Caleo Repair Instructions Ver 4.0

Contents

3.8

3.9

4

3.7.3

Testing the Integrated O2 Monitor PCB using the DrägerService mode 32

3.7.4

Replacing the Integrated O2 Monitor PCB ... 33

WT2 Sensor PCB ... 34 3.8.1

General information about the WT2 Sensor PCB ... 34

3.8.2

Checking the WT2 Sensor PCB using DrägerService mode ... 34

3.8.3

Replacing the WT2 Sensor PCB ... 35

O2 sensors (optional) ... 39 3.9.1

General information about the O2 sensors ... 39

3.9.2

Checking O2 sensors with DrägerService mode ... 39

3.9.3

Checking the O2 sensors during operation ... 39

3.9.4

Replacing O2 sensors ... 40 42

4.1

General information about the display housing ... 42

4.2

Display housing ... 43

4.4 For internal use only. Copyright reserved.

Testing the Integrated O2 Monitor PCB during operation ... 32

Display housing

4.3

R6150000T02IVZ.fm

3.7.2

4.5

6150.000 Caleo

4.2.1

Dismounting the display housing from the trolley ... 43

4.2.2

Mounting the display housing onto the trolley ... 45

Rear panel ...47 4.3.1

Opening the rear panel of the display housing ...47

4.3.2

Closing the rear panel of the display housing ... 48

4.3.3

Replacing the display housing ... 48

Electronic unit ... 52 4.4.1

Removing the electronic unit from the display housing ... 52

4.4.2

Opening the electronic unit ... 54

4.4.3

Fitting the electronic unit into the display housing ... 55

EL display ... 57

Repair Instructions

Page II

Contents

4.6

4.7

4.5.1

Checking the EL display during normal operation ... 57

4.5.2

Replacing the EL display ... 58

WT2 Controller PCB ... 63 4.6.1

General information about the WT2 Controller PCB ... 63

4.6.2

Checking the WT2 Controller PCB during normal operation ... 64

4.6.3

Testing the WT2 Controller PCB using the service LEDs ... 65

4.6.4

Replacing the WT2 Controller PCB ... 66

Lithium battery ... 72 4.7.1

4.8

4.9

Replacing the lithium battery ... 72

Membrane keypad ... 76 4.8.1

General information about the valve block ... 76

4.8.2

Checking the membrane keypad during normal operation ... 76

4.8.3

Checking the membrane keypad using the DrägerService Mode ... 77

4.8.4

Replacing the membrane keypad ... 77

Rotary transducer/control knob assembly ... 83 4.9.1

General information about the rotary transducer/control knob assembly 83

4.9.2

Checking the rotary transducer ... 83

4.9.3

Replacing the rotary transducer ... 83

For internal use only. Copyright reserved.

R6150000T02IVZ.fm

4.10 Loudspeaker ... 86

5

4.10.1

General information about the loudspeaker ... 86

4.10.2

Checking the loudspeaker during normal operation ... 86

4.10.3

Replacing the loudspeaker ... 86

Aggregate housing

89

5.1

Swinging the aggregate housing out of the basic housing ... 90

5.2

Removing the aggregate housing from the basic housing ... 93

5.3

Mounting the aggregate housing onto the basic housing ... 95

6150.000 Caleo

Repair Instructions

Page III

Contents 5.4

5.5

5.6

For internal use only. Copyright reserved.

