Rocket R54569 PSU Service Manual Rev 01 May 2017

Rocket Digital low vacuum/low flow Suction Pump – Service Manual

Revision History Rev. No. 01

Rev. Date 080517

Summary of Changes Initial Release

Chapters Affected -

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Service Manual for Rocket Chest Drain Pump. Purpose of Document This document is to assist trained service personnel in the routine maintenance and service of the Rocket Chest Drain (CDSU).

Table of Contents REVISION HISTORY ... 2 SERVICE MANUAL FOR ROCKET CHEST DRAIN PUMP. ... 3 PURPOSE OF DOCUMENT ... 3 1 Safety ... 4 1.1 Special Precautions... 4 1.2 Electrical Shock Hazard ... 4 1.3 Explosion Hazard... 4 2 Operating manual ... 5 3 Basic Trouble shooting guide ... 5 4 Specification ... 6 5 Warnings ... 7 6 Technical Description... 8 6.1 Power Supply. ... 8 6.2 User Interface... 8 6.3 System Control ... 8 6.4 System Safety ... 8 7 Calibration checks... 9 8 Routine service tasks ... 10 9 Disassembly / Reassembly... 11 9.1 Unit Top assembly... 12 9.2 Unit Base assembly ... 12 9.3 PCB Top ... 13 9.4 PCB Bottom ... 13 9.5 PCB Top Overlay ... 14 9.6 PCB Bottom Overlay ... 15 10 Circuit Diagram ... 16 11 Parts Listing ... 20 12 Contact Details ... 24

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Safety The CDSU is an external, mobile suction device for use with the Rocket Medical Chest Drainage range. Rocket Medical chest drains are required to prevent the build-up of air inside the body (pleura) whilst breathing and also remove any unwanted fluids after surgery. This development is a new design intended to be an alternative to existing hospital wall suction and will also allow the patient to become ambulatory in their recovery

1.1

Special Precautions The CDSU has been designed for electrical safety. All the safety and operating instructions should be read before operating the unit. Failure to do so could result in injury to the user, patient, or damage to the system and accessories. Always remove from the patient area when undertaking service on the unit. Always take anti-static precautions when service this unit, failure to do so will cause damage to the sensitive electronic circuits.

1.2 Electrical Shock Hazard Do not defeat the grounding integrity of this system. Protection against electrical shock, in the event of failure of insulation, is provided by the connection of the psu unit to the safety ground. Safety grounding occurs only when the 3-wire cable and plug provided with the system are connected to a properly grounded receptacle. Do not remove the system cover. The system should be serviced by trained and qualified personnel only. Contacting the hazardous voltages within the system could cause serious injury. Never attempt to open the mains power supply unit, this unit is sealed and must be returned to the factory if damaged or faulty. Do not use the system if the power cord has any cuts or openings. Do not use the unit or power supply if their enclosure is cracked. Do not immerse the unit or power supply in any liquids.

1.3 Explosion Hazard Do not operate or use this system in the presence of flammable anesthetics, gases or oxygen rich environments as it could lead to explosion.

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Operating manual Before undertaking any service on this unit read the system operating manual in full. If it is not available contact Rocket Medical who will provide an electronic copy The Manual will provide guidance on the use of the controls, identification and meanings of the symbols and guidance over the units use.

3

Basic Trouble shooting guide The Mobi distinguishes between warnings, alarms and internal errors. If Mobi detects any of these situations, an acoustic warning signal sounds and an error number will be displayed. The error number corresponds to the problem as shown below. Error

Problem Description

Trouble Shooting

Source of Error

501

Self test failed Sensor defect

Switch off unit and restart.

502

Battery low Connect power supply

Plug in Power Supply to recharge battery

503

Self test failed Battery defect Do not disconnect Power supply

Battery defect, do not disconnect power supply

Filter may not have been recognised, problem with sensor. Battery low on charge, approximately 30 mins of power remaining Battery has malfunctioned, possible battery replacement required.

504

No filter Please insert filter

505

Battery empty Please charge battery

Check to see if filter is in place. Remove pump from bottle to check filter in in position. Connect Power Supply to charge battery

506

Data storage error

507

Battery empty Power Off

508

Battery life cycle warning

Turn unit off and back on. If error occurs please contact manufacturer for service. Battery has no charge, connect power supply to charge or use connected to power supply. The battery in the unit has almost reached the maximum number of charges allowed for the battery to run efficiently. This warning is displayed with 50 charges remaining.

