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Tyco Healthcare KENDALL 6060 Novamedix A-V Impulse System Service Manual

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MODEL 6060
SERVICE MANUAL

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Summary of Contents for Tyco Healthcare KENDALL 6060 Novamedix A-V Impulse System

  • Page 1 MODEL 6060 SERVICE MANUAL...

  • Page 2: Table Of Contents

    Contents WARRANTY DECLARATION ........MAINTENANCE ..........2.1 Introduction .
  • Page 3 Contents 4.14 Replacing the EPROM ........4.15 Replacing the power supply assembly .

  • Page 4: Warranty Declaration

    1. LIMITED WARRANTY AND FACTORY SERVICE Kendall Healthcare Products Company hereafter called Kendall warrants that your A-V Impulse System® controller does not contain defective materials or workmanship. This warranty is for one year from the delivery of the controller to the original purchaser. If within the first year of purchase there is a fault on the unit, the controller should be returned to the Kendall Service Center at the address shown below, and Kendall will free of charge, inspect the unit and replace any part which upon their examination, appears to...

  • Page 5: Figure 1 View Of The Front Of The Controller

    Bed hook/handle Liquid crystal display Membrane switch panel Membrane fascia label Power switch Case front Figure 1: View of the front of the controller Communication port Patient left air Patient right air hose socket hose socket Case screws Instruction label Tamper Power cord retainer Ground test srew...

  • Page 6: Maintenance

    2. MAINTENANCE 2.1 INTRODUCTION Personnel servicing this equipment should be familiar with the Operator’s Instruction Manual and the operating principals of the A-V Impulse System® Controller. The alarm indicators displayed by the controller are useful in diagnosing problems. If a controller needs to be returned to Kendall for service, it should be accompanied by a description of the problem and any fault or error codes that are displayed along with a return materials authorization number.

  • Page 7: Computer Based Test Method

    2.2.9 Connect the Standard test load (1 litre) to the patient left and patient right channels. Check the pressure displayed is 130 mm Hg and the hold time is 3 seconds. Press the RUN . STOP Patient LEFT and the RUN . STOP Patient RIGHT buttons. Confirm that the check marks appear within 4 impulses on each channel.

  • Page 8: Preventative Maintenance

    2.5 PREVENTATIVE MAINTENANCE To maintain optimum functional performance and electrical safety it is recommended that after one year’s operation, and then every year, the controller be removed from use and checked. Carry out all of the procedures contained in Sections 2.5.1 through 2.5.8 inclusive, referring to the recommended service schedule throughout.
  • Page 9 2.5.4 Membrane Switch Panel and Display Switch ON the controller and check the Liquid Crystal Display (LCD) for sharpness, legibility and brightness. If the display appears dim or segments are missing, dismantle the display assembly and clean the contacts to the LCD (see Section 4.13).
  • Page 10 reservoir nipple and connect it to a pressure meter. Reinstate the controller to the upright position. Turn the controller power switch ON and read the pressure output. Controller test method For controllers with version 16 software the compressor output pressure can be tested directly on the controller using a Standard test load (1 litre) connected to the patient right channel.
  • Page 11 valve. Align the rubber seal, metal valve, and over extension stop accurately over one another and 0.25mm from the edge. Tighten the screw and confirm their position. OBSERVE HEALTH AND SAFETY PRECAUTIONS WHEN HANDLING CHEMICALS. Remove the piston assembly, complete with spring and spring seat. Clean out the inside of the compressor body by blowing with compressed air.

  • Page 12: Figure 3 Compressor User Serviceable Parts

    of the compressor body. Apply Loctite 454 to the rear cylinder housing mating surface of the compressor body adjacent to the fixing screw holes. Place the laminations and coils, with the wire grommet facing towards you, on top of the compressor body. With one hand keep the laminations elevated above the adhesive.
  • Page 13 Recommended Service Schedule PART DESCRIPTION SERVICE INTERVAL HOURS NUMBER 3000 5-6000 8-9000 11-12000 COMPRESSOR AV6534-00 Air filter element AV6531-00 Piston assembly AV6532-01 Front cylinder housing M U1 M U1 AV6708-01 Rear cylinder housing M U2 M U2 AV6710-00 Rear bearing insert AV6533-00 Spring AV6538-00...
  • Page 14 Key to Recommended Service Schedule Mandatory Replacement Upgrade Possible: Replacement of Front cylinder housing AV6532-00 with AV6532-01 to extend compressor service interval to 6000-hours Upgrade Possible: Replacement of Rear cylinder housing AV6708-00 with AV6708-01 to extend compressor service interval to 6000-hours Upgrade Advised: Replacement of Compressor lubricant AV6709-00 with AV6709-01 for improved lubrication.
  • Page 15 2.5.7 Alarms Kinked air supply hose. Connect the Standard test load (1 litre) to the patient right outlet. Switch ON the controller and press the RUN . STOP Patient RIGHT button, wait for the check mark to appear. Kink the air supply hose to the test load. At the next impulse the controller will detect that the air hose is kinked, the air should be dumped immediately through the vent valve and the check mark will disappear.
  • Page 16 2.5.8 Functionality and safety tests Close the case. Perform the controller safety tests to confirm the ground resistance and leakage current (see Sections 2.2.11 and 2.2.12). Perform the complete controller functionality tests (see Section 2.2 or 2.3).