R6150000T02IVZ.fm

5.7

5.8

6150.000 Caleo

Air heater ... 99 5.4.1

Stator/heating element assembly ... 100

5.4.2

Safety thermostat ... 106

5.4.3

WT2 Hallsensor PCB ... 110

5.4.4

Temperature sensor ... 115

Toroidal transformer ... 120 5.5.1

General information about the toroidal transformer ... 120

5.5.2

Checking the toroidal transformer in the DrägerService mode ... 120

5.5.3

Replacing the toroidal transformer ... 121

Water boiler (optional) ... 127 5.6.1

General information about the water boiler ... 127

5.6.2

Checking the water boiler during normal operation ... 127

5.6.3

Checking the water boiler using the DrägerService mode ... 128

5.6.4

Replacing the sealing rings in the water boiler ... 128

5.6.5

Bimetal thermostat ... 132

5.6.6

Replacing the water boiler ... 138

5.6.7

Safety thermostat of the water boiler ... 145

5.6.8

Replacing the safety thermostat ... 148

5.6.9

Water connecting pipe (optional) ... 152

Fan motor ... 154 5.7.1

Checking the fan motor during normal operation ... 154

5.7.2

Checking the fan motor using the DrägerService mode ... 155

5.7.3

Replacing the fan motor ... 155

E-box ... 163 5.8.1

General information about the E-box ... 163

5.8.2

WT2 Actuator PCB ... 164

5.8.3

Replacing the WT2 Actuator PCB ... 166

Repair Instructions

Page IV

Contents 5.9

6

Pneumatic O2 control (optional) ... 174 5.9.1

General information about the pneumatic O2 control ... 174

5.9.2

Checking pneumatic O2 control in normal operation ... 174

5.9.3

Checking the pneumatic O2 control with DrägerService mode ... 175

5.9.4

Replacing the pneumatic O2 control ... 175

Basic housing 6.1

Fresh-air channel ... 183 6.1.1

6.2

For internal use only. Copyright reserved.

R6150000T02IVZ.fm

7

Snap-to guides of fresh-air channel ... 183

Fresh-air filter ... 185 6.2.1

6.3

182

Replacing the fresh-air filter ... 185

Removing basic housing and aggregate housing from trolley ... 187 6.3.1

General information about removal ... 187

6.3.2

Removing basic housing and aggregate housing from trolley ... 187

6.4

Mounting basic housing/aggregate housing assembly onto trolley ... 192

6.5

Scales (optional) ... 195 6.5.1

Checking the scale during normal operation ... 195

6.5.2

Checking the scale using the DrägerService mode ... 196

6.5.3

Replacing the scale ... 196

Trolley

198

7.1

Removing the housing of the trolley ... 199

7.2

Mounting the housing of the trolley ... 201

7.3

Electronic unit of trolley ...203 7.3.1

WT2 Mains PCB ...204

7.3.2

Mains voltage fuses ... 212

7.4

Replacing the slide blocks of the bearing block ... 213

7.5

Replacing rolls of bearing block ... 214

6150.000 Caleo

Repair Instructions

Page V

Contents 7.6

Replacing trolley castor ... 215

7.7

Replacing the shaft of the trolley castor ... 216

7.8

Pedal (optional) ... 218

7.9

Bellows (optional) ...220 7.9.1

Replacing the bellows ...220

7.10 Motor (tilt adjustment) ...226 7.10.1

Replacing motor (tilt adjustment) ...226

7.11 Motor of height adjustment (optional) ...233 7.11.1

Swivel drawer (optional)

238

8.1

General information about the swivel drawer ...238

8.2

Mounting the swivel drawer ...239

For internal use only. Copyright reserved.

R6150000T02IVZ.fm

8

Replacing motor of height adjustment ...233

6150.000 Caleo

Repair Instructions

Page VI

Repair Procedure A B C

1

General information about the Caleo

1 2 3 4 5 6

Fig.

1 Front view of the Caleo

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Key 1

Canopy

2

Sensor unit

3

Display housing

4

Basic housing

5

Aggregate housing

6

Trolley

− non-adjustable trolley − electrically adjustable trolley (optional)

6150.000 Caleo

Version 4.0

Repair Instructions

Page 7 of 239

9 A

1

B C

8

2 3

7

6 5

4

Fig.

2 Side view of Caleo

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Key 1

Sensor unit, temperature connections

2

Mains connection

3

ON/OFF switch

4

Castors

5

Fresh-air filter

6

Connection (O2 control)

7

Water container

8

Telescopic iv pole

9

Central alarm indicator

6150.000 Caleo

Version 4.0

Repair Instructions

Page 8 of 239

2

Canopy, flaps, column elements

2.1

Canopy

2.1.1

General information about the canopy

A B C

In case of repair, replace the complete canopy. If a new canopy needs to be installed, attach the country-specific label ”Never leave baby unattended when doors are open” warning label (”Doors open” warning label) to the front of the new canopy. The ”Doors open” warning label is part of the country-specific label sets (Note: See ”Spare Parts List” for more information on label sets). The canopy is made of plexiglass. Attach warning label to specified area, see Fig. 3.

30 +- 5

1.

170 +- 5

Niemal s das B aby un be aufsi c wenn Hau ben öffn ung en nicht Non lasci ar e mai pann el li aperti !

incustod

Ne ja mais lais s er le bé bé s a ns lo rs q ue l'h abitac le est o uv ert.

Laat

het

kind

niet

alleen

Niemal s das B aby un be aufsi c wenn Hau ben öffn ung en nicht Non lasci ar e mai pann el li aperti !

incustod

Ne ja mais lais s er le bé bé s a ns lo rs q ue l'h abitac le est o uv ert.

