Physio Control LUCAS 2 Service Manual
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Physio Control LUCAS 2 Service Manual

Chest compression system
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LUCAS® 2 Chest Compression System -
3323809-001,
© 2017 Physio-Control, Inc.
1
LUCAS® 2
Chest Compression System
Service Manual
Service Manual

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Summary of Contents for Physio Control LUCAS 2

  • Page 1 LUCAS® 2 Chest Compression System Service Manual LUCAS® 2 Chest Compression System - Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 2 ® For more information regarding LUCAS please read: LUCAS 2 Chest Compression System - Instruction for Use (LUCAS 2.0 and LUCAS 2.1 Art. #:100666-XX) (LUCAS 2.2 Art. # 100901-XX) LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 3 RACKING All performed service where modules are replaced, the serial no./batch no. of each module shall be stated in the service report. This information is then sent to Physio-Control, Inc, on a monthly basis. The modules that have traceability are: Compression Module •...

  • Page 4: Table Of Contents

    Error Codes from The Protective CPU ............... 30 5.3.3. Error Codes from The Charger CPU ..............31 Practical Troubleshooting ...................... 32 5.4. Spare Parts and Accessory List ..................33 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 5 9.3.2. Reassembling ....................51 9.3.3. Test ........................51 Replacing the Drive Belt ......................52 9.4. 9.4.1. Disassembling ....................52 9.4.2. Reassembling ....................52 9.4.3. Test ........................53 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 6 9.10.1. Disassembling ....................68 9.10.2. Reassembling ....................68 9.10.3. Test ........................68 Replacing the Power Inlet ....................69 9.11. 9.11.1. Disassembling ....................69 9.11.2. Reassembling ....................69 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 7 11. Accessories ........................74 LUCAS® Battery Charger....................74 11.1. LUCAS® Car Cable ......................75 11.2. LUCAS® Power Supply ....................75 11.3. 12. Appendix A (wiring diagram) ..................76 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 8: Introduction

    This manual is a part of the Service Education Program that, together with hands-on technical training, will provide the Service Technician with the knowledge to examine and repair LUCAS. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 9: Warnings And Precautions

    Except the warnings stated below, there are also warnings and precautions mentioned in the following documents that are of relevance during service and maintenance of LUCAS. LUCAS® 2 Chest Compression System - Instruction for Use (LUCAS 2.0 and LUCAS 2.1 Art. #: 100666-XX) (LUCAS 2.2 Art. #: 100901-XX) 2.1. Electrical Hazard Use caution when examining or operating the device without its covers.

  • Page 10: The Function Of Lucas

    An electrical fan is situated at the bottom of the device for cooling the electrical motor and other electronics. The fan starts when the internal temperature reaches 40°C and stops when the temperature is below 30°C. See pictures on the following page. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 11 Figure 3.1-1: LUCAS User Control Panel Figure 3.1-2: Schematic picture of the electronics of LUCAS LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 12: Compression Mechanism

    The Suction Cup is adjusted to the patients’ chest with a servo aid system. It can easily be replaced with respect to hygiene. Figure 3.2-1: Schematic picture of the Compression Mechanism of LUCAS LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 13: Components Of The Lucas® 2 Chest Compression System

    6. Claw locks 17.Car Power Cable 7. Back Plate 18.Carrying Bag LUCAS Stabilization Strap: 8. DC input 9. Bellows 19.Cushion strap 10.Suction Cup 20.Buckle 11.Power Supply 21.Support leg strap LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 14: Lucas® 2 Program Loader

    Connect an USB cable between the computer and the device, the connector is situated at the lower left side of the Control PCB on LUCAS 2.2. (On LUCAS 2.0 and LUCAS 2.1 the connector is situated at the top left corner of the Protective PCB, according to picture below.) Start the device.

  • Page 15: Using The Software

    Normally the software detects the device at start. If not, set the USB Port setting to AUTO and then Click “Init COM”. Now the information about the device should appear in the designated windows. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 16: Update The Program

    Click START. Now the Calibration process will start. The progress can be followed in the Control CPU’s window. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 17: Failed Calibration

    Click POTCAL to make a new calibration. If also the second calibration fails it might be necessary to replace the Compression Module. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 18: Checksum

    If no printer is connected a message will appear which can be cancelled. The picture will be saved and can be printed at any time LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 19: Indications And Alerts During Normal Operation

