PrinterNOx Service Manual Rev 1.9 March 2019

Contents Safety Precaution ... 3 Important safeguards ... 3 Introduction ... 4 Before you begin ... 4 Overview ... 4 Servicing Kit – Check List ... 5 Tools and Equipment Required for Servicing ... 5 Estimate of Time Allocation for Servicing ... 5 Using this Guide ... 5 Document Conventions ... 6 Icons ... 6 1. Knowing the parts of the PrinterNOx ... 6 Safety Information... 6 Exploded Isometric View of PrinterNOx ... 7 Pipework Connections of PrinterNOx ... 8 2. Disassembling the PrinterNOx for Servicing ... 9 3. Replacing the Service Parts of the PrinterNOx & Reassembling ... 10 Check for Gas Leaks in Gas Sampling System ... 11 Fault Finding Gas Leaks ... 12 4. Calibration and Setting Ready for Operation ... 14 Fault Finding when the PrinterNOx will not Calibrate ... 15 Appendix A, Technical Data... 19 Specification : PrinterNOx ... 19 Appendix B, Technical Support ... 20 Appendix C, Circuit Description ... 20 Overview ... 20 Processor Control Section ... 20 Signal Conditioning Circuit ... 22 Printer Driver ... 23 Power Supply ... 23 Parts List ... 25 Circuit Diagram – Processor Section ... 30 Circuit Diagram – Printer Driver ... 31 Circuit Diagram – Sensor Conditioning Circuit ... 32

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Information in this document is subject to change without notice and does not represent a commitment on the part of Vyaire Medical GmbH. Only the parts supplied by Vyaire Medical GmbH should be used to complete the service operation described in this manual. If in any way you feel unsure about the successful completion of the service operation you should contact Vyaire Medical GmbH or its appointed agent in your country or region and arrange the despatch of the product to a Vyaire Medical GmbH Service Centre. At Vyaire we constantly strive to improve our products. This may result in minor changes to devices which affect the way service activities need to be conducted. If you find that the service instructions you have do not reflect the actions you need to take to service your device, it is likely that the device you have is of a slightly different design specification than covered by the service manual. In that case, please contact our Technical Services Department (See page 20) who will be happy to provide you with the details you need. Copyright 2019 by Vyaire Medical GmbH All rights reserved PrinterNOx is a trademark of Vyaire Medical GmbH. All other products are trademarks or registered trademarks of their respective owners.

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Safety Precaution The servicing of this device is intended to be carried out by a properly trained and competent electronics engineer, or experienced in the maintenance and servicing of medical devices. Read this manual thoroughly before proceeding with the service. If in any doubt please contact the service centre at Vyaire Medical GmbH or their accredited agent in your country or region. Please also read the Safety Information section on Page 6 of this service manual.

Important Safeguards •

Read all of the instructions.

•

Keep the instructions in a safe place for later use.

•

Follow all warnings and instructions marked on the product.

•

When replacement parts are required, be sure to use replacement parts specified by Vyaire that have the same characteristics as the original parts. Unauthorised substitutions may result in fire, electric shock or other hazards.

•

Do not use this product near water or in humid conditions.

•

Do not place on an unstable table.

•

The product should be operated only from the type of power source indicated on the label.

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Introduction This Service Manual provides you with information to carry out the servicing operation of the PrinterNOx. It is a process which is relatively straight forward but must be carried out in a logical sequence. Our advice is to familiarise yourself with the contents of this manual before attempting to carry out the procedure of replacing the parts supplied in the Service Kit for the PrinterNOx.

Before You Begin Before you begin the servicing operation, please read the following sections carefully: •

Overview of the servicing operation

•

Servicing Kit - Parts List

•

Check the servicing kit for latest information briefing sheets

Overview The service consists of four key stages, it is essential to complete each stage correctly to ensure that the device will operate as it is intended and you are advised to read this section carefully. If you would prefer to contact Vyaire Medical GmbH they will arrange servicing of the product for you. You will be given a service return reference number. Please do not despatch a product to us without clearly marking it with your return address and the service return reference number. You will also need to raise a purchase order from your organisation detailing Vyaire (or its agent) to carry out the servicing of the unit. Stage 1: Dismantling the PrinterNOx Open moulded casing, extract printed circuit board from the bottom part of main moulding, disconnect and remove nafion/gas sampling tubing, unplug and remove sampling pump. Stage 2: Service replacement of PrinterNOx parts Replacement of lithium battery, tubing, 2 off orifice restrictors, NO and NO2 sensors, gas sampling pump. Reconnect tubing to gas sampling pump/flow sensor. Check the gas tubing system for leaks using a rotameter. Stage 3: The Reassembling of the PrinterNOx Reverse the dismantling process. Replace thermal paper and the rear control panel adhesive label. Stage 4: Calibration and Setting the PrinterNOx Ready for Operation

