CompAir Mako CMM Operator's manual

CMM
User Instruction
Manual
CMM
User Instruction
Manual
Document No. - CMM Users Manual Rev 2

MAKO Compressors, LLC
1634 SW 17th Street
Ocala, Florida 34471
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web Site: www.compairmako.com/
CompAir UK Ltd.
Reavell House
53-56 - White House Rd.
Ipswich
Suffolk
IP15PB
England
Phone: [phone]
www.compair.com/Products/High_Pressure_Pistons--
Breathing_Air_Compressors.aspx#Mako
e-mail: [e-mail]

0-1
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.
This manual gives the end user all the information required to install and operate this unit and
carry out regularly scheduled maintenance to ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine MAKO replacement parts are provided through a
worldwide network of MAKO Distributors. If replacement parts are needed, the user should first
contact the local MAKO Distributor. If there is any difficulty contacting a local distributor the end
user may contact the MAKO factory representative.
The information given in this manual was correct at the time of it's creation. However, as part of
continuous development, modifications to parts and procedures may be made without notice that
could affect the maintenance requirements of this unit. Before any maintenance work is
undertaken the user is advised to contact the local MAKO Distributor who is supplied with revised
and up-dated information.
In any communication concerning these units it is essential to quote the MODEL, SERIAL NUMBER
and the YEAR of MANUFACTURE. This information is located on the units' nameplate. (see Fig. 1.3-
1)
Throughout this manual all pressures quoted are gauge pressures unless otherwise stated.
This manual is broken down by numbered chapters, sections and subsections shown in bold text
and separated by periods.
(Chapter #).(Section #).(subsection #).(subsection #)
would represent subsection 1 of subsection 2 of section 3 of chapter 4
There can be as many subsections as are needed.
Within this structure could be in bold which are not numbered.
The pages are designated by chapter and page separated by a dash.
(Chapter #)-(Page number within that chapter)
4-3 would indicate the third page of chapter four.
All illustrations are designated by chapter, section and subsection to which they are associated
followed by the number of the illustration separated by a dash
fig.(chapter and section designation)-(number of the illustration within the section
indicated)
fig. 4.3.2.1-3 would indicate the third illustration within section
Manual Configuration
4.3.2.1
headings
4.3.2.1

0-2
USE ONLY GENUINE MAKO PARTS. YOUR
WARRANTY COULD BE AFFECTED IF ANY SERVICE
OR REPAIR IS CARRIED OUT USING ANYTHING BUT
GENUINE MAKO PARTS.
Maintenance
Warranty
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. These
agreements provide the end user with the expertise of our factory trained technicians and the
guarantee that only Genuine MAKO parts will be used.
The conditions of the MAKO Warranty are set out in the Company's standard Conditions of Sale
available from the MAKO Distributor supplying the unit.

Mako is part of the
Group
1634 SW 17th Street
Ocala, Florida 34471
United States of America
Telephone [phone]
Facsimile [phone]
www.compairmako.com
_______________________________________________________
Engineering Manager - John Downing
_________________________
Date
_______________________________________________________
Location
Applicant:
CompAir USA Inc.
1634 SW 17th Street
Ocala, FL 34471 USA
Factory:
Machinery Description:
CompAir USA Inc.
1634 SW 17th Street
Ocala, FL 34471 USA
Compressors & High Pressure Air Equipment
Model/Type Number:
MK X AM
MKXCI
MKXH2
MK X T1
MKXVS
MK X AC
MKXH1
MKXH3
MK X T2
MKXMC
MKXSC
MKXSJ
MKXMJ
MKXHS
MK Series as listed:
I hereby declare that the machinery complies with the Essential Health
and Safety Requirements of the Machinery Directive (98,37/EC) as
amended, with the provisions of the Electromagnetic Compatibility
Directive (89/336/EEC) as amended and Personal Protective
Equipment Directive (89/686/EEC) as amended. This machine is
exempt from PED (97/23/EC), reference article 1 clause 3.3 and 3.6.
Emissions: EN61000-6-4:2001
immunity: EN61000-6-2:2001
DIN EN 12021
EN ISO 12100-1,-2
EN 60204-1
EN 1050
EN 1012-1
EMC Standards:
Respiratory Protection Devices Standard:
Machinery Standards:
DECLARATION OF
CONFORMITY
DECLARATION OF
CONFORMITY