    Below table describe the different situations of audible and visible signals that can occur during normal operation. The audible signals were updated in LUCAS 2.2 with regards to sound patterns; please refer to Instructions for Use 100901-XX for more information. Below the audible and visible signals for LUCAS 2 are showed in four different tables.
  • Page 20 Figure 5.1-1: Table 2/2 – Indications and alerts during normal operation LUCAS 2.2 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 21 LUCAS 2.1 and LUCAS 2.0 Figure 5.1-2: Table 1/2 – Indications and alerts during normal operation LUCAS 2.0 and LUCAS 2.1 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 22 Figure 5.1-2: Table 2/2 – Indications and alerts during normal operation LUCAS 2.0 and LUCAS 2.1 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 23: Lucas Malfunction Alarm

    Below is a list on all alarms that can occur on the LUCAS. The alarms can be muted for 60 seconds by pressing MUTE. The audible alarms were updated in LUCAS 2.2 with regards to sound patterns. Please refer to Instructions for Use 100901-XX for information.

  • Page 24: Error Codes

    5.2-2: Table – Malfunction alarms LUCAS 2.0 and LUCAS 2.1 5.3. Error Codes In the software, LUCAS 2 Program Loader, it is possible to read error codes from the device. Below tables show these codes and an explanation on how to find the cause and point out which module to replace.
  • Page 25 POT cables. 10mm at start. POT fault Compression module. or un- linear. Reference Check for voltages faults. voltage faults. Figure 5.2-3: Table 1/5 – Error code Control CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 26 > 70°C if Warning internal reference faults. INT_C_TEMP1 To High External Unknown Unknown No=0x35 temp 1 ( > T1_OFF °C) Figure 5.3-1: Table 2/5 – Error code Control CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 27 10mm. To high load compression module. If needed replace the and/or to low battery voltage. Locked compression module. module. Figure 5.3-1: Table 3/5 – Error code Control CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 28 Protective CPU. COM_MODE Incorrect Mode Unknown Unknown No=0x51 change COM_ACCESS DAF Protocol Unknown Unknown No=0x52 access violation Figure 5.3-1: Table 4/5 – Error code Control CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 29 Charger CPU. COM_I2C I2C Com faults too Disturbed I2C Protective or Control N0=0x56 high communication. board. Figure 5.3-1: Table 5/5 – Error code Control CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 30: Error Codes From The Protective Cpu

    See Charger errors See Charger errors detected CONTROL STOP Control system fault See Control errors See Control errors detected Figure 5.3-2: Table 1 – Error code Protective CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 31: Error Codes From The Charger Cpu

    Battery used more than 200 times. TOO OLD BATTERY Inserted battery is Too old battery used. Battery too old. 5.3-3: Table 1 – Error code Charger CPU LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 32: Practical Troubleshooting

    In chapter 12 Appendix A there is a wiring diagram that can be helpful when troubleshooting. If the device doesn’t start, first check the battery and if that’s ok check the connections from the Hood and the User Control Panel. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 33: Spare Parts And Accessory List

    150401-20 Including motor Carrying case, 21576-000016 LUCAS 2 REFURBISHING KIT 150402-00 patient straps and stabilization strap 21576-000008 LUCAS 2 HOOD W ITH USER PANEL 150403-00 21576-000067 LUCAS 2.2 HOOD W ITH USER 150403-20 21576-000009 LUCAS 2 BELLOW S 150404-00 Including brackets...

  • Page 34: Other Orderable Spare Parts

    TYPE LABEL 100630-00 2.0/2.1 serial TYPE LABEL LUCAS 21501-002854 2.2 serial 100905-00 QTY: 1, LUCAS 2 UDI Label, 21501-002855 LABEL, UDI placed on the opposite leg 100952-00 compared to the Type Label BRACKET, HOOD, QTY: 1, metal bracket for fixation...

  • Page 35: Accessory List

    6.3. Accessory List Catalog# Product description Drawing# Note 11576-000038 LUCAS 2 CARRYING BAG 150200-00 11576-000039 LUCAS 2 BATTERY 150201-00 21996-000064 LUCAS STABILIZATION STRAP 300020-00 11576-000050 LUCAS PATIENT STRAP (PAIR) 300021-00 11576-000046 LUCAS SUCTION CUP 100593-00 3-PACK 11576-000048 LUCAS CAR CABLE...

  • Page 36: Tools List

    Bits Torx 25 (T25) Hammer Mandrel Cutting Pliers Adjustable Pliers ESD Protection kit Break -Over torque wrench, 17mm open head, torque setting of 1.0 Nm REDEL extracting tool LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 37: Special Tools

    21576-000018 Compressed Air, Can 21300-001335 7.4. Software Description Catalog# LUCAS® 2 Program Loader 2.1B 21340-000787 LUCAS® 2 Program Loader 2.0 21340-000788 LUCAS® 2 Program Loader 2.2 21340-000833 LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 38: Preventive Maintenance Of Lucas

    The hood is opened according to instructions in Section 9.1. With the hood off, lubricate the Compression Module according to Section 8.3. • Connect the device to a laptop with the LUCAS 2 Program Loader Software according to Section 4. Check the software version in the device and upgrade if possible. •...