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Servicing Kit - Check List •

NO sensor (Cat No. CEL4800)

•

NO2 sensor (Cat No. CEL4801)

•

Orifice restrictor (Cat No. FIL4802)

•

Lithium battery (Cat No. BAT4815)

•

Rear control panel adhesive label (Cat No. LAB4208)

•

Nafion tubing assembly (Cat No. NTASSY)

•

Manifold to pump assembly (Cat No. MPASSY)

•

Gas sampling pump (Cat No. PMP4800A)

Tools and Equipment Required for Servicing •

Torque screwdriver (Set to 13 cNM)

•

¼" spanner

•

2.5mm Hex. Allen key

•

A pair of pliers

•

Calibration Gases Nitric Oxide (NO) and Nitrogen Dioxide (NO2)

•

Rotameter

Estimate of Time Allocation for Servicing The following information is provided as an estimate to facilitate the planning of the servicing procedure to assist with your time management, this of course assumes all procedures are carried out correctly and further faults do not have to be rectified: Dismantling

15 minutes

Parts replacement

30 minutes

The Reassembling of the PrinterNOx

10 minutes

Calibration and setting ready

10 minutes

Estimate of Total Time Allocation

Using this Guide This manual is arranged as follows: Components location and parts identification guide: 1. Knowing the parts of the PrinterNOx Step by step guide to the servicing process: 2. Disassembling the PrinterNOx for servicing 3. Replacing the service Parts of the PrinterNOx and reassembling 4. Calibration and Setting Ready for Operation Product specification: Appendix A, Technical Data Where to get help if things go wrong: Appendix B, Technical Support Understanding how the electronics work: Appendix C, Circuit description 5

1hr 05 mins.

Document Conventions Icons In this manual, icons are used to highlight areas of text that require your attention.

Cautions or warnings that must be taken note of. Information highlighted by this icon tells you how to avoid situations that could damage the operation of the PrinterNOx device Hints and tips that will help you to ensure a successful outcome to the servicing procedure. Information highlighted by this icon tells you about tasks that need prior knowledge to reach a successful conclusion. The following icons highlight a tool which is recommended to complete a specific task within the service procedure: Pliers

Main Purpose: when easing apart the tubing etc. of the gas sensing system.

Torque Screwdriver

Main Purpose: fixing the manifold retaining screws in place.

1. Knowing the parts of the PrinterNOx The PrinterNOx is a combined Nitric Oxide / Nitrogen Dioxide monitor based on electrochemical fuel cells and may be operated directly from the mains power or from the internal rechargeable NiCad battery pack. Fuel cells work through the reaction of the target gas with an electrolyte at one electrode and oxygen (from ambient air) at the other. This reaction generates an electrical current proportional to the gas concentration. The PrinterNOx is designed to: Monitor concentrations of delivered Nitric Oxide (NO) as a safety check on the delivery system. Monitor the by-product Nitrogen Dioxide (NO2) Safety Information Nitric Oxide is a highly toxic gas, exposure to levels as low as 200 parts per million (ppm) may be fatal even after very short exposures, and prolonged exposure to levels lower than this may also be harmful. All users of nitric oxide must familiarise themselves with appropriate safety regulations. When calibrating the PrinterNOx monitor it is important to ensure that the calibration gas is adequately vented and safely exhausted. Nitric oxide reacts with oxygen in air to form nitrogen dioxide, an extremely toxic gas with a maximum allowable industrial ambient level of 5ppm. You are advised prior to servicing the PrinterNOx to familiarise yourself with its operation by reading the User Manual supplied with the PrinterNOx.

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Vyaire does not accept any liability for injury resulting from malfunction and failure to follow these guidelines. Failure to follow instructions in this Service Manual and the User Manual may also result in dangerously inaccurate measurements being obtained.

Exploded Isometric View of PrinterNOx

Bat 3

NO 2 Cell Black restrictor NO Cell Flow transducer

Manifold

Manifold Brass backing plate

Brass backing plate Nafion tubing

Gas sampling pump

Black restrictor

The illus tration abov e will allow y ou to loc ate the c om ponents of the PrinterN Ox when c arry ing out the s erv ic e of this unit.

