................................................................................... 9
2.3 EMC issues ................................................................................................................................................................. 9
2.4 Basic Safety Information and Warnings .................................................................................................................... 10
2.5 Guidelines for Maintenance and Repair .................................................................................................................... 11
2.6 Air quality .................................................................................................................................................................. 12
2.7 Contraindications....................................................................................................................................................... 12
2.8 Accessories and Spare Parts .................................................................................................................................... 12
2.9 Responsibilities and Guarantees ............................................................................................................................... 12
3 Theory of operation ............................................................................................................ 13

3.1 Pneumatic Block Diagram ......................................................................................................................................... 13
3.2 Electronic Block Diagram .......................................................................................................................................... 14
4 Location of EVair Assemblies ........................................................................................... 15

4.1 Instrument overview .................................................................................................................................................. 15
4.2 Spare Parts ............................................................................................................................................................... 16
4.3 Assemblies ................................................................................................................................................................ 17
4.4 Accessories ............................................................................................................................................................... 20
5 Service Mode ...................................................................................................................... 21

5.1 Access Code ............................................................................................................................................................. 21
5.2 Overview ................................................................................................................................................................... 21
5.3 System Information ................................................................................................................................................... 22
5.4 System Test .............................................................................................................................................................. 22
5.5 Reset Alerts ............................................................................................................................................................... 23
5.6 Actuators Check ........................................................................................................................................................ 23
5.7 Statistical Information ................................................................................................................................................ 23
5.8 Change Settings ........................................................................................................................................................ 24
6 Troubleshooting ................................................................................................................. 25
7 Preparing for Maintenance and Repair ............................................................................. 29
7.1 Tools required ........................................................................................................................................................... 29
7.2 Removing and installing the compressor in the cart .................................................................................................. 30
7.3 Opening/closing the compressor at the left side........................................................................................................ 31
7.4 Opening/closing the compressor at the right side...................................................................................................... 32
7.5 Opening/closing the compressor at the back ............................................................................................................ 33
7.6 Removing/installing the front cover ........................................................................................................................... 34
8 Maintenance ........................................................................................................................ 37
8.1 Maintenance Schedule .............................................................................................................................................. 37
8.2 Weekly Check ........................................................................................................................................................... 38
8.3 Annually Check ......................................................................................................................................................... 39
8.4 Motor Service ............................................................................................................................................................ 45
8.5 Firmware Upgrade..................................................................................................................................................... 50
9 Repair .................................................................................................................................. 53
9.1 Repairs ...................................................................................................................................................................... 53
9.2 Tools required ........................................................................................................................................................... 53
9.3 Replacing the Fuse ................................................................................................................................................... 54
9.4 Replacing the AC Mains Filter Assembly .................................................................................................................. 55
9.5 Replacing the Check Valve ....................................................................................................................................... 56
9.6 Replacing the Compressor Plate or the Motor .......................................................................................................... 57
9.7 Replacing the 3/2 Valve ............................................................................................................................................ 61
9.8 Replacing the Motor Capacitor .................................................................................................................................. 64
9.9 Replacing the Fan & Temperature Sensor ................................................................................................................ 67
9.10 Replacing the High Temperature Tube ..................................................................................................................... 70

9.11 Replacing the Air Service Unit or parts of it ............................................................................................................... 72
9.12 Replacing the Membrane Dryer................................................................................................................................. 75
9.13 Replacing the Control Board or Display .................................................................................................................... 77
9.14 Replacing the Keypad ............................................................................................................................................... 79
9.15 Replacing the Air Connector ..................................................................................................................................... 81
10 Functional Test ................................................................................................................... 83

10.1 Functional Tests ........................................................................................................................................................ 83
10.2 Test Schedule ........................................................................................................................................................... 83
10.3 Check list Functional Test “Pressure 01”................................................................................................................... 84
10.4 Check list Functional Test “Pressure 02”................................................................................................................... 85
10.5 Check list Functional Test “Flow” .............................................................................................................................. 86
11 Contacts .............................................................................................................................. 87
11.1 Manufacturer’s address ............................................................................................................................................. 87
11.2 Technical Support Service ........................................................................................................................................ 87

1 Preface
1 Preface
Application
This documentation applies to the product described as:
• EVair
You will find this description on the label on the front of the EVair.
Firmware version
This documentation applies to the firmware version:
• SW Version 1.x
Service Manual Version

First edition of this service manual: July 2012
• Service Manual Version 1.1
Subject to technical modification without prior warning.
Symbols used in this manual

All information and warnings written in the boxes signed
with the are important notes according the safety of
the EVair and the user. Ignoring this notes can result
injury of patient and/or user or damage of the EVair.
Keys, compressor labels and information in the display: Keys, such as Enter, compressor labels, such as Air IN
are shown in bold, italic type.
References to pages and chapters: The symbol (► XY) is used for references to pages and
chapters (► 8.2 Weekly Check).
Ventilator information and instructions Refer to the Datex-Ohmeda, Inc. Ventilator User Refer-
ence Manual for ventilator information and instructions.
Version 1.1 Page 5 of 87

Positioning inside the cart
Orientation
Right side Front Left side Back

1 Preface
1.1 Operation Symbols The following symbols can be found on the EVair operating board:
Power switch:
On/Stand-by mode
Navigation and value setting key Up
Navigation and value setting key Down
Enter key: change menu level, apply changed

value.
Air Input Air IN for an external air supply network
Air Output Air OUT
Information alert:
Check Filters
Information alert:
Compressor Service
Information alert:
Temp too high
Consult operating instructions

1.2 Symbols The following symbols can be found on the device label.
Manufacturer
Dist. By: Distributed by
Type Type of compressor
REF Part number
SN: xxxx Serial number
Fabrication date: year-month
Fuse
Mains input:
220-240V~50-60Hz
or 110-120V~60Hz
IP21 Protection for housing acc. to EN 60 529.
electrical waste
must not be disposed as unsorted municipal waste
and must be collected separately
This device contains phthalates
Heavy object
CE number
Product is CSA certified for U.S. and Canadian

markets and meets the applicable standards.
Dangerous electrical voltage
Unplug AC power before opening/servicing
Caution for rotating fans

2 Safety Instructions
2.1 Symbols for Danger, Warn- The symbols below are used to draw your attention specifically to the re-
ings and Notes maining dangers associated with proper use and to emphasize important
technical requirements.
Information or directions / warnings to prevent any sort of dam-

age / risk.
2.2 Personnel
The EVair should only be operated by trained and authorized
personnel.
The repair work listed in this manual should only be carried out
by trained and authorized personnel. All other repairs should only be
carried out by trained and authorized service personnel. Always refer to
the individual manufacturer's User or Service manual.
2.3 EMC issues Changes or modifications to this system not expressly approved by the
manufacturer may result in increased emissions or decreased immunity
performance of the equipment or system and could cause electromagnetic
compatibility (EMC) issues with this or other equipment. This system is de-
signed and tested to comply with applicable regulations regarding EMC and
shall be installed and put into service according to the EMC information
stated as follows.
The EVair must not be used in MRI environment.
Use of portable phones or other radio frequency (RF) emitting

equipment near the system may cause unexpected or adverse opera-
tion.
The EVair shall not be used adjacent to, or stacked with, other
equipment. If adjacent or stacked use is necessary, the equipment or
system shall be tested to verify normal operation in the configuration in
which it is being used.
When installed in the cart the EVair can be stacked with a Datex-
Ohmeda Inc. critical care ventilator and its accessories.
To avoid the risk of electric shock, this equipment must only be

connected to a supply mains with protective earth.

2.4 Basic Safety Information

and Warnings
Make sure that the air intake and output of the EVair are always
unobstructed. The air intake is located on the side and the output is
located on the bottom of the EVair.
Only use clean, oil-free feeds from the EVair to the ventilator to
prevent any contamination of the compressed air.
Do not directly supply the patient with compressed air from the
EVair compressor.
Do not sterilize the EVair.
Only use the EVair in a clean environment.
If you notice that the EVair is damaged in any way, the supply
of air to the ventilator can no longer be guaranteed. Stop delivery of air
with the defective EVair immediately and use an independent air sup-
ply.
No modification on the EVair is allowed.

2.5 Guidelines for Maintenance

and Repair
Maintenance work must always be carried out in compliance
with all relevant safety regulations. Repairs, assembly, and use should
only be carried out by specialist personnel. Your EVair should be
checked by trained service personnel following every year or 5,000
hours of operation and every three years or 15000 hours of operation.
Only do the care and maintenance in a hygienic environment.

Always clean your hands before do the maintenance. Use only clean
replacement parts.
To ensure the safe and effective functionality of the EVair it is

imperative that maintenance is performed according to instructions.
Only use components recommended by the manufacturer.
(►4 Location of EVair Assemblies)
Never use lubricants sealants, threadlockers, oil grease or loc-

tite in or at air handing parts during maintenance and repair.
Always disconnect the pressure hoses by slowly removing the

hose connectors to let remaining pressure escape safely before you
start with maintenance or repair work.
To guarantee the safety of the device and the personnel always

switch off and disconnect the EVair from the mains supply.
To make sure the maintenances or repairs are completely done

and the functionality of the EVair can be guaranteed this service manu-
al provides check lists to go through the maintenances and repairs.