Unit may have been turned on without filter in place. Battery has been allowed to discharge fully Memory malfunction, failure in storage access Battery charge has been left to discharge fully. The unit does not have enough power to function The battery in the unit has a 500 charge life cycle. Please arrange for the unit to be serviced and the battery replaced.

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Specification Power Input to Pump: Power Supply: Consumption: Frequency: Maximum current: Environmental conditions: Service interval: Dimensions: Weight: Suction Ranges: Suction Range Accuracy:

18VDC 100 - 240VAC 50/60Hz 0.096 KW/h 50/60 Hz 2.5A @ 18V +5°C to +35°C 500 Battery charges W - 190mm x H - 118mm x D - 140mm Unit - 0.96Kg User Set: -0.5Kpa to -5Kpa ±10% at 2.5Kpa.

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Warnings  

   

     

Not intended for use where a suction (vacuum) value of over -5 Kpa or a flow of over 5L/min is required. The Mobi device is not approved for connection to any other device except the Rocket Medical R54571 single use filter and R54500 chest drain unit and tubing set (R54502, R54539). The R54500 chest drain unit and tubing set (R54502, R54539) are single use parts and their instructions for use must be followed at all times. Do not use in an area where flammable gases are present. If a persistent air leak is shown, check the filter is positioned correctly on the chest drain unit and that the suction unit is securely attached to the chest drain unit. Precautions for EMC safety should be observed. The Mobi complies with IEC606011-2:2007, however: - Electronic equipment in the vicinity of the Mobi device may affect its operation and potentially cause unpredictable operation of the device. - Wherever possible the Mobi device should be distanced from surrounding electromagnetic equipment and cables to this equipment in order to reduce possible electromagnetic interference. - The Mobi device power cable should only be connected to a correctly wired grounding receptacle in order to avoid the risk of electrical shock. When positioning the unit, ensure that access is available to the DC power cable located on the rear of the unit. To avoid damage to the unit only use the approved mains power adaptor supplied with the unit, Model Number: R54569-PSU-UK. The Mobi contains a Li-ion battery and that is not user replaceable and that unauthorised attempts to repair could lead to damage to the unit, environment and/or human health if incorrectly fitted, handled or disposed of improperly. The Li-ion battery must only be replaced by a suitably trained and Rocket Medical approved service centre. Fluids should not be allowed to enter the device as this may result in damage to the system. Only qualified personnel should service the device and the unit cabinet should not be opened except by these personnel due to the risk of hazardous electrical shock. All service requirements should be referred to a Mobi authorised representative.

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Technical Description The CDSU is an external, mobile suction device for use with the Rocket Medical Chest Drainage range. Rocket Medical chest drains are required to prevent the build-up of air inside the body (pleura) whilst breathing and also remove any unwanted fluids after surgery. This development is a new design intended to be an alternative to existing hospital wall suction and will also allow the patient to become ambulatory in their recovery. The unit is both mains and battery powered (rechargeable) for limited time use while mobile. The unit is intended to function only with a disposable filter set. The filter set will be a sterile, single use and is a disposable component. The filter will act as protection for the CDSU but also as a bacterial barrier for the patient. The CDSU consists of a vacuum pump, membrane keypad, LCD display (with backlight), monitoring electronics (pressure sensor & filter detection) and battery. The system will be mounted on top of the chest drainage bottle in which the vacuum is generated. Here it will control the vacuum at predetermined levels. The vacuum can be set to a level of suction between 0 – 50cmH20 at 5cmH20 intervals.

6.1 Power Supply. The unit operates from either an 18VDC input or from the built in 14.8V Lithium-ion battery. The voltages are switched internally to provide the main operating voltages of 12VDC and 3V3DC. The Lithium –ion battery is charged from the DC input supply using a specialised Charge IC BQ24610RGET which controls the charge current and monitors the temperature of the battery.

6.2 User Interface A back lit LCD provides the user messages and operating values of the device with a tactile 3 button keyboard allowing user interaction with the device to set pressure etc.

6.3 System Control The entire system is controlled by software within an Atmel ATSAM3S4CA-AU processor (32-Bit) with 256KB of program memory This provides the display information for the LCD display, the action from the key presses, the drive of the pump motor and monitors the feedback from the pump to provide volume flow and a pressure sensor for the pressure generated. Software within the device controls the system to the predetermined set values and stores these values for later USB transmission to data logging software.

