Welch Allyn PneumoCheck 61000 Service Manual
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Welch Allyn PneumoCheck 61000 Service Manual

Welch Allyn PneumoCheck 61000 Service Manual

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Service Manual
PneumoCheck™
Spirometer Model # 61000,
Printer Charger #'s 76100 & 76106
Welch Allyn Medical Division
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
Copyright 1997
Part 610132

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  • Page 1 Service Manual PneumoCheck™ Spirometer Model # 61000, Printer Charger #’s 76100 & 76106 Welch Allyn Medical Division 4341 State Street Road P.O. Box 220 Skaneateles Falls, NY 13153-0220 Copyright 1997 Part 610132...
  • Page 2 DRAWINGS AND/OR ILLUSTRATIONS AND/OR PART NUMBERS CONTAINED IN THIS DOCUMENT ARE FOR REFERENCE PURPOSES ONLY! FOR CURRENT REVISIONS CALL WELCH ALLYN. Service Manual 610132 Rev. E Pneumocheck Handle and Printer/Charger 1...
  • Page 3 2 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E...

  • Page 4: Table Of Contents

    Contents General Information ......................1.1 Handheld Spirometer ........................6 1.2 Printer ............................8 Service ..........................2.1 Bench Test Of Pneumocheck ....................12 2.2 Bench Test of Printer Charger ....................17 2.3 Required Tools and Equipment ..................... 21 2.4 Test and Adjustment Procedures ................... 22 Theory of Operation ......................
  • Page 5 Help Information: • All service and repairs must be performed by authorized Welch Allyn personnel or agents, using Welch Allyn replacement parts. Failure to do so will invalidate the product warranty. • If you have any questions about servicing the 61000 Pneumocheck or the 76100 or...

  • Page 6: General Information

    Section 1 - General Information General Information Basic Description - Handheld Spirometer Basic Description - Printer Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 5...

  • Page 7: Handheld Spirometer

    Section 1 - General Information 1.1 Handheld Spirometer The handheld spirometer is a small, battery operated device incorporating a laminar flow sensing pneumatic Refer to Owners Guide liquid crystal display, and electronic circuitry in an P/N 610140-3 injection molded case. The front panel of the handheld spirometer includes the eight character, alphanumeric display, two push-button keys labeled TEST and DATA, an ON/OFF slide switch...
  • Page 8 Section 1 - General Information When not in use, the handheld spirometer sits-in the cradle of the printer base (or it is connected to an outlet via a DC power adapter,) and the battery is charged. The battery indicator light remains on whenever a source of charge current is present.

  • Page 9: Printer

    Section 1 - General Information 1.2 Printer The printer base consists of a receptacle to hold the spirometer, a battery charging circuit, a high speed thermal line printer, and associated microprocessor a power circuitry, all housed in an injection molded case. The front panel of the printer includes 2 indicator lights, and 3 push button keys marked STOP, FEED, and PRINT.
  • Page 10 Section 1 - General Information The READY light is also used to indicate an error condition. Errors are numbered from one to three. When an error occurs, an alarm sounds and the READY light flashes in groups of 1, 2, or 3 flashes (at a rate of times per second), corresponding to the error that was detected.
  • Page 11 Section 1 - General Information If the value for either age or height fails outside of valid range, then the normal values are not calculated or printed on the report. The SEX switch is a slide switch. The up position indicates the patient is a female, while the down position indicates that the patient is male.