2.6 Air quality

The EVair can only deliver medical air of sufficient quality if all
the filters are maintained in accordance with instructions for care.
(► 8 Maintenance)
The air quality of the supply network connected to Air IN must

be according to ISO 7396-1:2007
2.7 Contraindications No known contraindications to the use of the EVair compressor.
2.8 Accessories and Spare

Parts
Use of accessories that are not listed in the associated product
documentation may cause unexpected or adverse operation.
2.9 Responsibilities and Guar- The manufacturer assumes no responsibility or guarantee, and exonerates
antees himself accordingly from liability claims, where the operator or any third
party has:
• Used the EVair improperly
• Disregarded technical data
• Tampered with the EVair in any way (modifications, changes, etc.)
• Operated the EVair using accessories that are not listed in the associ-
ated product documentation.

3 Theory of operation
3 Theory of operation
3.1 Pneumatic Block Diagram
3.1.1 Air Source The pneumatic block diagram shows the technical principle of the EVair.
The heart is a dual head piston compressor which provides oil free com-
pressed air. The flow restrictor 1 creates an internal pressure of approxi-
mately 450 kPa (4.5 bar, 71 psi). Two fans (FAN1, FAN2) are used for cool-
ing down the piston compressor.
3.1.2 Drying System The heat exchanger cools down the hot and compressed air to approxi-
mately 3 degrees above ambient temperature. The water trap dries the
compressed air by separating the moisture into the water trap bowl. The
water trap drains into a drain pan, which is heated by the temperature of the
motor. The pre-dried air flows through the membrane dryer. This membrane
dryer takes out additional moisture so that the dew point depression of the
compressed air will reach 7 to 10 degree below ambient temperature.
3.1.3 Output Pressure Control The 3/2 way distributor valve fills the air in the tank until the pressure,
measured with the pressure transducer (P1), reaches the pre-set output
pressure. When the pressure reaches the pre-set pressure the 3/2 way dis-
tributor valve switches the air to the silencer. A two point controller regulates
the output pressure within a tolerance of ±25 kPa (±0.25bar, ±3.6psi) of the
pre-set output pressure. The volume of the air tank is 2 L.
3.1.4 Filtering The EVair uses a three filter system that has a 5μm filter (micro filter/auto
drain), a 0.01μm micro filter, and an active carbon filter. This filter system
fulfils the ISO 8573 requirement for medical air.
3.1.5 Backup System The EVair can be used as a backup system for central air pipeline systems.
In this case the piped air will be connected to the inlet connector (Air IN)
and is directly available through the check valve 2 on the outlet connector
(Air OUT). The check valve 1 protects the internal pneumatic parts from
piped gases. The pressure transducer (P2) monitors the piped pressure. As
long as the piped pressure is above a pre-set threshold the EVair stays in
standby mode. If the piped pressure drops below a pre-set threshold, the
EVair will automatically start normal operation and provide medical air to the
outlet connector (Air OUT).

3.2 Electronic Block Diagram
3.2.1 Power Supply The device provides an EMC filter with two fuses for the mains input. The
voltage gets converted to electrically isolated 9V DC with a transformer and
a rectifier. A voltage regulator stabilised the voltage to 5V for the micro con-
troller.
3.2.2 User Interface The User Interface consists of a two-line character display and a Keypad for
user inputs.
3.2.3 Sensors The control board provides two pressure sensors P1 and P2 for pressure
monitoring and two temperature sensors for temperature measuring.
T1 is located on the control board and T2 in the compressor chamber.
3.2.4 Micro Controller The micro controller processes sensor signals and UI-signal inputs and
controls all actuators.
3.2.5 Actuators The actuators are controlled by the micro controller over electrically isolated
opto triode alternation current switches.

4 Location of EVair Assemblies
4.1 Instrument overview
5
9
10
10
6
6
1
8 2 2
11
13
7 4
12

4.2 Spare Parts

Reference Part No. Description
1 200-041-000 Fan MU Series 220-240V
1 200-041-001 Fan MU Series 110-120V
2 302-086-000 Filter bowl
3 302-100-000 Drain bowl
4 200-043-000 AC Mains Filter Assembly
5 302-012-000 Keypad EVair
6 301-963-000 Check Valve HCVU 08
7 200-042-000 Motor Capacitor 220-240V
7 200-042-001 Motor Capacitor 110-120V
8 302-066-000 High Temperature Tube EVair
9 302-013-000 Air Connector EVair
9a 9913-6557-800 DISS
9b 1505-3830-000 DISS Female
9c 1001-5826-000 NIST
9d 1010-7048-000 S90-116 Fitting
9e 1505-3831-000 SIS
9f 1010-3220-000 Seal
9g 1006-3614-000 O-Ring -019 70 EPDM
10 302-051-000 1/4 Turn Fastener
11 100-075-100 Exhaust Silencer
12 100-037-000 Rubber Buffer Motor
13 302-349-000 Air Intake Filter
2064368-001 Hose DISS/M16
2064371-001 Hose SIS/M16
2064369-001 Hose NIST/M16
2064370-001 Hose 590-116/M16
2064373-001 Hose DISS Body/M16
2066647-001 AC P-clip 1/4”
2066648-001 AC P-clip 3/8”
0140-6226-111 Screw M4x12 for P-clip
0144-1025-165 Washer flat for P-clip
302-089-000 EVair LCD Display
302-015-000 Display Cable EVair
302-026-000 Temperature Sensor NTC EVair
302-032-000 Well-Nut M6
0144-2131-918 M6 X 30 SKT HD for Well-Nut
1505-3034-000 Nylon Washer for Well-Nut
302-034-000 Packaging EVair (shipping material)
100-079-000 PEUR (Clear polyurethane) Tube 8 x 5.5mm
(per meter)
100-111-000 Tubular Stiffener
200-030-001 Fuse SPT 5x20 4 A (Ceramic) 220-240V
200-030-002 Fuse SPT 5x20 6.3A (Ceramic) 110-120V
302-090-000 EVair Control Board 220-240V

302-122-000 EVair Control Board 110-120V
302-016-000 Bottom Pad

4.3 Assemblies
302-031-000 Weekly Maintenance Kit
Cabinet Filter 140x260mm
302-082-000 Annual Maintenance Kit

Cabinet Filter 140x260mm
Air Intake Filter
Micro Filter 0.01μm
Active Carbon Filter
Filter 5μm (filter in watertrap)
500-017-000 Motor Kit
302-046-000 Filter Unit KSUS-014

Filter Unit KSUS-014
Threaded Fitting Male Connector 1/4 BSPT
Threaded Fitting Swivel Branch Tee 1/4 BSPT
DELTA PT Screw WN 5451 30x10
302-049-000 Water Trap KFIL-014

Water Trap KFIL-014
Threaded Fitting Swivel Elbow 1/4 BSPT
DELTA PT Screw WN 5451 30x10
302-099-000 Membrane Dryer Kit

Membrane Dryer
Exhaust Muffler
Cable tie
Isolation Tube 100mm


302-113-000 Compressor Plate EVair 220-240V
Motor EVair 220-240V
3/2 Valve EVair 220-240V
Compressor plate
Motor Capacitor 220-240V
302-118-000 Compressor Plate EVair 110-120V

Motor EVair 110-120V
3/2 Valve EVair 110-120V
Compressor plate
Motor Capacitor 110-120V
302-057-000 Motor EVair 220-240V

Pump 220-240V 50-60Hz
Compressor Cable Blue
Compressor Cable Brown
Isolation Tube
Rubber Buffer Motor
302-119-000 Motor EVair 110-120V

Pump 110-120V 60Hz
Compressor Cable Blue
Compressor Cable Brown
Cable Isolation Tube Ø10x360mm
Rubber Buffer Motor
302-088-000 3/2 Valve EVair 220-240V

3/2 Valve 6014 220-240V
Throttle Fitting
Exhaust Throttle
Rubber Buffer Valve
Hex Socket Head M4x6mm
302-121-000 3/2 Valve EVair 110-120V

3/2 Valve 6014 110-120V
Throttle Fitting
Exhaust Throttle
Rubber Buffer Valve
Hex Socket Head M4x6mm
302-006-000 Air Service Unit

Water Trap KFIL-014
Filter Unit KSUS-014
Mounting plate

301-994-000 EVair Compressor 220-240V
301-995-000 EVair Compressor 110-120V

4.4 Accessories 302-237-000 ICD 3 Programmer Kit

MPLAB ICD 3 module (ICD 3 programmer)
USB cable
RJ-11 cable
CD with MPLAB IDE software

5 Service Mode
5 Service Mode
5.1 Access Code The Service menu displays the different service access.
Press the down arrow 3 times, immediately after power-on, to enter the
service menu, with its various functions and information.
5.2 Overview The service mode includes six different monitoring screens.
• System information (► 5.3 System Information)
• System test (► 5.4 System Test)
• Reset alerts (► 5.5 Reset Alerts)
• Actuators check (► 5.6 Actuators Check)
• Statistical information (► 5.7 Statistical Information)
• Change settings (► 5.8 Change Settings)
Scroll through the menu, or select another display value by pressing the
navigation buttons Up and Down. To select an option, press the Enter but-
ton to exit an option press the Power button.

