Service Manual
116 Pages
Preview
Page 1
FLOWTRON® UNIVERSAL Service Manual
Flowtron Universal Service Manual
Service Bulletins Incorporated Bulletin
Content
Date incorporated
SERB008
Cleaning Instructions
Sep 2009
SERB022
Manifold Repair
Sep 2009
SERB023
Software Upgrade to V3.00
Sep 2009
SERB028
Flowtron Universal LCD Replacement
Sep 2009
SERB030
Software Upgrade to V3.01
Sep 2009
SERB034
PCB Changes
Sep 2009
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Ammendment Record Page i
Flowtron Universal Service Manual
Ammendment Record Page ii
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CONTENTS CHAPTER 1 Introduction... 1 About This Manual... 1 Warnings, Cautions and Notes... 1 General Description... 1 Technical Description... 3 Pressure Transducer Calibration... 3 Alarms... 3 Battery on the Control PCB Assembly (if fitted)... 3 Schematics... 3 System Operation... 4
CHAPTER 2 Troubleshooting... 1 Troubleshooting Table... 1 Alarm Cancel... 1
CHAPTER 3 Maintenance... 1 Service... 1 Cleaning Instructions... 2 Maintenance Checks... 3
CHAPTER 4 Testing... 1 Initialising the Pump... 1 Garment Recognition Test... 1 Checking the Basic Pump Operation... 3 Location of the Soft-Function Buttons on the Pump Membrane Label... 5 Using the Buttons below the Service Screen on the LCD Display... 5 Preparation of the Calibration Test Equipment... 6 Checking the Calibration of the Pressure Transducer... 7 Re-calibrating the Pressure Transducer... 10 Recalibrating the Pump Hose Set Assemblies... 12 Electrical Safety Testing... 14 Electrical Safety Checks... 14 Earth/Ground Continuity Test... 14
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Insulation Resistance Test... 15 Dielectric Strength Test (Flash Test)... 15 Leakage Earth/Ground Current Test (USA)... 15
CHAPTER 5 Pump Repair... 1 General... 1 Pump Labels... 3 Removing the Case IEC Cover... 6 Installing the Case IEC Cover... 6 Replacing the Inlet Filter Felt... 7 Removing the Mains/Power Cordset... 7 Installing the Mains/Power Cordset... 7 Removing the Hose Set Assembly... 9 Installing the Hose Set Assembly... 10 Removing the Rear Case from the Pump... 13 Installing the Rear Case onto the Pump... 13 Removing the Handle and Hook Assembly... 13 Installing the Handle and Hook Assembly... 13 Separating the Top Case Assembly from the Front Case... 15 Installing the Top Case Assembly onto the Front Case... 16 Replacing the Mains/Power Fuses on the Power Supply PCB Assembly... 17 Replacing the Air Inlet Filter on the Compressor Assembly... 17 Removing the Motor and Manifold Assembly... 19 Repairing the Motor and Manifold Assembly... 19 Installing the Motor and Manifold Assembly... 25 Including a Longer Transducer Tube on the Motor and Manifold Assembly... 25 PCB Part Numbers... 27 Interchangeability of PCBs... 27 Removing the Control Printed Circuit Board (PCB) Assembly... 29 Installing the Control Printed Circuit Board (PCB) Assembly... 29 Removing the Power Supply PCB (Printed Circuit Board) Assembly... 31 Installing the Power Supply PCB (Printed Circuit Board) Assembly... 31 Removing the LCD Sub-Assembly... 33 Removing the Control PCB Assembly from the Top Case Assembly... 33 Removing the LCD Sub-Assembly from the Control PCB Assembly... 33 Installing the LCD Sub-Assembly... 34 Installing the LCD Sub-Assembly onto the Control PCB Assembly... 34 Installing the Control PCB Assembly into the Top Case Assembly... 35
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Replacing the Membrane Label by removing the Control PCB Ass’y from the Top Case Ass’y . 37 Replacing the Membrane Label without removing the Control PCB Assembly... 39 Removing the Run Button... 40 Installing the Run Button... 40 Replacing the Top Case Assembly... 40 Replacing the Battery on the Control PCB Assembly (if fitted)... 41 Removing the Compressor Assembly and Mounting Bracket... 43 Installing the Compressor Assembly and Mounting Bracket... 43 Removing the Compressor Assembly from the Mounting Bracket... 45 Installing the Compressor Assembly onto the Mounting Bracket... 45 Replacing the Rear Case... 47 Replacing the Front Case... 49