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Pipework Connections

Exhaust

To SK6 on PCB

F

V

P

C B

Connect to flow transducer port P2

Connect to flow transducer port P1

Ventilation cover

E

D A

Black restrictor

Left-hand end cap

Inlet Nafion tubing assembly, Cat No. NTASSY, outlined in blue Manifold tubing assembly, Cat No. MPASSY, outlined in green NOTE: Tubing lengths not to scale. Colour for identification purposes only. 8

2. Disassembling the PrinterNOx for Servicing This chapter provides you with the step by step instructions to disassembling the PrinterNOx in preparation for the gas system, sensor and battery replacement. If you are not familiar with the internal parts of the PrinterNOx, we recommend that you read Section 1 before attempting to disassemble the unit. If you are not familiar with the operation of the PrinterNOx, we recommend you read the User Manual supplied with the unit. 1.

Disconnect all mains power supplies

2.

Remove paper roll and paper roll housing cover, put to one side.

3.

Remove the rear adhesive label and disregard. To release watertrap assembly from the lefthand end cap remove retaining screws and disconnect from luer fitting.

We recommend that you use a Philip Number Zero screwdriver for the following instruction.

4.

Place the PrinterNOx face down to remove the four screws in the lower moulding, put the screws to one side.

5.

Turn the unit face up before easing the upper and lower mouldings apart.

6.

Disconnect rechargeable NiCad battery pack - this will facilitate working on the rear side of the printed circuit board and components within the transducer housing.

7.

Ease the LCD display printed circuit board out of its plastic supports and rest inside of upper moulding and remove LCD supporting corners and put to one side.

8.

Ease the main printed circuit board (PCB) off the support legs and pins for supporting the LCD display printed circuit board.

9.

Disconnect [and replace either now or wait and replace later] the lithium battery (BAT3) (Cat No. BAT4815) on the main printed circuit board.

10. Place the main PCB in the upper moulding to reveal its lower side and the open side of the transducer housing. 11. Unplug sampling pump connector (SK7) from PCB. 12. Disconnect sampling pump tubing to ports V & P and then remove the pump/housing assembly completely from the transducer housing with a twisting and lifting motion. Using a 2.5mm Allen key loosen the grub screw to detach the sampling pump from its housing.

We recommend that you use a Philip Number One screwdriver for the following instruction.

13. Unscrew the four screws retaining each of the manifolds/brass backing plates and retain said items. 14. Disconnect and remove the NO and NO2 sensors from the main printed circuit board and disregard.

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15. Using illustration ‘Bottom moulding view of PrinterNOx’ as a reference, remove length of tubing (as illustrated in blue) and disregard. Using a ¼” spanner remove the black restrictor located on the left end cap and disregard. 16. Using illustration ‘Bottom moulding view of PrinterNOx’ as a reference, remove the length of tubing (illustrated in green) and disregard. Using a small spanner remove the black restrictor located on the left-hand manifold and disregard.

3. Replacing the Service Parts of the PrinterNOx & Reassembling This section provides you with the step by step instructions to the reassembling and bench testing of the PrinterNOx. When reassembling the main printed circuit board, and the lower and upper mouldings be sure not to trap the tubing between any of these components.

1.

Place the new sampling pump (Cat No. PMP4800A) in the pump housing and check correct orientation of the sampling pump as shown in figure 2. Using a 2.5mm Allen key, tighten the grub screw to secure the sampling pump in its housing.

2.

Place the new sampling pump/housing into the transducer housing pushing it towards the exhaust end cap allowing a gap of 4mm between the housing and the end cap.

3. 4.

Using the spanner fit a new black restrictor (Cat No. FIL4802) to the left-hand end cap. Taking the nafion tubing assembly (Cat No. NTASSY) feed the assembly under the ventilation cover so that the 25mm end of silicon tubing is at the end where the black restrictor has just been fitted. Connect the 25mm end of tubing to the black restrictor. Connect the other end of the nafion tubing assembly to the flow transducer port marked ‘P1’.

5.

Using the ¼" spanner take the pump to manifold assembly (Cat No. MPASSY) and fit the black restrictor to the left-hand PTFE manifold. Connect the other end of the pump to manifold assembly to the sampling pump port ‘P’.

6.

Remove the NO (Cat No. CEL4800) and NO2 (Cat No. CEL4801) sensors from the plastic containers. Be sure to remove the shorting link on the NO2 sensor before fitting.

7.

Fit the sensors into their respective positions, locating the four connection pins. Refer to figure 1 in Section 1 to ensure the correct fitting of the sensors. The following will help to ensure that each sensor is placed in the correct position: Viewing from the underside with the rear edge of the main printed circuit board closest to you: the left hand position is to be fitted with the NO sensor the right hand position is to be fitted with the NO2 sensor

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Make sure that the O-rings are in position on the top of the sensors, i.e. between the sensor and the manifold.