  • Page 39: Clean The Electric Fan And Mesh Grill

    With the hood off pull down the Piston and the Adjustment Tube until the Carry Ball Screw is visible in the Lubrication Hole. Carry Ball Screw Figure 8.2-2: Lubrication hole LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 40: Claw Lock Lubrication

    Open and lock the mechanism continuously to work in the lubricant. Figure 8.4-1: The picture shows where to lubricate the claw mechanism LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 41: Replacing Parts/Modules In Lucas

    Use caution when examining or operating the device without its covers. Replacing the Hood and Hood Bracket 9.1. 9.1.1. Disassembling Remove all four screws for the hood PH1. Set aside screws for reuse during assembly. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 42 Carefully lift off the Hood and disconnect the three cables between the Hood and the Protective PCB. Below the LUCAS 2.0 and LUCAS 2.1 is depicted, the Hood Communication Cable is released perpendicularly to the PCB. Hood Communication Cable Hood Ground Cable Hood Power Cable Below the LUCAS 2.2 is depicted, the Hood Communication Cable is released upwards.

  • Page 43: Reassembling

    Lock the four screws with thread lock fluid and tighten to 5 in-lbs / 0.6 Nm Torque wrench PH1. 9.1.3. Test Perform a Function Check according to Section 10. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 44: Replacing The Bellows

    Remove the Bellows ring, start by treading the bellows over the ring, then continue to take off the ring as described in picture. Remove the Bellows by treading it over the Piston. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 45: Reassembling

    / 1.0 Nm Torque Screwdriver Torx 10 (T10) or 13.0 in-lbs / 1.5 Nm Torque Screwdriver Torx 20 (T20) depending on the Bellows Clamp. The clamp should be positioned as far up as possible. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 46: Test

    Place the Bellows ring above the retaining ring. Thread the edge of the Bellows over the Bellows ring. Put back the Suction Cup. 9.2.3 Test Perform a Function Check according to Section 10. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 47: Replacing The Compression Module

    Take off the Suction Cup and remove the Bellows according to instructions in Section 9.2.1. Remove the Hood according to instructions in 9.1.1. Disconnect the following cables on LUCAS 2.0 and LUCAS 2.1 according to pictures below: Protective Pot Cable...
  • Page 48 Disconnect the following cables on LUCAS 2.2 according to pictures below: LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 49 From beneath, remove the four screws that hold the Compression Module Torx 25 (T25). Remove the two screws holding the Fan Bracket and remove it Torx 25 (T25). Loosen the two remaining screws without removing them. LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 50 Remove the four screws that hold the PCB brackets against the Compression Module, two on each side according to pictures Torx 10 (T10). LUCAS® 2 Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 51: Reassembling

    Re-connect all cables according to picture in Section 9.3.1 and fasten the Power Cables with new cable ties. For LUCAS 2.0 and LUCAS 2.1, make sure that the Protective Pot Cable is on the outside of the Communication Cable. Re-install the Hood, the Bellows, and the Suction Cup.

  • Page 52: Replacing The Drive Belt

    Thread the new Belt over the small Belt Wheel first. Continue to Thread it over the Large Belt Wheel and turn the wheel at the same time to get the belt in place. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 53: Test

    Module. Remove the Drive Belt according to Section 9.4. Remove the inner two screws and loosen the outer two screws holding the Motor Torx 20 (T20). Slide the Motor out from its bracket. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 54: Reassembling

    Slide the Motor onto the Bracket and tighten the screws to 17.5 in-lbs / 2.0 Nm, make sure to align the terminal as picture below Torque Wrench Torx 20 (T20). Terminal Motor Cable Outlet LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 55: Test

    Remove SD-card from old Controller PCB. Check that the SD-card is intact and readable/writeable. If SD-card is working properly keep it for the new Controller PCB. Warning: Always use ESD protection when handling PCB’s! LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 56: Reassembling

    Re-install the Suction Cup. 9.7.3. Programming Connect a laptop and program the Protective PCB according to chapter 4. Check that Device ID, Time and Date is correct. Tighten the Hood. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 57: Test

    Disconnect the Fan Cable on the Control PCB, See picture in Section 9.3.1. Remove the four screws that hold the Fan, Flat .5x0.8 mm (5.5). Take off the Threaded plate and lift out the Fan. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 58: Reassembling

