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FLOWTRON® UNIVERSAL - Frank`s Hospital Workshop

1. 9 1 9 2 9 3 9 4 9 5 Chap 5 Elbow Connector Turn Tube and Elbow Connector counterclockwise Figure 36 Releasing the Hose Set Connector Installing the Hose Set Assembly If you want to re fit the same hose set assembly which was removed from the pump then inspect the screw cover on the elbow retaining cover on the hose set assembly Refer to Figure 35 If the screw cover or hinge is damaged or split then replace the hose set assembly Note It is not necessary to replace both hose set assemblies if only one is damaged Put the hose set assembly Fig 34 Item 10 by the pump with the elbow retaining cover adjacent to the case cutout in the top of the pump Plug the hose set cable connector into the 6 way connector on the control board in the pump Note Make sure the hose set cable connector is pushed fully into the control board connector Carefully insert the excess hose set cable inside the pump case between the control board connector and the threaded pillar Refer to Figure 37 Note Do not insert the excess hose set cable the other side of the control board connector or it might get damaged by the lugs on the elbow retaining cover Note Make sure the cable is always clear of the pneumatic outlet in the pump Install the elbow retaining cover fully into the cutout in the pump case Note Make sure the two lugs on the elbow retaining cover are aligned with the correct slots in the cutout in
2. Figure 15 Only One Garment Connected 2 3 4 Ifthe LCD display shows either an incorrect garment graphic or a no garment graphic when one is connected then carry out the procedure for recalibrating the pump for a new hose set assembly Refer to Page 12 Section 9 Table 3 Garment Options and Default Therapy Parameters LCD Display Inflation Pressure Inflation Hold Cycle Garment Type Graphic mmHg seconds seconds Foot Single chamber Calf and Thigh Calf No Garment Connected Chap 4 Issue 2 Page 2 SERO009 Sep 2009 Flowtron Universal Service Manual Testing 3 1 3 2 3 3 3 4 3 5 3 6 Checking the Basic Pump Operation Initialise the pump Refer to Page 1 Section 1 Connect a garment to each pump hose set assembly Make sure the connection and garment types are confirmed correctly on the display Refer to Table 3 Note Although it is preferable to connect two different garment types to test the pump the pump can be tested with two identical garments or even just a single garment connected Press the green Run button Y on the top of the pump to start the pump and keep it depressed until the pump beeps The green LEDs on the front of the pump will illuminate and the compressor will start Figure 16 shows the pump running and the left calf garment inflated to 40 mmHg Note The green LEDs do not illuminate when operating from the battery Figure 16 LCD Di
3. 20 4 20 5 20 6 20 7 20 8 20 9 21 21 2 21 3 21 4 Installing the Motor and Manifold Assembly If the hose set assemblies were not removed make sure that the O ring is correctly installed on each hose set elbow connector Refer to Figure 43 Make sure the two LEDs adjacent to the transducer are vertical on the control PCB assembly and have not been knocked or moved during the removal procedure Refer to Figure 43 Carefully install the motor and manifold assembly Fig 43 Item 10 onto the control PCB and top case assemblies Fig 43 Items 20 and 30 Note If the hose set assemblies are still connected to the top case assembly the motor and manifold assembly will be a tight fit on the elbow connectors on the hose sets Install the four screws Fig 43 Item 40 to secure the motor and manifold assembly Connect one end of the longer transducer tube Item 60 onto the transducer outlet on the motor and manifold assembly Fig 43 Item 10 Connect the other end of the longer transducer tube Item 60 onto the top outlet on the transducer on the control PCB assembly Refer to Figure 43 CAUTION Do not handle the transducer on the control PCB assembly unnecessarily The transducer is a sensitive device To avoid damage put your finger at the back of the transducer while you push the tube onto the top outlet at the front of the transducer Connect the stepper motor connector onto the control PCB assembly Fig 43 PC
4. 9 5 1 There should be 801 3 01 in the Receive part of the dialog box where 3 01 is the correct version of the software downloaded to the pump This is the end of the software upgrade Continue the test at Para 9 6 below 9 5 2 Ifthe command is unsuccessful or the software version is NOT 3 01 then 9 5 2 1 The software upgrade has failed and the procedure must be repeated 9 5 2 2 The pump is faulty and must be rejected 9 6 Disconnect the pump from the mains power supply 9 7 Remove the Serial Communications Pack from the pump refer to Chapter 6 Updating the software Page 9 Connecting the Pump to a Laptop Desktop PC 10 Downloading the V3 01 Software Files to the Pump 10 1 Load the V3 01 Flowtron Universal pump software onto the PC as follows 10 1 1 The software for the Flowtron Universal pump is contained in the following three files which must be downloaded to the pump using the Communicator software FlowtronUniversal_V3 01 HO0 FlowtronUniversal_V3 01 H01 e FlowtronUniversal_V3 01 H02 10 1 2 These three software files will normally be supplied on either of the following media e CDROM File attachments on an email 10 1 3 If the three software files are supplied on a CD ROM load the CD ROM onto the PC 10 1 4 If the three software files are supplied as attachments on an email do the following 10 1 4 1 Open the email 10 1 4 2 Click on File followed by Save Attachments 10 1 4 3 Make sure all three f
5. No No Front Case Yes No Case Top Membrane Label Assembly Yes No Handle and Hook Assembly Yes No Motor and Manifold Assembly Yes No Compressor Assembly Yes No Compressor Inlet Filter Yes No Power Supply PCB Assembly Yes No Control PCB LCD Display Assembly Yes No Run Button Yes No Fuses on Power Supply PCB Assembly Yes No Rechargeable Battery Chap 5 Page 2 Yes SER0009 Issue 2 Sep 2009 Flowtron Universal Service Manual Pump Repair 2 Pump Labels Note The labels must be stuck on in the correct order 2 1 Stick the serial number label Fig 32 Item 10 onto the rear case Make sure the orientation of the text on the serial number label is correct Refer to Figure 32 2 2 Put the product label Fig 32 Item 20 over the serial number label and stick it onto the rear case Make sure the orientation of the text on the product label is correct Refer to Figure 32 Note Fit the Serial Number Label Item 10 first Note Check the orientation of the text on both labels before fitting Figure 32 Pump Labels Table 7 Pump Label Parts List Part Number Description REF Pump Serial Number Label LAB339 Pump Product Label Issue 2 Chap 5 Sep 2009 SERO009 Page 3 Pump Repair Flowtron Universal Service Manual Figure 33 Replacing the Mains Power
6. Before completing the installation check the membrane label on the top case assembly If it is damaged replace it refer to Chapter 5 Page 37 Section 30 Installing the Control PCB Assembly into the Top Case Assembly 29 8 Install the complete control PCB assembly including the LCD sub assembly into the top case assembly as follows refer to Chapter 5 Page 29 Section 25 29 8 1 Make sure the Run button is fitted in the cutout in the top case and the button return spring is fitted onto the Run button 29 8 2 Lower the control PCB assembly onto the four pillars in the top case assembly 29 8 3 Install the four screws to secure the control PCB assembly 29 8 4 Carefully push the end of the membrane cable into the membrane connector on the control PCB assembly Note Less than 2mm of the membrane cable can be inserted into the connector 29 8 5 Install the motor and manifold assembly onto the control PCB assembly 29 8 6 Install the top case assembly onto the front case assembly 29 8 7 Install the hoseset assemblies onto the pump Issue 2 Chap 5 Sep 2009 SERO009 Page 35 Pump Repair Flowtron Universal Service Manual Membrane Cable 10 Slot for Membrane Cable Top Case Assembly Figure 54 Replacing the Membrane Label when the Control PCB Assembly has been removed from the Top Case Assembly Table 22 Top Case Membrane Label Parts List Part Number Description 507397 Top Case Membrane Label Chap 5 Issue 2 P
7. If any parts are found to be damaged they must be replaced in accordance with Chapter 5 Pump Repair 3 1 Visually inspect the following for damage wear and potential faults e Outer casing Check for damage and security Run button Y Check function e Handle and hook assembly Check for damage and security e Output hose set assemblies Check for damage and security of pump connection e LCD display membrane label Check for damage and security to case e Mains power cord Check for damage and security of plug e Rubber feet 8 Off Check for security e Labels Check all labels are present and legible 3 2 Remove the rear case Refer to Chapter 5 Page 13 Section 10 and visually inspect the following for damage wear security and potential faults e Rechargeable battery on the control PCB e Compressor assembly e Compressor anti vibration pads Motor and manifold assembly e Control PCB and LCD display assembly e Power supply PCB assembly including fuses e Wiring Internal Tubing e Screws nuts and bolts Issue 2 Chap 3 Sep 2009 SERO009 Page 3 Maintenance Flowtron Universal Service Manual Chap 3 Issue 2 Page 4 SERO009 Sep 2009 Flowtron Universal Service Manual Testing CHAPTER 4 TESTING 1 Initialising the Pump 1 1 Make sure that NO garments are connected to either pump hose set assembly 1 2 Plug the pump into an electrical outlet and switch on 1 3 The pump will first go through a sel
8. Locating the Installation cfg File Chap 6 Issue 2 Sep 2009 Page 6 SER0009 Flowtron Universal Service Manual Updating the software 2 19 Click on the Installation cfg file and click Open The relevant files will be copied to complete the Communicator software installation process Note While the files are copied a Communicator Command amp Configuration Files dialog box is displayed refer to Figure 75 Ei Communicator Command amp Configuration Files Communicator Current File Version SERS001 03 Installation File ees Files Installation cfg Load new command and configuration files Files Transferred Restore Previous Load Another z EXIT Version Version Figure 75 Communicator Software Installation Command and Configuration Files 2 20 When the files have been copied the Communicator software will then start to run refer to Chapter 3 Using the Communicator Software 2 21 The installation is now complete and you can now safely remove the Communicator software CD ROM from the PC Issue 2 Chap 6 Sep 2009 SERO009 Page 7 Updating the software Flowtron Universal Service Manual FA Communicator 2 4 Application Please select COM port Serial Port 5d Please select software from list 00 PO O A aa Figure 76 Communicator Software Application Startup Screen 3 Serial Communicator Command List Event Log No command list loaded File Version SERS001 03
9. Replacing the Inlet Filter Felt a aaau aaa o 7 Removing the Mains Power Cordset oaoa a a e 7 Installing the Mains Power Cordset a 7 Removing the Hose Set Assembly 2 e e 9 Installing the Hose Set Assembly e o 10 Removing the Rear Case from the PUMP o e eee ee eee 13 Installing the Rear Case onto the Pump o e e 13 Removing the Handle and Hook Assembly 2 2 0 o 13 Installing the Handle and Hook Assembly 0 0 e e o 13 Separating the Top Case Assembly from the Front Case 15 Installing the Top Case Assembly onto the Front Case 16 Replacing the Mains Power Fuses on the Power Supply PCB Assembly 17 Replacing the Air Inlet Filter on the Compressor Assembly 0 17 Removing the Motor and Manifold Assembly o o e 19 Repairing the Motor and Manifold Assembly o e 19 Installing the Motor and Manifold Assembly 0 0 00002 e 25 Including a Longer Transducer Tube on the Motor and Manifold Assembly 25 PCB Part NumbetS ai a ass os eRe a ea es ae ee SE Poe EG 27 Interchangeability of PCBs aoaaa ee 27 Removing the Control Printed Circuit Board PCB Assembly 29 Installing the Control Printed Circuit Board PCB Asse
