Rocket R54569 PSU Service Manual Rev 01 May 2017

Page 1

Rocket Medical

R54569 Digital low vacuum/low flow Suction Pump

Service Manual

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 2

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

-

2

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 4

1

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.

4

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 5

2

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.

5

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 6

4

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.

6

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 7

5

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.

7

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 8

6

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.

8

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 9

7

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.

9

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 10

8

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.

10

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 11

9

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.

11

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 12

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

12

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 13

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

13

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 14

9.5 PCB Top Overlay

14

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 15

9.6 PCB Bottom Overlay

15

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 16

10 Circuit Diagram

16

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 17

17

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 18

18

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 19

19

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 20

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

20

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 21

C1, 3, 5, 6, 7, 11, 20, 24,

25, 28, 32, 33, 37, 40, 41,

42, 46, 47, 48, 49, 50, 52,

53, 54, 55, 56, 57, 58, 59,

60, 62, 63, 65

100nF X7R 50V Ceramic 0603

34

C4, 36

1uF X7R 25V Ceramic 0603

2

C12, 31

1uF X7R 25V Ceramic 1206

2

C13

1uF X7R 25V Ceramic 0805

1

C2

2u2 X5R 50V Ceramic 1206

1

C18, 21

2u2 X5R 50V Ceramic 0805

2

C8, 9, 10, 19

4u7 X5R 16V Ceramic 0805

4

C34, 35, 38, 39 44, 51, 66

10uF X7R 35V Ceramic 1210

7

C17, 23

22uF X5R 16V Ceramic 0805

2

C67

4u7F Tantalum 20V 10% case A

1

C14

33uF Tantalum 20V 10% case C

1

C45

100uF Electrolytic 16V SM FC

1

C64

100uF Electrolytic 6V3 SM FC

1

L4

10U-1A4-0R12-WE-PD2 74477310

1

L2

6U8-4A3-0R025-WE-PD 7447715006

1

L3

15U-5A0-0R027-WE-PD 744770115

1

L7

90Z-0A37-0R3-WE-CNSW-1206 744232090

1

L1, 5, 6

300Z-2A0-0R15-WE-CBF-742792641

3

T2, 4, 5, 7, 8,9,11, 12,13,15

Si7463ADP-T1-GE3

10

T1,3

CSD18504Q5A

2

T6,10, 14

BSS123

3

Q1,2

BSS84

2

T18

BC869

1

T19

BC869

1

D2,4, 6

SK56

3

D12,11

MMSZ4684T1G

2

D3,6,13

PMEG4005AEA

3

D1

SSB43L

1

D7,9

BAT54W

2

D14

BAS16WS

1

D11

1N4148W SOD123 package

1

LD1, 2, 3

SML-311UTT86K

3

D5

VLMT3100-GS08

1

D15

WE-TCS-824015

1

IC1

BQ24610RGET

1

IC2

TPS62177DQC

1

IC3

LM25085MY

1

IC4

FT232RL

1

21

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 22

IC5

ATSAM3S4CA-AU

1

IC6

AT25SF041-SSHD

1

IC7

PCF2129AT/2

1

IC8, 9

LM258DG

2

IC11

LM7301IM5/NOPB

1

SEN2

SQ277-14015 (pressure sensor)

1

BU1

DC Power Socket RASM712X

1

VAR1

VC080505C150DP

1

BU4

Connector FPC 32 way Wurth 68713214022

1

X4

USB connector Molex 67503-1020

1

ST4

Keypad 6 way TE 5-102523-4

1

ST1, 2

4 way connector B4B-EH-A

2

JP3

3 way connector B3B-EH-A

1

JP1, 2, 4, 6, 7

2 way connector JST B2B-EH-A

5

BU3

JTAG connector 20way FCI20021321-00020C4LF

1

-

4 way connector housing EHR4

2

-

3 way connector housing EHR3

1

-

2 way connector housing JST EHR2

5

Q3

Crystal 12.00MHZ-FUN-CM7050 (RS 478-9729)

1

BZ2

Sounder PKLCS1212E4001-R1

1

Clock Backup

Saft lithium

1

Battery

Lithium 4S1P BM18650Z3 Block

1

LCD

Display CG240160B-LB-FT-N6-CLO

1

Pump

Thomas Pump 14200500

1

Detection switch assy

Switch B3WN6002 + PCB

1

Speaker

Visaton K1650 OHM art 2816

1

Discharge Valve

Parker Valves 991-003063-014015

1

Tubing

Silicone 3mmID x 5mmOD

0.03

Tubing

Silicone 3mmID x 5mmOD

0.035

Tubing

Silicone 3mmID x 5mmOD

0.02

Tubing

Silicone 3mmID x 5mmOD

0.09

Tubing

Silicone 3mmID x 5mmOD

0.125

Tubing

Silicone 3mmID x 5mmOD

0.035

Tubing

Silicone 3mmID x 5mmOD

0.0245

Tubing

Silicone 3mmID x 5mmOD

0.1

Tubing

Silicone 3mmID x 5mmOD

0.07

Tubing

Silicone 3mmID x 5mmOD

0.04

Tubing

Silicone 3mmID x 5mmOD

0.04

Tubing

Silicone 2mmID x 3mmOD

0.16

22

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 23

Safety Valve

E-C-PP-1C1C-E-001 eoxshop.com

1

One Direction Valve

SCV67230 (Value Plastics)

1

Tube connections

right angle 10 -32 UNF 2mm tube KL220-6005

1

Tube connections

1

Tube connections

right angle 10 -32 UNF 3mm tube KL230-6005

streight connector M5 x 8mm 3 mm tube M52306005

Tube connections

T junction 3 mm tube 1/8 T230-6005

4

Membrain switch

1

1

Reset switch

Omron B3F-3100

1

Power Supply

XP Power AFM60US18

1

Mains Lead Set (UK)

Power Cord - Mededical Grade 13A to IEC socket

1

USB Lead

USB A plug- USB B mini plug 1M long

1

23

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517

Page 24

12 Contact Details

Customer Services:

Rocket Medical plc.

Sedling Road. WASHINGTON. NE38 9BZ. ENGLAND

Tel: +44(0)191 419 6988. Fax: +44(0)191 419 6989

Email: customerservices@rocketmedical.com

24

Copyright© 2017

Rocket Medical plc .

All rights reserved.

ZDOCK297

Rev:01

080517