Torque Screwdriver

Main Purpose: fixing the manifold retaining screws in place.

8. Place the retained PTFE manifolds/brass backing plates on top of the NO and NO2 sensors and fix to the main printed circuit board using the four screws for each manifold. When attaching the fixing screws set to a torque of 13 cNm. Be sure not to over tighten, as this may damage the main circuit board, but do ensure it is sufficiently tight to avoid gas leakage.

9.

If you have not already done so, replace the lithium battery (BAT3), (Cat No. BAT4815) at SK6 position on the main printed circuit board making sure that the velcro pad on the battery is mated to the velcro pad on the PCB.

10. Reassemble the PrinterNOx as far as placing the main printed circuit board into the lower moulding and locating it on the four LCD printed circuit board support pins. 11. Reconnect the Nickel Cadmium battery pack. If the NO sensor was purchased from Vyaire without a biasing board supplied then it will require a 2 week stabilising period before it can be calibrated. This is achieved by leaving the sensors on the PCB for a 2 week period before calibration. However, if a biasing board was purchased both NO and NO2 cells will require only a 24 hour stabilisation period prior to calibration Check for Gas Leaks in Gas Sampling System 1.

Fix a length of tubing approximately 30 cm (12 inches) onto the exhaust port and connect to a rotameter.

2.

Connect to power supply and turn the unit on and enter into measurement mode.

3.

Occlude the input port on the water trap.

4.

Check that the leak rate at the exhaust is less than 7mL /min.

5.

If no leaks are present then continue with the following points, otherwise check for leaks and repeat procedure (see following section on ‘Fault Finding Gas Leaks’).

6.

Turn the unit off; remove the power supply adapter.

7.

Place the LCD display panel supporting corners on to the support pins and place the panel onto them.

8.

Reassemble by replacing the four screws into the lower moulding, replacing the paper role and paper role housing cover.

9.

Stick the new rear control panel adhesive label (Cat No. LAB4208) on to the unit.

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Fault Finding Gas Leaks Refer to PIPEWORK CONNECTION DRAWING (Page 8) Connect the rotameter to the exhaust end of the PrinterNOx Turn the PrinterNOx unit ON and select option 1 (Measurement) Occlude the watertrap Luer fitting

Does the rotameter read less than 7ml/min

YES

END

NO Remove watertrap and occlude inlet valve located on left hand end cap of PrinterNOx Does the rotameter read less than 7ml/min

YES

Replace Watertrap

NO Take PrinterNOx unit apart, refer to section 2 Occlude position (A) with a pair of pliers

Does the rotameter read less than 7ml/min

YES

Check inlet and black orifice connection

NO A

B

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A

B

Occlude position (B) with a pair of pliers

Does the rotameter read less than 7ml/min

YES

Check connections to nafion tubing

NO Occlude position (C) with a pair of pliers

Does the rotameter read less than 7ml/min

YES

Check connections to either side of the flow sensor and at the reducers

NO Occlude position (D) with a pair of pliers

Does the rotameter read less than 7ml/min

YES

Check connections to either side of the pump and the reducer in line

NO Occlude position (E) with a pair of pliers

Does the rotameter read less than 7ml/min

YES

Check black orifice and pipework and torque on sensor manifold is 13cNM

NO A

B

13

A

B

Occlude position (F) with a pair of pliers

Does the rotameter read less than 7ml/min NO

YES

Check connectors between manifolds, all pipe work to the exhaust pipe and the setting on sensor manifold is 13cNM.

Return the unit to Micro Medical or a Micro Medical Service Centre for investigation.

4. Calibration and Setting Ready for Operation This section provides you with the step by step instructions to set the PrinterNOx unit ready for operation. 1.

Enter the New Sensor Calibration mode by turning the unit on and pressing keys 1 and 9 on the keypad simultaneously.

2.

Enter the correct password (please ring Vyaire)

3.

Press 1 to calibrate the new sensor.

4.

Press enter to zero the unit.

5.

After both NO and NO2 have been successfully calibrated press key 3 on the keypad.

If the unit does not calibrate, follow the following flow chart to determine the fault.

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Fault Finding when the PrinterNOx will not Calibrate Connect an External supply to the PrinterNOx unit and turn the PrinterNOx unit ON. Select option 1 (Measurement) and leave unit to run in this mode for 5 minutes.

Press the ‘ENTER’ key on the keypad to reveal the main menu. Select option 2 (Calibration)

The sampling pump will now start and the PrinterNOx will monitor the output of both sensors until a stable reading is obtained.

