CompAir Mako CMM User Instruction Manual

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User Instruction

Document No. - CMM Users Manual Rev 2

CMM

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Page 1 User Instruction User Instruction Manual Manual Document No. - CMM Users Manual Rev 2...
Page 2 MAKO Compressors, LLC 1634 SW 17th Street Ocala, Florida 34471 Phone: +1-352-732-2268 Fax: +1-352-351-5211 E-mail: email@compairmako.com Web Site: www.compairmako.com/ CompAir UK Ltd. Reavell House 53-56 - White House Rd. Ipswich Suffolk IP15PB England Phone: 011-44-1473-242000 www.compair.com/Products/High_Pressure_Pistons-- Breathing_Air_Compressors.aspx#Mako e-mail: sales@compair.com...
Page 3 GENERAL INFORMATION These units are for monitoring the Carbon Monoxide and Moisture levels in high pressure breathing air systems for use in Self Contained Breathing Apparatus (SCBA) or Self Contained Underwater Breathing Apparatus (SCUBA) and are not suitable for use with any other gasses. They are designed and manufactured to give optimum performance with long life and reliability.
Page 4 Maintenance To ensure the continued trouble-free operation of this unit it is important that periodic maintenance and servicing is carried out in accordance with the information given in the 'Maintenance' section of this manual. To assist in this matter your local MAKO Distributor can provide a number of optional maintenance agreements to suit your requirements.
Page 5 DECLARATION OF DECLARATION OF CONFORMITY CONFORMITY Applicant: CompAir USA Inc. 1634 SW 17th Street Ocala, FL 34471 USA Factory: CompAir USA Inc. 1634 SW 17th Street 1634 SW 17th Street Ocala, Florida 34471 Ocala, FL 34471 USA United States of America...
Page 6 Forward Notes On The Unit MAKO units are the result of many years of in addition, research and development. This experience - relevant accident prevention regulations combined with high quality standards - generally recognized safety regulations guarantee the manufacture of breathing air - national safety regulations have to be charging systems which will provide a long observed.
Page 7 Pressiond'admission, MakoCompressors,L.L.C. EingangDruck, Pressionedell'ingresso, 1634SW17thST. Presiondelaentrada Ocala,FL.34471 Ph.(352)732-2268 Safetyvalve, Fx.(352)732-7873 Soupapedesurete,Sicherheitsventil, Valvoladisicurezza, Valvuladeseguridad Bar/Min, FlowRestrictionRating,Estimationderestrictiond'ecoulement, Barre/minute www.compair.com Fluss-BeschrankungBewertung,Valutazionedilimitazionediflusso, Stab/Minute, Gradodelarestricciondelflujo Barra/minuto Diagramnumber,Nombredediagramme,Diagramm-Zahl, Numerodelloschema,Numerodeldiagrama ModelNumber,Numerodumodele, Modellnummer,NumeroModello,N°modelo DateofManufacture,Datedefabrication, Workorder,Bondetravail, Produktionsdatum, Datadifabbricazione, Arbeitsauftrag,Pedido, Fechadefabricacion Ordinedilavoro Serial Number, Numero de serie, Seriennummer, Numero di matricola, N°serie FillPressure,Remplirpression,Druckfullen, www.compairmako.com...
Page 8 Forward Guarantee Operate this unit only if you have an exact knowledge of the machine taking into respect these facts. MAKO cannot be held responsible for the safe operation of the unit if it is used in a manner that does not correspond to the intended use, or for other applications which are not mentioned in this manual.
Page 9: Table Of Contents
Table of Contents Section / Description Page General Information Manual Configuration Maintenance Warranty Declaration Of Conformity Forward Notes On The Unit Declaration Of Conformity Intended Use Maintenance Servicing In Case Of Queries Notes General Guarantee Safety Regulations Technical Changes Table Of Contents Safety Regulations Identification Of Safety Guidelines General Safety Instructions...
