Mixer Troubleshooting

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All rights reserved. Copyright reserved • R5132300T15_Mischer_Fehlersuche.fm 05.04.02 • Repair Instructions • Version 1.0 • Released
)LJ Mixer without cover, for legend see Table 1
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1 PRIMUS CPU PCB
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2 Gas inlet block
3 Mixer block
4 A-cone valve
5 Mixed gas tank
6 MIXER PCB
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Detail, gas inlet block, for legend see Table 2

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1 Pressure regulators (N2O, AIR, O2) regulate the
input pressure to the mixer to between 2.3 and
0.1 bar
2 Sintered-metal filter
3 ISO port (e.g. NIST for O2 cylinder supply)
4 Optional gas outlet (plug-in connection for AIR)
5 Non-return valve
6 Non-return valve for N2O gas inlet
7 CS sensor N2O
8 CS sensor AIR
9 CS sensor O2
)LJ Mixer block, for legend see Table 3
7DEOH /HJHQGWRFig.3
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1 Differential pressure sensors with PDMGSHI
2 piezo measuring bridge PDMGSLO
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3 Absolute pressure sensors with PSYS
4 integral amplifier PTANK
5 Tank vent valve VTANK

6 Temperature sensors TANKTEMP,
MGSTEMP
7 Connection for tank volume TANK
8 Gas inlet valves VMIXO2
9 VMIXAIR
10 VMIXN2O
11 Pressure inlets (N2O, AIR, O2) to
the gas inlet valves
12 O2 inlet to safety O2 adjuster and
flush button
13 Differential pressure sensor with PDMIX
piezo measuring bridge
14 Fresh gas flow valve (proportional VMGS
valve)
15 A-cone valve VSWAK
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RS232 extension (9-pin sub D female 79 01 808

connector on 9-pin sub D male connector,

length = 3 meters, with service coding)
Equipment voltmeter, voltage range 0 V to
30 V
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)LJ Connector positions and measuring points
The LEDs next to the jumpers for the supply voltages provide a quick and easy guide to whether the various voltages are
applied.
A distinction is made between two operating states:
− 9$ PRGH = Power cord is plugged in, Primus is off. For safety reasons, only the +15 V and the -15 V are
present on the PCB.

− 1RUPDOPRGH = Power cord is plugged in, Primus is on. All voltages are present: +15 V, -15 V, +24 V and +5 V.
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9$ PRGH QRUPDO PRGH
-15 V X X
+15 V X X
+24 V X
+5 V X
If the LEDs for -15 V, +15 V, +24 V and +5 V light up in normal mode, it is still appropriate to check the voltages.
Hold the ground measuring probe to the slot where no jumper is connected „Masse/GND“.
In 10 VA mode you can measure the supply voltages with the probe at jumper -15 V and at +15 V, as well as at ferrite core Z21.
In normal mode measure the other voltages at jumper +24 V, +5 V, at ferrite Z91 and Z22.
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When the mixer is being checked the internal

supply voltage +15 V and -15 V and +5 V and

+24 V is connected.
Use only approved and insulated test equipment.
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9ROWDJH 'HVLJQDWLRQ 7ROHUDQFH 9$ PRGH 1RUPDO PRGH
-15 V -15 V -13.85 V to -16.15 V X X
+15 V +15 V 13.85 V to 16.15 V X X
+24 V +24 V 22.5 V to 25.5 V X
+5 V +5 V 4.8 V to 5.15 V X
+24 V Z21 (ferrite) 22.5 V to 25.5 V X
+24 V Z22 (ferrite) 22.5 V to 25.5 V X
+12 V Z91 (ferrite) X X

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1. Launch Primus service mode and call up the mixer screen (see document: Service mode).
2. If the mixer is dismantled, connect only the AIR and N2O central supply gases to it. Do not connect O2, otherwise
O2 will be discharged into the atmosphere. If the mixer is fitted in the Primus, all central supply gases are
connected.
3. The mixer tank can be removed for test purposes.
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1. The pressure readout „PPO2“, „PPAIR“ and „PPN2O“ (service mode) show the current supply pressure applied. For
testing, the connectors are unplugged from two of the pressure sensors „PPO2“, „PPAIR“ and „PPN2O“ at a time
and swapped over. This enables you to distinguish between a sensor error and a PCB error. If the two pressure
values match, the mixer PCB is OK. If the two values drift apart, the mixer PCB is defective (for connector positions
see Fig.4).
2. Carrying out repairs see document: Mixer repairs.
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After checking the pressure sensors, make sure

you return them to their original positions (see
Fig.4).