10. USA ArjoHuntleigh 2349 W Lake Street Suite 250 Addison IL 60101 Tel 1 630 307 2756 Toll Free US 800 323 1245 Fax 1 630 307 6195 Chap 9 Page 1 ARJOHUNTLEIGH with people in mind Therapy amp Prevention Product Division ArjoHuntleigh 310 312 Dallow Road Luton Bedfordshire LU1 1TD United Kingdom T 44 0 1582 413104 F 44 0 1582 459100 W www arjohuntleigh com ArjoHuntleigh is a branch of Arjo Ltd Med AB Arjo Ltd Med AB Registered No FCO24121 ArjoHuntleigh Registered No BRO10203 England Registered Office As Above ptember 2009 09 N O Q O O O a Lu 09 CE 93 42 EEC 943447 MEMBER OF THE GETINGE GROUP
11. 38 4 2 Hold the compressor assembly and push the mounting bracket in towards the centre of the compressor assembly 38 4 3 At the same time carefully push the AV mount in the opposite direction and out of the slot in the mounting bracket 38 4 4 Repeat for the other three corners of the compressor assembly 39 Installing the Compressor Assembly onto the Mounting Bracket 39 1 Lay the compressor assembly Fig 59 Item 10 down with the AV mounts Fig 59 Item 60 on top and the two cables to the power supply PCB assembly at the front Refer to Figure 60 39 2 Lay the mounting bracket Fig 59 Item 20 on top of the compressor assembly with the angled part of the mounting bracket on top and at the back of the compressor assembly Refer to Figure 60 39 3 At one end of the compressor assembly carefully push the grooved part of the two AV mounts into the slots in the mounting bracket Refer to Figure 60 Push the Compressor Mounting Bracket inwards Compressor Mounting Push the AV Mount Bracket out of the slot in the Mounting Bracket AV Mount Compressor Assembly Cables to Power Supply PCB Assembly Figure 60 Removing the AV Mounts from the Mounting Bracket Issue 2 Chap 5 Sep 2009 SERO009 Page 45 Pump Repair Flowtron Universal Service Manual 39 4 39 5 39 6 39 7 39 8 At the other end of the compressor assembly do the following Refer to Figure 60 39 4 1 Hold the compressor
12. 4 Insert the battery pack connector into the slot in the front case and install the two screws Fig 50 Item 20 to secure it Note Make sure the wires from the power supply PCB assembly to the battery pack connector do not lie on top of the circular compressor support rubbers Fig 50 Item 40 27 5 Install the compressor assembly and mounting bracket into the pump Refer to Page 43 Section 37 Install the top case assembly onto the front case Refer to Page 16 Section 15 Issue 2 Chap 5 Sep 2009 SERO009 Page 31 Flowtron Universal Service Manual Pump Repair Control PCB Assembly May not be fitted UN LCD Sub Assembly on underside of Control PCB Assembly Figure 51 Removing the LCD Sub Assembly Screws from the Control PCB Assembly Table 20 LCD Sub Assembly Parts List Part Number Description Screw 2 5mm x 8mm PT FAS240 507126 LCD Sub Assembly Spares includes LCD Graphic Module Holder Diffuser and Spacer 20 LCD Cable ye Locating Hole i 7 Locating lug N7 y Switch Control PCB Assembly oe ZIF Zero Insertion Force Be Connector E Tue Sounder Figure 52 Installing the LCD Sub Assembly onto the Control PCB Assembly Chap 5 Issue 2 Page 32 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 28 Removing the LCD Sub Assembly Removing the Control PCB Assembly from the Top Case Assembly 28
13. 4730 4999 FRANCE HNE M dical SA 451 Chemin de Champivost BP20 69579 Limonest Cedex T 33 0 4 78 66 62 66 F 33 0 4 78 66 62 67 Issue 2 Sep 2009 GERMANY ArjoHuntleigh GmbH Peter Sander Strasse 10 DE 55252 MAINZ KASTEL T 49 6134 1860 F 49 3167 186 160 ITALY ArjoHuntleigh S p A Via Tor Vergata 432 IT ROMA 00133 T 39 06 87426214 F 39 06 87426222 NETHERLANDS ArjoHuntleigh BV Biezenwei 21 4004 MB TIEL Postbus 6116 4000 HC Tiel Tel 31 0 344 64 08 00 Fax 31 0 344 64 08 85 NEW ZEALAND Huntleigh Healthcare Ltd Unit 6 38 Eaglehurst Road Ellerslie Auckland New Zealand T 64 9 525 2488 F 64 9 525 2433 POLAND ArjoHuntleigh Polska Sp z o o ul Ks Wawrzyniaka 2 PL 62052 KOMORNIKI T 48 61 662 1550 F 48 61 662 1590 SOUTH AFRICA Huntleigh Africa Pty Ltd Willem Cruywagen Avenue Stand 120 Klerksoord Pretoria South Africa T 27 12 542 4680 F 27 12 542 4982 SERO009 SPAIN ArjoHuntleigh Ib rica S L Carratera de Rubi 88 1 planta A1 Sant Cugat del Valles ES BARCELONA 08130 T 34 93 583 1120 SWEDEN Huntleigh Healthcare AB Box 30012 S 200 61 Limhamm T 46 0 40 36 03 50 F 46 0 40 49 43 75 SWITZERLAND ArjoHuntleigh AG Florenzstrasse 1D CH BASEL 4023 T 41 0 61 337 97 77 F 41 0 61 311 97 42 UNITED KINGDOM Huntleigh Healthcare Ltd 310 312 Dallow Road Luton Bedfordshire LU1 1TD T 44 0 1582 413104 F 44 0 1582 459100
14. 58 Items 10 and 20 out of the front case 37 Installing the Compressor Assembly and Mounting Bracket 37 1 Before installing the compressor assembly and mounting bracket Fig 58 Items 10 and 20 check the following parts are installed correctly on it Refer to Figure 61 37 1 1 The air inlet filter into the air inlet filter holder 37 1 2 The eight push on cable connectors from the power supply PCB assembly Fig 58 PCB Con 6 and 7 37 2 Put the compressor assembly and mounting bracket into the front case Note Make sure the two locating holes at the outer ends of the mounting bracket are installed over the corresponding location spigots A and B in the front case Refer to Figure 58 Note Make sure the wires from the power supply PCB assembly to the battery pack connector do not lie on top of the circular compressor support rubbers Refer to Figure 50 37 3 Install the two screws Fig 58 Item 30 through the mounting bracket Fig 58 Item 20 and into the front case Note One hole in the left side of the mounting bracket is not used Refer to Figure 58 37 4 Connect the large diameter tube Fig 58 Item 50 onto the compressor assembly Note Make sure the other end of the tube is still connected to the correct inlet tube on the motor and manifold assembly Figure 41 37 5 Connect the two compressor cable connectors Fig 58 PCB Con 6 and 7 onto the power supply PCB assembly Fig 58 Item 40 37 6 Install the rear case onto the
15. Africa India Flowtron Universal Pump Serial Numbers affected Serial numbers LESS than 507025900 Note All pumps from serial number 507025900 onwards have been built with the modified motor and manifold assembly fitted 2 Chap 5 009 SERO009 Page 19 Pump Repair Flowtron Universal Service Manual 19 4 Reason for the repair As the rotor turns inside the motor and manifold assembly in the pump the rotor rubs against the module assembly creating plastic dust This dust can accumulate inside the motor and manifold assembly in two critical areas The silver positioning strip on the rotor This can result in the loss of positional synchronisation of the rotor The centre pivot area of the rotor This can increase friction and cause the rotor to stall These two conditions will cause the pump to fail and then the pump will usually display either of the following fault messages on the LCD screen Pump Fault Step alarm LO Low Pressure alarm To repair the pump proceed as follows 19 5 Remove and disassemble the motor and manifold assembly 507111 19 6 Discard the old rotor stator and module sub assemblies 19 7 Reassemble the motor and manifold assembly using the following new parts 19 7 1 507124 Pinned Rotor Assembly 19 7 2 507125 Module and Stator Subassembly Note All other parts in the motor and manifold assembly are re used 19 8 Re install the motor and manifold assembly into the pump 19 9 Rep
16. COM port on the PC refer to Page 9 Section 3 6 1 6 4 Click the Serial Communicator button to restart the program Re send the command to the pump 7 Closing the Communicator Software 7 1 To close the Communicator software do the following 7 1 1 Click Connection then click Exit on the drop down menu 7 1 2 The application startup dialog box is then displayed refer to Figure 76 7 1 3 Click Exit 7 1 4 The Communicator software is closed 7 2 If you try to close the Communicator software by selecting and closing the application startup dialog box directly you will be prevented from doing it refer to Figure 83 You must carry out the procedure detailed in Para 7 1 above Application m Please select COM port Serial Port COM2 id Please select software from list pu ere J Please wait for application to end MCM Calibrator Battery Pack Logger Figure 83 Communicator Software Closing the Software Issue 2 Chap 6 Sep 2009 SER0009 Page 13 Updating the software Table 31 Power Up Self Test Sequence Elapsed Time approx Duration approx Flowtron Universal Service Manual Sounder LCD Screen Software Version Silent Double beep Huntleigh Healthcare PLEASE WAIT running diagnostic Universal Rev 3 00 Chap 6 Page 14 Waiting to start treatment SER0009 Silent Standby Attach garments
17. Chap 6 Sep 2009 SERO009 Page 19 Updating the software Flowtron Universal Service Manual Chap 6 Issue 2 Page 20 SERO009 Sep 2009 Flowtron Universal Service Manual CHAPTER 7 TECHNICAL SPECIFICATION Technical Specification PUMP Model Flowtron Universal Part Numbers 507001 UK KSA 507003 USA Canada 507004DE Germany 507004DK Denmark Sweden 507004ES Spain 507004FR France 507004IT Italy 507004NL Dutch Belgium 507009AU Australia NZ 507009CN China 507009JP Japan 507009ZA South Africa India 507EUR Europe 507UNI Universal Pressure Range 40 5 mmHg Calf 130 5 mmHg Foot Supply Voltage 100 230 VAC Supply Frequency 50 60Hz Power Input 120 VA Size 254 x 267 x 152 mm 10 0 x 10 5 x 6 0 Weight 3 9 kg 8 5 Ib Case Material ABS Plastic Plug Fuse Rating 5A to BS1362 UK ONLY Fuse 2 x T3 15AL 250 V Degree of protection against electric shock Mains Connected Class Il with a Functional Earth Type BF Mains Not Connected Internally Powered Degree of protection against liquid ingress IPXO Mode of operation Continuous Issue 2 Sep 2009 SERO009 Chap 7 Page 1 Technical Specification Flowtron Universal Service Manual Standby Note Unit Do not dispose of is not isolated from et in the domestic By Alternating Current E Double Insulated Y mains supply refuse aia Referto e
18. Cordset and Inlet Filter Felt Table 8 Mains Power Cordset and Inlet Filter Felt Parts List Part Number Description Refer to Table 9 Mains Power IEC Cordset 507374 Inlet Filter Felt 507315 Case IEC Cover Chap 5 Page 4 FAS045 507413 Screw M3 x 10mm Pan Head Rubber Foot SERO009 Issue 2 Sep 2009 Flowtron Universal Service Manual Pump Repair Table 9 Main Power Cordset version part numbers Cable Part No Description Product Model No old Model No 507398 UK mains lead IEC 507375 USA mains lead IEC Schuko mains lead Australian mains lead IEC CAB302 Short male IEC to female IEC CAB312 China IEC straight coiled cable CAB310 Japan IEC straight coiled cable CAB311 S African Indian IEC straight coiled cable 507001 AC600 UK 507003 AC600 US 507004DE AC600 DE 507004DK AC600 DK 507004ES AC600 ES 507004FR AC600 FR 507004IT AC600 IT 507004NL AC600 NL 507009AU AC600 AU 507009CN AC600 CN 507009JP AC600 JP 507009ZA AC600 ZA 507EUR 507UNI 2 part lead 507UNI 2 part lead 507UNI 2 part lead Note Item marked CAB302 is a short male IEC to female IEC lead fitted to Chinese Japanese Indian and South African 507UNI pumps only along with the relevant country specifi
19. LCD Display Calibrate PT Selected Option Save Custom settings mJ t J lt q Normal User Buttons Press to scroll down Press to select the option Press to scroll up Figure 20 LCD Display Calibrate RFID 6 Preparation of the Calibration Test Equipment 6 1 Use a standard foot garment Fig 21 Item 10 as part of the test equipment 6 2 Find the approximate position of the middle of the foot garment tube and using a sharp knife cut the foot garment tube in two 6 3 Insert a T connector Fig 21 Item 30 into the two cut ends of the foot garment tube 6 4 Insert the remaining port on the T connector into the tube connected to the calibrated pressure meter Fig 21 Item 20 Chap 4 Issue 2 Page 6 SER0009 Sep 2009 Flowtron Universal Service Manual Garment Connector Right Hose Set Assembly Left Hose Set Assembly Testing Note The Test Equipment must be connected to the Right Hose Set Assembly The Left Hose Set Assembly is not used Figure 21 Calibration Test Equipment for the Pressure Transducer Table 4 Calibration Test Equipment for the Pressure Transducer Test Equipment Part Number 10 Foot Garment FG100 FG200 20 Calibrated Pressure Meter Accuracy lt 1 mmHg Range gt 200 mmHg 30 T Connector 7 Checking the Calibration of the Pressure Transducer The test consists of running the compressor at 8 output