  • Page 12: Service

    Section 2 - Service Service Bench Test of Pneumocheck Bench Test of Printer/Charger Required Tools and Equipment Test and Adjustment Procedures Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 11...
  • Page 13 Section 2 - Service 2.1 BENCH TEST OF PNEUMOCHECK Remove pneumotach if necessary. SECTION A Caution: Adequate ESD protection Obtain a good set of batteries and insert in must be worn at all times when pneumocheck. working on the Pneumocheck, handle or printer/charger.
  • Page 14 Section 2 - Service Depress & release test button: Ambient temperature should be displayed. 20 degrees C = 68 degrees F 22 degrees C = 72 degrees F 24 degrees C = 75 degrees F 25 degrees C = 77 degrees F 27 degrees C = 81 degrees F 30 degrees C = 86 degrees F If unit displays a reading outside ambient...
  • Page 15 Section 2 - Service Disassemble Unit: SECTION B Wear ESD wrist strap when performing the following operations. Observe backplate; notice what must be present: If there is a raised surface where the ‘flat’ should be and/or if there is no recessed circle, replace backplate (610015-503).
  • Page 16 Section 2 - Service If required, change Red LED to orange (230015-6). If necessary, change software. You must remove digital board from front plate to do this. PROM is location U4 on digital board. If necessary, reverse side contacts. To do this, remove the two metal contacts from the black plastic piece.
  • Page 17 Section 2 - Service Once transducer is replaced, calibrate according to Section B, step 6. Once transducer is calibrated, re-assemble unit. With unit assembled and good batteries in, without the pneumotach (top piece), insert into working printer charger. With a DC ammeter, measure current between the top of each battery.
  • Page 18 Section 2 - Service 1. ESD protection is required whenever working with the pneumocheck printer. 2.2 Bench Test of the Pneumocheck Printer/charger 2. Apply power to the unit. It should beep twice and the “power LED” will light. The “data” light should not be lit.
  • Page 19 Section 2 - Service D. Install a paper roll if one is not installed. Measure the dc voltage between the ground contact in printer well and pin 3 of the J1 connector. The J1 connector is the smaller of the two groups of pins in front of the printhead.
  • Page 20 Section 2 - Service 11. Set dip switches on bottom of printer to “on” position. On top of printer, set the following: Age: 59; Height: 96; Race: 1; Sex: M. Depress and release the print button to obtain a printout. Observe printout. The printout should agree with the settings.
  • Page 21 When loading paper, feed about 2-3 inches, put leading edge of paper through paper cutter envelope before putting paper cutter in place. Any questions call Welch Allyn Technical Service at 800-535-6663, Technical Support.
  • Page 22 Section 2 - Service Required Tools: Tools and Test Equipment Listing Compression ring tool - Welch Allyn tool number T8608 Snap ring pliers (external) VACO #22 #1 Phillips head screwdriver 1/4 inch flat head screwdriver 3/32" Hex Key Required Test Equipment...
  • Page 23 Section 7 with reference made to them here. The following tests should be done before the unit is returned to the customer. Calibrate and test the handle per specification drawing A01945. “Calibrating with Welch Allyn Spirometer. Perform all tests on specification drawing A01951, “Dynamic Waveform Testing”...

  • Page 24: Theory Of Operation

    Section 3 - Theory of Operation Theory of Operation Spirometer Circuit Description Spirometer - Printer Circuit Description Messages Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 23...

  • Page 25: Spirometer Circuit Description

    Section 3 - Theory of Operation Spirometer Circuit The handheld spirometer’s electronics are contained on Description two boards, designated the “Digital Board” and the “Analog Board”. The analog board contains the power control circuitry, as well as the analog signal amplifiers. The digital board contains the digital circuitry, as well as the front panel components.
  • Page 26 Section 3 - Theory of Operation In this state: VA+ and VA- are not present U12 and U13 are not powered iii. U8 is not operating CR1 is oscillating (8Mhz) The CPU clock (pin 22 of U4) is running (2Mhz) In normal operation this state will terminate and return to the sleep state as soon as the p r o c e s s o r has nothing to do, such as while it is waiting for a...
  • Page 27 Section 3 - Theory of Operation 3. Spirometer Power The battery charge is supplied by U14 which is a voltage Circuit Description regulator wired as a 12ma current source. D6 and D7 provide reverse polarity protection. Transistor T1 is the source for the current used in the spirometer if it is turned on while plugged into the printer.
  • Page 28 Section 3 - Theory of Operation TP2 and TP3 should measure +/- 3.90 to 4.10 volts. These voltages power the pressure transducer as well a U10 to U11. The switched analog voltage is also, regulated by U15B and T2 to give an isolated 5v +/- 0.10 volts at TP6. This voltage powers the A/D and U12.
  • Page 29 Section 3 - Theory of Operation The output of U11B (TP5) depends upon the particular transducer, the charge pump and the adjustment of R33 and R36. The nominal output is 0.125 volt with no pressure applied and 2.10 volts with a pressure corresponding to 12 L/S of airflow (approximately 6cm O).
  • Page 30 Section 3 - Theory of Operation First, there is a signal from pin 5 of U9 which will go low 6. Low Battery Detection if Vcc comes out of regulation. This will occur if the battery voltage falls below about 6.3 volts, depending on the load.

