Zoll Multifunction Aspirator Model 330 Service Manual Rev B Feb 2018

The issue date for the ZOLL 330 Multifunction Aspirator Operator’s Guide (REF 9650-000278-01 Rev. B) is February, 2018. Copyright © 2018 ZOLL Medical Corporation. All rights reserved. ZOLL, AEV, Eagle II, EMV+, and Smart Help are trademarks and/or registered trademarks of ZOLL Medical Corporation in the United States and/or other countries. All other trademarks are the property of their respective owners.

Limited Copyright Release Permission is hereby granted to any military/governmental agency to reproduce all materials furnished herein for use in a military/governmental service training program and/or other technical training program.

Contents

Preface Product Description ... 1-1 How to Use this Manual ... 1-1 Related Documents ... 1-2 Service Manual Updates... 1-2 Symbols on the Aspirator... 1-2 Symbols on the Aspirator’s Graphical User Interface (GUI) ... 1-4 Conventions ... 1-5 Abbreviations and Acronyms ... 1-6 General Warnings ... 1-7 Power Use Warnings ... 1-7 Service Technician Safety Warnings... 1-7 Technical Service... 1-8 Returning a Device for Service ... 1-8

Chapter 1

Performing Maintenance Tests

Overview... 1-1 Testing Guidelines ... 1-1 Before You Begin the Maintenance Tests ... 1-1 330 PM Test Kit... 1-2 Assembling the Test Setup ... 1-2 Instructions ... 1-4 Testing ... 1-4 Instructions ... 1-5 Testing ... 1-5

Chapter 2

Troubleshooting

Overview... 2-1 330 Multifunction Aspirator Service Codes ... 2-1 About Service Codes ... 2-1 Service Code List ... 2-2

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

i

Chapter 3

Replacement Part Installation

Overview... 3-1 Required Equipment ... 3-1 Safety Precautions... 3-2 Replacement Part Installation Procedures... 3-2 Battery Compartment Replacement ... 3-3 Required Tools and Other Items ... 3-3 Instructions ... 3-3 Battery Compartment Cover Replacement ... 3-5 Required Tools and Other Items ... 3-5 Instructions ... 3-5 Battery Replacement ... 3-6 Required Tools and Other Items ... 3-6 Instructions ... 3-6 Back Cover Replacement ... 3-7 Required Tools and Other Items ... 3-7 Instructions ... 3-7 Power Input Assembly Replacement ... 3-8 Required Tools and Other Items ... 3-8 Instructions ... 3-8 Exhaust Muffler Block and Baffle Replacement ... 3-11 Required Tools and Other Items ... 3-11 Instructions ... 3-11 Exhaust Muffler Foam Replacement ... 3-13 Required Tools and Other Items ... 3-13 Instructions ... 3-13 Power Interface Module Installation ... 3-14 Required Tools and Other Items ... 3-14 Instructions ... 3-14 Smart Aspirator Module (SAM) Replacement ... 3-17 Required Tools and Other Items ... 3-17 Instructions ... 3-17 Vacuum Pump Replacement ... 3-20 Required Tools and Other Items ... 3-20 Instructions ... 3-20 UIM Adapter Board Replacement ... 3-24 Required Tools and Other Items ... 3-24 Instructions ... 3-24 UIM Stack Assembly Replacement ... 3-27 Required Tools and Other Items ... 3-27 Instructions ... 3-27

Chapter 4

Replacement Parts

Overview... 4-1 Available Replacement Parts... 4-2 Determining Replacement Part Item Number ... 4-2 Replacement Part List ... 4-15

ii

www.zoll.com

9650-000278-01 Rev. B

Chapter 5

Functional Description

Appendix A Maintenance Test Checklist Overview...A-1 ZOLL 330 Multifunction Aspirator Maintenance Checklist ...A-2

Appendix B Specifications General ...B-1 Device Classification...B-3 Emissions and Immunity Compliance ...B-4 Basic Safety and Essential Performance...B-5 Electrical ...B-5 Class I ...B-5 Class II ...B-5

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

iii

Preface This chapter provides general information about the ZOLL 330 Multifunction Aspirator and the ZOLL 330 Multifunction Aspirator Service Manual. Specifically, this chapter provides: • A brief description of the aspirator • Information about this manual (ZOLL 330 Multifunction Aspirator Service Manual) • Tables that describes the symbols that appear on the aspirator itself and its display screen • A list of Warnings regarding the servicing of the aspirator

Product Description The 330 Multifunction Aspirator is a small, extremely durable, multifunction digital aspirator designed to operate in hospitals and severe or under-resourced environments. It can be used in prehospital, field hospital and hospital settings.