Laat

kind

niet

alleen

3 View of the canopy front with ”Doors open” warning label

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig.

het

6150.000 Caleo

Version 4.0

Repair Instructions

Page 9 of 239

2.1.2 A

2.

B C

Removing the canopy

Hold canopy at both lateral recessed grips, lift carefully, and place on a stable soft surface.

Recessed grips

Fig.

4 Side view of Caleo

2.1.3 1.

Mounting the canopy

Hold canopy at both recessed grips and carefully place it vertically onto the column elements.

The guide pins should glide into the recesses on the column elements.

Recessed grips

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Guide pins

Fig.

5 Side view of Caleo

6150.000 Caleo

Version 4.0

Repair Instructions

Page 10 of 239

2.1.4 A

Guide and cap assembly

In case of repair, replace the complete guide an cap assembly.

B C

Replacing the guide and cap assembly 1.

Place the canopy on a stable, non-scratching, surface.

2.

Remove screws (a).

3.

Dispose of faulty guide and cap assembly according to local waste disposal regulations.

Guide and cap assembly

Fig.

Secure new guide and cap assembly with screw (a) using the preferred mounting position of the guide and cap assembly, see Fig. 6 (Note: The tightening torque of the screw is 1.5 -0.5 Nm!).

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

4.

6 View of one guide and cap assembly

6150.000 Caleo

Version 4.0

Repair Instructions

Page 11 of 239

2.1.5 A B C

Double wall (optional)

Removing the double wall 1.

Hold canopy at both lateral recessed grips, lift carefully, and place on a stable soft surface.

2.

Slightly compress double wall at point (a) and disengage from canopy holders at elongated holes (b).

b

b Double wall

a

Fig.

7 Canopy

Mounting the double wall into the canopy 1.

Turn canopy upside down and place on a soft, stable surface.

2.

Place double wall into canopy.

3.

Insert double wall into holders (b) on one long side of the canopy.

4.

Slightly compress double wall and insert into holders on opposite side of canopy.

Holder

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Double wall

Fig.

8 Sectional view of canopy

6150.000 Caleo

Version 4.0

Repair Instructions

Page 12 of 239

2.2

Doors

2.2.1

General information about the large doors

A B C

The large door comprises the hand ports, levers, latches, large seal, and hinges. In case of repair, replace the complete large door. If the large door needs to be replaced, attach the country specific labels ”Drawer” and ”Warm air” to the front of the new large door. The labels ”Drawer” and ”Warm air” are part of a country-specific label set (Note: See ”Spare Parts List” for more information on label sets).

Replacing the large door 1.

Open latches of faulty large door and fold large door down.

2.

Hold faulty large door and loosen screws (1) until retaining clips are slackened such that door can be disengaged from holders.

9 Left and right side view of the large door

3.

Dispose of faulty large door according to local waste disposal regulations.

4.

Secure new large door to holders using screws (1), see Figure above (Note: The tightening torque of the screws is 2.5 +0.5 Nm!).

5.

Fold large door up and close using latches.

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig.

6150.000 Caleo

Version 4.0

Repair Instructions

Page 13 of 239

6.

Attach label ”Drawer” to the front of the large doors, see Fig. 10.

A

1,5 +10

B C

Niemal s das B aby un be aufsi chti gt l as sen, wenn Hau ben öffn ung en nicht gesc hl os sen Non lasci ar e mai pann el li aperti !

incustodito

il

neonat o

Ne ja mais lais s er le bé bé s a ns lo rs q ue l'h abitac le est o uv ert.

Laat

het

kind

niet

alleen

achter

Niemal s das B aby un be aufsi chti gt l as sen, wenn Hau ben öffn ung en nicht gesc hl os sen

si nd!

coi

Non lasci ar e mai pann el li aperti !

s urv eilla nc e

bij

Ne ja mais lais s er lo rs q ue l'h abitac l

geopende

deur!

Laat

het

+5

kind

incustodito

le

il

neonat o

bé bé s a ns o uv ert.

achter

si nd!

coi

s urv eilla nc e

bi

j

geopende

deur!

+5

10 - 0

10 - 0 Label ”Drawer”

Fig. 10 Front view of Caleo, label ”Drawer”

Attach label ”Warm air” to the front of the large doors, see Fig. 11.

1,5 +10

7.

Niemal s das B aby un be aufsi chti gt l as sen, wenn Hau ben öffn ung en nicht gesc hl os sen Non lasci ar e mai pann el li aperti !

incustodito

il

neonat o

Ne ja mais lais s er le bé bé s a ns lo rs q ue l'h abitac le est o uv ert.