20. NOT being replaced then carry out the following procedure to replace the membrane label The hoseset assemblies can remain connected to the pump 31 1 Separate the top case assembly from the front case assembly refer to SEROOOY Chapter 5 Pump Repair Page 13 Section 14 Note Do NOT remove the hoseset assemblies or control PCB assembly from the top case assembly Note Turn the top case assembly over so that the control PCB assembly is on top Note Remove the membrane cable from the membrane connector on the control PCB assembly refer to Figure 55 Note Turn the top case assembly over so that the membrane label is on top Note Remove the self adhesive membrane label Fig 56 Item 10 from the top case assembly and withdraw the membrane cable out through the slot in the top case assembly Note If you use a sharp tool to remove the membrane label be careful not to scratch or damage the surface of the top case Note The old membrane label must be discarded because of the loss of adhesive and possible damage to it during the removal process 31 2 Inspect the surface of the top case from where the membrane label was removed Carefully remove any adhesive residue 31 3 Remove the backing paper from the new self adhesive membrane label Fig 56 Item 10 31 4 Make sure the orientation of the membrane label is correct and then do the following 31 4 1 Pass the end of the membrane cable through the slot in the top case a
21. Norns Connector Rechargeable Motor and Battery if fitted Manifold Assembly Ribbon Cable Fuses Power Supply PCB Assembly ES 7 Mains Power Cordset 2 Battery Pack Connector Series 6 Compressor Assembly Figure 9 Electrical Schematic Chap 1 Issue 2 Page 8 SERO009 Sep 2009 Flowtron Universal Service Manual Troubleshooting CHAPTER 2 TROUBLESHOOTING 1 Troubleshooting Table The Flowtron Universal pump features an audible and visual alarm If a problem occurs the system will sense the fault and briefly flash a message on the LCD display on the top of the pump If the same fault continues for 10 successive inflations up to 10 minutes the audible alarm will sound the red alarm lights on the front of the pump flash and a message will appear on the LCD display until corrective action is completed The exception to this is a Pump Fault alarm which will alarm immediately Alarm Cancel After a fault has been corrected the alarm can be cancelled by either of the following two methods Press the Run button Y on the pump twice or until the green lights are lit and the pump is running e With the exception of a Pump Fault alarm correct the fault and allow the pump to run until it senses a normal inflation It will then reset itself Page 2 Table 2 contains fault symptoms their possible causes and suggests
22. PCB faulty Power Supply PCB faulty Replace Chapter 5 Page 27 Section 22 Chapter 5 Page 29 Section 25 Replace Chapter 5 Page 31 Section 26 Chapter 5 Page 31 Section 27 Pump Fault RFID Hose set electrical connections are not fitted correctly to pump Check hose set assemblies and replace if necessary Chapter 5 Page 9 Section 8 Chapter 5 Page 10 Section 9 Pump Fault Step Chap 2 Page 2 Motor and manifold assembly failed SER0009 Replace Chapter 5 Page 19 Section 18 Chapter 5 Page 25 Section 20 Issue 2 Sep 2009 Flowtron Universal Service Manual Maintenance CHAPTER 3 MAINTENANCE WARNING BEFORE DISMANTLING THE PUMP UNIT MAKE SURE THE UNIT HAS BEEN ISOLATED FROM THE MAINS POWER SUPPLY BY REMOVING THE MAINS POWER PLUG FROM THE WALL SOCKET WARNING A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS ON THE POWER SUPPLY PCB ASSEMBLY WHEN THE CASE IS OPENED EVEN WITH THE PUMP SWITCHED OFF CAUTION Static Sensitive Devices Electrostatic discharge can seriously damage the control and power supply PCB assemblies This pump should only be opened by personnel trained in ESD methods and with appropriate equipment and anti static protection 1 Service The pump should be serviced every 12 months To service the pump do the following 1 1 Carry out the maintenance checks detailed below Refer to Chapter 3 Page 3 Section 3 1 2 Replace the
23. Top Case Assembly onto the Front Case Install the case style gasket Fig 40 Item 30 fully onto the top case assembly Fig 40 Item 20 Place the top case assembly by the top of the front case Fig 40 Item 10 The inside surface of the front case and the five holes in the top case assembly must both be uppermost Connect the following between the top case assembly and the front case Refer to Figure 40 15 3 1 The ribbon cable connector onto the top of the power supply PCB assembly 15 3 2 The large diameter tube Fig 40 Item 40 onto either the motor and manifold assembly or the compressor assembly Note Make sure the tube is connected to the correct inlet tube on the motor and manifold assembly Refer to Figure 41 Install the top case assembly onto the front case Note Make sure the three spigots at the top of the front case locate in the corresponding holes on the underside of the top case assembly Install the handle and hook assembly and the rear case onto the pump Refer to Page 13 Section 13 If the hose set assemblies were removed from the pump then inspect and install new or the original hose set assemblies Refer to Page 10 Section 9 Connect the large diameter tube to the Pneumatic Inlet port Motor and Manifold Assembly Figure 41 Pneumatic Inlet on the Motor and Manifold Assembly Issue 2 6 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 16 Replacing the Mains Power Fuses
24. assembly includes the battery pack connector which is hard wired to it 26 1 Separate the top case assembly from the front case Refer to Page 15 Section 14 26 2 Remove the compressor assembly and mounting bracket from the pump Refer to Page 43 Section 36 26 3 Remove the two screws Fig 50 Item 20 and the battery pack connector from the front case 26 4 Remove the four screws Fig 50 Item 20 and the power supply PCB assembly Fig 50 Item 10 from the front case 27 Installing the Power Supply PCB Printed Circuit Board Assembly WARNING DO NOT CONNECT THE MAINS POWER CORDSET TO THE POWER SUPPLY PCB ASSEMBLY AND SWITCH ON THE MAINS POWER SUPPLY WHEN THE REAR CASE IS REMOVED FROM THE PUMP VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC ARE PRESENT ON THE POWER SUPPLY PCB ASSEMBLY AND CAN IN CERTAIN CIRCUMSTANCES BE LETHAL 27 1 Put the power supply PCB assembly Fig 50 Item 10 onto the front case and install the four screws Fig 50 Item 20 to secure it 27 2 f anew power supply PCB assembly is being installed stick a new connector sealing strip Fig 50 Item 30 to the back of the battery pack connector If the original power supply PCB assembly is being re installed make sure the connector sealing strip is still stuck to the back of the battery pack connector Refer to Figure 50 27 3 Make sure there is a second connector sealing strip stuck to the front case adjacent to the battery pack connector slot 27
25. carry out the following procedure 8 1 Using a small flat bladed screwdriver carefully lift the screw cover on the elbow retaining cover to reveal the screw underneath Refer to Figure 35 8 2 Remove the screw Fig 34 Item 20 and retain for future use Closed Screw Cover Raised Screw Cover Elbow Retaining Cover Screw Elbow Connector Insert small flat bladed screwdriver here Tube Figure 35 Lifting the Hose Set Connector Flap 8 3 Turn the elbow retaining cover approximately 20 degrees counterclockwise to the free position Refer to Figure 36 Note To turn the elbow retaining cover more easily use the tube and elbow connector to provide extra leverage Turn the tube and elbow connector counterclockwise until the elbow connector touches the screw cover and then continue turning them to turn the elbow retaining cover Refer to Figure 36 Issue 2 Chap 5 Sep 2009 SERO009 Page 9 Pump Repair Flowtron Universal Service Manual 8 4 8 5 in Secured Position Carefully lift the elbow retaining cover and elbow connector out of the pump case to reveal the cable connection between the elbow retaining cover and the pump Disconnect the hose set cable connector from the 6 way connector on the control board assembly in the pump Refer to Figure 37 and remove the hose set assembly from the pump Screw Cover in Free Position 20 degrees Elbow i Elbow Retaining Cover pa i Elbow Retaining Cover
26. full user control of the pump On some PCs new software can only be installed by someone with Administrator privileges e g your IT department Table 29 Communicator Software Parts List Test Equipment Part Number ArjoHuntleigh Communicator Software Issue 03 or higher SERS001 03 2 1 Make sure that any other programs running on the PC have been closed 2 2 Load the Communicator software CD ROM Table 30 Item 10 into the PC The Communicator software should start to auto install 2 3 After a few seconds the Initialisation dialog box should be displayed refer to Figure 64 Copying Files please stand by Figure 64 Communicator Software Installation Initialisation 2 4 If there is a Log On as Administrator or similar error message displayed immediately the auto installation process starts then contact your IT department to install the software Note Normally only IT personnel will have the correct privileges to log on as Administrator Chap 6 Issue 2 Page 2 SERO009 Sep 2009 Flowtron Universal Service Manual Updating the software 25 After the Initialisation dialog box has been displayed the Close Other Applications dialog box will be displayed refer to Figure 65 2 Communicator 2 4 Setup xi EA Welcome to the Communicator V2 4 installation program g Setup cannot install system files or update shared files if they are in use Before proceeding we recommend that you close any app
27. lOptionsl Issue 2 Sep 2009 Flowtron Universal Service Manual Updating the software Initialising the Pump Connect the pump to a PC using the Serial Communications Pack refer to Chapter 6 Updating the software Page 9 Connecting the Pump to a Laptop Desktop PC Run the Communicator software on the PC refer to Chapter 6 Updating the software Page 11 Launching the Communicator Software Connect the pump to a suitable mains power supply The pump will perform a power up self test sequence as detailed in Table 31 When the power up self test sequence is complete and before upgrading the pump software make sure that the PC can communicate correctly with the pump as follows refer to Chapter 6 Updating the software Page 12 Executing Commands on the Command Menu 8 8 1 8 2 8 3 8 4 8 5 8 5 1 8 5 2 8 5 3 8 5 4 8 5 5 Issue 2 Sep 2009 The pump must be left in Standby Scroll through the menu of Flowtron Universal Commands on the Communicator software on the PC to the section heading VERSIONS Send the command 801 Read_Software_Version to the pump Check that the command is successful 801 X XX should appear in the Receive part of the dialog box where X XX is the software version currently loaded on the pump If the command is unsuccessful then carry out the procedure detailed in Chapter 6 Updating the software Page 13 Communication Error when Exe