How to Use this Manual The ZOLL 330 Multifunction Aspirator Service Manual provides information that service technicians need for the safe and effective repair of the aspirator. It is important that all persons servicing this device read and understand all information contained within. Before performing service procedures, please thoroughly read the information found in this manual related to the following topics. • Warning and Caution regarding the operation and servicing of the aspirator • Service Codes • Replacement Part Installation

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

Preface-1

Preface

Related Documents The following documents are related to this manual. • ZOLL 330 Multifunction Aspirator Operator’s Guide • ZOLL Remote Calibration System Operator’s Manual

Service Manual Updates An issue or revision date for this manual is shown inside its front cover. If more than 3 years have elapsed since this date, contact ZOLL Medical Corporation to determine if additional product information updates are available. All users should carefully review each update to understand its significance and then file it in its appropriate section within this manual for subsequent reference. Product documentation is available through the ZOLL website at www.zoll.com. From the Products menu, choose Product Manuals.

Symbols on the Aspirator The following symbols appear on the aspirator, its display, or in this manual. Symbol

Description Device Off

Device On

Mute/Cancel: Identifies the button that mutes the active alarms or cancels the parameter selection.

Accept / Confirm: Identifies the button that accepts (confirms) a parameter selection.

Identifies the Rotary Encoder Dial that allows the selection of parameter values.

ESD: Warns that connector pins should not be touched.

Menu icon. This icon identifies the button that, when pressed, displays a menu of options that you can select to configure the aspirator.

Preface-2

www.zoll.com

9650-000278-01 Rev. B

Preface Symbol

Description Do Not Re-Use: This item should not be re-used.

Do Not Discard: Follow all governing regulations regarding the disposal of any part of this medical device.

Serial Number: Numbers following “SN” indicate the serial number.

BF Symbol: Protection against electric shock, Type B with floating (F-type) parts.

Direct Current: Identifies the location to connect external DC Power.

Power Input Orientation: Locates the DC input identifying its point of insertion.

Manufacturer: This symbol shall be adjacent to the name and address of the manufacturer.

Manufacture Date: Manufacture Date Symbol identifies the device’s date of manufacture.

Consult Instruction: Consult the instructions for use or operation manual.

Refer to instruction manual.

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

Preface-3

Preface

Symbols on the Aspirator’s Graphical User Interface (GUI) The following symbols appear on the aspirator’s Graphical User Interface (GUI) during operation. Symbol

Description Alarm Bell: Identifies the number of off-screen alarms.

Alarm Bell Outline: Identifies alarm limit settings; Identifies the on-screen alarms.

Attention: High Priority Alarm Active.

Caution: Medium Priority Alarm Active.

Warning: Low Priority Alarm Active.

Mute: Active Alarm Audible Signal Muted.

Speaker: Active Alarm Audible Signal.

Plot: Identifies active off-screen plot available.

Plot: Identifies active off-screen plot has been selected.

External Power: Indicates the device is operating using an external power source.

No External Power: Indicates the device is operating without an external power source.

Preface-4

www.zoll.com

9650-000278-01 Rev. B

Preface Symbol

Description Internal Battery: Provides indication of battery capacity and charging. The number below the icon displays the percent (%) of charge for the battery.

EXT BATT

Indicates that an external battery is powering the aspirator.

No Internal Battery: Indicates when the internal battery is not an available power source.

off on

Feature off -- feature or alarm is not operational.

Feature on -- feature or alarm is operational.

Conventions This manual uses the following conventions: Within text, the names and labels for physical buttons and softkeys appear in boldface type (for example, “Press the Confirm button”). This manual uses uppercase italics for text messages displayed on the screen (for example, Self Check Fault).

Warning!

Warning statements alert you to conditions or actions that can result in personal injury or death.

Caution

Caution statements alert you to conditions or actions that can result in damage to the device.