Page 10 Table of Contents Section / Description Page Layout And Function General Description 4.1.1 CO Option 4.1.1.1 Solenoids - CMM Control Panel 4.1.2 MO Option 4.1.3 Bypass Option 4.1.4 Wall Mount Option Standard CMM Overlay Transportation And Installation Transport Machine Location Power Supply Wall Mount Installation Initial Startup Procedure...
Page 11 Table of Contents Section / Description Page Reset Factory Menu 8.4.1 CONFIG Menu 8.4.2 Initialization Menu 8.4.3 Test Menu 8.4.4 Time Menu 8.4.5 Serial Number Menu Screen Message Chart Factory Code Chart Appendices Daily Log Book Sheet APP-A Typical P&ID APP-B Wall Mount Electrical Schematic APP-C...
Page 12: Maintenance
Safety regulations I d e n t i f i c a t i o n S a f e t y Guidelines I n s t r u c t i o n s , i n c l u d i n g s u p e r v i s o r y MAKO is not liable for any damage or injury responsibility and duty of notification for...
Page 13: Selection And Qualification Of Personnel; Basic Responsibilities
Safety regulations For the execution of maintenance work, tools Unauthorized changes to the machine are not and workshop equipment adapted to the task permitted for safety reasons. at hand are absolutely necessary. Genuine MAKO parts were especially designed and selected for this unit. The The personnel must be made familiar with the installation and/or use of any parts other than location and operation of fire extinguishers!
Page 14: Special Work/Maintenance
Safety regulations Check regularly that Check the unit at the beginning of each startup all means of protection are correctly and at least once every 8 hours of operation installed and secured. for visible damage or problems. Report any all hoses and/or pipes within the system problems changes machine's...
Page 15: Maintenance And Repair
Safety regulations Follow adjusting, maintenance elimination of danger has to be maintained inspection activities and schedule set out in regularly and functionally checked at least the operating instructions. These activities once a year. Faults observed have to be must only be carried out by skilled personnel, immediately rectified and/or reported to the under qualified supervision.
Page 16: Warning Of Special Dangers
Safety regulations After cleaning, remove covers make sure that the premises are adequately masking completely and allow the unit to dry ventilated (risk of explosion)! before returning unit to service! Observe adhere existing Always re-tighten all threaded connections regulations valid for the place of operation! which have been loosened for maintenance and repair work.
Page 17: Symbols And Explanations
Safety regulations Symbols And Explanations The Following Symbols may be used on the unit. fig. 3.7-4 Read Operators Manual before continuing fig. 3.7-1 No Access for Unauthorized Personnel fig. 3.7-5 Read Technical Manual before continuing fig. 3.7-2 Warning, Electrical Shock or Electrocution fig.
Page 18: Logs And Daily Inspection
Safety regulations appropriate service personnel. After problem is resolved the unit is put back in service, the solution is documented, initialed and dated in the daily log. Daily Inspection & log Entries 1) Check the log to see that no one has taken the unit out of service.
Page 19: Layout And Function
Layout and Function fig. 4.1-1 CMM panels & Wall Mount unit. Legend General Description 1) CMM Panel for BAC units. Mako monitoring systems (See Fig. 4.1-1) incorporates the functions required to check high pressure breathing air 2) CMM for BAM units. for safe levels of Carbon Monoxide and Moisture content.
Page 20: Co Option
Layout and Function 4.1.1 CO Option Excessive heat buildup can be detrimental to the life and operation of the CO cell. Therefore The CMM monitors system air (air exiting the a red rubber hose has been added to direct the purification system) for high levels of carbon air flow out of the upper control panel and monoxide only while the compressor is...
Page 21: Mo Option
Layout and Function Each solenoid is equipped with a LED that blinking green LED on the right side of the illuminates when energized. As operation display. Moisture (MO) stabilization time can demands change, whether for standard be adjusted from 5-15 minutes. (See section compressor running or calibration, the LEDs 6.3.4.2) are an instrumental aid in determining proper...