  • Page 17: Fault Diagnosis

    3. FAULT DIAGNOSIS THE CONTROLLER SHOULD ALWAYS BE DISCONNECTED FROM LINE VOLTAGE BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICING PROCEDURE. Before undertaking any fault diagnosis, check the fuses. If, when the controller is switched ON, a replacement fuse blows immediately, the controller should be returned to the Kendall Service Center for repair.

  • Page 18: Compressor

    If the LCD elements are incomplete dismantle the display and clean the zebra elastomer and contact surfaces (see Section 4.13). If the LCD is entirely blank check the power supply output voltages. Confirm the power supply voltages conform to the table (see Section 3.1). If the voltages are correct then check the fit of the EPROM into the socket.

  • Page 19: Error Codes

    3.5 ERROR CODES See the table below for controller error codes. CODE DESCRIPTION CAUSE REMEDY RAM error Failure on processor Replace the processor PCB assembly PCB assembly ADC error ADC output is not zero Check that there is no at switch ON pressure on the transducer at switch ON Replace the valve driver...
  • Page 20 CODE DESCRIPTION CAUSE REMEDY NVR setup A new software version Switch OFF and ON has failed to update Non-Volatile RAM Over Temperature Over Temperature Check the fan grills are not Cutout Cutout exceeded obstructed 113°F (45°C) Check the fan is operating at normal speed and efficiency Replace the fan...

  • Page 21: Component Replacement Procedures

    4. COMPONENT REPLACEMENT PROCEDURES THE CONTROLLER SHOULD ALWAYS BE DISCONNECTED FROM LINE VOLTAGE BEFORE OPENING THE CASE. Before replacing any component, read the procedure completely. If you have any doubts about how to replace a component, contact the Kendall Service Center. Incorrect servicing could lead to components being damaged.

  • Page 22: Replacing An Air Hose Socket 'O' Ring Seal

    wires or tubes trapped, which will prevent the case from being closed properly. Turn the controller over, and secure it with the four 3mm hexagon screws. Perform the complete controller functionality tests (see Section 2.2 or 2.3). Fit a new tamper label over the case retaining screw (see Figure 2). Processor PCB assembly Compressor Valve driver...

  • Page 23: Replacing An Air Hose Socket Body

    4.3 REPLACING AN AIR HOSE SOCKET BODY Pull the tube off the socket body. Use a screwdriver with a narrow (approximately, 3mm) flat blade to gently pry apart the gap in the case molding which holds the socket in place, until it comes out. Insert the new socket body in the correct orientation.

  • Page 24: Figure 5 View Of The Processor Pcb Assembly And Liquid Crystal Display

    LCD Bezel Liquid crystal display Connector for 7 way flat flexible cable Figure 5: View of the Processor PCB assembly and Liquid Crystal Display...

  • Page 25: Replacing The Compressor

    rectangular hole. Before pressing down, make sure that the cut out is precisely lined up with the recessed edges of the LCD window. Smooth the membrane switch panel down, starting from the LCD window and always working away from it, ensuring that there are no air bubbles. Remove completely the backing paper on the new membrane fascia label (USA).

  • Page 26: Replacing The Reservoir

    4.7 REPLACING THE RESERVOIR Use standard antistatic precautions when handling the electronic PCB’s. Remove the old reservoir Disconnect the 14 way ribbon cable from the processor PCB assembly to the valve driver PCB assembly at PL4 and the small 4 way connector from the power supply assembly at PL3.

  • Page 27: Figure 6 View Of Compressor And Valve Driver Pcb Assembly Showing The Pneumatic And Electrical Connections

    Replace each valve coil in the correct position, with the recessed circular face at the threaded end of the valve stem. Fit a rubber washer and secure the coil with a knurled nut. Rebuild the new reservoir Connect the moisture drain assembly to the nipple on the end of the reservoir with two reservoir mounting rings.

  • Page 28: Replacing A Fill Or Vent Valve Piston

    Connect the patient right air supply tube to the patient right air outlet port on the reservoir. Connect the air supply tube from the compressor to the nipple at the end of the reservoir with one mounting ring. Refit the moisture drain into the tubing clip on the compressor chassis and push the tube onto the reservoir nipple.