5.3 System Information The initial monitoring screen shows the software version and serial number
of the EVair
5.4 System Test The second monitoring screen shows the full system test, including leakage
test.
Occlude the Air OUT fitting on the front panel. (15).
Press Enter to start the test. When the test completes the results are shown
on the monitoring screen.
• If the EVair passes the system test, the function of the EVair can be
guaranteed.
• If the EVair does not pass the system test, the function of the EVair
cannot be guaranteed. Do the following maintenance:
□ Check all tubes for leaks.
□ Check all connectors and the drain valve.
□ Perform the system test again.
If the EVair still does not pass the system test, perform Actuator Check (see
5.6). Replace any actuators that are defective. (► 9 Repair)
If no actuators need to be replaced, do the motor service. (► 8.5 Motor
Service)

5 Service Mode
5.5 Reset Alerts To reset the alerts use the reset warning screen by pressing Enter twice.
5.6 Actuators Check Use this monitoring screen to test each actuator separately. Press Enter to
switch on/off an actuator. Use the Up and Down Keys to navigate between
the available actuators.
5.7 Statistical Information This monitoring screen shows statistical information for the number of times
the valve has opened and closed, the maximum input/output pressure, and
the temperature of the Control Board or compressor.
To reset a statistic, navigate to the monitoring screen, and then press Enter
twice.

5.8 Change Settings Use this monitoring screen to change the settings of the EVair. Press Enter
and the Up/Down button to change the value.
Screen 30:
Lower pressure threshold at the Air IN for the automatic backup start.
Range: 240 to 320 kPa (34.8 to 46.4 psi, 2.4 to 3.2 bar)
Screen 31:
Higher pressure threshold at the Air IN for the automatic backup stop.
Range: 20 to 100 kPa (2.9 to 14.5 psi, 0.2 to 1.0 bar)
Screen 32:
The displayed unit of the pressure values.
Displayed units: kPa, psi, bar

6 Troubleshooting
6 Troubleshooting
Symptom Problem Troubleshooting Actions Required

Cannot pass the Engström Air Timing of the calibration of the If the calibration fails two or three consecutive
Flow Control Valve Calibration flow valve is not allowing the calibration routines identify another source of Air,
compressor reservoir to re- (Air Cylinder/w regulator or Pipeline Air source)
fresh due to flow demand. Re run calibration
Compressor does not reach There is a leak internal or • Make sure the ventilator is off
the 300kpa in 15 seconds external • Perform System Test (► 5.4 System Test)
• Check the connection from the compressor
to the ventilator for leaks
• Check the “O” ring between the M16 adapter
and the compressor fitting (AIR OUT) for
leaks
• Check compressor internal tubing connec-
tions for leaks
•
Compressor test section pres- The difference between the • Check the hose connection (Jumper) at the
sure difference (► 10.3 Check two displayed pressures ex- compressor “AIR OUT” to the “AIR IN”.
list Functional Test “Pressure ceeds 60kPa (0.6 bar, 8.7 psi) • Perform System Test (► 5.4 System Test)
01”) step 4 fail
Compressor test section check Max Pout value exceeds • If Max Pout exceeds 50kPa after 9 minutes
valves (► 10.4 Check list 50kPa (0.5bar, 7.3 psi) after 9 check valve 1 is leaking  change check
Functional Test “Pressure 02”) minutes valve 1
step 5 fail
Max Pin value exceeds 50kPa • If Max Pin exceeds 50kPa after 20 seconds
(0.5bar, 7.3 psi) after 20 sec- check valve 2 is leaking  change check
onds valve 2
Compressor fails System Test Leak is > specified rate • Check the “O” ring between the M16 adapter
(► 5.4 System Test) and the compressor fitting (AIR OUT and AIR
IN) for leaks
• Check tubing connections and filters
• Check connections at the drain valve
• Disconnect the hose at the ventilator and
attach to the AIR IN connection (Create a
jumper) Turn the compressor ON. Use leak
solution (Soap and water) to check connec-
tions for leaks. Repair leaks or replace
clogged filters
Compressor flow test (► 10.5 Measured flow is < 35 LPM at • Check tubing connections and filters
Check list Functional Test 300kpa +0/-20kkpa • Check connections at the drain valve
“Flow”) Fails • Disconnect the hose at the ventilator and
attach to the AIR IN connection (Create a
jumper) Turn the compressor ON. Use leak
solution (Soap and water) to check connec-
tions for leaks. Repair leaks.


No pressure at Air Out Compressor unable to supply Enter the service mode and go to the “ON/OFF
Air to vent Actuators” mode. Turn the compressor ON and
the Solenoid valve ON.
• If the pump motor is not running

o Check for AC voltage going to the
pump motor. If not present at the
control board replace the control
board
o If AC voltage is present replace the
motor cap or pump assembly
• If the motor is running.
o Toggle the solenoid valve and listen
for a click to verify the switching. If it
does not click the issue could be the
solenoid or the control board.
o Turn compressor off remove the tub-
ing going to the solenoid and turn
compressor back ON. If no pressure
is present from the pump replace the
pump.
• If pressure is present at the pump and after
the solenoid in this mode but not in normal
operation the issue could be the control
board.
In the service mode select “Show Statistics” and

reset the valve switching numbers. Turn the
compressor OFF and then back ON. Allow the
compressor run for a couple of minutes and enter
the service mode again and look at the solenoid
valve numbers. If the there is no change in the
value numbers the control board could be the
issue.
5,000hr maintenance/filter The 5,000 maintenance/filter replacement should
replacement alarm be performed
LCD pointer
15,000hr motor maintenance The 15,000hr motor maintenance should be per-

required formed.
LCD pointer

6 Troubleshooting

Internal high temperature • Use the service mode to navigate to
condition. “Show Statistics” and look at the Max T
Comp for high temperatures.
• In the service mode go to Actuators
Check. Go to the Fan screen and turn
LCD Pointer the fans “ON” verify both fans are run-
ning. Replace the fan(s) that are not run-
ning.
Both 5,000hr and 15,000hr Perform both 5,000hr and 15,000hr filter/motor
maintenance are required maintenance
LCD Pointers
Compressor does not turn on AC Inlet fuse open In standby mode the LCD’s backlight (Green in
color) should be illuminated. Check AC fuses at
the AC main inlet module. Replace the fuse(s)
LCD Backlighting is not AC Inlet fuse open/Bad dis- Check AC fuses at the AC mains inlet module.
illuminated play board Replace the fuse(s). If the fuses are OK and the
compressor turns “ON” replace the display board.


7 Preparing for Maintenance and Repair
7.1 Tools required The following list includes all tools that are required to do the maintenance or
repair work.
Allen wrench 2.0; 2.5; 3.0mm
Open end wrench 8.0; 12.0; 14.0; 17.0mm
Torx No. 15; 25
Philips screwdriver No. 5
Flat head screwdriver No. 1
Service handle (5370055)

requires 2
Flow measuring device with
adjustable valve
a) 1505-8578-000 c d
b) 9913-6557-800 DISS a b
1001-5826-000 NIST
1505-3831-000 SIS
c) 0221-1002-883 DISS H-I-T
Fem Air (Obtain locally for e
NIST or SIS adapters) f
d) 1006-3666-000
e) 0219-5060-000
f) 1605-3134-000

7.2 Removing and installing the compressor in the cart
7.2.1 Removing the compressor from the cart:
Description Picture OK
Lock the casters on the ventilator cart. a

□
If the cart has trim pieces on the side extrusions, remove
them. (a)
b
□
Tap in a screwdriver blade at the base of the trim, and
then use the screwdriver to pry the trim loose. (b)
Install a handle (5370055) into each side of the compres-

sor and tighten them with your hand. (c) □
Remove the four M6x30 screws and Nylon Washers from
the mounting holes on the cart. (d) □
c
d
With a person on each side of the compressor holding a
handle, lift the compressor and slide it out of the ventilator
e
□
cart.
The well nuts may dislodge from the cover when the d
compressor is removed. (e)
7.2.2 Installing the compressor on the cart:
Lock the casters on the ventilator cart.

□
Install a handle (5370055) into each side of the compres-
□
a
sor and tighten them with your hand. (a) c
b
With a person on each side of the compressor holding a

handle, lift the compressor and slide it onto the ventilator c
□
cart. (b)
Align the mounting holes on the cart with the holes on the
compressor. Remove the handles after the compressor is □
positioned.
Insert the four M6x30 screws and Nylon Washers through

the mounting holes, and then tighten them with the 5mm □
hex wrench to 0.9 Nm. (c)
If the cart has trim pieces, install them on the extrusions.

□

7.3 Opening/closing the compressor at the left side
7.3.1 Opening the left side:
Turn the two quarter turn fasteners (a) 90° CCW with a
Philips screwdriver No. 5. □
The panel is slotted on the left side. Open the panel from
the right side. When removing the cover be aware of the
a
□
grounding cable. Grounding cable
Disconnect the grounding cable.

a □
7.3.2 Closing the left side:
Connect the grounding cable.

□
Close the cover.
a □
Turn the two quarter turn fastener 90° CW. Grounding cable
□
a

7.4 Opening/closing the compressor at the right side
7.4.1 Opening the right side:
Remove the two fasteners (b) with a 2.5mm Allen wrench.

□
The panel is slotted on the left side. Open the panel from
the right side. When removing the cover be aware of the
Grounding cable □
grounding cable. b
Disconnect the grounding cable.