6.4 System Safety Pressure safety is controlled by an electronic over pressure valve opening when the values are outside the prescribed range with a backup mechanical discharge valve to protect from system failures. Electronic system failures are protected from short circuits by built in protection in the Lithium – ion battery pack. The unit is reverse voltage protected via an input protection diode when connected to an external DC power supply.

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Calibration checks

System calibration checks can be made by connecting a suitable flow meter to the input tube of a collection bottle and the pressure can be checked by connected a pressure meter to the top of the bottle. The following photograph is an example of a calibration check system. Unit Under Test Digital Pressure Meter

Digital Flow Meter Flow control

Collection bottle with 800mL of water

Set the pressure to a suitable level and control the flow by restricting the input tube. The measure values on the pressure meter and flow rate of the device should be within 10%. There are no PCB adjustments for pressure or flow, the system is entirely digital so if the unit is not correct then the control pcb will need to be exchanged.

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Routine service tasks

The following parts should be part of a regular service maintenance program.       

Replace mechanical safety valve. Replace one direction flow valve Replace lithium ion battery Perform and document system test Reset system use parameters Electrical safety test power supply unit. Software upgrade if available. (only available from a factory service)

WARNING: Take care when replacing the lithium battery, ensure correct connection and that the new battery is correctly fitted into the moulding recess. Dispose of used lithium battery correctly and with care, observing current legislation. Never use a replacement part that is not supplied by Rocket Medical. It is recommended that these takes are undertaken every two years or sooner if indicated by the system notifying the user of charge 500 cycles.

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Disassembly / Reassembly Parts identification: 1) Carry handle 2) Unit On/Off button 3) User selection buttons 4) LCD display 5) Rotating locking bar 6) Position for single use filter

To disassemble remove locking bar retention block. Rotate Locking bar (5) so that it is removed from the unit base. This reveals fixing screws, remove all the screws. The unit will then separate to reveal the PCB in the top of the unit and the battery / pump in the base.

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9.1 Unit Top assembly

LCD

Key Pad

Control PCB

9.2 Unit Base assembly

Unit Lithium ion battery

Electronic Discharge Valve

Mechanical one way valve Mechanical Over pressure dump valve

Pump

Alarm Speaker

Clock Battery Backup

Filter present detection

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9.3 PCB Top Display backlight connector

Keypad connector Display connector

Alarm speaker connector

Lithium ion battery connector

Pump Connector

System pressure sensor

Unit DC input connector

Clock Battery Backup connector

System USB connector

9.4 PCB Bottom

Main CPU

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9.5 PCB Top Overlay

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9.6 PCB Bottom Overlay

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10 Circuit Diagram

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11 Parts Listing

Chest Drain R54569 Part Number

Ref

Description

Quantity Per

R3

2R2 1% 1206

1

R23

10R 1% 1206

1

R45, 46

0.01R 1% 2010

2

R61

0.02R 1% 2010

1

R7

100R 1% 0603

1

R24

330R 1% 0603

1

R26

150R 1% 0603

1

R33, 60, 66

750R 1% 0603

3

R2, 4, 17, 58

1K 1% 0603

4

R30

1K5 1% 0603

1

R27

2K4 1% 0603

1

R41, 42

4K7 1% 0603

2

R57

9K1 1% 0603

1

R5

9K31 1% 0603

1

R11, 21, 32, 35, 37, 54, 63, 64, 65, 70, 72, 76

10K 1% 0603

12

R50

11K 1% 0603

1

R29

12K 1% 0603

1

R13

14K7 1% 0603

1

R51

15K 1% 0603

1

R62

30K 1% 0603

1

R12, 68, 69, 71

33K 1% 0603

4

R28

75K 1% 0603

1

R1, 8, 9, 10, 14, 15, 16, 18, 19, 22, 25, 31, 34, 39, 44, 47, 49, 53, 56, 67, 73, 74, 75, 77, 78, 79, 80

100K 1% 0603

27

R48, 52

240K 1% 0603

2

R59

270K 1% 0603

1

R6, 38

430K 1% 0603

2

R55

470K 1% 0603

1

R36

1M 1% 0603

1

R20, 22

5M1 1% 1206

2

R40

Resistor 0R 0603

1

22pF COG 50V 0603

1

27pF COG 50V 0603

2

C15

3n3F X7R Ceramic 0603

1

C26

10nF X7R Ceramic 0603

1

C43

47nF X7R Ceramic 0603

1

C16 C27, 30

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