  • Page 31: Spirometer - Printer Circuit Description

    Section 3 - Theory of Operation 3.2 Spirometer - Printer Circuit Description This board is based on the Mitsubishi 50734 processor 1. Digital Circuit Desription which has an integral stepping motor driver, a UART and a four channel 8 bit A/D converter. This makes the digital circuitry very simple.
  • Page 32 Section 3 - Theory of Operation The two inverters connected to the CPU pin 23 functions as a latch which powers up in the low state but which can be forced to a latched high state by software. It is used to provide a reliable mechanism by which the software can distinguish between power-up reset and a reset caused by the front panel reset key.
  • Page 33 Section 3 - Theory of Operation The 24 volt output is fed into a divider network made up of R27 and R28. The output of the divider network is then fed into the error amplifier, ERR1. The 5 volt reference voltage is reduced through a divider made up of R37, R38, and R39 to 2 volts, and also fed into ERR1.

  • Page 34: Messages

    Section 3 - Theory of Operation 3.3 Messages The following is a tabulation of the various messages Quality Messages that may be displayed by the spirometer and/or printer by the printer: NEW BEST Indicates that this test has a greater FVC+FEV1 than the one currently in memory.
  • Page 35 Section 3 - Theory of Operation GOOD CAL Each of the 3 calibration maneuvers was within 1/2% of the average. The existing calibration factor will be replaced with the cal factor from this calibration. CF=XXX Shows calibration value after a successful calibration was completed.
  • Page 36 Section 3 - Theory of Operation CHARGE Indicates that the device has begun charging the spirometer batteries. Asks the operator or patient to hold the spirometer STEADY steady (with no movement) while it references the machine to zero flow in order to establish a baseline for future data.
  • Page 37 Section 3 - Theory of Operation Exception Messages The flow during a maneuver has exceeded the flow FLOW LIM sensor’s capacity of 14 liters/second (minimum). VOL LIM The volume during a maneuver has exceeded the spirometers capacity of liters (minimum). TOO SOON Flow was present as a sampling started.
  • Page 38 Section 3 - Theory of Operation TRIM LIM The device cannot trim the baseline out. This is usually due to an abrupt thermal change. The machine must be allowed to return to an acceptable temperature range before proceeding. Encountering either the TEMP LIM or TRIM LIM messages during normal operation may indicate a possible hardware failure.
  • Page 39 38 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E...

  • Page 40: Troubleshooting

    Section 4 - Troubleshooting Troubleshooting Technical Troubleshooting Customer Service Questions and Answers Service Manual 610132 Rev. E Pneumocheck Handle and Printer/Charger 39...
  • Page 41 Section 4 - Troubleshooting 4.1 PneumoCheck Handle Technical Troubleshooting Model Number: 61001 (Most frequent problems at top) i t c i t c t a l t a l o i t i t c o i t ) l i o i t o i t .

  • Page 42: Pneumocheck Handle Technical Troubleshooting

    Section 4 -Troubleshooting PneumoCheck Handle Technical Troubleshooting Model Number: 61001 e l i e l i e l i i g i l a t i g i l a t e l i e l i a t l b i l e l i s l i...
  • Page 43 Section 4 -Troubleshooting PneumoCheck Printer Troubleshooting Model(s): 76101 (Most frequent problems at top) c t i a t l t a l t a l , r o t i c t i c e l i t n i o i t t n i i t c...