CHAPTER 6 Updating the software... 1 Introduction... 1 Installing the Communicator Software... 2 Connecting the Pump to a Laptop / Desktop PC... 9 Launching the Communicator Software... 11 Executing Commands on the Command Menu... 12 Communication Error when Executing Commands... 13 Closing the Communicator Software... 13 Initialising the Pump... 15 Checking the Version of the Pump Software... 17 Downloading the V3.01 Software Files to the Pump... 17
CHAPTER 7 Technical Specification... 1 Pump... 1 Accessories... 2
CHAPTER 8 Parts List... 1 General... 1 Pump Parts List... 1
CHAPTER 9 Service Contact Details... 1
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Introduction
CHAPTER 1 INTRODUCTION 1
About This Manual
ArjoHuntleigh strongly recommend that their equipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own equipment. In no event will ArjoHuntleigh be responsible for any service performed by customers or third parties. This manual contains information on maintenance, servicing, repair, troubleshooting and testing for the Flowtron® Universal pump. Read and understand this manual before attempting to service or repair the equipment. Numbering and Cross-Referencing in this Manual For all chapters in this manual: •
Page, section and paragraph numbering re-start at “1”.
•
Figure and table numbering continue from the previous chapter.
•
Cross-references which include a chapter number (and/or chapter title) refer to text in a different chapter. Cross-references which do NOT include any chapter number (or chapter title) refer to text within the same chapter.
Warnings, Cautions and Notes WARNINGS given in this manual identify possible hazards in procedures or conditions which, if not correctly followed, could result in death, injury or other serious adverse reactions. CAUTIONS given in this manual identify possible hazards in procedures or conditions which, if not correctly followed, could result in equipment failure or damage. Notes given in this manual are used to explain or amplify a procedure or condition.
WARNING: BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES, ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY DECONTAMINATED. WARNING: BEFORE DISMANTLING THE PUMP, ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET. WARNING: VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN, IN CERTAIN CIRCUMSTANCES, BE LETHAL. WHEN WORKING ON EQUIPMENT REQUIRING EXPOSURE TO LIVE/HOT, UNPROTECTED CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT, EXTREME CARE MUST BE EXERCISED.
2
General Description
The Flowtron Universal system is a non-invasive external intermittent pneumatic compression system for reducing the incidence of deep vein thrombosis (DVT). The application of external intermittent pneumatic compression has two effects: •
Augments venous blood flow velocity, thereby reducing stasis.
•
Enhances fibrinolytic activity to reduce the risk of early clot formation.
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Chap 1 Page 1
Introduction
Flowtron Universal Service Manual
The system comprises a pump that can be used in conjunction with a pair of ArjoHuntleigh single-patientuse compression garments. The pump provides intermittent cycles of compressed air to the two connected compression garments, which are inflated alternately. The pump can be used with a number of different ArjoHuntleigh singlepatient-use compression garments, including: •
Foot garments, e.g. FG100-200.
•
Single-chamber calf and thigh/calf garments, e.g. DVT10-40, 60.
The pump automatically adjusts the correct therapy profile for the garment type being inflated. An optional battery pack is available which allows the pump to be used independently of the mains/power supply. The battery pack slides onto the base of the pump, and recharges itself when the pump is operating from the mains/power supply. The pump has the following controls (Refer to Figure 1): •
A Run/Standby push-button. This is used to start and stop the therapy applied to the patient.
•
An illuminated graphic LCD display. This indicates:
•
•
The type of garment(s) connected.
•
The pressure delivered to each garment.
•
Alarm indications.
A membrane label which contains the following four soft-function buttons: •
A three-button keypad below the LCD display. These are used during the normal operation of the pump.
•
A single “hidden” button above the LCD display. This is used during service and repair operations only.
•
Red and green LED indicators on the front of the pump to show alarm and run status.