□
b
7.4.2 Closing the right side:

□
Close the cover.
Grounding cable □
b
Tighten the two fasteners with a 2.5mm Allen wrench.
□

7.5 Opening/closing the compressor at the back
7.5.1 Opening the back:
Remove the four fasteners (c) with a 2.5mm Allen wrench.

□
Take off the cover. When removing the cover be aware of
the grounding cable.
Grounding cable
□
Disconnect the grounding cable. c c
□
c c
7.5.2 Closing the back:

□
Close the cover. Grounding cable
□
Tighten the four fasteners with a 2.5mm Allen wrench. c c
□
c c

7.6 Removing/installing the front cover
7.6.1 Removing the front cover:
Remove all fasteners:

□ Remove the fastener (a) at the left side with a
□
2.5mm Allen wrench.
□ Remove the fastener (b) at the right side with a
2.5mm Allen wrench.
□ Remove the two fasteners (c) at the back with a a b
2.5mm Allen wrench.
□ Remove the four fasteners (d) at the front of the
EVair with a 2.5mm Allen wrench.
c c
d d
d d
Disconnect the tubes:

□ Disconnect tube including the tubular stiffener (e), e f
□
(f) and (g). g
Disconnect the cables:

□ Disconnect all cables from the Control Board.
□
Remember to disconnect the green cable in the h
back.
□ Disconnect the grounding cable (h) above the AC
mains filter assembly at the left side of the EVair.
Remove the front cover:

□

7.6.2 Closing the front cover:
Install the front cover:

□
Connect the cables:
□ Connect the grounding cable (h) above the AC
□
mains filter assembly at the left side of the EVair. h
□ Connect all cables to the Control Board. Remem-
ber to connect the green cable in the back.
Disconnect the tubes:

□ Connect tube including the tubular stiffeners (e),
□
(f) and (g). e f
g
Tighten all fasteners:

□ Tighten the fastener (a) at the left side with a
2.5mm Allen wrench.
□ Tighten the fastener (b) at the right side with a
2.5mm Allen wrench.
□ Tighten the two fasteners (c) at the back with a
a b
2.5mm Allen wrench.
□ Tighten the four fasteners (d) at the front of the
EVair with a 2.5mm Allen wrench.
c c
d d
d d


8 Maintenance
8 Maintenance
8.1 Maintenance Schedule To ensure the long term reliability and precision of the compressor, the fol-
lowing maintenance procedures must be done regularly.
To make sure the maintenances are completely done and the

functionality of the EVair can be guaranteed use the following check list
to go through the maintenances.
To prevent damage to the EVair, ESD approved clothes must

be worn when opening, repairing, or maintaining the compressor.
Before & After every use Once a week or after 48 hours of operation
Weekly Check includes: • Check, clean or replace the cabinet filter
Annual Maintenance The internal filter replacement is recommended to be replaced every 5000
hours or annually, whichever comes first on compressors that are used as
the primary source of air.
Compressors that are used as backup only require filter inspection and
functional checks annually. The internal filter replacement is still recom-
mended at 5000 hours.
The information alert appears after 5,000 hours of operation.

Annual Maintenance • Cleaning or Replacing the Cabinet Filter
includes: (►8.2 Weekly Check)
• Replace the water trap filter
(► 8.3.1 Replacing the Water Trap Filter)
• Replace the micro filter
(► 8.3.2 Replacing the Micro Filter)
• Replace the active carbon filter
(► 8.3.3 Replacing the Active Carbon Filter)
• Replace the air intake filter
(► 8.3.4 Replacing the Air intake filter)
• Perform the functional tests
(► 10 Functional Test)
Motor Maintenance Every three years or after 15,000 hours of operation, whichever comes first.
The information alert appears after 15,000 hours of operation.
Motor Check includes: • Do the motor check
(► 8.4 Motor Service)
• Perform the functional tests
(►10 Functional Test)

8.2 Weekly Check
Replacing or Cleaning the Cabinet Filter
Note:
This is user function and is documented in the URM.
Necessary spare parts:
Weekly Maintenance Kit (302-031-000) □
1. Pull out the cabinet filter:
The cabinet filter (a) is located on the left side of the □
EVair.
2. Check the filter:

Check if the filter is clean. If filter is soiled a little, □
clean it with water. Replace the filter if there are any
tears or holes in the material or if it is heavily soiled.
3. Replace or clean the filter:
Replace or clean the filter. (302-031-000) □
The cabinet filter is cleanable by careful washing in a
mild detergent.
Do not install the filter until it is completely

dry.

8 Maintenance
8.3 Annually Check All procedures in this section can be performed with the compressor in the
cart.
Description OK
Annual Maintenance Kit (302-082-000) □
1. System Test:
Condition before Annually Check. It is not necessary to pass the test. (► 5.4 System Test) □
2. Replacing or cleaning the Cabinet Filter:
(► 8.2 Weekly Check) □
3. Replacing the Water Trap Filter:
(► 8.3.1 Replacing the Water Trap Filter) □
4. Replacing the Micro Filter:
(► 8.3.2 Replacing the Micro Filter) □
5. Replacing the Active Carbon Filter:
(► 8.3.3 Replacing the Active Carbon Filter) □
6. Replacing the Air intake Filter:
(► 8.3.4 Replacing the Air intake filter) □
7. Functional Test:
(► 10 Functional Test) □
8. System Test:
Condition after Annually Check. The EVair must pass the test. (► 5.4 System Test) □

8.3.1 Replacing the Water Trap Filter

1. Turn off the EVair:
To guarantee the safety of the EVair and the service technician always turn off and disconnect the □
EVair from the mains supply.
2. Disconnect all pressure hoses:
Always disconnect the pressure hoses to let remaining pressure escape safely before starting any □
maintenance or repair work.
3. Remove the compressor from the cart:
(► 7.2 Removing and installing the compressor in the cart) □
4. Open the EVair:
Open the left side of the compressor. (► 7.3 Opening/closing the compressor at the left side) □
5. Open the filter housing:
□ To drain the filter housing, change from auto drain c d
□
to manually drain. Grasp the metal part of the wa- a a
ter valve (a) and turn CW until it stops.
Auto drain: space (c) is visible

Manually drain: space (d) is hidden
Auto drain Manually drain
□ Open the filter housing (b) by turning it CW.

□
b
6. Release the filter component:

Release the filter component (a) by turning it CW. □
a
7. Replace the filter:

Replace the white filter (a). □
a

8 Maintenance
8. Install the filter component:

Install the filter component. Make sure the pieces are □
assembled correctly.
Assembled properly Assembled wrong
9. Close the filter housing:

□ Turn the water valve (a) to auto drain. Grasp the c d
□
metal part of the water valve and turn CCW until it a a
stops.
Auto drain: space (c) is visible

10. Close the EVair:

Close the left side of the compressor. (► 7.3 Opening/closing the compressor at the left side) □
11. Install the compressor to the cart:

8.3.2 Replacing the Micro Filter

4. Open the EVair:
Open the filter housing (b) by turning it CW. a a) Micro filter
□
with housing
b) Housing
6. Release the micro filter:

Release the micro filter (b) by turning it CW.
a a) Micro filter
□
without housing
b) Micro filter
b
7. Insert the new micro filter:

□ Insert the new micro filter (green). a
a) Micro filter □
without housing & with-
□ Make sure to use the correct filter (b). out filter
b) Color code “green”
□ Close the filter housing.
b
8. Close the EVair:


8 Maintenance
8.3.3 Replacing the Active Carbon Filter

4. Open the EVair:
Open the filter housing by turning the filter housing (b) a a) Active carbon filter
□
CW. with housing
b) Housing
6. Release the active carbon filter:

Release the active carbon filter (b) by turning it CW.
a a) Active carbon filter
□
without housing
b b) Active carbon filter
7. Insert the new active carbon filter:

□ Insert the new active carbon filter (b). a a) Active carbon filter
□
□ Make sure to use the correct filter unit color. without housing and
without filter
□ Close the filter housing.
b
b) Color code “black”
8. Close the EVair:


8.3.4 Replacing the Air intake filter

4. Open the EVair:
5. Dismantle the air intake filter:
Open the two quarter turn fastener (a) and take out □
the air intake filter with a Philips screwdriver No. 5.
a a
6. Remove the air intake filter:

Remove the air intake filter by turning it with a 17mm □
wrench.
7. Install the new air intake filter:

□ Install the new air intake filter.
□
□ Tighten the two quarter turn fasteners.
a a
8. Close the EVair:


8 Maintenance
8.4 Motor Service

Motor Kit (599-017-000) □
4. Open the EVair:
Open the right side of the compressor. (► 7.4 Opening/closing the compressor at the right side)
Open the back of the compressor. (► 7.5 Opening/closing the compressor at the back)
5. Remove the compressor plate:
a a
Part 1: Remove fasteners:
□ Remove the two fasteners at the left side (a) with
b b □
a 3mm Allen wrench.
□ Remove the two fasteners at the right side (b) a) Left side b) Right side
with a 3mm Allen wrench.
Part 2: Disconnect Tubes:

a d □
□ Disconnect tube a, b and c. Make sure to not lose
the tubular stiffeners (e). e
□ Disconnect high temperature tube (d) with a
14mm wrench. b
c
Tubes connected Tubular stiffener
Part 3: Disconnect the cable: a

b
□
□ Remove the cable twister (a) at the left side of the a
EVair.
□ At the right side, disconnect the brown, blue and
the grey cables (b) from the Control Board.
a) Remove the cable b) Cables to remove
twister
Part 4: Remove the compressor plate completely: Compressor plate

□

6. Remove the motor from the motor plate:

□ Disconnect the two cables (a) from Motor Capaci-
b b □
tor.
□ Turn the motor upside down.
□ Remove the four screw nuts (b) with a 8mm
a
wrench. While removing the screw nuts, hold the

b
rubber buffer/mount with a 12mm open end b
wrench (c). Set the four lock washers aside.
□
□ Remove the plate from the motor.
□
c
Remove the four rubber buffers (c) from the motor
with a 12mm open end wrench. Note the position
of the rubber buffer for ease reassembly.
□
7. Disassembly:
a □
□ Thoroughly clean the outside of the compressor a
a
using a damp, lint-free cloth. Make sure, the com-
pressor is dry. a a
□ Loosen the eight head fastener (a) and remove

a
the compressor head with a Torx wrench No. 25. a
□ Lift off the valve plate. Remember the position of
a
the valve plate to ease reassembly.