1-1
1. Forward
fig. 1.1-1 CE
1.2 Intended Use
This unit has been constructed in accordance
with state-of-the-art technology and
recognized safety regulations. Nevertheless,
its use may constitute a risk to life and limb of
the user or third persons or cause damage to
the machine or to other material property, if
- it is not used as intended,
- it is operated by unqualified personnel
- it is improperly modified or changed
- the safety regulations are not observed
Therefore, any person entrusted with the
operation, maintenance or repair of this unit
must read and follow all safety regulations in
this manual. If required, this has to be
acknowledged by signature.
1.1 Notes On The Unit
Declaration Of Conformity
MAKO units are the result of many years of
research and development. This experience
combined with high quality standards
guarantee the manufacture of breathing air
charging systems which will provide a long
service life, high reliability and cost-effective
operation.
This unit and its accessories as supplied by
MAKO conform to the basic health and safety
requirements included in the Machinery
Directive 98/37/EC and the EMC Directive
89/336/EEC and the Personal Protective
equipment Directive 89/686/EEC. The
compliance with these directives is signified
by the "CE mark" (See fig. 1.1-1)
in addition,
- relevant accident prevention regulations
- generally recognized safety regulations
- national safety regulations have to be
observed.
This system must be operated under
technically perfect conditions and in
accordance with its intended use and the
instructions set out in the operating manual.
This system must be operated only by safety-
conscious personnel who are fully aware of
the dangers involved in the operation of this
system. If any functional problem is detected
or suspected stop the operation of this
system. Report the problem to the
appropriate maintenance or service
personnel. The problem must be resolved
before the system is returned to operation.
Operating the unit within the limits of its
intended use also involves observing the
instructions set out in the operating manual
and complying with the inspection and
maintenance directives.
Carefully performed maintenance is
imperative, this ensures that your unit can
meet all the requirements for which it was
intended. It is therefore imperative to adhere
to the specified maintenance intervals and to
carry out the maintenance work with
deliberate care, especially when the unit is
utilized under harsh operating conditions.
Please contact your authorized MAKO
distributor in the case of malfunctions or
when spare parts are required. Our fully
trained personnel will ensure that all repairs
are carried out properly. Using only genuine
MAKO spare parts. Genuine MAKO spare parts
are manufactured utilizing state-of-the-art
technology, thus guaranteeing the continued
reliable performance of the unit.
1.3 Maintenance
Servicing