    Figure 9.8-1: Fan assembly Connect the Fan Cable to the “Optional” connector on the Control PCB. Place the cable between the coils according to pictures below. LUCAS 2.0 and LUCAS 2.1 LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 59: Test

    Now set the device in adjust mode, the fan should continue running. Check that there is no unusual sound from the fan. When the temperature inside the hood has decreased to 30°C the fan should stop. Continue with the Function Check. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 60: Replacing The Support Leg

    9.9.1. Disassembling LUCAS 2 devices with S/N up to 3012 4632 (LUCAS 2.0 and LUCAS 2.1) have Shaft Seals assembled. On LUCAS 2 devices with a S/N greater than 3012 4632, the Shaft Seals are replaced with a Snap Ring and a Bumper with integrated shaft seal.
  • Page 61 Using the metal Pin or similar tool and Hammer, push the bottom, non-press-fitted Angel Shaft out of Support Leg. Always knock out the non- press fitted Angle Shaft first. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 62 Angel Shaft Metal Pin Press Fitted Side with Key The bottom, non-press fitted Angel Shaft LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 63 Turn the leg on the other side; and use the Angel Shaft Tool (optional tool) or similar tool with a Hammer to knock out the press fitted Angle Shaft, which is fitted into the Main Body. Remove the Support Leg. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 64: Reassembling

    Insert the Spring with the rounded end first, all the way down through both Angle Shafts. Use a Mandrel to fully seat the spring into the Angle Shaft. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 65 Turn the leg inwards to its correct position. Ensure the L shaped end of the spring is properly seated inside the Angle Shaft LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.
  • Page 66 If not equipped with Shaft Seals, install Snap Rings according to the picture below (two sides), place the open end of the ring downwards. Install Snap Ring according to picture. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 67: Test

    Thread the Bumper over the shaft seals and the patient strap holder on both sides. Note: There is only Shaft Seals on older LUCAS 2 Mount back the Patient Strap. If the replaced Support Leg had a Type Label with serial number, contact Physio-Control to obtain a new label. 9.9.3. Test Do the following tests to verify that the repair/replacement has been performed correctly: Check the locking function by locking and unlocking against the Back plate.

  • Page 68: How To Replace The Battery Connector Board

    Carefully re-install screws by turning the screws counter clockwise until the existing thread are found, then tighten finger tight. Re-install the Hood. 9.10.3. Test Perform a Function Check according to Section 10. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 69: Replacing The Power Inlet

    Remove the four Torx 20 screws to remove the Main Body Lid. Use the extraction tool to remove the wires from the Power Inlet. With the wires removed you can now remove the nut and Power Inlet. 9.11.2. Reassembling LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 70: Test

    Install the Main Body Lid and tighten all four Torx 20 screws to 13 in-lbs / 1.5 Nm Re-install the Controller PCB, Protective PCB, Compression Module, and Hood. 9.11.3. Test Perform a Function Check according to Section 10. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 71: Replacing The Main Body/Frame Assembly

    LUCAS® 2 is an advanced system consisting of both mechanics and electronics. After each repair or maintenance, a Function Check should be performed to establish all vital functions of the device. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 72: Mechanics Test

    Release Ring from side to side. If the Support Ring is tight against the Support Leg with no play, then the check has failed. Figure 10.2-1: Release Ring Check LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 73: Electronics Test

    Push the Suction Cup back up to its top position. Check that it runs smoothly. Connect a charger to the device and check that the charging sequence begins (the battery LED’s show a “running” light). Disconnect the charger. Turn the device off. LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 74: Accessories

    OR MORE INFORMATION ABOUT DIFFERENT COUNTRY SPECIFIC VARIANTS SEE THE CCESSORY LIST SECTION HERE ARE NO SERVICEABLE PARTS IN THE ATTERY HARGER IF BROKEN REPLACE W ITH A NEW Figure 11.1-1: LUCAS® Battery Charger LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 75: Lucas® Car Cable

    OR MORE INFORMATION ABOUT DIFFERENT COUNTRY SPECIFIC VARIANTS SEE THE CCESSORY LIST SECTION HERE ARE NO SERVICEABLE PARTS IN THE OW ER UPPLY IF BROKEN REPLACE W ITH A NEW. Figure 11.3-1: LUCAS® Power Supply LUCAS® Chest Compression System – Service Manual 3323809-001, © 2017 Physio-Control, Inc.

  • Page 76: Appendix A (Wiring Diagram)

    12. Appendix A (wiring diagram)

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