•
Automatic detection of the connected garment type. Run/Standby Button LCD Display + Membrane Label
Power/Alarm LED Indicators
Hose Set Assemblies to Garments Figure 1 - Flowtron Universal Pump
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3
Introduction
Technical Description
The pump consists of an electronically controlled air compressor with associated air routing and alarm facilities. The operation of all the pump features is driven by microcontroller software. The key parts of the pump are as follows: •
Compressor. This provides a flow of air to the pneumatic system, thus allowing inflation of the garments. The output of the compressor is fed to the motor and manifold assembly.
•
Motor and Manifold Assembly. This includes a rotary valve which routes the air pressure to the garments. The rotary valve also makes sure that as one garment is being inflated, the other garment is vented to the atmosphere.
•
Pressure Transducer. This provides the monitoring system with the means of accurately measuring the pressure fed to each garment.
•
Control Printed Circuit Board (PCB). This PCB controls the compressor, the motor and manifold assembly, and the illuminated graphic LCD display panel. It also performs a continuous check of the operation and performance of the pneumatic circuit. In the event of a detected fault, the electronic monitoring system generates both visual and audible alarms.
•
Power Supply Printed Circuit Board (PCB). In addition to generating the DC voltages for use in the pump, the PCB provides interfaces to the compressor and the optional battery pack.
•
Automatic Garment Recognition Facilities. The connector on the end of each pump hose set contains a sense coil which is connected to the control PCB, and is used to automatically recognise the type of garment fitted to the connector (foot garment, or single chamber calf garment).
Pressure Transducer Calibration The pump utilizes a precise and accurate pressure measurement and control system, which is not expected to require re-calibration until after several years of continuous use. The measurement system automatically handles any adverse effects due to drift or temperature change and should not require any user intervention. The pump is factory-calibrated, and should not normally require field re-calibration. However, the pressure shown on the LCD display should be verified for accuracy during each routine maintenance.
Alarms The pump has both audible and visual alarms. If a problem occurs, the system will detect the fault and flash a message on the LCD display. If the same fault continues for 10 successive inflation cycles (which will be between 5 and 12 minutes depending on the garment types connected to the pump), the audible alarm sounds, the red alarm LEDs flash and a description of the fault condition is indicated on the LCD display. If the fault condition is unaltered, the audible alarm will increase in pitch until the fault is corrected and/or the system is reset. Note: If a Pump Fault is detected, the pump will alarm immediately.
Battery on the Control PCB Assembly (if fitted) The battery on the control PCB assembly provides power for the real time clock. The battery should not require replacement until after several years of continuous use. If the battery has to be replaced, then it must be replaced in less than 20 seconds, or else the real time clock will lose its time and date settings. If the time and date settings are lost, they have to be reloaded from a PC-based service tool, so the procedure should only be carried out in a ArjoHuntleigh service environment.
Schematics Refer to Figure 8 for the Pneumatic/Control Schematic of the pump. Refer to Figure 9 for the Electrical Schematic of the pump.
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Introduction
Flowtron Universal Service Manual
4
System Operation
4.1
Plug the pump into an electrical outlet, and switch on.
4.2
The pump will first go through a self-test routine (Refer to Figure 2).
Figure 2 - LCD Display - Running Diagnostic 4.3
At the end of the self-test routine, the pump will “beep” and go into Standby mode, where it will remain until required for use (Refer to Figure 3).
Figure 3 - LCD Display - Standby 4.4
Connect the garments to the pump hose set assemblies and make sure the connectors click into place.
4.5
Check that the connection and garment type are confirmed correctly on the display. Figure 4 shows two single-chamber calf garments connected to the pump.
Figure 4 - LCD Display - Garments Connected 4.6
Typical garment options and default therapy parameters are detailed in Table 1. Table 1 - Garment Options and Default Therapy Parameters Garment Type and LCD Display Graphic
Chap 1 Page 4
Inflation Pressure (mmHg)
Inflation Hold (seconds)
Cycle (seconds)
Foot
130
3
30
Single-chamber, Calf and Thigh/Calf
40
12.5
60
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4.7
Introduction
To start the therapy, press the green Run button on the top of the pump, and keep it depressed until the pump “beeps”. The green LEDs on the front of the pump will illuminate and therapy will begin. Figure 5 shows the pump running, and the left calf garment inflated to 40 mmHg.
Note: The green LEDs do not illuminate when running from the battery pack.
Figure 5 - LCD Display - Therapy Started
4.8
To stop the therapy, press the green Run button a second time, and keep it depressed until the pump “beeps”. The green LEDs on the front of the pump will extinguish and therapy will stop.