1. Forward
1-2
In Case Of Queries
General
Please enter the data on the nameplate of
your unit into the nameplate shown in (fig.
1.3-1). In the case of queries or spare parts
orders, please refer to the units series & type
as indicated on the nameplate, the
identification no. and the year of construction.
These operating instructions are intended to
familiarize the user with the unit and its
intended use. The instructions contain
important notes on how to operate the unit
safely and cost-effectively.
1.4 Notes
Observing these instructions will help to avoid
risks, reduce repair costs, down times and to
increase the reliability and service life of the
unit.
The operating instructions in this manual are
in addition to any applicable local, regional or
national, laws, rules and regulations
regarding the prevention of accidents and
environmental protection. They must always
be available at the location of the unit. The
operating instructions must be read and
followed by any person carrying out work in
connection with the unit, i.e. operation,
setting up, disposal of any waste and
consumables, maintenance, inspection,
repair, and transport.
fig. 1.3-1 MAKO Nameplates
www.compairmako.com
MakoCompressors,L.L.C.
1634SW17thST.
Ocala,FL.34471
Ph.[phone]
Fx.[phone]
ModelNumber,Numerodumodele,
Modellnummer,NumeroModello,N°modelo
DateofManufacture,Datedefabrication,
Produktionsdatum, Datadifabbricazione,
Fechadefabricacion
Serial Number, Numero de serie,
Seriennummer, Numero di matricola, N°serie
Workorder,Bondetravail,
Arbeitsauftrag,Pedido,
Ordinedilavoro
~
VHz
FillPressure,Remplirpression,Druckfullen,
Riempirelapressione,Llenarlapresion
Safetyvalve,
Soupapedesurete,Sicherheitsventil,
Valvoladisicurezza,
Valvuladeseguridad
PSI
BAR
bar
Bar
A
PSI
BAR
bar
Bar
1. 2.
BAR
bar
Bar
3. PSI
InletPressure,
Pressiond'admission,
EingangDruck,
Pressionedell'ingresso,
Presiondelaentrada
BAR
bar
Bar
PSI
BAR
bar
Bar
PSI
1. 2. 3.PSI
BAR
bar
Bar
PSI
FlowRestrictionRating,Estimationderestrictiond'ecoulement,
Fluss-BeschrankungBewertung,Valutazionedilimitazionediflusso,
Gradodelarestricciondelflujo
Bar/Min,
Barre/minute
Stab/Minute,
Barra/minuto
BAR
bar
Bar
Diagramnumber,Nombredediagramme,Diagramm-Zahl,
Numerodelloschema,Numerodeldiagrama
www.compair.com
www.compairmako.com
MakoCompressors,L.L.C.
1634SW17thST.
Ocala,FL.34471
Ph.[phone]
Fx.[phone]
ModelNumber,Numerodumodele,
Modellnummer,NumeroModello,N°modelo
DateofManufacture,Datedefabrication,
Produktionsdatum, Datadifabbricazione,
Fechadefabricacion
Serial Number, Numero de serie,
Seriennummer, Numero di matricola, N°serie
Workorder,Bondetravail,
Arbeitsauftrag,Pedido,
Ordinedilavoro
~
VHz
FillPressure,Remplirpression,Druckfullen,
Riempirelapressione,Llenarlapresion
Safetyvalve,
Soupapedesurete,Sicherheitsventil,
Valvoladisicurezza,
Valvuladeseguridad
PSI
BAR
bar
Bar
A
PSI
BAR
bar
Bar
1. 2.
BAR
bar
Bar
3. PSI
InletPressure,
Pressiond'admission,
EingangDruck,
Pressionedell'ingresso,
Presiondelaentrada
BAR
bar
Bar
PSI
BAR
bar
Bar
PSI
1. 2. 3.PSI
BAR
bar
Bar
PSI
FlowRestrictionRating,Estimationderestrictiond'ecoulement,
Fluss-BeschrankungBewertung,Valutazionedilimitazionediflusso,
Gradodelarestricciondelflujo
Bar/Min,
Barre/minute
Stab/Minute,
Barra/minuto
BAR
bar
Bar
Diagramnumber,Nombredediagramme,Diagramm-Zahl,
Numerodelloschema,Numerodeldiagrama
www.compair.com

1. Forward
1-3
Guarantee
Safety Regulations
Technical Changes
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.
Warranty claims will not be accepted in the
case of
- Operating errors
- Incorrect maintenance
- Wrong auxiliary materials
- Use of spare parts other than genuine
MAKO spare parts
- Modifications and changes to the
installation
The warranty and liability conditions of the
general terms and conditions of MAKO will not
be extended by the notes above.
Any unauthorized change to this unit, or the
installation of components not accepted by
the manufacturer (i.e. fine separator) will
result in the withdrawal of the CE mark. As a
consequence, any liability and warranty
claims will not be accepted by the
manufacturer.
In the course of technical development we
reserve the right to modify the units without
further notice.
The safety regulations in chapter 3 of the
operating instructions must be strictly
observed.
Danger!

2. Table of Contents
2-1
1. Forward 1-1
General Information 0-1
Page
3. Safety Regulations 3-1
2. Table Of Contents 2-1
1.1 Notes On The Unit 1-1
Declaration Of Conformity 1-1
Maintenance
Manual Configuration
0-2
0-1
Warranty
Declaration Of Conformity
0-2
0-3
3.1 Identification Of Safety Guidelines 3-1
3.2 General Safety Instructions 3-1
Organizational Measures
Selection And Qualification Of Personnel; Basic Responsibilities
3-1
3-2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
Changes And Modifications To The Unit
Installation And Normal Operation
Special Work / Maintenance
Warning Of Special Dangers
Symbols And Explanations
Logs And Daily Inspection
Daily Log Book
Out Of Service
Daily Inspection And Log Entries
Electric Energy
Gas, Dust, Steam And Smoke
Rooms Subject To Explosion Hazards
Pneumatics
Lock Out Procedure
Maintenance And Repair
Normal Operation
3-2
3-2
3-3
3-5
3-6
3-7
3-7
3-7
3-7
3-5
3-5
3-5
3-5
3-3
3-4
3-2
1.2 Intended Use 1-1
1.3 Maintenance 1-1
Servicing
In Case Of Queries
General
Guarantee
Safety Regulations
Technical Changes
1-1
1-2
1-2
1-3
1-3
1-3
1.4 Notes 1-2
Section / Description