Laat

het

kind

niet

alleen

achter

Niemal s das B aby un be aufsi chti gt l as sen, wenn Hau ben öffn ung en nicht gesc hl os sen

si nd!

coi

Non lasci ar e mai pann el li aperti !

s urv eilla nc e

bij

geopende

Ne ja mais lais s er lo rs q ue l'h abitac l

deur!

+5

10 - 0

Laat

het

kind

incustodito

le

il

bé bé s a ns o uv ert.

achter

neonat o

si nd!

coi

s urv eilla nc e

bi

j

geopende

deur!

+5

10 - 0 Label ”Warm air”

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig. 11 Front view of Caleo, label ”Warm air”

6150.000 Caleo

Version 4.0

Repair Instructions

Page 14 of 239

Hand ports A

Replace complete hand port if damaged (hand port window cracked, hinge faulty, etc.).

B C

Replacing the hand port 1.

Swing canopy support open and place canopy onto support.

2.

Open faulty hand port.

3.

Hold faulty hand port and remove screws and plastic washers (a).

4.

Dispose of faulty hand port according to local waste disposal regulations.

5.

Mount new hand port using screws and plastic washers (a) (Note: Make sure plastic washers are centered in order to avoid jamming of hand ports; tightening torque of screws is 2 –0.5 Nm!).

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig. 12 Mounting the hand ports

6150.000 Caleo

Version 4.0

Repair Instructions

Page 15 of 239

Lever A

In case of repair, replace lever.

B C

Replacing the lever 1.

Swing canopy support open and place canopy onto support.

2.

Hold lever and remove screw and plastic washer (a).

3.

Dispose of faulty lever according to local waste disposal regulations.

Lever

Fig. 13 Securing the lever

4.

Make sure that locking spring (b) is in the correct fitting position.

5.

Mount new lever using screw and plastic washer (a) (Note: The tightening torque of the screw is 2 -0.5 Nm!).

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig. 14 Locking spring

6150.000 Caleo

Version 4.0

Repair Instructions

Page 16 of 239

Latch A

Replace latches if latch pin is broken or secure locking of doors is no longer possible.

B C

Replacing the latch 1.

Swing canopy support open and place canopy onto support.

2.

Carefully remove screw (a) to avoid losing washer.

3.

Remove faulty latch and dispose of according to local waste disposal regulations.

Latch pin

Latch Fig. 15 Latch

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

4.

Fit washer (b) onto thread of screw (a) and secure new latch with screw (a) using correct fitting position (Notes: The tightening torque of screw (a) is 1 +0.5 Nm; red lock mark on front of latch must be visible when front door is open; turn-lock must move smoothly; tighten up screw a little if turn-lock has too much play!) .

Fig. 16 Mounting the latch

Seal (large) Replace large seal with new one if sticky, brittle, or torn.

6150.000 Caleo

Version 4.0

Repair Instructions

Page 17 of 239

Replacing the seal (large) A B C

1.

Open latches on right and left sides of large door and fold large door down.

2.

Pull out faulty large seal at guide groove and dispose of according to local waste disposal regulations.

3.

Push new large seal (1) into guide groove of large door according to preferred fitting position (Note: Stretch seal such that large door is sealed completely!), see Fig. 17

Fig. 17 Mounting the large seal

Fold large door up and close using latches.

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

4.

6150.000 Caleo

Version 4.0

Repair Instructions

Page 18 of 239

Hinges A

• Replace hinges if damaged (hinge or retaining clip broken).

B C

Replacing the hinges 1.

Open latches of large door and fold large door down.

2.

Hold large door and loosen screws (1) until retaining clips are slackened such that door can be disengaged from holders, see Fig. 18.

Fig. 18 Left and right side view of the large door

3.

Place large door on stable and soft surface.

4.

Remove screws (1) of faulty hinge, see Fig. 19.

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

Fig. 19 Attachment of hinge to large door

5.

Dispose of faulty hinge according to local waste disposal regulations.

6.

Secure new hinge to large door using screws (1) (Note: The tightening torque of the screws is 2 -0.5 Nm!), see Fig. 19.

6150.000 Caleo

Version 4.0

Repair Instructions

Page 19 of 239

7.

Secure large door to holders of Caleo using screws (1) (Note: The tightening torque of the screws is 2.5 +0.5 Nm!), see Fig. 20.

A B C

Fig. 20 Attachment of large door

Fold large door up and close using latches.

For internal use only. Copyright reserved.

R6150000T02.fm 22.08.01

8.

6150.000 Caleo

Version 4.0

Repair Instructions

Page 20 of 239