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

Preface-5

Preface

Abbreviations and Acronyms ACLS- Advanced Cardiac Life Support

LCD- Liquid Crystal Display

ALS- Advanced Life Support

LED - Light Emitting Diode

ATLS- Advanced Trauma Life Support

LPM - Liters Per Minute

AMC- Alarm Message Center

ml - Milliliters

APOD- Advanced Probe Off Detection

mm - Millimeter

ATPD - Atmospheric Temperature and Pressure Dry

mm Hg -- Millimeters of Mercury

B/V - Bacterial/Viral Filter

O2- oxygen

CASS - Continuous Aspiration of Subglottic Secretions

PMC - Periodic Maintenance Check

CPR - Cardiopulmonary Resuscitation

psig - Pounds per Square Inch Gage

CPU- Central Processor Unit

RF- Radio Frequency

dBA- Decibel

RGA #- Returned-Goods-Authorization number

DISS - Diameter Index Safety System

RTC- Real time clock

EMC- Electromagnetic Compatibility

SAM- Smart Aspirator Module

ESD - Electrostatic Discharge

USP - United States Pharmacopeia

GMP - Good Manufacturing Practices

UTC - Coordinated Universal Time

HME - Heat and Moisture Exchanger

VAC - Volts AC

HMEF - Heat and Moisture Exchanger/Bacterial Viral filter combined

VDC - Volts DC

Hz – Hertz (as in frequency, cycles per second) ID - Internal Diameter L - Liters

Preface-6

www.zoll.com

9650-000278-01 Rev. B

Preface

General Warnings Understand the following general warnings: • The information contained herein is restricted for use by personnel certified by ZOLL

Medical Corporation in the care and servicing of this product. ZOLL does not authorize or assume any obligations resulting from unauthorized servicing of its products nor will it be held liable for any injuries or damages incurred therefrom.

Power Use Warnings Understand these warnings regarding power and grounding: • The device must be connected to a grounded AC power supply when connected to AC •

• • •

power. Connect the device only to a three-wire, grounded, hospital-grade receptacle! The threeconductor plug must be inserted into a properly wired three-wire receptacle; if a three-wire receptacle is not available, a qualified electrician must install one in accordance with the governing electrical code. Do not under any circumstances remove the grounding conductor from the power plug. Do not use extension cords or adapters of any type! The power cord and plug must be intact and undamaged. If there is any doubt about the integrity of the protective earth conductor arrangement, operate the oximeter on internal battery power until the AC power supply protective conductor is fully functional.

Service Technician Safety Warnings Be attentive to these warnings when servicing an aspirator: • Possible explosion hazard if used in the presence of flammable anesthetics or other

flammable substances in combination with air, oxygen-enriched environments, or nitrous oxide. • This device is not intended for use in explosive atmospheres. • Pins of connectors identified with the ESD warning symbol should not be touched. Always use precautionary procedures with ESD-sensitive connections.

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

Preface-7

Preface

Technical Service If a unit requires service, contact the ZOLL Technical Service Department. Telephone:

1-978-421-9655 (Direct) 800-348-9011 (Toll-Free (US))

Fax: 1-978-421-0010 Email

General Email: [email protected] Military Email: [email protected]

When requesting service, please provide the following information to the service representative: • Device serial number • Description of the problem • Department using the equipment and name of the person to contact • Purchase order to allow tracking of loan equipment • Purchase order for a unit with an expired warranty

Returning a Device for Service Before sending a unit to the ZOLL Technical Service Department for repair, obtain a service request (SR) number from the service representative. The Lithium ion battery should remain inside the unit. Follow directions provided on the Return Materials Authorization (RMA). Pack the unit with its cables in the original containers (if available) or equivalent packaging. Be sure the assigned service request number appears on each package. Return the unit to: ZOLL Medical Corporation 269 Mill Road Chelmsford, MA 01824 Attention: Technical Service Department (SR number)

Preface-8

www.zoll.com

9650-000278-01 Rev. B

Chapter 1 Performing Maintenance Tests Overview This chapter includes procedures for maintenance tests. It is necessary to perform maintenance tests to ensure that the 330 Multifunction Aspirator functions properly. This chapter describes the following maintenance tests: • Cosmetic and Hardware • Performance • Bleed Valve Note:

Make copies of the checklist in Appendix A “ZOLL 330 Multifunction Aspirator Maintenance Tests Checklist” to record results of the maintenance tests.

Testing Guidelines Observe the following guidelines when performing maintenance tests. • • • •

Schedule an hour to conduct the entire maintenance test. Perform the tests in the order presented. Perform all the steps of each test procedure. Complete all the steps of the procedure before evaluating the test results.

Before You Begin the Maintenance Tests Before you begin testing, do the following: • Assemble the test setup using items contained in the 330 PM Test Kit. • Keep an extra, fully charged, 330 Multifunction Aspirator battery available.