28. pump Refer to Page 13 Section 11 Issue 2 Chap 5 Sep 2009 SERO009 Page 43 Pump Repair Flowtron Universal Service Manual aa Ri CT i Figure 59 Removing the Compressor Assembly from the Mounting Bracket Table 26 Compressor Assembly and Mounting Bracket Parts List Part Number Description 509051 Compressor Assembly Series 6 5 5V 50 60Hz 507316 Compressor Mounting Bracket 507380 Compressor Bracket Grommet 507317 Compressor Bump Stop FAS223 Screw 3 dia x 10 Pan Head 509307 Anti vibration AV Mount Series 6 Chap 5 Issue 2 Page 44 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 38 Removing the Compressor Assembly from the Mounting Bracket 38 1 Remove the compressor assembly and mounting bracket from the pump Refer to Page 43 Section 36 38 2 Lay the compressor assembly Fig 59 Item 10 and mounting bracket Fig 59 Item 20 down with the mounting bracket on top Refer to Figure 60 38 3 Remove the two screws Fig 59 Item 50 and compressor bump stops Fig 59 Item 40 from the compressor assembly Fig 59 Item 10 and mounting bracket Fig 59 Item 20 38 4 The compressor assembly is still attached to the mounting bracket via the four anti vibration AV mounts Fig 59 Item 60 Separate the compressor assembly from the mounting bracket as follows Refer to Figure 60 38 4 1 Start at one corner of the compressor assembly
29. start If so continue the procedure at Para 10 9 below Note It is normal for the Flash Loader Fail dialog box to be displayed the first time you click Load with Flash Loader 10 8 1 2 If the Flash Loader Fail dialog box continues to be displayed every time you click Load with Flash Loader then carry out the procedure detailed in Chapter 6 Updating the software Page 13 Communication Error when Executing Commands 10 9 As the software is downloaded the progress is shown in the dialog box as follows refer to Figure 86 e The Status part of the dialog box shows Loading Bank 0 followed by Loading Bank 1 and then Loading Bank 2 and a moving Progress status bar The Tx Rx box counts up from BO SO OK to BO S128 OK followed by B1 SO OK to B1 S128 OK and then B2 SO OK to B2 S128 OK 10 10 The software download is complete when The Status part of the dialog box is empty when the Loading Bank 2 and the moving Progress status bar have been removed The count in the Tx Rx box gets to B2 128 OK 10 11 At the end of the download the pump will automatically start a self test sequence as detailed in Page 14 Table 31 10 11 1 If the self test sequence is successful check the version of the software on the pump to make sure the software has been downloaded correctly refer to Page 19 Section 10 11 2 10 11 2 If the pump fails the self test sequence the pump is faulty and must be rejected Issue 2
30. 1 Remove the complete control PCB assembly including the LCD sub assembly from the top case assembly as follows refer to Chapter 5 Page 29 Section 24 28 1 1 Remove the hoseset assemblies from the pump 28 1 2 Separate the top case assembly from the front case assembly 28 1 3 Remove the motor and manifold assembly from the control PCB assembly 28 1 4 Remove the membrane cable from the membrane connector on the control PCB assembly 28 1 5 Remove the four screws and remove the complete control PCB assembly including the LCD sub assembly from the top case assembly Removing the LCD Sub Assembly from the Control PCB Assembly 28 2 Ifthe membrane label on the top case assembly is to be replaced carry out the procedure detailed in Chapter 5 Page 36 Section 28 3 Put the complete control PCB assembly on a flat surface so that the LCD Fig 52 Item 20 sub assembly is on the underside refer to Figure 51 Note Ifthe LCD sub assembly is to be re used make sure the outer face of the LCD sub assembly is protected from damage 28 4 Remove the four screws Fig 51 Item 10 which secure the LCD sub assembly to the control PCB assembly Retain the screws for the installation procedure Note Do NOT separate the LCD sub assembly from the control PCB assembly They are still connected together via the short LCD cable Table 21 LCD Spare Part Numbers Part No Description 507126 LCD Sub Assembly Spares includes LCD
31. 2 LCD Display Calibrate PT 7 6 Using the Down and Up buttons below the LCD display Refer to Page 5 Section 4 scroll down the list of options to Calibrate PT and select it using the V button below the LCD display A new list of options will appear Refer to Figure 23 0 lt 4_ Output Pressure Decrease Zero aes Gain 35 30 lt amp Note These 2 values Run Compressor a A amp J Figure 23 LCD Display Run Compressor 7 7 To start the test scroll down the list of options to Run Compressor and select it using the a button The compressor will start running at output level 5 indicated by the 5 on the LCD display and the Output Pressure shown on the LCD display should rise and then stabilize Refer to Figure 24 Increase Zero 7 lt Output Pressure Decrease Zero i increase Gain 35 30 typical value Decrease Gain 5 Output Level 4 w V Figure 24 LCD Display Output Pressure 7 8 Compare the value of the Output Pressure on the LCD display with the value shown on the external pressure meter Fig 21 Item 20 7 8 1 If the value of the Output Pressure on the LCD display is within 5 mmHg of the value shown on the pressure meter then continue with the test Go to Para 7 9 7 8 2 Ifthe value of the Output Pressure on the LCD display is NOT within 5 mmHg of the value shown on the pressure meter then do the following Chap 4 Issue 2 Page 8 SERO009 Sep 2009 Flowtron Universal Ser
32. 23 Interchangeability of PCBs 23 1 PCB Assemblies 23 1 1 The NEW control PCB Assembly can only be used with the NEW Power Supply PCB Assembly The NEW PCB assemblies MUST NOT be mixed with the OLD assemblies 23 1 2 When the 507061 Control PCB is no longer available it can be replaced with 507131 but the Power Supply MUST also be changed to a 507137 23 2 Software Versions 23 2 1 OLD Control PCB assemblies 507061 are only compatible with software versions up to and including V3 001 NEW Control Boards 507131 are only compatible with software versions from V6 0026 Note Do not attempt to install incompatible software on OLD or NEW boards as this may cause damage to the PCB assembly Issue 2 Chap 5 Sep 2009 SER0009 Page 27 Pump Repair Flowtron Universal Service Manual Control PCB Assembly Run Switch Run Button Button Return Spring Top Case Assembly Figure 49 Installing the Control PCB Assembly Chap 5 Issue 2 Page 28 SERO009 Sep 2009 Flowtron Universal Service Manual 24 Pump Repair Removing the Control Printed Circuit Board PCB Assembly CAUTION Electrostatic discharge can seriously damage the control PCB assembly 24 1 24 2 24 3 24 4 25 25 1 25 2 25 3 25 4 25 5 25 6 25 7 Issue 2 Sep 20 Adequate earthing grounding precautions must be taken when handling it Remove the hose set assemblies Refer to Page 9 Section 8 Remove the motor and manifold assembly fr
33. 4 Pinned Rotor Assembly Spares 507125 Module and Stator Sub Assembly Spares includes 507494 507494 Silicone Tube 1 5mm ID 3 5mm OD 160mm long part of 507125 19 13 Hold the spring mount down and lift the stepper motor and mounting bracket off the spring mount and module and stator sub assembly 19 14 Lightly press the spring mount and old pinned rotor assembly together so that the four springs are retained between them and do the following 19 14 1 Lift them off the module and stator sub assembly 19 14 2 Turn them over and place them on a flat surface so that the pinned rotor assembly is on top Note lt will be easier to disassemble and re assemble the components if the pinned rotor assembly is on top Issue 2 Sep 2009 Chap 5 SERO009 Page 21 Pump Repair Flowtron Universal Service Manual 19 15 19 16 Pinned Rotor Assembly 19 17 19 18 19 19 19 20 19 21 19 22 19 23 19 24 Carefully lift the pinned rotor assembly off the spring mount refer to Figure 45 Note Make sure you do not lose any of the four springs Discard the old pinned rotor assembly and old module and stator sub assembly Spring 4 off Peg 4 off Spring Mount Figure 45 Assembling Springs to Rotor and Spring Mount Make sure the spring mount is on a flat surface with the four pegs and springs on top refer to Figure 45 Note Make sure the four springs are st
34. 5 Chap 5 Page 8 Hose Set Assembly Spares Item Screw M3 x 10mm Pan Head Issue 2 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 8 Removing the Hose Set Assembly WARNING BEFORE REPLACING THE HOSE SET ASSEMBLY MAKE SURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS POWER SUPPLY BY REMOVING THE MAINS POWER PLUG FROM THE WALL SOCKET CAUTION The elbow retaining cover on the hose set assembly is not designed to be removed from the pump more than a couple of times If the screw cover is opened and closed more than two or three times the screw cover hinge may split and then the complete hose set assembly will have to be replaced The hose set assembly Fig 34 Item 10 comprises a length of tube with a pump connector at one end and a garment connector at the other The pump connector comprises an elbow connector through which the pneumatic flow is directed and an elbow retaining cover which secures the elbow connector to the top case assembly on the pump The garment connector contains a sense coil which is used to automatically recognise the type of garment fitted to the connector e g foot garment or single chamber calf garment A cable passes through the middle of the tube and out of the side of the elbow retaining cover to connect the sense coil in the garment connector to a 6 way connector on the control board assembly in the pump To remove the hose set assembly from the top of the pump
35. 9 To connect only one garment to the pump 4 9 1 When the pump is in standby connect one garment to either hose set assembly 4 9 2 The LCD display will confirm that only one garment is connected Refer to Figure 6 Note If a garment is disconnected while the pump is running the system will alarm Lo If the single garment option is still required simply press the Run button Y to reset the system and press the Run button Y again to restart therapy Note If at any time a second garment is connected while the pump is running the pump will automatically change to two garment operation y Hone Press UR to Run Ortions Y Figure 6 LCD Display Single Garment Connected 4 10 To connect different garments on each limb 4 10 1 Simply connect the garments to either hose set assembly and the correct therapy cycle will be administered for each garment 4 10 2 Check on the display panel to confirm the garment types connected Refer to Figure 7 Figure 7 LCD Display Different Garments Connected Issue 2 Chap 1 Sep 2009 SERO009 Page 5 Introduction Flowtron Universal Service Manual 4 11 To change the language displayed on the pump 4 11 1 Press the function button adjacent to Options 4 11 2 Use the arrow buttons to highlight the Language change option Audio Alarm volume Patient hours meter xl A t amp y 4 11 3 Press the Y button to continue 4 11 4 Use the arrow buttons to scroll through the ava
36. B Con 9 Install the top case assembly onto the front case Refer to Page 16 Section 15 If the hose set assemblies were removed from the pump then inspect and install new or the original hose set assemblies Refer to Page 10 Section 9 Including a Longer Transducer Tube on the Motor and Manifold Assembly Originally the transducer tube was part of the control PCB assembly The pressure outlet is in a different position on the new modified motor and manifold assembly 507420 Therefore if a new motor and manifold assembly is installed the short transducer tube must be replaced by the new longer transducer tube 507494 Refer to Figure 47 and Table 17 which detail the longer tube To remove the motor and manifold assembly spares item 507420 carry out the procedure detailed in Chapter 5 Page 19 Section 18 with the following changes 21 3 1 Instead of paragraph Chapter 5 Page 19 Section 18 3 follow this instruction Disconnect the small diameter transducer tube from the transducer on the control PCB assembly 21 3 2 Ignore the CAUTION after Chapter 5 Page 19 Section 18 3 To install the motor and manifold assembly spares item 507420 carry out the procedure detailed in Chapter 5 Page 25 Section 20 with the following changes 21 4 1 Instead of paragraph Chapter 5 Page 25 Section 20 5 follow this instruction Connect one end of the longer transducer tube Fig 47 Item 10 onto the transducer outlet on the motor and m