  • Page 44: Customer Service Questions And Answers

    Section 4 -Troubleshooting 4.2 Customer Service Questions and Answers Reading On LCD Solutions Make sure they are not attempting to calibrate while Calibration the handle is in the printer well. Make sure they realize there is a CALIBRATION CHECK and a RECALIBRATION. When performing calibration, 3 liter syringe must be operated smoothly and evenly with consistent speed.
  • Page 45 Section 4 -Troubleshooting Infrequently customer complains of Error 23. Have Error 23 them turn handle off/on to see if it will reset-perhaps leave for a couple minutes and try again. In talking the Tech. Rep., they have not been able to duplicate problem inhouse.
  • Page 46 Section 4 -Troubleshooting Low Batt Message Are batteries within warranty? Check battery voltage should be 3.5 volts. Are the printer & handle power lights (orange) on? Put in charger overnight, try again. Has it been in the printer charger? If error 5 appears after unit has been in printer for more than 3 hours, let unit cool down.
  • Page 47 Section 4 -Troubleshooting Pneumocheck handle is in test mode-you will No % Or Norms on Printout received no % norms in the print-Turn on w/out Page 54 in Operating Instructions buttons depressed. Remove handle-turn unit off turn cont’d handle on into normal mode. They may have blown a fuse.
  • Page 48 If retrim occurs regularly, or if it will not advance after the 1 minute, handle must be returned for service. Standards Compliance The Welch Allyn PnuemoCheck complies with American Thoracic Society OSHA Service Manual 610132 Rev. E...
  • Page 49 Section 4 -Troubleshooting Handle cannot trim the baseline. May be due to an Trim.Lim abrupt thermal change or weak battery. If not, may be hardware failure. If so, turn handle off/on. If unit does not clear, return for service. Broken or bent contact in handle or printer? Push TX Fail (Transmission Fails) paper feed button - Does paper feed through machine.

  • Page 50: Disassembly And Repair

    Section 5 - Disassembly and Repair Disassembly and Repair Pneumocheck Handle Pneumocheck Printer/Charger Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 49...

  • Page 51: Pneumocheck Handle Disassembly Procedures

    Section 5 - Disassembly and Repair ITEM NUMBERS REFERENCED ON DRAWING 5.1 PNEUMOCHECK 610135 (SPIROMETER ASSEMBLY) HANDLE DISASSEMBLY PROCEDURES This section describes how to remove the following subassemblies and major components: MOUTH PIECE ASSEMBLY (Item 3) PNEUMOTACH ASSEMBLY (Item 18) REAR BASE ASSEMBLY (Item 2) ELECTRONIC COMPONENT ASSEMBLY (Item 6)
  • Page 52 Section 5 - Disassembly and Repair Reassembly is the reverse of disassembly. NOTE: Torque the studs (item 19) to 5 - 8 in. lbs. Removing the REAR BASE ASSEMBLY (item Remove the PNEUMOTACH ASSEMBLY (item 18) as instructed in Part B. Remove the two pressure port gaskets (item 11), the two retaining rings (item 14), and the compression ring (item 12).
  • Page 53 Section 5 - Disassembly and Repair Removing the ELECTRONIC COMPONENT ASSEMBLY (item 6) NOTE: The ELECTRONIC COMPONENT ASSEMBLY consists of two P.C. boards (see parts drawing), the analog assembly and the digital assembly. These P.C. boards are a matched set, and must always be replaced as a matched set.
  • Page 54 Section 5 - Disassembly and Repair Remove the ELECTRONIC COMPONENT ASSEMBLY. NOTES: Torque items 20 and 7 to 5 - 6.25 in. lbs. Torque item 5 to 1.1 to 1.3 in. lbs. Reassembly is the reverse of disassembly. Removing the FRONT HOUSING ASSEMBLY (item 21) Remove the PNEUMOTACH ASSEMBLY (item 18) as instructed in...
  • Page 55 Section 5 - Disassembly and Repair NOTE: These instructions apply only to assemblies where the BATTERY CONTACTS are glued to the P. C. Board. Also, anytime old BATTERY CONTACTS are removed, the new BATTERY CONTACTS must be soldered onto the P.
  • Page 56 Section 5 - Disassembly and Repair Remove the PNEUMOTACH ASSEMBLY (item 18) as instructed in Part B. Remove the REAR BASE ASSEMBLY (item 2) as instructed in Part C, Steps 2 - 5. Remove the ELECTRONIC COMPONENT ASSEMBLY (item 6) as instructed in Part D, Steps 3 - 8.