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

1-1

Performing Maintenance Tests

330 PM Test Kit To perform maintenance tests, you need to assemble the test setup from items contained in the 330 PM (Preventive Maintenance) Test Kit (REF: 8600-000020-01). The 330 PM Test Kit contains the following item. Jar, disposable with Lid (REF: 410-0004-00) Kit, Hose, M330 (REF: 540-0050-00) Fluke Meter (REF:0350-000090) Brass Barbed Hose Fitting 3/8” Hose ID, 1/3 NPTF (Female End) (REF: 0301-000344) Straight One-Way Valve (Check Valve) 22M to 22F (REF: 0301-000070) Note: The valve is not required to assemble the test setup. Use the valve to perform Cosmetic and Hardware test 1.6 (See, 1.0 Cosmetic and Hardware Tests in this chapter. • • • • •

Assembling the Test Setup To assemble the test setup, follow these steps: 1. Attach the brass barbed hose fitting to the NPT connector of the Fluke Pressure Gauge. 2. Using a piece of tubing from the tubing kit, connect the aspirator VACUUM port to the center port of the collection canister (also labeled VACUUM). 3. Using a second piece of tubing, connect the collection canister PATIENT port to the Fluke pressure gauge (barbed hose fitting attached to the gauge in Step 1). When the test setup is assembled, connect the aspirator power supply to the aspirator and to AC mains. (AC power outlet).

1-2

www.zoll.com

9650-000278-01 Rev. B

Performing Maintenance Tests

1.0 Cosmetic and Hardware Tests Test Name

Do this...

Observe this...

Pass / Fail

1.1

Power Switch Check

Turn the aspirator power switch on, and then turn the power switch off.

Aspirator turns off and on.

o

o

1.2

Self Check

Power on the aspirator.

Aspirator turns on with no self check alarms present.

o

o

1.3

LCD Contrast Check

Under menu options, choose adjust the contrast in both directions.

Contrast is adjustable to be both lighter and darker.

o

o

1.4

LCD Visual Inspection and Contrast Check

Power aspirator on and inspect LCD for physical blemishes, faulty pixels, and contrast.

No blemishes or faulty pixels exist and contrast is set such that information on the screen is readable.

o

o

1.5

Button Check

Power on the aspirator on and individually press all seven right parameter buttons (For Smart Flow Cal button: after pressing, press cancel to exit from the popup).

Aspirator responds to all button presses.

o

o

Green, Yellow, and Red LEDs are all present and functioning.

o

o

Press the Main Menu button. Press the Accept button. Press the Mute/Cancel button. Run a procedure and press the Standby button. 1.6

LED Check

Power on the aspirator and look for the green and yellow LEDs to be illuminated in an alternating sequence. Select Intermittent mode, set ON time to 5 seconds, set OFF time 40 seconds, and vacuum target to 200 mm Hg.

Note: The Medium Priority Alarm (#2111) displays only for a few seconds.

Place the 22 mm O.D. check valve in the exhaust port and begin running the intermittent procedure. Look for a medium priority alarm (#2111) with the red LED present.

Check Valve 1.7

Encoder Dial Check

Power aspirator on and select the Main Menu. Turn the Dial right and left multiple times and in multiple increments.

Dial scrolls through menu choices on screen.

o

o

1.8

Buzzer Check

Power aspirator on with external power connected. Unplug external power to generate an alarm.

Buzzer is audible during alarm.

o

o

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

1-3

Performing Maintenance Tests

2.0 Performance Tests Instructions 1. Power on the aspirator. 2. Select “Continuous” Mode and “Surgical” procedure from the parameter buttons. 3. In the order listed under Test Results, set the aspirator to each vacuum target indicated by the table. Record the vacuum level as indicated by the Calibrated Pressure Gauge and the aspirator in the table. Record a Pass or Fail for each result. 4. Repeat all vacuum measurements with “Smart Flow” set to “OFF.” Note:

Performance Tests must be performed in the order presented below. The CASS procedure parameter button must be selected to test at 20 mm Hg.