Page 22: Standard Cmm Overlay
Layout and Function fig. 4.2-1 provide an accurate reading of the moisture Standard CMM Overlay content levels being monitored. 1) Display This display will provide information, warnings and menu options 3) Carbon Monoxide Level Indicator - This needed by the operator, maintenance is a standard feature of the CMM unit and will operate as follows.
Page 23: Transportation And Installation
Transportation and installation 5.4 Wall Mount Installation Transport 1) Locate an appropriate area for mounting the CMM unit and secure as noted in Important! section 5.2 Machine Location. Care should be exercised when removing the unit from its shipping carton to avoid 2) Connect wall mount...
Page 24: Initial Startup Procedure
Transportation and installation (Other Compressor Units) 3) To make the harness connections it will be necessary to drill into the upper Connections remain the same as illustrated control panel. First, open door to upper above. The two wires to the hour meter control door and look for a clear spot to provide power to the internal relay forwarding drill a hole sufficient to fit the relay...
Page 25: Operating Instructions
Operating Instructions fig. 6.1-1 Standard CMM Controls Start-Up Danger! Before beginning start-up inspect unit & Please read your owner's manual carefully check logs (see section 3.8 and 3.8.1) for important safety information. The CMM retrofit panels will be powered Standard CMM Controls up along with the compressor system.
Page 26: Cmm Commands
Operating Instructions CMM Commands to be changed to meet local rules and regulations. The CMM unit will monitor the compressed CO PPM LIMIT 10ppm output of the system and stop the Range(5 - 10) compressor in the event of high Carbon Monoxide levels or high Moisture levels, if PPM: optional Moisture level option is purchased.
Page 27: Calibrate Now
Operating Instructions 6.3.3 Calibrate Now The CMM unit must be on for a minimum of 30 TURN OFF BOTTLES! minutes before calibration can be started. PRESS 1 This time will allow the CO sensor cell to stabilize. By pressing “2” while in the main menu (see section 6.3.1) you will access the “CALIBRATE NOW”...
Page 28: To Cancel The Co Or Mo By-Pass
Operating Instructions Danger! CO ALARM or MO ALARM HAS BEEN BY-PASSED! 6.3.4.1 To Cancel The CO or MO By-Pass (In this example we will show the cancel CO monitor bypass procedure. The cancel MO monitor bypass follows the same pattern.) From the “CO ALARM BYPASSED”...
Page 29: Maintenance
Maintenance DANGER! Announce that the unit has power to During installation, inspections and before other personnel. carrying out any maintenance work be sure Document that lockout has been that all pressure is released from the lifted and any actions taken in the system and the machine is electrically daily log book.
Page 30: Co Replacement
Maintenance 7.2 CO Replacement 4) Static Strap should be put on at this point. The average life span of this CO cell is 5) Remove four Nylon wing nuts see fig. 7.2- approximately 2 years depending on usage. When calibration fails three consecutive times it indicates a failure that could result in replacement.
Page 31: Replacement Of Mo Cell
Maintenance 9) Remount CO Housing and secure with four nylon wing nuts. Tighten securely but do not over tighten or damage will occur to board. 10) Close door and re-latch. 11) Perform manual calibration as listed in section 6.3.3 of this manual. 7.3 Replacement of MO Cell fig7.3-2 Typically, the MO sensor cell does not need...
Page 32: Troubleshooting
Troubleshooting 8.0 General 8.2.1 (P5) Moisture Cable Plug The bottom line of the display is strictly for This plug is only used when the moisture messages/alarms that indicate the CMM is option has been installed with the CMM operating outside of normal parameters.
Page 33: Config Menu
Troubleshooting 8.3 Reset The two configurations are: The CMM has a reset button that simulates a power on/off 19 = Carbon Monoxide and Moisture cycle. The primary use is after a program has been loaded. However, it may be used at any time. It does not 5 = Carbon Monoxide only reset the CMM board to factory settings.