2. Table of Contents
2-2
5. Transportation And Installation 5-1
4.2
5.1
5.2
5.3
Standard CMM Overlay
Transport
Machine Location
Power Supply
4-4
5-1
5-1
5-1
5.4
Wall Mount Installation 5-1
4. Layout And Function 4-1
4.1 General Description 4-1
6. Operating Instructions 6-1
6.1
6.2
6.3
6.2.1
6.3.1
6.3.2
6.3.2.1
6.3.2.2
6.3.2.3
6.3.3
6.3.4
Standard CMM Controls
Start-up
CMM Commands
Shut-Down
Menu Access
CO Setup
CO Set Point
Cal Interval
Automatic Cal
Calibrate Now
By-Pass CO or MO Monitors
6-1
6-1
6-2
6-1
6-2
6-2
6-2
6-2
6-2
6-3
6-3
7. Maintenance 7-1
7.1
Lock Out Procedure
Maintenance Schedule
7-1
7-1
6.3.4.1 To Cancel The CO or MO By-Pass 6-4
Page
Section / Description
5.5
Initial Startup Procedure 5-2
7.2 7-2
7.3 Replacement of MO Cell 7-3
4.1.1 CO Option 4-2
4.1.1.1 Solenoids - CMM Control Panel 4-2
4.1.2 MO Option 4-3
4.1.3 Bypass Option 4-3
4.1.4 Wall Mount Option 4-3
6.3.4.2 MO Time-Out Menu 6-4
CO Replacement
8. Troubleshooting 8-1
8.1 Initial Investigation 8-1
8.2 CMM Wiring 8-1
8.2.1 (P5) Moisture Cable Plug 8-1
8.2.2 (P7) Harness Plug 8-1
8.2.3 (P6) Power Plug 8-1

2. Table of Contents
2-3
PageSection / Description
Daily Log Book Sheet
Appendices
APP-A
8.3 Reset 8-2
8.4 Factory Menu 8-2
8.4.1 CONFIG Menu 8-2
8.4.2 Initialization Menu 8-2
8.4.3 Test Menu 8-2
8.4.4 Time Menu 8-3
8.4.5 Serial Number Menu 8-3
Screen Message Chart 8-4
Factory Code Chart 8-6
Typical P&ID APP-B
Wall Mount Electrical Schematic APP-C
Parts List APP-D

3. Safety regulations
3-1
3.1 Identification Of Safety
Guidelines
3.2 General Safety Instructions
MAKO is not liable for any damage or injury
resulting from the non-observance of these
safety instructions or negligence of the usual
care and attention required during
installation, handling, operation,
maintenance or repair, even if this is not
explicitly mentioned in these operating
instructions.
If any of the regulations contained in these
instructions - especially with regard to safety
- does not correspond to the local legal
provisions, the stricter of both shall prevail.
Passages marked with this designation
indicate a possible danger to personnel.
Passages marked with this designation
indicate possible damage to unit.
Passages marked with this designation
provide technical or procedural information
for the optimal cost-effective use of the unit.
The operating instructions must always be at
hand at the place of operation of the unit!
In addition to the operating instructions, all
other generally applicable legal and other
mandatory regulations relevant to accident
prevention and environmental protection
must be adhered to and passed on to others!
These compulsory regulations may also deal
with the handling of hazardous materials or
the issuing/wearing of personal protective
equipment, or traffic regulations.
Organizational Measures
Danger!
Important!
Note.
Instructions, including supervisory
responsibility and duty of notification for
taking into account in-plant factors, for
example regarding work organization,
sequences of operations, personnel assigned
to certain tasks, are to be kept with the
operating manual.
The personnel entrusted with the operation
and/or maintenance of the unit must have
read the operating instructions and in
particular the chapter on safety regulations
before starting work. Reading the instructions
after work has begun is too late. This applies
especially to persons working only
occasionally on the machine, e.g. for setting
up or maintenance.
supervisors should check on a regular basis
that the personnel are carrying out the work
in compliance with the operating instructions
and that they are paying attention to the
safety requirements!
Observe all safety and warning notices
attached to the unit!
See to it that safety instructions and warnings
attached to the machine are always complete
and perfectly legible.
In the case of safety-relevant changes to the
unit or its operating behavior, stop the unit
immediately and report the fault to the
responsible department or person!
Spare parts have to comply with the technical
requirements specified by the manufacturer.
This can always be ensured by using only
genuine MAKO spare parts.
High pressure hoses have to be changed
within stipulated and periodic intervals, even
if no safety-relevant faults have been
detected.
Adhere to prescribed intervals or those
specified in the operating instructions for
routine checks and inspections!