4.9
To connect only one garment to the pump: 4.9.1
When the pump is in standby, connect one garment to either hose set assembly.
4.9.2
The LCD display will confirm that only one garment is connected (Refer to Figure 6). Note: If a garment is disconnected while the pump is running, the system will alarm Lo. If the single garment option is still required, simply press the Run button to reset the system and press the Run button
again to restart therapy.
Note: If at any time a second garment is connected while the pump is running, the pump will automatically change to two garment operation.
Figure 6 - LCD Display - Single Garment Connected 4.10
To connect different garments on each limb: 4.10.1
Simply connect the garments to either hose set assembly, and the correct therapy cycle will be administered for each garment.
4.10.2
Check on the display panel to confirm the garment types connected (Refer to Figure 7).
Figure 7 - LCD Display - Different Garments Connected
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Introduction
4.11
Flowtron Universal Service Manual
To change the language displayed on the pump: 4.11.1
Press the function button adjacent to “Options”
4.11.2
Use the arrow buttons to highlight the “Language” change option.
4.11.3
Press the button to continue.
4.11.4
Use the arrow buttons to scroll through the available languages.
4.11.5
Highlight the desired language and press the button to select.
4.11.6
Press the button again to confirm the selection.
4.11.7
Use the arrow buttons to highlight “Exit” (in the new language):
4.11.8
Press the button to continue.
4.11.9
The screen will now display the main menu in the new language:
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Membrane Label
Introduction
LCD Display
Alarm LED
Alarm LED Control Electronics
Run/Standby LED
Run/Standby LED Buzzer Pressure Transducer
Exhaust to Atmosphere
Garment Sleeve
Quick Connect
Hose Set
Recognition Sense Coil Garment Sleeve Quick Connect
Compressor
Motor
Hose Set
Optical Position Sensor
Recognition Sense Coil
Rotary Valve
Electrical Connections Pneumatic Connections Mechanical Link
Figure 8 - Pneumatic/Control Schematic
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Introduction
Flowtron Universal Service Manual
Membrane Label Connector
Control PCB Assembly Hose Set Assemblies Recognition Sense Coils
LCD Display + Membrane Label
LCD Display Connector
Rechargeable Battery (if fitted)
Motor and Manifold Assembly Ribbon Cable Fuses
Power Supply PCB Assembly
Mains/Power Cordset
Battery Pack Connector Series 6 Compressor Assembly
Figure 9 - Electrical Schematic
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Troubleshooting
CHAPTER 2 TROUBLESHOOTING 1
Troubleshooting Table
The Flowtron Universal pump features an audible and visual alarm. If a problem occurs, the system will sense the fault and briefly flash a message on the LCD display on the top of the pump. If the same fault continues for 10 successive inflations (up to 10 minutes), the audible alarm will sound, the red alarm lights on the front of the pump flash and a message will appear on the LCD display until corrective action is completed. The exception to this is a Pump Fault alarm, which will alarm immediately.
Alarm Cancel After a fault has been corrected, the alarm can be cancelled by either of the following two methods: •
Press the Run button running.
on the pump twice, or until the green lights are lit and the pump is
•
With the exception of a Pump Fault alarm, correct the fault and allow the pump to run until it senses a normal inflation. It will then reset itself.
Page 2, Table 2 contains fault symptoms, their possible causes and suggests steps to rectify the problem. Where possible, reference is made to the relevant repair chapter.
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Troubleshooting
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Table 2 - Troubleshooting Table Fault “LO” (Low Pressure Alarm)
Possible Cause Garment
Hose disconnected at garment.
Check the hose connections at the garment end.
Loose fitting garment.
Rewrap snugly.
Garment leak.
Check garment and replace if necessary.
Kinked tube to the transducer on the control PCB.
Check tube for kinks or obstructions.
Damaged/disconnected internal tube.
Check internal tubes and replace if necessary.
Damaged hose set assembly.
Check hose set assemblies, and replace if necessary. (Chapter 5, Page 9, Section 8) (Chapter 5, Page 10, Section 9)
Blocked air filters.
Replace inlet filters on the rear case and compressor assembly. (Chapter 5, Page 7, Section 5) (Chapter 5, Page 17, Section 17)
Motor and manifold assembly failed.