Page 34: Time Menu
Troubleshooting 8.4.4 Time Menu This menu will coordinate the date and time of the CMM unit with real-time. This is important to set correctly for the CO calibration period to function as expected. The date/time should be entered by the factory, however, it should also be checked at start-up.
Page 35 Troubleshooting SCREEN MESSAGES THAT CAN OCCUR ON THE CMM SCREEN AND POSSIBLE SOLUTIONS Message Possible Cause Possible Solution CO LEVEL 1) Check surrounding area for idling vehicles which would cause high levels CO Level above programmed limit HIGH of CO. CO content of incoming air to high 2) Remote mount the air intake to an area for a clean air source.
Page 36 Troubleshooting Message Possible Cause Possible Solution RH SENSOR FAIL RH sensor failed to communicate Check wiring from CMM board to moisture board. Cable disconnected Check CMM program version of 1.51 or later. Bad RH sensor module FILTER MISSING Detected missing moisture filter Check wiring from CMM board to moisture board.
Page 37 Troubleshooting THESE CODES ARE TO ONLY USED BY TECHNICIANS OR DISTRIBUTORS THE FOLLOWING ARE FACTORY SETTINGS FOR DATE, TIME AND OTHER MI SC FUNCTIONALITY. PRESS "MENU" BUTTON THEN 9684075 AND THIS WILL BRING YOU TO THE FACTORY SE TTINGS MENU. NOTE: THE NUMBERS WILL NOT DISPLAY ON THE SCREEN WHEN YOU TYPE TYPE MENU SCREEN READS...
Page 38 Daily Log Book Sheet Date Alarms / Comments APP-A...
Page 39 Appendix B - P&ID of Typical CMM Legend Item No. Description Item No. Description High Pressure Regulator 0 PPM Cylinder Valve Pressure Gauge 0 PPM Quick Disconnect Pressure Relief Valve 0 PPM Cylinder Low Pressure Regulator Flow Restrictor Orifice Pressure Sample Gauge CO Sensor Cell System Air Solenoid Valve Pressure Sensor...
Page 40 APP-C...
Page 41 Item No View Description Part No. Qty. Item No View Description Part No. Qty. 300 Inlet Manifold Assembly ---- 0 PPM Cylinder 009006-7800 ----- Strain Reliew - Bulkhead EL016 CMM Overlay, with Membrane 003CMM08319 400 Moisture Sensor Assembly Cable ----- CMM Door, Wall Mount 008PUR09011 200 Internal View of Enclosure ----- Switch - On/Off - Green LED...
Page 42 Item No View Description Part No. Qty. Item No View Description Part No. Qty. ---- Fitting, QD, Male, 1/8" 003MEC-TUBQDM ----- CO Sensor Cell 003MEC-5 Fitting, Bulkhead, QD, Female 1/8" 003MEC-TUBQDF ---- Hose, Exhaust Red Rubber 003E440 ----- Power Supply IN: 110V-240VAC OUT: 24VDC EL065 ----- Connector, Hose Barb 003E407...
Page 43 Item No View Description Part No. Qty. ----- Fitting, Bulkhead 1/4 MNPT x 1/4 MJIC 003MEC-5 ---- Gauge, Back Mount 0-160 PSI 00977413 ----- Regulator, Pressure In: 6000 PSI Out: 0-140 003BB13AL2KVA4 ----- Fitting, Tee 1/4 MNPT-1/4 FNPT CONSM1350 ----- Fitting, Nipple 1/4 MNPT CONSM1357 ----- Gauge, Back Mount 0-30 PSI 003X0404...
Page 44 Item No View Description Part No. Qty. ----- Chamber, Final Purification ----- ---- O-Ring (Not Sold Seperately) ----- ----- Back-Up O-Ring (Not Sold Seperately) ----- ----- Screw, Pan Head 4-40 x 3/8" 003Z0719 ----- PCB, Moisture Sensor 003MEC-7 ----- Spacer 00381F4267 ---- Plug, Chamber, Final Purification...