1. Carry out the final test (see section 8 Final tests).
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1. The pressure readouts „PCO2“ and „PCN2O“ (service mode) show the current supply pressure. For testing, the
connectors of pressure sensors „PCO2“ and „PCN2O“ are swapped over (for connector positions see Fig.4). If the
two pressure values match, the mixer PCB is OK. If the two values drift apart, the mixer PCB is defective.

Fig.4).
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1. To calibrate the „PDMGSHI“ flow sensor offset, use the turn knob to select and activate test step 4. For the
tolerances refer to the Test Certificate.
2. To calibrate the „PDMGSLO“ flow sensor offset, use the turn knob to select and activate test step 5. For the
tolerances refer to the Test Certificate.
3. For testing on the mixer PCB, swap the connectors of „PDMGSLO“ and „PDMGSHI“ (for connector positions see
Fig.4).

4. Activate the relevant test step for each flow sensor. Test step 4 for PDMGSHI and test step 5 for „PDMGSLO“.
Swapping the sensors means the applicable tolerances are those of the sensor and not of the channel. Example:
After moving „PDMGSLO“ to the „PDMGSHI“ slot and starting test step 4, the limits and tolerances of test step 5
apply (see Test Certificate).
5. If the two values match, the mixer PCB is OK. If the limits and tolerances stipulated on the Test Certificate cannot be
maintained, the sensor is defective.

Fig.4).
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1. To check „PDMIX“ WKHPL[HUWDQNPXVWEHLQVWDOOHG.

2. To calibrate the „PDMIX“ offset, use the turn knob to select and activate test step 55.
3. For testing of „PDMIX“ on the mixer PCB, swap the connectors of „PDMIX“ and „PDMGSHI“ (for connector positions
see Fig.4).
4. Start test step 4 and, taking account of „PDMGSHI“, check the sensor tolerances according to the Test Certificate
(see Test Certificate). If the two pressure values match, the mixer PCB is OK. If the two values drift apart, the mixer
PCB is defective. If the limits and tolerances stipulated on the Test Certificate cannot be maintained, the sensor is
defective.


you return the sensor connectors to their original
positions (see Fig.4).
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1. Do not swap the sensors for this test!
1. On the mixer screen (see document: Service mode) the Master and Supervisor pressure values are displayed.
2. If both sensor values drift, the sensor is defective. If only one readout drifts, the mixer PCB is defective.
3. In doing this, note that the pressures for „PTANK“ and „PRP“ are identical. The differing resolutions of the sensors
produce differing readouts, however. The „PTANK“ sensor limits the pressure readout to 2,550 bar; the „PRP“
sensor indicates the actual value applied.

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1. Launch Primus service mode and call up the mixer screen (see document: Service mode).
2. If the mixer is dismantled, connect only the AIR and N2O central supply gases to it. Do not connect O2, otherwise
O2 will be discharged into the atmosphere. If the mixer is fitted in the Primus, all central supply gases are
connected.
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1. To check the actuation of the valves, all the valves on the mixer PCB can be swapped over (for slots see Fig.4).
2. Use the „VTANK“ softkey to close the valve. When the valve is closed the „VTANK“ LED lights up (for LED positions
see Fig.4).
3. Use the „VMIXO2“ softkey to open the valve. The „VMIXO2“ LED lights up and the „TANK“ is filled. The pressure
readout „PRP“ rises to between 2.0 bar and 2.6 bar, plus approx. 1 bar ambient pressure.
4. For further tests, vent the „TANK“. When the mixer is connected to the central supply, one valve can always be
operated.
5. Use the „VMIXAIR“ softkey to open the valve. The „VMIXAIR“ LED lights up and the tank is filled (for LED positions
see Fig.4).
6. For further tests, vent the „TANK“. When the mixer is connected to the central supply, only one valve at a time can
be operated.
7. Use the „VMIXN2O“ softkey to open the valve. The „VMIXN2O“ LED lights up and the tank is filled (for LED
positions see Fig.4).
8. If a previously operational valve can no longer be operated after swapping the valve connectors, the mixer PCB is
defective.

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After checking the valves, make sure you return

the valve connectors to their original positions

(see Fig.4).
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+24 V is connected.
1. Use the „VSWAK“ softkey to operate the relevant valve. The „VSWAK“ LED lights up if the „VSWAK“ valve is
switched to internal (for LED positions and slots see Fig.4). Pressing the „VSWAK“ softkey again switches the valve
to external mode. The following voltages are applied to the „VSWAK“ connector (see following table).
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Internal 24 V 0V
External 24 V -24V

1. The switchover signal to actuate the „VSWAK“ valve is connected between pins 1 and 2. Activate the Hold function
on the voltmeter. Then the pulse signal to actuate the „VSWAK“ can be checked. To do so, select the voltage range
0-20 V. Expected switching pulses: +/-14 V to +/-18 V.
2. If no switching pulse is applied, the mixer PCB is defective. If a switching pulse is applied but the valve does not
operate, the valve is defective.