3. Safety regulations
3-2
Unauthorized changes to the machine are not
permitted for safety reasons.
Genuine MAKO parts were especially
designed and selected for this unit. The
installation and/or use of any parts other than
genuine MAKO parts can therefore affect the
active and/or passive safety and reliability of
this unit.
The manufacturer is not liable for damage
resulting from the use of non-genuine MAKO
parts or special accessories. This applies also
to the installation and setting of safety
equipment and valves as well as to welding on
structural or pressurized parts.
In addition to the general technical operation
in accordance with the stipulations of the local
authorities, we would like to refer in particular
to the following regulations.
The system has to be installed in such a way
that it is adequately accessible.
The pressure line connected to the air outlet
of the system must be fitted stress-free.
The installed unit-specific safety valves only
assume the pressure safeguarding function of
this unit provided in currently valid standards
and regulations.
Electrical connections must meet the local
regulations. Power units must be connected
to earth and protected from short-circuits by
means of fuses.
The maximum system pressure of the unit
can be located on the nameplate of the unit.
Take the necessary precautions to ensure that
the unit is used only when in a safe and
reliable state!
Operate the machine only when all protective
equipment are in place and fully functional!
3.4 Installation And Normal
Operation
Normal Operation
For the execution of maintenance work, tools
and workshop equipment adapted to the task
at hand are absolutely necessary.
The personnel must be made familiar with the
location and operation of fire extinguishers!
Observe all fire-warning and fire-fighting
procedures!
Work on or with the unit must be carried out
by reliable personnel only. Statutory
minimum age limits must be observed!
Employ only trained or instructed personnel
and clearly set out the individual limits and
responsibilities of the personnel for operation,
set-up, maintenance and repair!
Ensure that only authorized personnel work
on or with the unit!
Define the machine operator's responsibilities
giving the operator the authority to refuse
instructions by third persons that are contrary
to safety regulations.
Do not allow persons to be trained or
instructed or persons taking part in a general
training course to work on or with the unit
without being continuously supervised by an
experienced person!
Work on the electrical equipment of the unit
must be carried out only by a skilled
electrician in accordance with electrical
engineering rules and regulations.
Work on system elements such as high
pressure hoses may only be carried out by
personnel with special knowledge and
experience.
Do not make any changes, modifications or
attachments to the unit, which could affect
safety, without the supplier's prior
permission!
Selection And Qualification Of
Personnel; Basic Responsibilities
3.3 Changes And Modifications
To The Unit