8 Maintenance
8. Motor service:
To avoid confusion, only service one side of

□
b
the compressor at a time.
Rod: a
□ Remove the cylinder (a)

□ Remove the fastener (b) from the cup retainer (c)
with a Torx wrench No. 25.
□ Remove the cup retainer (c) and the piston cup
(d).
□ Replace the cylinder, fastener and the piston cup.
□ Install the new cylinder (a)
□ Put the piston cup and the cup retainer on the top
of the rod. Make sure it is assembled correctly.
□ Screw in the fastener.
c d
b
a
Valve plate:
□ Remove both O-rings (e).
e □
□ Remove the fastener (f) for the valve flapper (g).
Valve plate
□
f
Remove the valve flapper (g) and the valve keep- g bottom
er (h). h
□ Thoroughly clean all of the valve plate using a
damp, lint-free cloth. Make sure, the compressor
is dry.
□ Replace the O-rings, valve flapper and valve
keeper. e
□ Install the new O-ring, seating it firmly into the f
groove with your finger. h
□ Install the new valve flapper, placing the valve
Valve plate top
keeper on top so that the word “UP” is visible. g

9. Reassembly:
□
□ Put the valve plate on the top of the compressor
motor. Make sure the valve flappers are posi-
tioned, correctly on the right side (b).
□ Install the compressor head by tightening the
eight head fasteners (a) with a Torx wrench No.
25 and a torque of 4.5Nm.
a
a
a a b
b
a
a
10. Install the motor to the compressor plate:

□ Turn the motor upside down. c
□
□ Tighten the four rubber buffer (c) to the motor with
a 12mm wrench. To ensure the safety of the de-
vice, use a new rubber buffer to reassemble the
motor to the plate.
□ Install the four rubber buffers (c). making sure
they are horizontal to the motor b b
□ Put the plate on the motor.
□ Tighten the four screw nuts (b) with a 8mm
wrench. Do not forget to install the four lock
washers. While tightening the screw nuts, hold
the rubber buffer with a 12mm wrench (c). b b a
□ Connect the two cables (a) to the Motor Capaci-
tor.

8 Maintenance
11. Install the compressor plate:

□
Part 1: Put in the compressor plate: b
a
Part 2: Connect the cable:
□ On the right side, connect the brown, blue and the
a □
grey cable (b) to the Control Board.
□ Install the cable twister (a) (a) at the left side of
the EVair.
Part 3: Connect Tubes:

□ Connect high temperature tube (d) with a 14mm
a d □
wrench.
e
□ Make sure tubular stiffeners (e) are inserted into
the tubes. Connect Tube a, b and c. b
c

Part 4: Install all fasteners:
□ Tighten the two fasteners at the right side (b) with
a 2.5mm Allen wrench. a a
□ Tighten the two fasteners at the left side (a) with a b b □

2.5mm Allen wrench.
a) Left side b) Right side

Close the right side of the compressor. (► 7.4 Opening/closing the compressor at the right side)
Close the back of the compressor. (► 7.5 Opening/closing the compressor at the back)
14. Turn on the compressor:
□
15. Functional test
Do the functional tests. (► 10 Functional Test) □

8.5 Firmware Upgrade
8.5.1 Prepare Firmware Upgrade Environment:
Necessary software equipment:

-Microsoft Windows Operating System (XP or higher) □
-Microchip MPLAB IDE v.8.88 (or higher) software package
(download software ZIP package from http://www.microchip.com/)
1. Decompress MPLAB IDE software package:

Decompress the MPLAB IDE software package (ZIP) □
into a directory of your choice.
2. Execute Installation Wizard:
Start the setup wizard (setup.exe). □
3. Work through the installation steps:
The installation wizard will lead you through the re- □
quired steps to install the MBLAB IDE software.
4. Install ICD 3 drivers

A dialog with help topics will automatically appear af- □
ter the installation of the MPLAB IDE. Select the
“MPLAB ICD3 USB Driver Installation” (a) topic. Open a
the instructions by pushing the “View Selected File”
button (b). Follow the instruction in the instructions
page that appears (c).

8 Maintenance
8.5.2 Firmware Upgrade:
Necessary hardware equipment:

-PC or Laptop with at least one USB port
a c
□
-Programmer (302-237-000)
• MPLAB ICD3 module (a)
• USB cable to connect PC/Laptop with ICD 3 (b)
• RJ-11 cable to connect ICD 3 and EVair (c) b
-EVair compressor
Necessary software equipment:

-Microsoft Windows Operating System (XP or higher) □
-Installed MBLAP IDE software (v. 8.88 or higher)
-EVair Compressor.mcw (MPLAB project file)
-Firmware Hex-File
1. Turn off EVair:
Turn off and disconnect EVair from the mains supply. □
Always disconnect the pressure hoses to let remain- □
ing pressure escape safely before starting any
3. Open the EVair:
Open the left side of the compressor. (► 7.3 Open- □
ing/closing the compressor at the left side)
4. Open the EVair Compressor project file:
Open the EVair Compressor project file (.mcw) on the □
PC/Laptop (a). The project file opens the MPLAB IDE
(b) software which is used to program the firmware on a
the compressor.
5. Import the Firmware HEX File:

Import the firmware HEX file with the menu option □
File/Import….
6. Select the Programmer:
Select the ICD3 programmer with the menu option □
Programmer/Select Programmer/MPLAB ICD3.

7. Connect ICD 3 programmer to PC/Laptop:

Connect the ICD 3 programmer with the PC/Laptop by □
use of the USB cable. The programmer will perform a
self-test and will be ready for programming after a few
seconds. Read the “Voltage Caution” dialog carefully
and press the OK button.
8. Connect the RJ-11 cable to EVair
Connect the RJ-11 cable (b) to EVair programming
port (a). Make sure the RJ-11 cable is plugged into a
the programming port in the right orientation (c).
9. Connect the EVair compressor with main supply

□
10. Connect ICD 3 programmer to EVair:
Connect the RJ-11 cable (b) with the IEC 3 program- □
mer.
11. Download the firmware onto EVair:
Download the firmware onto EVair by using the menu □
option Programmer/Program. After a few seconds the
programming should be finished successfully.
12. Remove programming cable from EVair:
□
13. Enter serial number in Setup Mode:
Enter the serial number in EVair Setup Mode which □
appears after successful firmware upgrade.
14. Function Test:
Do the functional tests. (►10 Functional Test) □
Close the left side of the compressor. (► 7.3 Open- □
ing/closing the compressor at the left side)

9 Repair
9 Repair
9.1 Repairs
To make sure the repairs are completely done and the func-
tionality of the EVair can be guaranteed use the following check list to
go through the repairs.
To prevent damage to the EVair, ESD approved clothes must

be worn when opening, repairing, or maintaining the compressor.
This chapter includes the most common repairs, such as:
► 9.3 Replacing the Fuse P. 54

► 9.4 Replacing the AC Mains Filter Assembly P. 55
► 9.5 Replacing the Check Valve P. 56
► 9.6 Replacing the Compressor Plate or the Motor P. 57
► 9.7 Replacing the 3/2 Valve P. 61
► 9.8 Replacing the Motor Capacitor P. 64
► 9.9 Replacing the Fan & Temperature Sensor P. 67
► 9.10 Replacing the High Temperature Tube P. 70
► 9.11 Replacing the Air Service Unit or parts of it P. 72
► 9.12 Replacing the Membrane Dryer P. 75
► 9.13 Replacing the Control Board or Display P. 77
► 9.14 Replacing the Keypad P. 79
► 9.15 Replacing the Air Connector P. 81
Do not replace any parts of the EVair without first consulting an

authorized GE service representative. (► 11 Contacts)
9.2 Tools required The following list includes all tools that are required to do the maintenance
or repair work.
Allen wrench 2.0; 2.5; 3.0mm
Open end wrench 8.0; 12.0; 14.0; 17.0mm
Torx No. 15; 25
Philips screwdriver No. 5

9.3 Replacing the Fuse
Fuse 220-240V (4AT) (200-030-001) □
Or: Fuse 110-120V (6.3AT) (200-030-002)
3. Open the fuse barrier:
The fuses are above the AC mains connector at the □
bottom front of the EVair. Remove the barrier and
fuses by pressing the two mounting links together and
pulling out the barrier.
4. Replace the fuses:

Fuse 220-240V (4A) (200-030-001) □
Fuse 110-120V (6.3A) (200-030-002)
5. Reinsert the barrier:

□
□
7. System test:
Do the system test. (► 5.4 System Test) □

9 Repair
9.4 Replacing the AC Mains Filter Assembly

AC mains filter assembly (200-043-000) □
4. Open the EVair:
5. Disconnect cable:
Disconnect the grounding and the power cables (a) □
from the AC mains filter assembly.
6. Remove and change the AC mains filter assembly:

□ Remove the two fasteners (a) with a 2mm Allen
AC mains
filter assembly □
wrench.
□ Replace the AC mains filter assembly with the
new one. a a
□ Install the new AC mains filter assembly with the
two fasteners and connect the cables. (Part No.
200-043-000)
7. Close the EVair:
9. Turn on the compressor.
10. System test:

Do the System test. (► 5.4 System Test) □

9.5 Replacing the Check Valve

Check Valve HCVU 08 (301-963-000) □
4. Open the EVair:
5. Disconnect the tubes:
Disconnect the tubes on both sides of the check valve □
(a or b). Make sure to not lose the tubular stiffeners.
a b
a
b
6. Change and connect the Check Valve:

Make sure tubular stiffeners are inserted into the □
tubes. Connect the new check valve with the two
tubes. There is an arrow on the check valve for refer-
ence when installing.
7. Close the EVair:
10. Functional test:


9 Repair
9.6 Replacing the Compressor Plate or the Motor

Compressor Plate EVair 220-240V (302-113-000) Or: Motor EVair 220-240V (302-057-000) □
Or: Compressor Plate EVair 110-120V (302-118-000) Or: Motor EVair 110-120V (302-119-000)
4. Open the EVair:
a a
b b □
a 3mm Allen wrench.

a d □
□ Disconnect Tube a, b and c. Make sure to not
lose the tubular stiffeners (e). e
14mm wrench. b
c

b
□
□ Remove the cable twister (a) (a) at the left side of a
the EVair.
□ At the right side disconnect the brown, blue and
the grey cable (b) from the Control Board.
a) Remove the cable b) Cable to remove
twister
Part 4: Remove the compressor plate completely: Compressor plate □

6. Change the compressor plate:

Change the broken compressor plate with the new □
compressor plate.
220-240V ( 302-113-000)
110-120V (302-118-000)
7. Remove the motor from the compressor plate:

□ Disconnect the two cables (a) from the Motor Ca-
b b □
pacitor.
□ Remove the four screw nuts (b) with a 8mm
a
wrench. While removing the screw nuts lock the

b
rubber buffer with a 12mm open end wrench (c). b
Take care of the 4 lock washers.
□ Remove the plate from the motor.
□ Remove the four rubber buffer (c) from the motor
with a 12mm open end wrench. Note the position
of the rubber buffer for ease reassembly. c
8. Replace the motor:

Replace the old motor with the new one.
220-240V (302-057-000)
110-120V (302-119-000)

9 Repair
9. Install the motor to the compressor plate:

□ Tighten the four rubber buffer (c) to the motor with
a 12mm wrench. To ensure the safety of the de-
vice, use a new rubber buffer to reassemble the
motor to the plate. c
□ Install the four rubber buffers (c) making sure they
are horizontal to the motor.
□ Put the plate on the motor.
□ Tighten the four screw nuts (b) with a 8mm
wrench. Do not forget to install the four lock
washers. While tightening the screw nuts, hold the
b b
rubber buffer with a 12mm wrench(c).
□ Connect the two cables (a) to the capacitor.
b b a

□
Part 1: Put in the compressor plate:
b
□
Part 2: Connect the cable: a
□ On the right side, connect the brown, blue and the a

□ Install the cable twister (a) (a) at the left side of
the EVair.

a d
□
wrench
□ Make sure tubular stiffeners (e) are inserted into e
the tubes. Connect Tube a, b and c.
b
c
Part 4: Install all fasteners

□ Tighten the two fasteners at the right side (b) with
a 2.5mm Allen wrench.
a a
b b
□
□ Tighten the two fasteners at the left side (a) with a
2.5mm Allen wrench.





9 Repair
9.7 Replacing the 3/2 Valve


3/2 Valve EVair 220-240V (302-088-000) □
Or: 3/2 Valve EVair 110-120V (302-121-000)
4. Open the EVair:
a a
b b □
a 3mm Allen wrench.

a d □
14mm wrench. b
c

b
□
□ Remove the cable twister (a) (a) at the left side of a
the EVair.
twister
Part 4: Remove the compressor plate completely:

Compressor plate
□

6. Remove the 3/2 Valve:

□ Remove the four fastener (a) at the bottom of the
□
motor kit with a 3mm Allen wrench. a
□ Remove the 3/2 valve. The cable is included in

the new 3/2 valve.
7. Install the new 3/2 Valve:

To install the new 3/2 valve, use the old fasteners. □
220-240V (302-088-000)
110-120V (302-121-000)

□
b
□

□ Install the cable twister (a) at the left side of the
EVair.

a d
□
wrench.
b
c

□
□ Tighten the two fasteners at the right side (b) with a a
a 2.5mm Allen wrench. b b
2.5mm Allen wrench.

9 Repair
9. Close the EVair:

□
Do the functional tests. (► 10 Functional Tests) □

9.8 Replacing the Motor Capacitor

Capacitor, Motor 220-240V (200-042-000) □
Or: Capacitor, Motor 110-120V (200-042-001)
4. Open the EVair:
a a
b b □
a 3mm Allen wrench.

a d □
14mm wrench. b
c

b
□
EVair.
twister
Part 4: Remove the compressor plate completely: Compressor plate □

9 Repair
6. Remove the Motor Capacitor:

□ Disconnect the two cables (a).
□
□ Cut the two tie wraps (b).
b b
a
7. Install the new Motor Capacitor:

□ To install the new Motor Capacitor use the tie
□
wraps delivered together with the new Motor Ca-
pacitor.
□ Connect the two cables.
220-240V (200-042-000)
110-120V (200-042-001)
□
b
□

EVair.

a d
□
wrench.
b
c

□
2.5mm Allen wrench.

9. Close the EVair:

□

9 Repair
9.9 Replacing the Fan & Temperature Sensor
Fan MU Series 220-240V (200-041-000) Or: Temperature Sensor NTC EVair (302-026-000) □
Or: Fan MU Series 110-120V (200-041-001)
4. Open the EVair:
a a
b b □
a 3mm Allen wrench.

a d □

14mm wrench. b
c
□
b
a
Part 3: Disconnect the cable:
EVair.
the grey cable (b) from the Control Board. a) Remove the cable b) Cable to remove
twister
Part 4: Remove the compressor plate completely:

Compressor plate
□

6. Remove and replace the fan:

Disconnect the black cable (a) from the Control □
Board. Cut the tie wrap (d) and pull out the cable.
Remove the eight fasteners (b) and lock washers with
a 3mm Allen wrench to remove the fans. a
While removing the fans note the location of

the temperature sensor cable (c). It is located at the
first fastener at the left side.
Install the new fans with the fastener and the lock
b b
washers packaged with the fans.
220-240V (200-041-000) c
110-120V ( 200-041-001) d
Connect the temperature sensor cable to the original b b

location on the fan. b b
b b
7. Remove and replace the temperature sensor:

To remove the temperature sensor cable, remove the □
first fastener at the left side (b) with a 3mm Allen
wrench. Cut the tie wrap (c) and pull out the cable at
the left side of the EVair and disconnect it from the
Control Board (a).
a
Connect the new temperature sensor cable
(302-026-000) to the Control Board and pull it into the
hole to the motor.
Install the cable to the fan with the fastener.

b

9 Repair

□
b
□

EVair.

a d
□
wrench.
b
c

□
2.5mm Allen wrench.
9. Close the EVair:

□

9.10 Replacing the High Temperature Tube
High Temperature Tube EVair (302-066-000) □
4. Open the EVair:
5. Remove the front cover:
(► 7.6 Removing/installing the front cover) □
6. Remove the high temperature tube:
Disconnect the high temperature tube (a) from the □
motor (b) and from the heater exchanger (c) with two
wrenches.
To disconnect the high temperature tube

from the heater exchanger, use 14mm and a 12mm
wrench (d).
7. Install the new high temperature tube:

Connect the high temperature tube (302-066-000) to □
the motor and the heater exchanger with two wrench-
es.
To connect the high temperature tube to the

heater exchanger, use a 14mm and a 12mm wrench
(d).

9 Repair
8. Install the front cover:

9. Close the EVair:
□

9.11 Replacing the Air Service Unit or parts of it

Air Service Unit (302-006-000) □
Or: Filter Unit KSUS-014 (302-046-000) Or: Filter bowl (302-086-000)
Or: Water Trap KFIL-014 (302-049-000) Or: Drain bowl (302-100-000)
4. Open the EVair:
6. Remove the Air Service Unit:
□ To drain the filter housing, change from auto drain
c c
b
b
b
b
□
to manually drain. Grasp the metal part of the wa- c b
ter valve (a) and turn CW until it stops.
□ Disconnect tubing at connectors (b). Make sure to
not lose the tubular stiffeners.
□
c
Remove the four fasteners (c) with a 3mm Allen b
wrench and remove Air Service Unit. Air service unit
d e
a a
Auto drain: space (d) is visible
Manually drain: space (e) is hidden
7. Replacing the Air Service Unit:
Change the air service unit.