37. Commands on the Command Menu 5 1 Run the Communicator software on the PC refer to Page 9 Section 3 Make sure that 5 1 1 The Flowtron Universal Commands menu is displayed 5 1 2 The screen is maximised to view the Tx Rx box refer to Figure 79 5 2 The Flowtron Universal Commands menu is comprised of two columns refer to Figure 79 5 2 1 The Code column This is the 3 digit command code sent to the pump 5 2 2 The Name column This is a description of the command for the service engineer 5 2 3 If there is a 3 digit number in the Code column then this is a command which will be sent to the pump e g 201 Read_Service_Hours 5 2 4 Ifthe Code column is blank then this is not a pump command but a comment or instruction to the service engineer e g SERVICE 5 3 To send a command to the pump 5 3 1 Click on the appropriate command on the left side of the dialog box e g 201 Read_Service_Hours 5 3 2 If instructed by the test procedure add or change any parameters on the right side of the dialog box above the Send button 5 3 3 Click Send to send the command to the pump 5 3 4 The command and its parameters are displayed in the Tx Rx box 5 3 5 Any response from the pump is displayed in the Receive part of the dialog box and also in the Tx Rx box 5 4 Ifthe command is successful SUCCESS is usually displayed in the Receive part of the dialog box e g 703 SUCCESS where 703 is the command sent to the pump 5 5 Ifa command is not recognis
38. FLOWTRON UNIVERSAL ARJOHUNTLEIGH Service Manual Flowtron Universal Service Manual Service Bulletins Incorporated Date Bulletin Content incorporated SERB008 Cleaning Instructions Sep 2009 SERB022 Manifold Repair Sep 2009 SERBO23 Software Upgrade to V3 00 Sep 2009 SERBO28 Flowtron Universal LCD Replacement Sep 2009 SERBO30 Software Upgrade to V3 01 Sep 2009 SERB034 PCB Changes Sep 2009 Issue 2 Ammendment Record Sep 2009 SERO009 Page i Flowtron Universal Service Manual Ammendment Record Issue 2 Page ii SERO009 Sep 2009 Flowtron Universal Service Manual CONTENTS CHAPTER 1 Introduction lt ei de se ca ee a ee a we A A 1 About This Manuala a e A A eR a ara Bar eb ar eal lad 1 Warnings Cautions and Notes 1 2 1 General Description ee 1 Technical Description vito seg ae ate oe ee a Ge OR ee de Ps 3 Pressure Transducer Calibration ooa a a ee 3 NA Oc en a E a A e S NE E E A 3 Battery on the Control PCB Assembly if fitted a a aa a 3 Schematics ia a oe ea lhe bee ba bas GAS hee AA 3 System Operation s ica ae ake BE a Seki a Ea Se ee eve ae dee 4 CHAPTER 2 Troubleshooting se ew a a a 1 Troubleshooting Table ee ee 1 Alarm Cancel te o a A ol ei Bee ey 1 CHAPTER 3 Maintenance stos ue Sie his de ico a Se Se is E ab e a o ds GS Oa BR 1 SONICO Es
39. Function Buttons on the Pump Membrane Label Refer to Figure 19 for the position of the following four soft function buttons on the membrane label 4 1 A three button keypad below the LCD display These are used 4 1 1 During the normal operation of the pump 4 1 2 During service and repair operations Refer to Page 5 Section 5 4 2 A single hidden Service button above the LCD display 4 2 1 This is used during service and repair operations only 4 2 2 To access the service screen on the LCD display 4 2 2 1 Press and hold the Service button 4 2 2 2 The pump beeps when the service screen appears Note To prevent accidental operation of the Service button during normal pump operation the Service button must be depressed for approximately 30 seconds before the service screen appears 5 Using the Buttons below the Service Screen on the LCD Display 5 1 A typical service screen is shown in Figure 20 5 2 To scroll though the list of options on the service screen press the normal user buttons below the LCD display as follows 5 2 1 Press the Down A icon to scroll down Issue 2 Chap 4 Sep 2009 SER0009 Page 5 Testing Flowtron Universal Service Manual 5 2 2 Press the Up amp icon to scroll up 5 3 To select the highlighted option on the LCD the relevant text is shown inverted i e white text on a black background press the Select W button below the LCD display Pump Info Set LCD Contrast
40. Graphic Module Holder Diffuser and Spacer 507397 Top Case Membrane Label a The LCD Sub Assembly is fully assembled and ready to install Issue 2 Chap 5 Sep 2009 SERO009 Page 33 Pump Repair Flowtron Universal Service Manual 28 5 28 6 LCD Cable Total Travel less than 2mm a sega i Plate Locking Plate Closed and Connector Locking Plate Open and LCD Cable Secured Body LCD Cable Released Figure 53 ZIF Zero Insertion Force Socket Hold the LCD sub assembly in position on the control PCB assembly and turn the complete control PCB assembly over so that the LCD sub assembly is on top Carefully lift the LCD sub assembly off the control PCB assembly and rotate it in the direction of the LCD cable until it is lying on a flat surface adjacent to the edge of the control PCB assembly refer to Figure 52 CAUTION Do NOT attempt to pull the LCD cable out of the connector on the control 28 7 29 PCB assembly or you could damage the cable and the connector This is a ZIF zero insertion force connector which must be unlocked before the cable can be removed To remove the LCD cable from the ZIF socket on the control PCB assembly do the following refer to Figures 52 and 53 28 7 1 Using your thumbnails or a small tool which will not damage the ZIF socket gently push the outer edges of the locking plate away from the connector body on the ZIF socket until the l
41. Install the battery socket cover onto the base of the pump Remove the Battery Socket cover Data Cable connection to PC Reset Status Latch Figure 78 Test Equipment Table 30 Test Equipment Description Part Number Serial Communications Pack with Data Cable 507104 Laptop Desktop PC with serial port running Microsoft Windows Iss ArjoHuntleigh Communicator Software Version 03 or higher SERS001 03 ue 2 Chap 6 Sep 2009 SERO009 Page 9 Updating the software Flowtron Universal Service Manual Y Serial Communicator Flowtron Universal Connection Option Help Command List Bank Loader Flowtron Universal Commands File Version SERS001 03 Code Name Parameter 1 SERVICE CY Read_Service_Hours Set_Service_Hours Parameter 2 MANUFACTURE Read_Manufacture_Data Set_Manufacturing_Date Set_GMT_Clock Send Set_PCB_Serial Number Set_Pump_Serial_ Number Set_Pump_Model_Number Receive Set_Compressor_Serial_No Set_PSU_Serial_No CUSTOMER Read_Customer_Data Read_Clock Set_Local_Time Load_Customer_Name yl Command File C Program Files Communicator V2 4 SER 001 03 Flowtron Universal Command Flowtron Universal Commands ctg Database Path C Program Files Communicator v2 4 SER 001 03 Flowtron Universal EventLog Data FlowtronUniversal mdb Flowtron Universal 24 05 2006 10 16 Z Figure 79 Communicator Software Flowtron Universal Commands with Screen Maximis
42. M is still loaded in the PC 2 15 Click Yes to start copying the additional files and then the Communicator program will be started automatically The File Location dialog box is then displayed refer to Figure 72 File Location xi Please locate Installation cfg file on CD ROM Figure 72 Communicator Software Installation File Location Issue 2 Chap 6 Sep 2009 SERO009 Page 5 Updating the software Flowtron Universal Service Manual 2 16 Click OK and the Open File dialog box is displayed refer to Figure 73 open 2hxs Look in 4 SERS001 03 D 7 ee E History G Desktop ee E My Documents T om My sie File y E Files of type CFG Installation cfa 7 My Network P 7 Open as read only di Figure 73 Communicator Software Installation Locating Communicator Files on the CD ROM 2 17 Click on the down arrow on the right side of the Look in box at the top of the dialog box and browse for SERS001 03 the Communicator software CD ROM and select it 2 18 Click on Communicator Files and click Open refer to Figure 74 open as Look in ja Communicator Files e eS EJ SER5001 03 Installation cfg History G Desktop PN i My Documents a Mas sd File name Installation cfg Files of type CFG Installation cfg Cancel My Network P T Open as read only Figure 74 Communicator Software Installation
43. O009 Page 1 Introduction Flowtron Universal Service Manual The system comprises a pump that can be used in conjunction with a pair of ArjoHuntleigh single patient use compression garments The pump provides intermittent cycles of compressed air to the two connected compression garments which are inflated alternately The pump can be used with a number of different ArjoHuntleigh single patient use compression garments including e Foot garments e g FG100 200 Single chamber calf and thigh calf garments e g DVT 10 40 60 The pump automatically adjusts the correct therapy profile for the garment type being inflated An optional battery pack is available which allows the pump to be used independently of the mains power supply The battery pack slides onto the base of the pump and recharges itself when the pump is operating from the mains power supply The pump has the following controls Refer to Figure 1 A Run Standby push button This is used to start and stop the therapy applied to the patient An illuminated graphic LCD display This indicates The type of garment s connected e The pressure delivered to each garment Alarm indications Amembrane label which contains the following four soft function buttons e A three button keypad below the LCD display These are used during the normal operation of the pump A single hidden button above the LCD display This is used during service and repair ope
44. Parameter 1 poet ________ Parameter 2 pe Send Receive Select Connection First 23 05 2006 17 07 Figure 77 Communicator Software No Command List Loaded Serial Communicator Chap 6 Issue 2 Page 8 SER0009 Sep 2009 Flowtron Universal Service Manual Updating the software 3 2 3 3 Connecting the Pump to a Laptop Desktop PC The connection between the pump and the PC laptop or desktop is via the Serial Communications Pack Fig 78 Item 10 The Serial Communications Pack is installed directly onto the bottom of the pump The Serial Communications Pack connects to a serial communications port on the PC via an external cable and to the pump via an internal serial link To install the Serial Communications Pack onto the pump refer to Figure 78 3 2 1 Remove the battery socket cover from the base of the pump 3 2 2 From the front of the pump slide the Serial Communications Pack over the guides on the base of the pump and click into place 3 2 3 Connect one end of the Data Cable to the 9 way connector on the Serial Communications Pack and the other end to the serial port on the PC To remove the Serial Communications Pack from the pump refer to Figure 78 3 3 1 Remove the Data Cable from the Serial Communications Pack and the PC 3 3 2 Depress the Reset Status Latch at the rear of the Serial Communications Pack 3 3 3 Slide the Serial Communications Pack out towards the front of the pump 3 3 4
45. Procedure 500 Vdc is applied to the insulation and the measured resistance must be greater than 2MQ Note This test can be conducted using a Portable Appliance Tester Earth Ground Leakage Current Test USA This test measures the current flowing through the earth ground wire in accordance with the ANSI AAMI ESI 1993 Standard American National Standard Safe Current Limits for Electromedical Apparatus or as specified in UL 60601 1 WARNING DANGER OF ELECTRIC SHOCK DO NOT TOUCH ANY EXPOSED PARTS WHILE CONDUCTING THIS TEST DO NOT TOUCH ANY PART OF YOUR BODY WITH THE CONTACTS OF THE PROBES Issue 2 Chap 4 Sep 2009 SERO009 Page 15 Testing Flowtron Universal Service Manual Chap 4 Issue 2 Page 16 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair CHAPTER 5 PUMP REPAIR WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET 1 General This chapter details repair procedures for the Flowtron Universal pump All repairs should be carried out by ArjoHuntleigh approved service personnel CAUTION Do NOT remove the hose set assemblies from the pump unless it is part of the particular repair procedure The elbow retaining covers on the hose set assemblies are not designed to be removed from the pump more than a couple of times If the hose set assemblies are removed unnecessarily the screw cover hinges on them may split and then the c