3. Safety regulations
3-3
Check regularly that
- all means of protection are correctly
installed and secured.
- all hoses and/or pipes within the system
are in good condition, firmly fixed and do
not chafe.
- there are no air leaks.
- all fittings are firmly tightened.
- all wires are connected correctly and are
in good condition.
- all safety valves and other pressure relief
mechanisms are in good order and not
blocked by e.g. dirt or paint.
- the safety mechanisms are fully
functional.
If compressed air hoses are used they must
be of the proper size and suitable for the
relevant operating pressure. Do not use
chafed or damaged hoses.
Only use hose couplings and fittings of the
right type and the correct size.
Before blowing through a hose or an air pipe
ensure that the open end is positively held. A
free end whips and can cause injuries.
Before loosening or disconnecting any
connection ensure that it in not under
pressure.
Refrain from any working method which is
doubtful in terms of safety.
Never play around with compressed air from
this unit!
Never aim compressed air from this unit at
yourself or at any other person!
Never use compressed air from this unit to
clean your clothing.
Never use compressed air from this unit to
clean equipment.
Never operate the system at pressures and
temperatures below or above the values
indicated in the technical data sheet.
All access panels, etc. have to be closed at all
times during the operation of this unit.
Check the unit at the beginning of each startup
and at least once every 8 hours of operation
for visible damage or problems. Report any
problems or changes in the machine's
operating Behavior to the responsible
department or person immediately. In the
case of any problem which might effect the
safe operation of this unit, stop the unit
immediately! Have any problem resolved
before restarting the unit!
Follow the start-up and shut-down procedures
according to the operating instructions.(see
section 6)
During installation, inspections,
cleaning and Before carrying out any
maintenance work be sure that all pressure is
released from the system and the machine is
electrically isolated. Never attempt to
straighten badly bent tubing or re-use
damaged fittings.
On retrofit units that are hardwired into the air
system, a lock-out procedure must be
followed during installation, inspections,
maintenance, or repairs.
1) Announce the lock-out to other
personnel.
2) Turn off site power box to the unit.
3) Lock site power box to the unit in the o f f
position and place warning tag on box.
4) Put key in your pocket.
5) Make sure unit is clear of all personnel.
6) Test lock-out by trying to start the unit.
7) Complete required operations.
8) Announce that the lock-out condition is
being ended and clear the unit of all
personnel.
9) Take key out of your pocket.
10) Unlock the power box and remove
warning tag from box.
11) Turn the power box on.
12) Announce that the unit has power to
other personnel.
3.5 Special Work/Maintenance
Lock Out Procedure
DANGER!

3. Safety regulations
3-4
elimination of danger has to be maintained
regularly and functionally checked at least
once a year. Faults observed have to be
immediately rectified and/or reported to the
responsible person.
Use only genuine MAKO spare parts.
Before removing or opening pressurized
components, positively isolate any source of
pressure and depressurize the entire system.
Never weld any pressure reservoir or change
it in any way.
If work which produces heat, flames or sparks
has to be carried out on or near this unit, the
adjacent components of this unit have to be
protected by means of non inflammable
material.
Before releasing this unit for operation after
maintenance or overhaul check that the unit
is functioning properly and the regulating,
shut-down equipment and safety interlocks
are working properly.
Electrical components and regulating
equipment have to be protected from the
ingress of humidity at all times.
Never use etching solvents which could attack
the materials used.
Avoid damage to the safety valves and other
pressure reducing components. Check in
particular for clogging caused by paint, oil
carbon or the accumulation of dust, which
could deteriorate the effectiveness of these
components.
Check the accuracy of pressure and
temperature indicators at regular intervals. If
the admissible tolerance limits have been
exceeded, these devices must to be replaced.
Before cleaning the machine with water or
steam jet (high pressure cleaner) or other
cleaning agents, initiate an electrical lock-out
procedure(see section 3.5), cover all
openings which have to be protected from the
ingress of water, steam or detergents for
safety and/or functional reasons, in particular
electrical cabinets, components and
connections.
Follow the adjusting, maintenance and
inspection activities and schedule set out in
the operating instructions. These activities
must only be carried out by skilled personnel,
under qualified supervision.
Maintenance and repair work may only be
carried out under the supervision of a person
who is qualified to do the work.
Inspection, maintenance and repair work may
only be carried out with the unit being at rest
and depressurized. Protective equipment to
be removed for this work has to be properly
refitted after completion of these activities.
Always use the correct tools for maintenance
and repair work.
Never use inflammable solvents or carbon
tetrachloride to clean parts. Take precautions
against poisonous vapors from cleaning
agents.
In any work concerning the operation or
adjustment of the unit and its safety-oriented
devices or any work related to maintenance,
inspection and repair, always observe the
start-up and shutdown procedures set out in
the operating instructions.
Ensure that the maintenance area is
adequately secured.
During maintenance and when carrying out
repair work, cleanliness is very important.
Avoid the ingress of dirt by covering parts and
free openings with a clean cloth, paper or
adhesive tape.
After the completion of each repair, check that
all lines and components are clear of any
foreign material before assembly.
Care must be taken any time this unit is in
operation!
The employer has to inform the employee of
the dangers possibly arising during the repair
and maintenance of this unit as well as on how
to avoid them; the employee has to observe
all measures for safety at work. Safety
equipment for the prevention or
Maintenance And Repair