Replace. (Chapter 5, Page 19, Section 18) (Chapter 5, Page 25, Section 20)
Compressor assembly failure or low output.
Replace. (Chapter 5, Page 45, Section 38) (Chapter 5, Page 45, Section 39)
Garment
Garment hose kinked.
Check garment hose for kinks or obstructions.
Pump
Hose set assembly kinked.
Check hose set assemblies for kinks or obstructions.
Pump
Control PCB faulty.
Replace. (Chapter 5, Page 27, Section 22) (Chapter 5, Page 29, Section 25)
Power Supply PCB faulty.
Replace. (Chapter 5, Page 31, Section 26) (Chapter 5, Page 31, Section 27)
Pump
“HI” (High Pressure Alarm)
“Pump Fault”
Remedy
“Pump Fault RFID”
Pump
Hose set electrical connections are not fitted correctly to pump.
Check hose set assemblies, and replace if necessary. (Chapter 5, Page 9, Section 8) (Chapter 5, Page 10, Section 9)
“Pump Fault Step”
Pump
Motor and manifold assembly failed.
Replace. (Chapter 5, Page 19, Section 18) (Chapter 5, Page 25, Section 20)
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Maintenance
CHAPTER 3 MAINTENANCE WARNING: BEFORE DISMANTLING THE PUMP UNIT, MAKE SURE THE UNIT HAS BEEN ISOLATED FROM THE MAINS/POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET. WARNING: A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS ON THE POWER SUPPLY PCB ASSEMBLY WHEN THE CASE IS OPENED, EVEN WITH THE PUMP SWITCHED OFF. CAUTION: Static Sensitive Devices. Electrostatic discharge can seriously damage the control and power supply PCB assemblies. This pump should only be opened by personnel trained in ESD methods and with appropriate equipment and anti-static protection.
1
Service The pump should be serviced every 12 months. To service the pump, do the following:
1.1
Carry out the maintenance checks, detailed below (Refer to Chapter 3, Page 3, Section 3).
1.2
Replace the inlet filter felt on the rear case (Refer to Chapter 5, Page 7, Section 5).
1.3
Carry out the following function tests on the pump: 1.3.1
Garment recognition test, in accordance with Chapter 4, Page 1, Section 2.
1.3.2
Checking the calibration of the pressure transducer, in accordance with Chapter 4, Page 7, Section 7. Note: The pump is designed to remain accurate throughout its working life. This test checks the accuracy of the pressure shown on the LCD display. The pump is factory-calibrated, and should not normally require field re-calibration.
1.4
Carry out an electrical safety tests on the pump in accordance with Chapter 4, Page 14, Section 10.
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Maintenance
2
Flowtron Universal Service Manual
Cleaning Instructions If the pump is to be cleaned by spraying cleaning solutions directly onto it, the following (Refer to Figure 10) instructions must be observed:
2.1
Lay the pump down on its rear case, so that the cleaning solution will not collect on the top cover assembly adjacent to the two hose set assemblies.
2.2
Use a soft cloth to remove any unwanted cleaning solution from the top cover assembly.
Hose Set Assemblies
Front Case
Top Case Assembly
Note: Do not let any cleaning solution collect here
Rear Case
Figure 10 - Top Cover Assembly and Hose Set Assemblies
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3
Maintenance
Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Chapter 5, Pump Repair.
3.1
Visually inspect the following for damage, wear and potential faults: • Outer casing: • Run button
3.2
Check for damage and security. :
Check function.
• Handle and hook assembly:
Check for damage and security.
• Output hose set assemblies:
Check for damage and security of pump connection.
• LCD display + membrane label:
Check for damage and security to case.
• Mains/power cord:
Check for damage and security of plug
• Rubber feet (8 Off):
Check for security.
• Labels:
Check all labels are present and legible
Remove the rear case (Refer to Chapter 5, Page 13, Section 10) and visually inspect the following for damage, wear, security and potential faults: • Rechargeable battery on the control PCB. • Compressor assembly. • Compressor anti-vibration pads. • Motor and manifold assembly. • Control PCB and LCD display assembly. • Power supply PCB assembly, including fuses. • Wiring. • Internal Tubing. • Screws, nuts and bolts.
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Chap 3 Page 3