46. S223 e Screw 3 dia x 10 Pan Head 507305 e Run Button 507411 e Button Return Spring 507306 e Case Style Gasket Front Case Assembly 507396 Front Case Printed Flowtron Universal 507058 e Power Supply PCB Assembly Spares Item 507137 e Power Supply PCB Assembly New item 507422 e Fuse 3 15A 20mm Type T Spares Item 507410 e Connector Sealing Strip BP027 e Compressor Support Rubber FAS223 e Screw 3 dia x 10 Pan Head 509051 e Compressor Assembly Series 6 5 5V 50 60Hz 509317 e Air Inlet Filter Compressor Assembly 509320 e Air Inlet Filter Holder Chap 8 Page 2 Flowtron Universal Service Manual Description Flowtron Universal Pump refer to Table 9 SERO009 Fig tem Qty 39 30 40 20 43 30 48 20 43 20 48 10 57 30 43 20 48 10 57 30 43 10 57 10 57 20 40 40 58 50 43 40 48 30 48 50 48 60 40 30 39 20 40 10 63 10 58 40 50 10 58 40 50 10 42 10 50 30 63 50 50 40 50 20 58 10 59 10 42 20 42 30 Issue 2 Sep 2009 Flowtron Universal Service Manual Parts List Part Number Description Fig tem Qty 507316 e Compressor Mounting Bracket 58 20 1 59 20 507380 e Compressor Bracket Grommet 59 30 2 507317 e Compressor Bump Stop 59 40 2 509307 e Anti vibration AV Mount Series 6 59 60 4 FAS218 e Screw 4mm dia x 12 Pan Head 58 30 2 FAS223 e Screw 3 dia x 10 Pan Head 59 50 2 BP027 e Compressor Support Rubber 63 20 2 BP042 e Ferrite Magnet 63 30 1 507386 e Magn
47. age 36 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 30 Replacing the Membrane Label by removing the Control PCB Ass y from the Top Case Ass y If the pump is being dis assembled to replace the LCD sub assembly then carry out the following procedure to replace the membrane label 30 1 Remove the complete control PCB assembly from the top case assembly refer to Chapter 5 Page 29 Section 24 30 2 Remove the Run button and button return spring from the top case assembly 30 3 Turn the top case assembly over so that the membrane label is on top 30 4 Remove the self adhesive membrane label Fig 54 Item 10 from the top case assembly and withdraw the membrane cable out through the slot in the top case assembly Note If you use a sharp tool to remove the membrane label be careful not to scratch or damage the surface of the top case Note The old membrane label must be discarded because of the loss of adhesive and possible damage to it during the removal process 30 5 Inspect the surface of the top case from where the membrane label was removed Carefully remove any adhesive residue 30 6 Remove the backing paper from the new self adhesive membrane label Fig 54 Item 10 30 7 Make sure the orientation of the membrane label is correct and pass the end of the membrane cable through the slot in the top case assembly refer to Figure 54 Note Do not bend or crease the membrane cable 30 8 Align the membrane label with t
48. anifold assembly 21 4 2 Instead of paragraph Chapter 5 Page 25 Section 20 6 follow this instruction Connect the other end of the longer transducer tube Fig 47 Item 10 onto the top outlet on the transducer on the control PCB assembly 21 4 3 Observe the CAUTION after Chapter 5 Page 25 Section 20 6 Issue 2 Chap 5 Sep 2009 SERO009 Page 25 Pump Repair Flowtron Universal Service Manual Battery may 40 not be fitted 7 Gao Con 10 Membrane Cable Membrane Cable Figure 48 Replacing the Control PCB and Run Button Table 17 Control PCB and Run Button Parts List Part Number Description REF Control PCB Assembly Spares Item 507421 Top Case Assy with Window amp Membrane Label Spares Item FAS223 Screw 3 dia x 10 Pan Head REF Screw 2 5mm x 8 Pan Head 507305 Run Button Chap 5 Page 26 507411 Button Return Spring Issue 2 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 22 22 1 PCB Part Numbers The software for the new control board has been up issued to V6 0026 or higher to run on the new control PCB assembly This new software version includes all available languages which can be selected from the options menu Table 18 Old and New PCB Part Numbers Old Part No New Part No Description 507058 507137 Power Supply PCB Assembly 507061 507131 Control PCB Assembly
49. arth pin on the mains power plug and the earth terminal on the PSU PCB On the Flowtron Universal the earth ground wire is connected to a special earth ground test pad on the PSU PCB assembly Refer to Figure 31 A voltage is established between this earth ground test pad and the earth ground pin of the pump s mains power cordset and the resistance is checked To access this earth ground test pad there is an earth ground access point a small hole approximately 3 mm diameter underneath the case IEC cover on the rear case of the pump Refer to Figure 30 The earth ground test pad itself is approximately 90 mm below this access point on the corner of the control PCB assembly Therefore the test probe needs to have the following approximate dimensions e Minimum Length 100 mm Maximum Diameter 2 mm This long test probe Table 5 Item 5 must be inserted carefully to make sure that it makes contact with the earth ground test pad and does not miss the control PCB assembly completely Refer to Figure 30 Test Procedure WARNING BEFORE REMOVING THE CASE IEC COVER MAKE SURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS POWER SUPPLY BY REMOVING THE MAINS POWER PLUG FROM THE WALL SOCKET Note Refer to Figures 30 and 31 to carry out this procedure 10 1 Remove the case IEC cover from the rear case of the pump Chapter 5 Page 6 Section 3 10 2 Make sure the mains power cordset connector is pushed fully into the IEC connector on th
50. ase locate in the corresponding holes in the top case assembly 11 3 Install the four screws Fig 39 Item 40 to secure the rear case to the front case 11 4 Install the mains power cordset to the pump Refer to Page 7 Section 7 12 Removing the Handle and Hook Assembly 12 1 Remove the rear case from the front case Refer to Page 13 Section 10 12 2 Lay the front case Fig 39 Item 20 and top case assembly Fig 39 Item 30 down with the inside surface pointing upwards 12 3 Lift the handle and hook assembly Fig 39 Item 50 out of the front case 13 Installing the Handle and Hook Assembly 13 1 Lay the front case Fig 39 Item 20 and top case assembly Fig 39 Item 30 down with the inside surface pointing upwards 13 2 Install the handle and hook assembly Fig 39 Item 50 into the semi circular cutouts in the front case Note Make sure the orientation of the handle and hook assembly is correct The open part of the hook should point upwards Refer to Figure 39 13 3 Install the rear case onto the front case Refer to Page 13 Section 11 Issue 2 Chap 5 Sep 2009 SERO009 Page 13 Pump Repair Flowtron Universal Service Manual Spigot i iaa Control PCB onto Power Supply PCB connector 3 o Figure 40 Separating the Top Case Assembly from the Front Case Table 12 Top Case and Front Case Parts List Part Number Description 507396 F
51. assembly and push the mounting bracket in towards the centre of the compressor assembly 39 4 2 At the same time carefully push the grooved part of the remaining two AV mounts into the slots in the mounting bracket Install the two compressor bump stops Fig 59 Item 40 through the compressor bracket grommets Fig 59 Item 30 and over the spigots in the compressor assembly Install the two screws Fig 59 Item 50 to secure the compressor bump stops Check that the two wire assemblies long and short are correctly connected to the compressor assembly Refer to Figure 61 for the correct wire colours and compressor terminal connections Note The two wire assemblies are part of the compressor assembly Install the compressor assembly and mounting bracket into the pump Refer to Page 43 Section 37 Compressor Assembly Compressor Terminal Identification Short Wire Assembly Wire Colour Key White Black Long Wire Assembly Air Inlet Filter Air Inlet Filter Holder Wire Assembly Connections Short Item 20 White wires 6 and 8 Long Item 30 White Wires 2 and 4 Black wires 5 and 7 Black Wires 1 and 3 Figure 61 Compressor Assembly Chap 5 Issue 2 Page 46 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 40 Replacing the Rear Case 40 1 Remove the mains power cordset from the pump Refer to Page 7 Section 6 40 2 Remove the handle and hook assembly and the rear case from the pu
52. c mains lead CAB310 Japanese CAB311 South African Indian and CAB312 Chinese Issue 2 Chap 5 Sep 2009 SERO009 Page 5 Pump Repair Flowtron Universal Service Manual 3 Removing the Case IEC Cover WARNING BEFORE REMOVING THE CASE IEC COVER MAKE SURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS POWER SUPPLY BY REMOVING THE MAINS POWER PLUG FROM THE WALL SOCKET 3 1 Lay the pump face down on a flat surface 3 2 Remove the two screws Fig 33 Item 40 the case IEC cover Fig 33 Item 30 and the inlet filter felt Fig 33 Item 20 out of the rear case Note The case IEC cover is a tight fit in the rear case Removal of this cover is made easier if the two screws are removed completely from the cover and then the mains power cordset Fig 33 Item 10 is gently moved up and down while the cover is removed 4 Installing the Case IEC Cover 4 1 Make sure the mains power IEC cordset connector Fig 33 Item 10 is pushed fully into the IEC connector inside the pump Place the cordset cable into the groove in the rear case Note Make sure the cordset cable is not pulled tight when it is installed into the rear case There should be some slack in the cordset cable under the case IEC cover 4 2 Push the case IEC cover Fig 33 Item 30 and inlet filter felt Fig 33 Item 20 into the slot in the rear case 4 3 Install the two screws Fig 33 Item 40 to secure the case IEC cover Chap 5 Issue 2 Page 6 SERO009 Sep 2009 Flowtron Univer
53. cuit In the event of a detected fault the electronic monitoring system generates both visual and audible alarms e Power Supply Printed Circuit Board PCB In addition to generating the DC voltages for use in the pump the PCB provides interfaces to the compressor and the optional battery pack e Automatic Garment Recognition Facilities The connector on the end of each pump hose set contains a sense coil which is connected to the control PCB and is used to automatically recognise the type of garment fitted to the connector foot garment or single chamber calf garment Pressure Transducer Calibration The pump utilizes a precise and accurate pressure measurement and control system which is not expected to require re calibration until after several years of continuous use The measurement system automatically handles any adverse effects due to drift or temperature change and should not require any user intervention The pump is factory calibrated and should not normally require field re calibration However the pressure shown on the LCD display should be verified for accuracy during each routine maintenance Alarms The pump has both audible and visual alarms If a problem occurs the system will detect the fault and flash a message on the LCD display If the same fault continues for 10 successive inflation cycles which will be between 5 and 12 minutes depending on the garment types connected to the pump the audible alarm sounds the