Part No. 302-006-000

9 Repair
8. Replacing the filter unit or the water trap:

a a □
To remove the filter unit remove the two fasteners (a)
with a Torx wrench No. 15.
b b
Part No. 302-046-000
To remove the water trap remove the two fasteners

(b) with a Torx wrench No. 15.
Part No. 302-049-000
Install the new filter unit or water trap.
Make sure the filter unit or water trap is in-

stalled in the correct direction.
9. Replacing the bowl of the filter unit:

Part No. 302-086-000 □
Remove the bowl of the filter unit and replace it with
the new one.
10. Replacing the bowl of the water trap:

Part No. 302-100-000 □
a b
□ Disconnect the tube at the bottom of the bowl.
□ Remove the bowl of the water trap and replace it
with the new one.
□ Make sure the water valve is in the auto drain
mode.
Auto drain: space (a) is visible

Manually drain: space (b) is hidden

11. Install the Air Service Unit: c c b

b
b
□
□
b
Put in the Air Service Unit. c b
□ Tighten the four fasteners (c) with a 3mm Allen

wrench.
□ Make sure tubular stiffeners are inserted into the c
tubes. Connect all tubes (b). b
Air service unit
□ Switch the water valve (a) to the auto drain mode.

□
c d
a
Auto drain: space (c) is visible a

□

9 Repair
9.12 Replacing the Membrane Dryer

Membrane Dryer Kit (302-099-000) □
4. Open the EVair:
6. Disconnect the membrane dryer:
Disconnect the tube (a) at the back and tube (b) at the b □
left side. Make sure to not lose the tubular stiffeners.
Back Left side
7. Remove the membrane dryer:

Cut the tie wrap (a) to remove the membrane dryer: □
Position the foam over the bleed holes on the re- a
placement dryer.
8. Install the new membrane dryer:

Install the new membrane dryer with the new tie □
wraps.
Part No. 302-099-000
Make sure to install the membrane dryer in

the correct direction. Note the direction arrow on the
dryer part.

9. Connect the membrane dryer:

Make sure tubular stiffeners are inserted into the □
tubes. Connect the tube (a) at the back and tube (b)
at the left side.
□

9 Repair
9.13 Replacing the Control Board or Display
EVair Control Board 220-240V (302-090-000) Or: EVair LCD Display (302-089-000) □
Or: EVair Control Board 110-120V (302-122-000) Or: Display Cable EVair (302-015-000)
4. Open the EVair:
6. Replace the control board:
□ Turn the front cover upside down.
□
□ Disconnect the display cable (a).
c c
□ To disconnect the keypad cable (b) you must re-
lease the cable by pulling out the two locks (c). b
□ Carefully remove the six flat washers and fasten-

ers (d) with a 3mm Allen wrench.
□ Take off the control board and replace it with the d a d d
new one. Use the same fasteners to install it.
d
220-240V (302-090-000) d
110-120V (302-122-000)
d
7. Replace the display or the display cable:

□
Replace the display:
□ Disconnect the display cable (a). b b
□ Remove the four fasteners (b) carefully with a

a
Philips screwdriver. b
b
□ Take off the display and replace it with the new
one. Use the same fasteners to install it.
Part No. 302-089-000
Replace the cable:

□ Disconnect the cable from the control board and
the display.
□ Replace the display cable.
Part No. 302-015-000


9. Close the EVair:
□

9 Repair
9.14 Replacing the Keypad

Keypad EVair (302-012-000) □
4. Open the EVair:
6. Disconnect the keypad cable:
Turn the front cover upside down. Disconnect the □
keypad cable (a). To do that you must release the ca-
ble by pulling out the two locks (b). b b
7. Remove the Air IN and Air OUT connectors

(► 9.15 Replacing the Air Connector) □
8. Remove the keypad:
The keypad is glued on the front cover. To remove it, □
use a cutter or a putty knife. Clean the surface with
alcohol.
9. Attach the new keypad:
□
Put the keypad cable into the cable hole (a) and con- a
nect it to the Control Board. Front cover
without key-
Remove the film to expose adhesive and install the pad
keypad.
Part No. 302-012-000


□

9 Repair
9.15 Replacing the Air Connector
Air Connector EVair (302-013-000) □
4. Open the EVair:
6. Remove the air connector:
□ Turn the front cover upside down. a
a
□
□ Disconnect the tubes from the air connector by b
removing the threaded fitting (a) from the air con-
nector. a
b
□ Remove the air connector by removing the nuts
(b) with a 24mm wrench.
Air connector with Air connector with-
tubes out tubes
7. Install the new air connector:

□ Install the new air connector with a 24mm wrench.
□
□ Connect the tubes.
□ Make sure they are connected properly.
Part No. 302-013-000


9. Close the EVair:
□

10 Functional Test
10 Functional Test
10.1 Functional Tests

Perform all functional tests after any maintenance or repairs are
done to the compressor to guarantee the correct supply of air to the
ventilator.
To make sure the functional tests are completely done and the
functionality of the EVair can be guaranteed use the following check list
to go through the tests.
10.2 Test Schedule Perform electrical safety tests after any maintenance or repairs.

10.3 Check list Functional Test “Pressure 01”

Always disconnect the pressure hoses by slowly un-
□
tightening the hose connectors to let remaining pres-
sure escape safely before you start with the functional
test.
2. Connect Air OUT and Air IN:
Disconnect the hose from the ventilator air connection
□
and connect it to the compressor AIR IN connection.
If the air supply hose is connected to the Air IN, re-
move the hose in order to connect the ventilator hose.
3. Start the EVair
Press the Power Button.
4. Functional test
□
□ Allow the compressor to run until it reaches the
standby setpoint (compressor will stop).
The display will show the AIR IN and AIR OUT
pressure. The difference between the two displayed
pressures must not exceed 60 kPa (0.6 bar, 8.7
psi).
□ Turn the compressor power off.
□ Disconnect the hose from the compressor AIR IN
connection and reconnect the hose to the ventilator
air connection.
□ Turn on the EVair. The compressor pressure
should reach 300 kPa (3.0 bar, 43.5 psi) within 15
seconds or less.
5. Values OK:
If the values are ok, the proper function of the EVair
□
can be guaranteed.
6. Values not OK:
If the values are out of the range, the proper function of
□
the EVair cannot be guaranteed. (► 6 Troubleshoot-
ing)

10 Functional Test
10.4 Check list Functional Test “Pressure 02”

Always disconnect the pressure hoses by slowly un-
□
tightening the hose connectors to let remaining pres-
sure escape safely before you start with the functional
test.
2. Lock the AIR IN:
Use the flow measuring device with adjustable valve to
□
lock the AIR IN.
3. Display Values Max Pout Max Pin
□ Enter the service mode (► 5 Service Mode)
□ Reset Max Pout and Max Pin, see statistical infor-
mation. (► 5.7 Statistical Information)
4. Supply AIR OUT

Connect a pressure hose to the AIR OUT connector
□
and supply with >300kPa.
5. Functional test
□
□ Connect a pressure hose to the air OUT connector
and supply with >300kPa for.
□ Max Pout value must not exceed 50kPa (0.5bar,
7.3 psi) after 9 minutes.
□ Max Pin value must not exceed 50kPa
(0.5 bar, 7.3psi) after 20 seconds.
7. Values OK:
If the values are ok, the proper function of the EVair
□
can be guaranteed.
6. Values not OK:
If the values are out of the range, the proper function of
□
the EVair cannot be guaranteed. (► 6 Troubleshoot-
ing)

10.5 Check list Functional Test “Flow”
Scope:
The functional test for the flow is designed to check
the Power of the EVair concerning the flow.
1. Connect Air OUT to a valve:

Connect the Air OUT with a hose to a pressure con- □
trol valve.
2. Connect the Valve to a Flow measurement Instru-

ment:
Flow
□
Connect this pressure control valve with another hose
measuring
to a flow measuring instrument. 1)
Valve instrument
1)
Flow measuring device capable of measuring flows
of greater than 35L/min
3. Adjust the valve to 300 kPa:
Adjust the pressure control valve to set the Evair at □
300 +0/-20 kPa (3 bar, 43.5 psi)
4. Check Value:
In this case the flow value measured by the flow □
measuring instrument should be >35L/min.
5. Values OK:
If the values are ok, the proper function of the EVair □
can be guaranteed.
6. Values not OK:

If the values are out of the range, the proper function □
of the EVair cannot be guaranteed and you must do
the following maintenance:
□ Check all tubes for any leakages.
□ Check filters (► 8.3 Annually Check).
□ Go through the functional test again.
□ Overhaul the compressor heads.
(► 8.4 Motor )
□ If the EVair still could not pass the functional test,
check if something has to be replaced.
(► 9 Repair)

11 Contacts
11 Contacts
11.1 Manufacturer’s address imtmedical ag

Gewerbestrasse 8
CH-9470 Buchs
Switzerland
Tel: +41 (0)81 750 66 99

Fax: +41 (0)81 750 66 95
E-mail: sales@imtmedical.com
www.imtmedical.com
11.2 Technical Support Service In the event of questions or problems, please contact your nearest regional
office located on the back of the manual.