Testing

Vacuum Setting Pass Criteria

Calibrated Pressure Gauge Measurement

Aspirator Vacuum Display

Vacuum Setting ± (8 % of Setting + 2 mm Hg)

Measured Vacuum ± (8 % of Setting + 2 mm Hg)

Result

Smart Flow: ON

Pass / Fail

2.2

550 (Max) mm Hg Pass Range:(504-596)

Pass Range:(504-596)

o

o

2.3

20 mm Hg

Pass Range:(16.4-23.6)

Pass Range:(16.4-23.6)

o

o

2.4

400 mm Hg

Pass Range:(366-434)

Pass Range:(366-434)

o

o

2.5

50 mm Hg

Pass Range:(44-56)

Pass Range:(44-56)

o

o

2.6

200 mm Hg

Pass Range:(182-218)

Pass Range:(182-218)

o

o

2.7

90 mm Hg

Pass Range:(80.8-99.2)

Pass Range:(80.8-99.2)

o

o

2.8

110 mm Hg

Pass Range:(99.2-120.8)

Pass Range:(99.2-120.8)

Smart Flow: OFF

 Pass  Fail Pass / Fail

2.9

550 (Max) mm Hg Pass Range:(504-596)

Pass Range:(504-596)

o

o

2.10

20 mm Hg

Pass Range:(16.4-23.6)

Pass Range:(16.4-23.6)

o

o

2.11

400 mm Hg

Pass Range:(366-434)

Pass Range:(366-434)

o

o

2.12

50 mm Hg

Pass Range:(44-56)

Pass Range:(44-56)

o

o

2.13

200 mm Hg

Pass Range:(182-218)

Pass Range:(182-218)

o

o

2.14

90 mm Hg

Pass Range:(80.8-99.2)

Pass Range:(80.8-99.2)

o

o

2.15

110 mm Hg

Pass Range:(99.2-120.8)

Pass Range:(99.2-120.8)

o

o

1-4

www.zoll.com

9650-000278-01 Rev. B

Performing Maintenance Tests

3.0 Bleed Valve Test Instructions 1. Set the aspirator to “Intermittent” Mode with the settings indicated by the Bleed Valve Functional Test table. 2. Record the Maximum Vacuum (minimum pressure) level achieved during the “On” phase of the intermittent cycle. 3. Record the Minimum Vacuum (maximum pressure) level achieved during the “Off” phase of the intermittent cycle. 4. Record the overall Pass or Fail for the two measurements.

Testing

Do this...

Do this...

Ventilator Settings

Calibrated Pressure Gauge Measurements

Mode 3.1

Intermittent

Vacuum Setting

ON Time

OFF Time

Maximum Vacuum (ON)

Minimum Value (OFF)

100

15

40

Pass Range: (90-100)

Pass Range: (-2-2)

Observe this...

Acceptance Criteria

Maximum Vacuum (On): ± (8 % of Setting + 2 mm Hg)

Pass / Fail

o

o

Minimum Vacuum (Off): 0 mm Hg (± 2 mm Hg)

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

1-5

Chapter 2 Troubleshooting Overview This chapter contains a list of error messages that users may see if the unit is not operating properly. If the errors you encounter are not listed below, call ZOLL Medical Corporation’s Technical Service Department for further assistance. (See the “Technical Service” section the Preface.)

330 Multifunction Aspirator Service Codes This section describes service codes, provides a list of service codes, and their associated alarm description, and the Service Kit part number (or other resolution) for restoring proper aspirator operation.

About Service Codes Service Codes are 4-digit numbers associated with an aspirator alarm. • 1### (indicates a High Priority Alarm) • 2### (indicates a Medium Priority Alarm) • 3### (indicates Low Priority Alarm)

The Alarm Message Center (AMC) appearing in the upper left-hand corner of the aspirator display screen shows the service code along with alarm information, as in the following example:

9650-000278-01 Rev. B

ZOLL 330 Multifunction Aspirator Service Manual

2-1

Troubleshooting

Service Code List The following is a list of the 330 Multifunction Aspirator that may appear on your display. The table provides the Service Code number, associated alarm name, description, and information on what you can do to correct the situation.

Service Code 1001

Alarm Name/Mitigation/Resolution Self Check Failure - Pneumatic System Alarm triggers when the vacuum pump fails to operate or fails to provide the flow required to deliver a vacuum. Mitigation/Info: Pneumatic System: Vacuum, Manually Aspirate Patient, **Contact Service Center*

1010

Self Check Failure - Bleed Valve Alarm triggers when the bleed valve fails to reduce the applied vacuum Mitigation/Info: Manually Aspirate Patient, **Contact Service Center*

2-2

www.zoll.com

9650-000278-01 Rev. B