54. cuting Commands Chap 6 SERO009 Page 15 Updating the software Software file Click here to selected for browse for Bank 0 software file Y Serial Communicator Flowtron Universal Connection Option comments NY Evens tog gt File Names BankO enable Bank 0 Select Bank1 Select Vv Bank2 Select Vv A AA Download Option Load with monitor Load with Flash Loader Status 0n801 0 AFS1 0H801 3 00 9D25 Flowtron Universal Service Manual Click here to maximise the screen to view the TxRx box DKK Bank Loader Click here to enable Auto Run Click here to start the software download with the Flash Loader TxRx Box Flowtron Universal 30 05 2006 Figure 84 Communicator Software Initialising the Bank Loader Chap 6 Page 16 Standby Attach garments Options Figure 85 Pump LCD Screen Standby SERO009 Issue 2 Sep 2009 Flowtron Universal Service Manual Updating the software 9 Checking the Version of the Pump Software 9 1 Look at the LCD screen and make sure the pump is in Standby refer to Figure 85 9 2 Onthe Communicator software click on the Command List tab refer to Figure 84 9 3 Scroll through the menu of Flowtron Universal Commands on the Communicator software to the section heading VERSIONS 9 4 Send the command 801 Read_Software_Version to the pump 9 5 Check the Receive part of the dialog box
55. cuting Commands on the Command Menu Communication Error when Executing Commands Closing the Communicator Software Initialising the Pump Checking the Version of the Pump Software Downloading the V3 01 Software Files to the Pump CHAPTER 7 CHAPTER 8 Parts List General Pump Parts List CHAPTER 9 Service Contact Details Issue 2 Sep 2009 SER0009 Bracket aa Tio a o Eee Page v Flowtron Universal Service Manual Issue 2 Page vi SER0009 Sep 2009 Flowtron Universal Service Manual Introduction CHAPTER 1 INTRODUCTION 1 About This Manual ArjoHuntleigh strongly recommend that their equipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own equipment In no event will ArjoHuntleigh be responsible for any service performed by customers or third parties This manual contains information on maintenance servicing repair troubleshooting and testing for the Flowtron Universal pump Read and understand this manual before attempting to service or repair the equipment Numbering and Cross Referencing in this Manual For all chapters in this manual e Page section and paragraph numbering re start at 1 Figure and table numbering continue from the previous chapter e Cross references which include a chapter number and or chapter title refer to text in a different chapter Cross references which do NOT include any chapter number or chap
56. d manifold assembly onto the control PCB assembly and back into the pump Refer to Page 25 Section 20 Install the hose set assemblies Refer to Page 10 Section 9 Chap 5 09 SERO009 Page 29 Pump Repair Rear view of Battery Pack Connector showing position of Connector Support Strip Item 30 Flowtron Universal Service Manual Battery Pack Connector Figure 50 Replacing the Power Supply PCB Assembly Table 19 Power Supply PCB Assembly Parts List Part Number Description REF Power Supply PCB Assembly Spares Item FAS223 Screw 3 dia x 10 Pan Head 507410 Connector Sealing Strip BP027 Chap 5 Page 30 Compressor Support Rubber SERO009 Issue 2 Sep 2009 Flowtron Universal Service Manual Pump Repair 26 Removing the Power Supply PCB Printed Circuit Board Assembly WARNING DO NOT CONNECT THE MAINS POWER CORDSET TO THE POWER SUPPLY PCB ASSEMBLY AND SWITCH ON THE MAINS POWER SUPPLY WHEN THE REAR CASE IS REMOVED FROM THE PUMP VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC ARE PRESENT ON THE POWER SUPPLY PCB ASSEMBLY AND CAN IN CERTAIN CIRCUMSTANCES BE LETHAL CAUTION Electrostatic discharge can seriously damage the power supply PCB assembly Adequate earthing grounding precautions must be taken when handling it Note The power supply PCB
57. e control PCB assembly inside the pump 10 3 Insert the long test probe Table 5 Item 5 through the earth ground access point in the rear case and down onto the earth ground test pad on the control PCB assembly Note This is made easier if the pump is horizontal and the probe is inserted vertically Chap 4 Issue 2 Page 14 SER0009 Sep 2009 Flowtron Universal Service Manual Testing 10 4 Connect the other end of the test equipment to the earth ground pin on the pump s mains power cordset 10 5 A 25A nominal current is passed for 10 seconds between the earth ground test pad on the control PCB assembly and the earth ground pin of the mains power cordset The resistance should NOT exceed 0 20 Note If the test equipment shows a very high resistance value it is probably due to the test probe not touching the earth ground test pad Remove and re insert the test probe or a broken earth ground wire Note This test can be conducted with a Portable Appliance Tester Alternatively a Multimeter Continuity Tester can be utilised but the resistance is tested using a much lower current 10 6 Remove the test probe from the earth ground access point on the pump 10 7 Install the case IEC cover to the rear case of the pump Chapter 5 Page 6 Section 4 Insulation Resistance Test This test checks the integrity of the pump s insulation This test is applied between the live and neutral wires connected together and earth ground Test
58. e Refer to the User accompanying Manual documents Y Dangerous voltage Type BF SN Serial Number Ref Model Number With respect to electric shock fire and Se mechanical hazards c us only in accordance with UL60601 1 and Puse caxesacz22 CAN CSA C22 2 No 601 1 MEDICAL EQUIPENT ENVIRONMENTAL INFORMATION Condition Temperature Range Relative Humidity Atmospheric Pressure Operating 10 C to 40 C 30 to 75 Pump amp Battery Pack 700hPa to 1060 hPa Storage and Transport 40 C to 70 C 10 to 95 500 hPa to 1060 hPa Pump non condensing Storage and Transport 10 C to 30 C 30 to 75 500 hPa to 1060 hPa Battery Pack ACCESSORIES Part Battery Pack Part Number BBP600 Size 242 x 37 x 118 mm Weight 0 8 kg Electrical Rating 13 8V DC ZZZ 4Ah NiMh Symbols X Do not dispose of in domestic refuse n a amp Recycle Chap 7 Issue 2 Page 2 SERO009 Sep 2009 Flowtron Universal Service Manual Parts List 1 General CHAPTER 8 PARTS LIST On the left side of the Description column in the main parts list the inclusion of none one or two leading bullets is used to indicate the different levels of assembly and sub assembly as detailed below Symbol Assembly Level Example Blank Level 1 or Top Assembly Front Case Printed Flowtron Universal Single Bullet Level 2 or Sub Assembly Power Supply PCB Ass
59. e the pump Refer to Page 1 Section 1 Make sure that no garments are connected to either pump hose set assembly Press the hidden Service button on the membrane panel to access the service screen on the LCD display Refer to Page 5 Section 4 Using the Down and Up buttons Refer to Page 5 Section 5 scroll down the list of options to Calibrate RFID and select it using the W button Refer to Figure 28 Pump Info Set LCD Contrast Calibrate PT Save Custom settings A t v Figure 28 LCD Display Calibrate RFID A new list of options will appear Scroll down the list of options to Save as No Garment and select it using the W button Refer to Figure 29 Back Exit Phase A 17 17 Phase B 15 15 a VJ Figure 29 LCD Display Save as No Garment Scroll down the list of options to Exit and select it using the W button to end the test If at any time the LCD display shows Pump Fault RFID then the hose set electrical connections are not fitted correctly at the pump end of the hose set assemblies Check and rectify the electrical connections or replace the hose set assemblies Issue 2 Page 12 SER0009 Sep 2009 Flowtron Universal Service Manual Testing Test Probe Make sure the mains power cordset connector is pushed securely into the pump Case IEC Cover Earth Ground Access Point Rear Case of Pump Mains Power Cordset Note Insert the end of the test probe
60. ed Fail to send command Try to disable debug Figure 80 Communicator Software Communication Error Chap 6 Issue 2 Page 10 SER0009 Sep 2009 Flowtron Universal Service Manual Updating the software 4 Launching the Communicator Software Make sure that the Communicator software is installed on the PC Refer to Chapter 4 Installing the Communicator Software and that the Serial Communications Pack Fig 78 Item 10 is connected to the base of the pump and to the PC via the Data Cable refer to Page 9 Section 3 4 1 Double click the Communicator icon on the desktop of the PC Note If there is no Communicator icon visible instead click on Start Programs Huntleigh Healthcare and Communicator as shown in Figure 81 The view may vary slightly depending on your Windows installation LE Roxio Easy CD Creator 5 gt D wnze 3 ScanSoft OmniPage Pro 12 0 gt ES Huntleigh Healthcare 44 Communicator cy Documents By Settings N Search BD Help ka Run EP Shut Down oy vw Figure 81 Launching Communicator from the Start Menu 4 2 A welcome dialog box is briefly displayed followed by the application startup dialog box refer to Figure 76 4 2 1 Using the Please select COM port drop down menu set the Serial Port to that which the Serial Communications Pack is connected to normally either COM1 or COM2 4 2 2 Click the Serial Communicator button on the Please select software fr
61. ed by the pump the Receive part of the dialog box will show NOT_AVAILABLE e g 501 NOT_AVAILABLE where 501 is the command sent to the pump Y Serial Communicator DER Connection Option Help Aura Freedom Flowtron Universal Auto Logic Phoenix C File Version SERS001 03 Nimbus Logic Parameter 1 Battery Pack Parameter 2 Send Receive Command File Database Path Select Connection First 24 05 2006 09 51 Figure 82 Communicator Software Selection of Flowtron Universal Command List Chap 6 Issue 2 Page 12 SERO009 Sep 2009 Flowtron Universal Service Manual Updating the software 6 Communication Error when Executing Commands 6 1 If there is no immediate response from the pump when you send a command then it means that there could have been a communication error between the PC and the pump 6 1 1 The Send button is greyed out 6 1 2 There will be no response in the Receive box 6 1 3 If you look in the Tx Rx box you will see 10 attempts to send the command to the pump After 10 failed attempts a Communication Error dialog box is displayed refer to Figure 80 6 1 4 Check that the pump is powered up and in Standby 6 1 5 Check the connections between the PC Serial Communications Pack and the pump 6 1 6 Select the other COM port on the PC as follows 6 1 6 1 Click Connection then click Exit on the drop down menu 6 1 6 2 The application startup dialog box is then displayed refer to Figure 76 6 1 6 3 Select another
62. embly Double Bullet Level 3 or Sub Sub Assembly Fuse 3 15A 20mm Type T 2 Pump Parts List Part Number Description Fig tem Qty Pump General Assembly 1 507001 Flowtron Universal Pump UK KSA previously AC600 UK 507003 Flowtron Universal Pump USA Canada previously AC600 US 507004DE Flowtron Universal Pump Germany previously AC600 DE 507004DK Flowtron Universal Pump Denmark Sweden previously AC600 DK 507004ES Flowtron Universal Pump Spain previously AC600 ES 507004FR Flowtron Universal Pump France previously AC600 FR 507004IT Flowtron Universal Pump Italy previously AC600 IT 507004NL Flowtron Universal Pump Dutch Belgium previously AC600 NL 507009AU Flowtron Universal Pump Australia NZ previously AC600 AU 507009CN Flowtron Universal Pump China previously AC600 CN 507009JP Flowtron Universal Pump Japan previously AC600 JP 507009ZA Flowtron Universal Pump South Africa India previously AC600 ZA 507EUR Flowtron Universal Pump refer to Table 9 Issue 2 Chap 8 Sep 2009 SERO009 Page 1 Parts List Part Number 507UNI Top Case Assembly 507421 Top Case Assy with Window amp Membrane Label Spares Item 507061 e Control PCB Assembly Spares Item 507131 e Control PCB Assembly New Item 507420 e Motor and Manifold Assembly Spares Item 151457 e Rechargeable Battery Spares Item BP196 e Cable Tie 631073 e Tube 100mm long Compressor Motor amp Manifold Assy FA