  • Page 57: Pneumocheck Printer/Charger Disassembly Procedures

    Section 5 - Disassembly and Repair 5.2 PNEUMOCHECK PRINTER/CHARGER ITEM NUMBERS REFERENCED ON DRAWING DISASSEMBLY 761168 (DOMESTIC EXPLODED VIEW MODEL PROCEDURES 76101) ITEM NUMBERS REFERENCED ON DRAWING 761170 (INTERNATIONAL EXPLODED VIEW 220V MODELS 76102, 76104, 76106) These procedures describe how to remove the following subassemblies and major components: TOP PANEL ASSEMBLY (Item 1) CONTROL P.
  • Page 58 Section 5 - Disassembly and Repair Remove the AC line cord from the AC outlet and from the back of the PRINTER/ CHARGER. Remove the PAPER ROLL (item 4) and the SPINDLE (item 5). Refer to the parts drawing when following procedures.
  • Page 59 Section 5 - Disassembly and Repair The RED wire of the connector to the rotary board (part of the TOP PANEL ASSEMBLY) should be to the RIGHT. Torque (items 18 and 19) to 3 - 4 in. lbs. Torque (item 2) to 2.7 - 3 - 4 in. lbs. Removing the CONTROL P.
  • Page 60 Section 5 - Disassembly and Repair NOTE: If original contact springs are damaged replace with: 1 Spring contact P/N 761009 1 Contact block P/N 761010 Use 3/32" hex key to tighten 4-40 x 1 SHCS P/ N 106119-6 (4 required) Removing the MAIN P.C.
  • Page 61 Section 5 - Disassembly and Repair Remove the three nuts and washers (items 2 and 23) securing the THERMAL PRINTER and the PRINTER WELL (item 6) to the MAIN P.C. BOARD ASSEMBLY (item 14). Remove the nut and washer (items 21 and 22) securing the GEAR COVER (item 3) and the PRINTER WELL (item 6) to the MAIN P.C.
  • Page 62 Section 5 - Disassembly and Repair Removing the TRANSFORMER ASSEMBLY (item 8) Remove the TOP PANEL ASSEMBLY (item 1) as instructed in Part A. Remove the MAIN P.C. BOARD ASSEMBLY (item 14) as instructed in Part D, Steps 2-4 Unplug the BROWN, BLUE, and GREEN/YELLOW wires from the RFI FILTER (item 7) Remove the bolt (items 19, 21, and 22)
  • Page 63 Section 5 - Disassembly and Repair Removing the RFI FILTER (item 7) Remove the TOP PANEL ASSEMBLY (item 1) as instructed in Part A. Remove the MAIN P.C. BOARD ASSEMBLY (item 14) as instructed in Part D, Steps 2 - 4. Unplug the BROWN, BLUE and GREEN /YELLOW wires from the RFI FILTER to the BASE HOUSING...
  • Page 64 Section 5 - Disassembly and Repair NOTE: Torque the bolt (item 19, 21, and 22) to 3 - 4 in. lbs. Removing the BASE HOUSING ASSEMBLY (item 17) Remove the TOP PANEL ASSEMBLY (item 1) as instructed in Part A. Remove the MAIN P.C.
  • Page 65 64 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E...

  • Page 66: Pneumocheck Handle And Printer/Charger Spare Parts

    Section 6 - Spare Parts List Pneumocheck Handle and Printer/Charger Spare Parts Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 65...
  • Page 67 Section 6 - Spare Parts List 66 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E...

  • Page 68: List Of Drawings And A Specs

    Section 7 - Drawing and ASpecs List of Drawings and A Specs y l l Service Manual 610132 Rev. E Pneumocheck Handle and Printer/Charger 67...
  • Page 69 68 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E...

This manual is also suitable for:

Pneumocheck 76100Pneumocheck 76106

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