Has the PrinterNOx sampling pump started to work

NO

Take the PrinterNOx unit apart refer to section 2 and check that the pump circuitry is working as explained in Appendix C Circuit description - PUMP

YES Has a series of asterisks appeared on the LCD display

NO

The processor has probably locked up. Turn the unit OFF and then ON. If this happens again take the PrinterNOx unit apart – refer to section 2 and check the processor Circuitry as explained in Appendix C - Circuit description.

YES Has the LCD display changed to read ‘Calibrate NO or NO2 or EXIT’

Take the PrinterNOx unit apart refer to section 2 and check that the sensor conditioning circuitry is working as explained in Appendix C

A

B

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A

B

Press ‘1’ on the keypad to calibrate NO

Does the LCD display change to read,’Enter NO calibration gas Concentration’ 00.0ppm

NO

The processor has probably locked up. Turn the unit OFF and then ON If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor circuitry as explained in Appendix C – Circuit description.

YES Enter the required gas concentration as is indicated on the gas bottle and press the ‘ENTER’ key on the keypad

Does the LCD display change to read ‘Pass Calibration gas through Instrument’.

NO

The processor has probably locked up. Turn the unit OFF and then ON. If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor Circuitry as explained in Appendix C – Circuit description

YES Supply a flow of ‘NO’ gas into the water trap on the PrinterNOx unit as shown in the operating manual. Press ‘ENTER’ on the keypad.

Does the LCD display read ‘Calibrating NO’ and a series of asterisks appear on the LCD display.

NO

The processor has probably locked up. Turn unit OFF and then ON. If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor circuitry as explained in Appendix c – Circuit description.

YES A

B

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A

B

Does the LCD display change to read ‘Calibrate NO or NO2 or EXIT’

NO

Take the PrinterNOx unit apart refer to section 2 and check that the Sensor Conditioning circuit is working as explained in Appendix C – Circuit description.

YES Press 2 on the keypad to calibrate NO2.

Does the LCD display change to read,’Enter NO2 calibration gas Concentration 00.0ppm’

NO

The processor has probably locked up. Turn the unit off and then ON. If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor circuitry as explained in Appendix C – Circuit description.

YES Enter the required gas Concentration as is indicated on the gas bottle and press the ‘ENTER’ key on the keypad

Does the LCD display change to read ‘Pass Calibration gas through Instrument’.

NO

The processor has probably locked up. Turn the unit OFF and then ON. If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor Circuitry as explained in Appendix C – Circuit description.

YES Supply a flow of ‘NO’ gas into the water trap on the PrinterNOx unit as shown in the operating manual. Press ‘ENTER’ on the keypad.

A

B

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A

B

Does the LCD display read ‘Calibrating NO’ and a series of asterisks appear on the LCD display.

The processor has probably locked up. Turn the unit OFF and then ON. If this happens again take the PrinterNOx unit apart – refer to Section 2 and check the processor NO circuitry as explained in Appendix C – Circuit description.

Does the LCD display change to read ‘Calibrate NO or NO2 or EXIT’

Take the PrinterNOx unit apart refer to section 2 and check that the Sensor Conditioning circuit is working as explained in Appendix C – Circuit description.

NO

The PrinterNOx unit is now been calibrated successfully.

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Appendix A, Technical Data Specification: PrinterNOx Gases detected

Nitric Oxide (NO) Nitrogen Dioxide (NO2)

Sensor type Measurement range

Resolution

Accuracy

Response time

Alarm range

Safety cut-out operation

Alarmed conditions

Electrochemical fuel cells NO

100 Parts per million (ppm)

NO2

20 ppm

NO

0.05 ppm

NO2

0.05 ppm

NO

+/-5% or 0.05ppm whichever is greater

NO2

+/-5% or 0.05ppm whichever is greater

NO

Less than 10 seconds (90% FSD)

NO2

Less than 30 seconds (90% FSD)

NO

lower and upper 0 to 99ppm

NO2

upper 0 to 19ppm

NO

100 ppm

NO2

9ppm

Water trap full Sample line occluded Battery low

Sensor life

>1 year

Sidestream flow rate

250 ml/minute

Input pressure range

0 to 100 cm H2O

Data storage

24 hours

Printer type

320 dot/line, low power thermal printer

Paper type

11 cm thermal paper

Power supply

primary 100 - 250V 50 - 60Hz secondary 12V 1.5A DC

Battery pack

Rechargeable NiCad 7.2V 600mA-hours

Dimensions

315 x 120 x 90 mm

Weight

1.2kg

Operating temperature

0 to +40°C

Operating humidity

30% to 90% RH

Operating pressure

Atmospheric +/-10%

Storage temperature

-20 to +70°C

Storage humidity

30% to 90% RH

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