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After checking the valves, make sure you return

the valve connectors to their original positions
(see Fig.4).
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+24 V is connected.

1. To check the VMGS and the pressure sensor, vent the tank. At the „VMGS“ connector, between pins 1 and 2, the
measured voltage is 0 V.
2. Use the „setting VMGS“ softkey to preset the flow. Use the turn knob to set a flow of 5/Lmin, for example.
3. The „VMGS“ LED lights up (for LED positions and slots see Fig.4). Check the voltage connected to the „VMGS“
valve connector between pins 1 and 2. The expected value is around 24 V.

4. Close with the „VTANK“ softkey. Use the „VMIXAIR“ softkey to open the air feed from the central supply.
5. The tank is filled. The voltage at the „VMGS“ connector adjusts to about 13 V.
6. If the expected voltages are not reached, the mixer PCB is defective.
7. If the expected voltages are reached but the valve does not operate, the valve is defective.
8. If you detect errors, carry out repairs see document: Mixer repairs.

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+24 V is connected.
1. To check the fan actuation, at the „FAN“ connector check the voltages and signals (for LED positions and slots see
Fig.4).
2. In operation, a voltage of approx. 10.3 V is connected between pins 2 and 3. This voltage is slightly increased for a
brief moment during the power-up phase (to around 11.8 V) because of the 10 VA mode.
3. The fan scan signal is connected to the „FAN“ connector between pins 1 and 3. In operation, this signal is 2.5 V. At
standstill, or if the signal is missing, +5 V or 0 V is connected here (depending on the position of the fan wheel).

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1. Launch Primus service mode and call up the mixer screen (see document: Service mode). The temperatures of the
Master and the Supervisor are displayed.
2. The connectors of the temperature sensors for „TANKTEMP“ and „MGSTEMP“ can be swapped for test purposes
(for slots see Fig.4). If the „TANKTEMP“ sensor plugged into the „MGSTEMP“ slot, or vice versa, indicates the
wrong temperature value at variance with the starting position, the temperature sensor is defective. If the actual
temperature value is displayed after swapping, the mixer PCB is defective.
3. If the temperatures of the Master and Supervisor are shown as differing, the mixer PCB is defective.
4. In case of error, both temperature sensors are always replaced.
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After checking the temperature sensors, make

sure you return the sensor connectors to their
original positions (see Fig.4).

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1. Carry out the gas type test according to the Test Certificate (see Test Certificate).
2. If sensors have been replaced, carry out the leak test according to the Test Certificate (see Test Certificate).
3. If repairs have been carried out in the Primus, run the STK.
4. Switch on the Primus and run through the checklist.

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5HSDLU,QVWUXFWLRQV *HQHUDOLQWURGXFWLRQ

)LJ Mixer without cover, for legend see Table 1

)LJ Mixer block, for legend see Table 3

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5 Tank vent valve VTANK

RS232 extension (9-pin sub D female 79 01 808

connector on 9-pin sub D male connector,

)LJ Connector positions and measuring points

present on the PCB.

When the mixer is being checked the internal

supply voltage +15 V and -15 V and +5 V and

Use only approved and insulated test equipment.

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After checking the pressure sensors, make sure

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1. Carry out the final test (see section 8 Final tests).

After checking the pressure sensors, make sure

1. Carry out the final test (see section 8 Final tests).

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After checking the pressure sensors, make sure

1. Carry out the final test (see section 8 Final tests).

1. To check „PDMIX“ WKHPL[HUWDQNPXVWEHLQVWDOOHG.

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5. Carrying out repairs see document: Mixer repairs.

After checking the pressure sensors, make sure

1. Carry out the final test (see section 8 Final tests).

1. Do not swap the sensors for this test!

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After checking the valves, make sure you return

the valve connectors to their original positions

1. Carry out the final test (see section 8 Final tests).

When the mixer is being checked the internal

Use only approved and insulated test equipment.

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operate, the valve is defective.

After checking the valves, make sure you return

1. Carry out the final test (see section 8 Final tests).

When the mixer is being checked the internal

Use only approved and insulated test equipment.

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valve connector between pins 1 and 2. The expected value is around 24 V.

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When the mixer is being checked the internal

Use only approved and insulated test equipment.

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After checking the temperature sensors, make

1. Carry out the final test (see section 8 Final tests).

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)LJ Mixer without cover, for legend see Table 1

)LJ Mixer block, for legend see Table 3

)LJ Connector positions and measuring points

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