3. Safety regulations
3-5
After cleaning, remove all covers and
masking completely and allow the unit to dry
before returning unit to service!
Always re-tighten all threaded connections
which have been loosened for maintenance
and repair work.
If the set-up, maintenance or repairs require
the removal of safety equipment, this
equipment has to be replaced and checked
immediately.
Ensure that consumables and replacement
parts are disposed of in a safe and
environmentally friendly manner in
accordance with all applicable local, regional
and national laws, rules and regulations.
Use only genuine MAKO fuses with the
specified current rating. Switch off the
machine/unit immediately if trouble occurs.
Work on the electrical system or equipment
must only be carried out by a skilled
electrician or by specially instructed
personnel under the control and supervision
of such an electrician and in line with the
relevant electrical engineering rules.
The electrical equipment of this unit is to be
inspected and checked at regular intervals.
Defects such as loose connections or
scorched cables must be rectified
immediately. Necessary work on live parts
and elements must be carried out in the
presence of a second person who can cut off
the power supply in case of danger by
operating the emergency shutdown or main
power switch. Secure the working area. Use
insulated tools only.
Carry out welding, flame-cutting and grinding
work on the machine/unit only if
this has been expressly authorized, as there
may be a risk of explosion and fire.
Before carrying out welding, flame-cutting
and grinding operations, clean the
machine/unit and its surroundings from dust
and other inflammable substances and
3.6 Warning Of Special Dangers
Electric energy
Gas, Dust, Steam, And Smoke
make sure that the premises are adequately
ventilated (risk of explosion)!
Observe and adhere to any existing
regulations valid for the place of operation!
Work on high pressure air equipment must
only be carried out by persons with special
knowledge and experience of high pressure
air systems.
Check all lines, hoses and threaded
connections regularly for leaks and obvious
damage. Damage must be Repaired
immediately. High pressure air may cause
serious injury or death.
Depressurize all system sections, pressure
pipes, tubing and hoses which are to be
removed in accordance with the specific
instructions for the assemblies concerned
before carrying out any repair work.
Compressed-air lines must be laid and fitted
properly. Ensure that no connections are
exchanged. The fittings, lengths and quality
of hoses must comply with the technical
requirements.
Units must never be operated in areas subject
to explosion hazards!
(Exception: Special units with the
corresponding technical modifications)
Pneumatics
Rooms Subject To Explosion Hazards
Danger !

3. Safety regulations
3-6
3.7 Symbols And Explanations
The Following Symbols may be used on the
unit.
fig. 3.7-2
Warning, Electrical Shock or Electrocution
fig. 3.7-3
Warning, Pressurized Bottle
fig. 3.7-1
No Access for Unauthorized Personnel
fig. 3.7-4
Read Operators Manual before continuing
fig. 3.7-5
Read Technical Manual before continuing
fig. 3.7-6
Warning! See the User Instruction Manual for
specific hazards associated with this unit.
See the section of the users manual
associated with this area of this unit for
specific hazards associated with this area.

3. Safety regulations
3-7
fig. 3.7-7
Warning, Release of Pressure
fig. 3.7-8
Lock-Out Procedure Required
Keep
this log book with the unit at all times.
The daily log book should be checked each
and every time before the unit is turned on.
After any automatic shut down or perceived
problem unit must be taken out of service and
“Out Of Service” must be written in daily log.
Do not try and restart unit until problem is
resolved.
Report any such shut-down or problem to
3.8 Logs And Daily Inspections
MAKO Supplies a daily log sheet, appendix-A.
We recommend that additional copies be
made and a daily log book be created.
3.8.1 Daily Log Book
Out of service
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.
1) Check the log to see that no one has
taken the unit out of service.
2) After the unit is determined to be in
service, , enter the date
and time in the daily log and begin your
inspections.
3) Walk around unit and look for problems.
If any problems are found that could effect
the safe operation of the unit take the unit out
of service and report the problem to the
appropriate service personnel.
Document any actions taken in daily log.
If no problems are found after unit has been
inspected place a check in “Inspection”
column and continue.
4) Close all access doors. All access panels
must be in place.
5) Place Your initials in the operator
column.
6) Unit can now be started.
7) Listen and look for air leaks. If an air
leak is detected take the unit out of
service. Report leak to the service
personnel.
High pressure air leaks can be very
dangerous.
Document any actions, alarms, concerns or
observations in the “Alarms and Comments”
column.
When the unit is shut down record the time in
the “Start/Stop” column.
Daily Inspection & log Entries
Do not start the unit
Danger!