imtmedical ag Asia/Pacific Japan Thailand France Sweden
GE Yokogawa GE Medical Systems GE Healthcare GE Healthcare IT AB
China Medical Systems (Thailand) Ltd. Information Technologies Box 110 70
4-7-127 Asahigaoka, 7th Floor & Perinatal Care 161 11 Bromma
GE (China) Co. Ltd - Hino-shi, Thanapoom Tower 11, avenue Morane Sweden
Healthcare Tokyo 191-8503 1550 New Petchburi Road Saulnier Tel +46 20-389550
3F No 1 Hua Tuo Rd. Japan Makasan, Ratthewi 78457 Velizy Cedex Fax +46 8-293530
Zhangjiang Hi-Tech Park Tel 81 42 585 5111 Bangkok 10400 France
Pudong Fax 81 42 585 5360 Thailand Tel +33 1 34 49 53 00 United Kingdom
imtmedical ag 201203 Shanghai Tel +662 624 8444 Fax +33 1 34 49 53 01
Gewerbestrasse 8 China Korea Datex-Ohmeda Ltd.
Fax +662 624 8431
9470 Buchs Tel 86-21-38777888 Ohmeda House
GE Healthcare
Switzerland Fax 86-21-38777451 GE Healthcare Korea Vietnam 71 Great North Road
Zac de Sans-Souci
7, 8 F POBA Gangnam 1211 Chemin de la Bruyère Hatfield Hertfordshire
Tel: +41 81 750 66 99 GE Medical Systems Tower 343 Hakdong-ro, GE Viet Nam Limited AL9 5EN
69578 Limonest Cedex
Fax: +41 81 750 66 95 (China) Co., Ltd. Gangnam-gu Seoul, Metropole Centre England
France
No. 19 Changjiang Road, 135-820 Suite 606-2 Tel +33 (0)4 78 66 62 10 Tel 44 1707 263570
Wuxi Korea 56 Ly Thai To Street Fax +33 (0)4 78 43 26 58 Fax 44 1707 260191
North America National Hi-Tech Tel +82 2 6201 3114 Hanoi
Development Zone, Fax +82 2 6201 3674 Vietnam Germany
Jiangsu, PR China 214028 Tel +844 934 4254 Latin America,
United States Malaysia
Tel 0510-85225888 Fax +844 825 0551 GE Medical Systems Caribbean
Fax 0510-85226688 Information Technologies
Customer Service, General Electric GE Viet Nam Limited GmbH
Technical Support and International Inc.
Hong Kong Sun Wah Tower Munzinger Strasse 3 GE Healthcare
Distribution Center Suite 3B-8-3, Block 3B Suite 1202 79111 Freiburg 3350 SW 148th Avenue
GE Healthcare Level 8, Plaza Sentral 115 Nguyen Hue Street Germany
Physical address: Suite 301
Hong Kong Ltd. Jalan Stesen Sentral 5 Ho Chi Minh City Tel +49 761 4543 0
Datex-Ohmeda, Inc. Miramar FL 33027-3259
11/F, The Lee Gardens, Kuala Lumpur Sentral Vietnam Fax +49 761 4543 233
3030 Ohmeda Drive USA
33 Hysan Avenue 50470 Kuala Lumpur Tel +848 812 9399
Madison, WI 53718-6794 Tel 954 744 5600
Causeway Bay Malaysia Fax +848 821 9482 GE Service Center
USA Fax 954 744 5613
Hong Kong Tel +603 2273 9788 T: 0800 434325842273
Tel 1 800 345 2700 Fax +603 2273 3486
Tel +852 2100 6300 GE Healthcare
Fax 1 608 221 4384
Fax +852 2100 6292 Australia/ Italy Rua Tomas Carvalhal
Philippines
Mail address: India
New Zealand GE Healthcare
711 - Bairro Paraiso
Datex-Ohmeda, Inc. GE Philippines, Inc. San Paulo, SP 04006-002
Clinical Systems srl
PO Box 7550 2291 Don Chino Roces Brazil
WIPRO GE Medical Via Galeno 36
Madison, WI 53707-7550 Avenue Ext. GE Healthcare Tel 55 11 3053 2500/2537
Systems Pvt. Ltd. 20126 Milan
USA Makati City 1231 Australia Pty. Ltd.
4 Kadugodi Industial Area Italy
Philippines Parklands Estate,
Sadaramangala Tel +39 02 26001111 Middle East/
Equipment Service Center Tel +632 815 8761 Building 4B
Bangalore Fax +39 02 26001599
GE Healthcare Karnataka 560067 Fax +632 816 4997 21 South Street Africa
1701 Military Trail, Rydalmere NSW 2116 Netherlands
India
Suite 150 Singapore Australia
Tel +914 1801 0000
Jupiter FL 33458-7887 Tel +61 2 9846 4000 GE Healthcare Datex-Ohmeda
Fax +91 28 452 926 GE Pacific Pte. Ltd.
USA Fax +61 2 9846 4001 De Wel 18 Regional Head Office
298 Tiong Bahru Road Postbus 22 PO Box 70071
Tel 1 561 575 5000 Indonesia #15-01/06 Central Plaza
Fax 1 561 575 5070 3870 CA Hoevelaken GR-16610 Glyfada -
PT GE Technology Singapore 168730 Europe Netherlands Athens
Indonesia Tel +65 291 8528 Tel 31 33 2541 222 Greece
BRI Building Tower II Fax +65 277 7688
Canada Fax 31 33 2541 223 Tel +30 10 9625136-7
26th Floor CIS/Baltics Fax +30 10 9623687
GE Healthcare Taiwan Spain
Jln. Jend Sudirman Kav.
2300 Meadowvale Blvd Datex-Ohmeda
44-46 Jakarta 10210, GE Healthcare Taiwan
Mississauga, Ontario Regional Head Office GE Healthcare
Indonesia 11F, 420 Fu Hsin N Road
L5N 5P9 PO Box 70071 Gobelas, 35-37
Tel +6221 573 0545 Taipei, 104 GR-16610 Glyfada - E-28023
Canada Fax +6221 574 7117 Taiwan
Tel 1 800 668 0732 Athens Madrid
Tel +886 22 2516 5280 Greece Spain
Fax 1 905 858 5292 Fax +886 22 2516 5290 Tel +30 10 9625136-7 Tel +34 91 663 2500
Fax +30 10 9623687v Fax +34 91 663 25 01
© Datex-Ohmeda, Inc. – All rights reserved.
GE and GE Monogram are trademarks of

General Electric Company.
Datex-Ohmeda, Inc., a General Electric Company,

doing business as GE Healthcare.
EVair Medical Air Compressor

Technical Reference Manual
English
Part no. GE Healthcare: 2066031-001
Part no. imtmedical: 302-208-000
12 12 B 13 13 04
Printed in USA

5384 EVAir Compressor

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Page 2 of 87 Version 1.1

2 Safety Instructions ...............................................................................................................9

3 Theory of operation ............................................................................................................ 13

4 Location of EVair Assemblies ........................................................................................... 15

5 Service Mode ...................................................................................................................... 21

9.10 Replacing the High Temperature Tube ..................................................................................................................... 70

10 Functional Test ................................................................................................................... 83

Page 4 of 87 Version 1.1

Service Manual Version

Subject to technical modification without prior warning.

Symbols used in this manual

Version 1.1 Page 5 of 87

Positioning inside the cart

Page 6 of 87 Version 1.1

Navigation and value setting key Up

Navigation and value setting key Down

Enter key: change menu level, apply changed

Air Input Air IN for an external air supply network

Air Output Air OUT

Consult operating instructions

Version 1.1 Page 7 of 87

Dist. By: Distributed by

Type Type of compressor

REF Part number

SN: xxxx Serial number

Fabrication date: year-month

IP21 Protection for housing acc. to EN 60 529.

This device contains phthalates

Product is CSA certified for U.S. and Canadian

Dangerous electrical voltage

Unplug AC power before opening/servicing

Caution for rotating fans

Page 8 of 87 Version 1.1

Information or directions / warnings to prevent any sort of dam-

The EVair must not be used in MRI environment.

Use of portable phones or other radio frequency (RF) emitting

To avoid the risk of electric shock, this equipment must only be

Version 1.1 Page 9 of 87

2.4 Basic Safety Information

Do not sterilize the EVair.

Only use the EVair in a clean environment.

No modification on the EVair is allowed.

Page 10 of 87 Version 1.1

2.5 Guidelines for Maintenance

Only do the care and maintenance in a hygienic environment.

To ensure the safe and effective functionality of the EVair it is

Never use lubricants sealants, threadlockers, oil grease or loc-

Always disconnect the pressure hoses by slowly removing the

To guarantee the safety of the device and the personnel always

To make sure the maintenances or repairs are completely done

Version 1.1 Page 11 of 87

2.6 Air quality

The air quality of the supply network connected to Air IN must

2.7 Contraindications No known contraindications to the use of the EVair compressor.

2.8 Accessories and Spare

Page 12 of 87 Version 1.1

3.1 Pneumatic Block Diagram

Version 1.1 Page 13 of 87

3.2 Electronic Block Diagram

Page 14 of 87 Version 1.1

4 Location of EVair Assemblies

4.1 Instrument overview

Version 1.1 Page 15 of 87