  • Page 29: Replacing A Valve Coil

    4.9 REPLACING A VALVE COIL Use standard antistatic precautions when handling the valve driver PCB assembly. Remove the three retaining screws and washers from the valve driver PCB assembly, but do not disconnect anything. Cut the heat shrink tubing off the connectors on the faulty coil and unsolder the leads.

  • Page 30: Figure 7 Diagram Of Valve Driver Pcb Assembly Showing Pneumatic

    14 way ribbon cable To processor PCB assembly To patient left fill valve To patient right fill valve Patient Patient left side right side To patient left vent valve To patient right vent valve P1 Hose to patient right side of manifold To power supply assembly P2 Hose to patient left...

  • Page 31: Replacing The Valve Driver Pcb Assembly

    4.11 REPLACING THE VALVE DRIVER PCB ASSEMBLY Use standard antistatic precautions when handling the valve driver PCB assembly. Disconnect all electrical connectors from the valve driver PCB assembly, avoiding pulling them by the wires, and carefully pull off the air tubes from the pressure transducer ports.

  • Page 32: Figure 8 Exploded View Of Both Display Assemblies

    LCD bezel (snap fit) Liquid crystal display Zebra elastomer Backlight Guide pins Processor PCB LED’s Membrane switch panel connector Holes for guide pins Slots for LCD bezel (snap fit) LCD bezel (screw fit) Liquid crystal display Zebra elastomer Backlight Guide pins Processor PCB LED’s Membrane switch panel connector...

  • Page 33: Replacing The Eprom

    Carefully unhook the bezel clips / undo the four retaining screws from the PCB and remove the display components. BE CAREFUL not to let the LCD fall out. With an Isopropyl Alcohol (IPA) swab, wipe the PCB contact area. Position the backlight over the LEDs, matching the holes in the panel with the guide pins in the PCB.

  • Page 34: Replacing The Power Supply Assembly

    Fit the new EPROM into the socket ensuring the correct orientation. Close the case. Switch ON the unit and confirm that both check marks shown on the LCD. Perform the complete controller functionality tests (see Section 2.2 or 2.3). 4.15 REPLACING THE POWER SUPPLY ASSEMBLY Use standard antistatic precautions when handling the power supply assembly.

  • Page 35: Replacing The Power Cord

    Perform the controller safety tests to confirm the ground resistance and leakage current (see Sections 2.2.11 and 2.2.12). Perform the complete controller functionality tests (see Section 2.2 or 2.3). 4.16 REPLACING THE POWER CORD This is done without opening the case. Remove the power cord retainer, and remove the power cord from the power inlet.

  • Page 36: Replacing A Fuseholder

    Insert the new power inlet in the case, with the central ground terminal to the bottom of the case, making sure that it clips into place. The correct orientation is essential to allow the power cord to be inserted so that it can be secured by the power cord retainer.

  • Page 37: Replacing The Power Switch

    Slide a half-inch length of " diameter heat shrink tubing onto both wires, and solder them to the fuseholder, making sure of the correct wire orientation. Shrink on the pieces of heat shrink tubing Replace the insulation cover, and replace the fuse. Close the case.

  • Page 38: Upgrade Items

    5. UPGRADE ITEMS The controller specification is subject to a policy of continuous improvement and in accordance with this policy particular items are available as retrofit upgrades for in- service controllers. All upgrades are user installable by a competent person or can be implemented during a controller service.

  • Page 39: List Of Supporting Items

    6. LIST OF SUPPORTING ITEMS Air supply hose ........... 5007 Case and handle grip set .
  • Page 40 ‘O’ ring seal ............AV6555-00 Operator's Instruction Manual model 6060 .

  • Page 41: Figure 13 Electrical Schematic

    Communication port Processor PCB assembly 14 way 7 way flat flexible ribbon cable cable to membrane switch panel Fan assembly Valve driver Power supply PCB assembly assembly Compressor Patient Patient left right Brown (line) fill fill Blue (neutral) Power switch Patient Patient left...

  • Page 42: Figure 14 Pneumatic Schematic

    Compressor Patient right Patient left socket face socket face Valve driver PCB assembly Reservoir ‘O’ ring ‘O’ ring assembly Patient left Patient socket body right socket body Patient left hose to pressure transducer Moisture drain assembly Patient right hose to pressure transducer Figure 14: Pneumatic schematic.
  • Page 43 Update notes Distributed by: Mansfield MA 02048 Kendal Customer Service 1-800-421-8268 Novamedix, A-V Impulse System and ImPad are Registered Trademarks of Novamedix Distribution Limited. Kendall and T.E.D. are Registered Trademarks of The Kendall Company. Webril is a Trademark of Veratec, Inc. Made in England under one or more of the following Patents: U.S.

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