4. Layout and Function
4-1
fig. 4.1-1 CMM panels & Wall Mount unit.
Legend
1) CMM Panel for BAC units.
2) CMM for BAM units.
3) CMM Wall Mount unit to be added
to any existing high pressure
breathing air system.
NOTE: A purification chamber may be
needed for full functionality. Consult
salesman for details.
4) Calibration Sample Gas Bottles.
The gas in these bottles is used to
calibrate the CMM unit. One of the
bottles contains “Pure Air” with no
CO and the other bottle contains
“Carbon Monoxide”” with a CO
content of 20 PPM.
20 PPM sample gas bottle - Part #
003M4884-1
Pure Air sample gas bottle - Part #
009006-7800
4.1 General Description
Configurations
The Mako CMM monitoring systems
(See Fig. 4.1-1) incorporates the functions
required to check high pressure breathing air
for safe levels of Carbon Monoxide and
Moisture content.
There are two (2) possible CMM options.
1) CO Only
2) CO and MO
The CMM option provides monitoring of air for
unsafe levels of Carbon Monoxide (CO) and
Moisture (MO) content in PPM or parts per
million per unit volume. The CO only
configuration measures carbon monoxide in
PPM and displayed in real-time as the
compressor system is running.
Danger!
Do not use CMM monitor for any application
other than with breathing air systems.
2
1
3
4

4. Layout and Function
4.1.1 CO Option
The CMM monitors system air (air exiting the
purification system) for high levels of carbon
monoxide only while the compressor is
running. This is controlled by two systems
comprising of a solenoid valve and auxiliary
contacts. When the motor contactor engages
it closes the auxiliary contact which sends a
signal to the CMM that the compressor is
running. Once the CMM receives this signal it
opens the supply air solenoid allowing air to
cross over the CO cell. The monitor has a built
in 5 second delay to allow the system air to
purge the ambient air in the CO cell housing
ensuring the user that the displayed reading
is accurately reading the system air free of
any ambient contamination.
The supply air is controlled by two regulators.
These regulators reduce the system high
pressure to 5 PSI that the CMM can accurately
determine CO levels. Set the first regulator to
100 PSI and the second to 5 PSI.
fig 4.1.1-1 CO Pressure Reducing Regulators
The CMM monitors supply air input to the CO
sensor by a small pressure switch mounted on
the CMM board. If no pressure is detected
after a short amount of time the CMM will shut
the compressor down, alarm, and indicate no
CO pressure. This safety ensures the user
that adequate flow to the sensor is available
for proper monitoring.
Excessive heat buildup can be detrimental to
the life and operation of the CO cell. Therefore
a red rubber hose has been added to direct the
air flow out of the upper control panel and
maintain a cool environment as much as
possible. The CMM is equipped with a
temperature sensor that detects the
temperature inside the CO sensor housing to
ensure the cell does not see temperatures
above operating levels.
Calibration can be completed in a few simple
steps. The first is to turn on the zero and
twenty PPM calibration cylinders, select
calibration from the CMM menus and then
observe monitor for completion. (See Section
6.3.3) The first step in the calibration sequence
will turn on the 20 PPM calibration solenoid and
measure the cylinder for sufficient pressure to
calibrate. If insufficient pressure is observed
an alarm will sound, stop the calibration
process, and indicate the cylinder is empty.
The second operation will be to allow flow
across the CO cell for sixty seconds. Once this
time has elapsed the twenty PPM solenoid
closes and the sequence repeats with the 0
PPM calibration cylinder.
4-2
4.1.1.1 Solenoids - CMM Control Panel
Inside the CMM control panel are three small
solenoids as shown in fig. 4.1.1.1-1.
The solenoids control the flow of the pure air
and 20ppm calibration bottles, as well as, the
inlet supply air from the compressor.
To extend the life of the CO cell the CMM limits
the flow of dry air across the cell for only the
duration of the running compressor by
operating the supply air solenoid.
fig.4.1.1.1-1 Solenoid Valves