63. et Mounting Pad 63 40 1 Rear Case Assembly 507302 Rear Case 39 10 1 62 10 507419 e Handle and Hook Assembly Spares Item 39 50 1 e Mains Power IEC Cordset 33 10 1 507374 e Inlet Filter Felt 33 20 1 507315 e Case IEC Cover 33 30 1 BP027 e Compressor Support Rubber 62 20 2 507413 e Rubber Foot 33 50 10 FAS223 Screw 3 dia x 10 Pan Head 39 40 4 FAS045 Screw M3 x 10mm Pan Head 33 40 2 Hose Set Assemblies 507500 Hose Set Assembly Standard 34 10 2 507501 Hose Set Assembly 13 ft long A R 507502 Hose Set Assembly Installation Kit Consists of 2 x 507501 A R FAS045 e Screw M3 x 10mm Pan Head 34 20 2 Pump Label Sets LAB339 Pump Product Label 32 20 1 Issue 2 Chap 8 Sep 2009 SERO009 Page 3 Parts List Flowtron Universal Service Manual Chap 8 Issue 2 Page 4 SERO009 Sep 2009 Flowtron Universal Service Manual CHAPTER 9 Service Contact Details SERVICE CONTACT DETAILS AUSTRALIA ArjoHuntleigh Pty Ltd PO Box 330 Hamilton Hill Western Australia 6963 T 61 8 9 337 4111 F 61 8 9 337 9077 AUSTRIA ArjoHuntleigh GmbH Dorrstrasse 85 AT 6020 INNSBRUCK T 43 512 20 4160 0 F 43 512 20 4160 75 BELGIUM ArjoHuntleigh NV SA Evenbroekveld 16 B 9420 ERPE MERE T 32 0 53 60 73 80 F 32 0 53 60 73 81 DENMARK Huntleigh Healthcare A S Vassingergdvej 52 DK 3540 LYNGE T 45 4 913 8486 F 45 4 913 8487 FINLAND ArjoHuntleigh OY Vanha Porvoontie 229 FI 01380 VANTAA T 35 8 9 4730 4320 F 35 8 9
64. f test routine Refer to Figure 11 PLEASE WAIT running diagnostic Figure 11 LCD Display Running Diagnostic 1 4 At the end of the self test routine the pump will beep and go into Standby mode where it will remain until required for use Refer to Figure 12 Standby Attach Garments Figure 12 LCD Display Standby 2 Garment Recognition Test 2 1 Initialise the pump Refer to Page 1 Section 1 2 2 Connect a garment to each pump hose set assembly Make sure the connectors click into place 2 3 Make sure the connection and garment types are confirmed correctly on the display as follows Note There is a separate graphic for each hose set assembly and each of these can be one of a number of graphics to indicate the garment type Refer to Table 3 2 3 1 Figure 13 shows two single chamber calf or thigh calf garments connected to the pump Press Q to Run Ortions T Figure 13 LCD Display Two Single Chamber Calf or Thigh Calf Garments Connected Issue 2 Chap 4 Sep 2009 SER0009 Page 1 Testing Flowtron Universal Service Manual 2 3 2 Figure 14 shows a foot garment and a single chamber calf or thigh calf garment I connected to the pump Press op to Run Figure 14 Foot and Single Chamber Calf or Thigh Calf Garments Connected 2 3 3 Figure 15 shows a foot garment connected to one hose set assembly and no garment connected to the other Horne a Press op to Run Ortions T
65. he recess in the top case and lower the membrane label onto the top case Press down firmly on the membrane label to secure it to the top case Note Make sure the alignment is correct before you stick the membrane label to the top case If you have to remove the membrane label to re align it then the membrane label will have to be discarded because of the loss of adhesive and possible damage to it 30 9 Turn the top case assembly over so that the membrane label is on the underside 30 10 Put the Run button into the cutout in the top case and put the button return spring over the shaft of the Run button 30 11 Install the complete control PCB assembly into the top case assembly refer to Chapter 5 Page 29 Section 25 Issue 2 Chap 5 Sep 2009 SERO009 Page 37 Pump Repair Flowtron Universal Service Manual Cutout in Control Membrane Cable May not Control PCB PCB Assembly L be fitted Assembly Q Membrane Connector Top Case Assembly Figure 55 Connecting the Membrane Cable to the Membrane Connector on the Control PCB Assembly Membrane Cable Rear Egde of Top Case Assembly Slot for Membrane Cable Top Case Assembly Figure 56 Replacing the Membrane Label without removing the Control PCB Assembly from the Top Case Assembly Chap 5 Issue 2 Page 38 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 31 Replacing the Membrane Label without removing the Control PCB Assembly If the LCD sub assembly is
66. hen 8 12 1 1 Scroll down the list of options to Exit and select it using the W button The compressor will stop 8 12 1 2 Goto Para 8 13 and continue the test 8 12 2 If the value of the Output Pressure on the LCD display is NOT within 2 mmHg of the value shown on the pressure meter then adjust the gain calibration factor of the pump as follows 8 12 2 1 To increase the Output Pressure value scroll through the list of options to Increase Gain Each time the W button is pushed the Output Pressure value will increase 8 12 2 2 To decrease the Output Pressure value scroll through the list of options to Decrease Gain Each time the W button is pushed the Output Pressure value will decrease 8 12 2 3 When the value of the Output Pressure on the LCD display is within 1 mmHg of the value shown on the pressure meter scroll down the list of options to Back and select it using the W button 8 12 2 4 Scroll down the list of options to Real pressure display and select it using the W button 8 12 2 5 Scroll down the list of options to Exit and select it using the W button The compressor will stop 8 12 2 6 Goto Para 8 13 and continue the test 8 13 Run the test to check the calibration of the pressure transducer Refer to Page 7 Section 7 Issue 2 Chap 4 Sep 2009 SERO009 Page 11 Testing Flowtron Universal Service Manual 9 1 9 2 9 3 9 4 9 5 9 6 9 7 Chap 4 Recalibrating the Pump Hose Set Assemblies Initialis
67. ilable languages Enalish Peutach eder lands Italiano A e Y 4 11 5 Highlight the desired language and press the Y button to select 4 11 6 Press the W button again to confirm the selection ee Exit SA Y 4 11 7 Use the arrow buttons to highlight Exit in the new language as amg Fa Tea Langue Sortie SA Y 4 11 8 Press the oY button to continue Wolume alarme audio Compteur Patient Lanaye e Y 4 11 9 The screen will now display the main menu in the new language Chap 1 Issue 2 Page 6 SERO009 Sep 2009 Flowtron Universal Service Manual Introduction Membrane Label LCD Display qal Alarm LED SO OE Alarm LED 2 gt Control 4c R LED none RO Electronios POO FuniStandby Buzzer Pressure Garment Transducer Sleeve Exhaust to Atmosphere Quick Connect Recognition Hose Set Sense Coil Garment Sleeve Quick Connect Compressor Recognition gt Motor Hose Set Sense Coil Optical Position Sensor Rotary Valve Electrical Connections Pneumatic Connections Mechanical Link Figure 8 Pneumatic Control Schematic Issue 2 Chap 1 Sep 2009 SERO009 Page 7 Introduction Flowtron Universal Service Manual Membrane Label Control PCB Assembly Connector Hose Set Assemblies l Recognition LCD Display Sense Coils Membrane Label LCD Display fer
68. iles are selected and click OK 10 1 4 4 Browse in the Save Attachment dialog box for a suitable location to save the two files and click Save 10 2 Initialise the pump refer to Page 15 Section 8 10 3 Look at the LCD screen and make sure the pump is in Standby refer to Figure 85 10 4 On the Communicator software click on the Bank Loader tab refer to Figure 84 10 5 Click the middle button at the top right of the dialog box to maximise the screen to view the Tx Rx box at the bottom of the dialog box Note At this stage ignore any text in the Tx Rx box 10 6 On the left side of the dialog box under File Names select the three pump software files as follows refer to Figure 84 10 6 1 Click in the boxes on the right of Bank 0 Bank 1 and Bank 2 to enable them The text will become visible and there will be a tick Y in each box Issue 2 Chap 6 Sep 2009 SERO009 Page 17 Updating the software Flowtron Universal Service Manual 10 6 2 Make sure that Bank 3 to Bank 7 are not enabled The text will be greyed out and the boxes on the right of Bank 3 to Bank 7 will be blank 10 6 3 Select the FlowtronUniversal_V3 01 H00 software file for Bank 0 as follows 10 6 3 1 Click the Select button on Bank 0 The Browsing for Files dialog box will open 10 6 3 2 Search for the three pump software files on the CD ROM or the PC refer to Para 10 1 10 6 3 3 Select FlowtronUniversal_V3 01 H00 and click Open 10 6 3 4 The Bank L
69. ill located on the pegs Turn the new pinned rotor assembly Table 15 Item 10 so that the four locating holes are on the underside refer to Figure 45 Lower the pinned rotor assembly down onto the spring mount making sure that the four pegs and springs on the spring mount are located in the four locating holes in the pinned rotor assembly Lightly press the spring mount and new pinned rotor assembly together so that the four springs are retained between them and do the following refer to Figure 44 19 20 1 Turn them over so that the spring mount is on top 19 20 2 Place the spring mount and pinned rotor assembly onto the stator on the module and stator sub assembly Table 15 Item 20 Note Make sure the hole in the centre of the pinned rotor assembly is located over the bush in the centre of the stator 19 20 3 With the orientation of the module and stator sub assembly as shown in Figure 46 turn the spring mount and pinned rotor assembly round so that the slot in the drive dog is in the approximate East West position shown Note This alignment is necessary so that the stepper motor drive shaft can be assembled onto the pinned rotor assembly refer to Para 19 24 below Carefully release your pressure on the spring mount Note Make sure that the four springs do not push the spring mount up and off of the pinned rotor assembly Put the stepper motor and mounting bracket on a flat surface with the drive shaft on to
70. inlet filter felt on the rear case Refer to Chapter 5 Page 7 Section 5 1 3 Carry out the following function tests on the pump 1 3 1 Garment recognition test in accordance with Chapter 4 Page 1 Section 2 1 3 2 Checking the calibration of the pressure transducer in accordance with Chapter 4 Page 7 Section 7 Note The pump is designed to remain accurate throughout its working life This test checks the accuracy of the pressure shown on the LCD display The pump is factory calibrated and should not normally require field re calibration 1 4 Carry out an electrical safety tests on the pump in accordance with Chapter 4 Page 14 Section 10 Issue 2 Chap 3 Sep 2009 SERO009 Page 1 Maintenance Flowtron Universal Service Manual 2 1 2 2 Chap 3 Page 2 Cleaning Instructions If the pump is to be cleaned by spraying cleaning solutions directly onto it the following Refer to Figure 10 instructions must be observed Lay the pump down on its rear case so that the cleaning solution will not collect on the top cover assembly adjacent to the two hose set assemblies Use a soft cloth to remove any unwanted cleaning solution from the top cover assembly Hose Set Assemblies Front Case Top Case Assembly Note Do not let any cleaning solution collect here Rear Case Figure 10 Top Cover Assembly and Hose Set Assemblies Issue 2 SERO009 Sep 2009 Flowtron Universal Service Manual Maintenance 3 Maintenance Checks
71. lace the small diameter transducer tube between the motor and manifold assembly and the control PCB assembly with a new longer tube since the pressure outlet is in a different position on the new manifold assembly Spare Parts List The following new spare part assemblies are required Note These spare parts are fully assembled and ready to install Part No Description 507124 Pinned Rotor Assembly Spares 507125 Module and Stator Sub Assembly Spares includes Silicone Tube 1 5 ID 3 5 OD 160 mm long 19 10 Remove the motor and manifold assembly from the pump Chapter 5 Page 19 Section 18 19 11 Remove the old transducer tube from the motor and manifold assembly and the control PCB assembly and discard it 19 12 Put the motor and manifold assembly on a flat surface and using a Torx T8 screwdriver remove the three screws which secure the stepper motor mounting bracket to the old module and stator sub assembly refer to Figure 44 Chap 5 Issue 2 Page 20 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair Torx T8 Screw 3 off Stepper Motor Stepper Motor Mounting Bracket Spring Mount Spring 4 off Support Pillars 3 off Bush Te Ata SEL Stator f z wp L ANE OOOO OUOU el Figure 44 Replacing the Motor and Manifold Sub Assemblies Table 15 Motor and Manifold Sub Assemblies Part Number Description 50712
72. levels 5 10 15 20 25 30 31 and 32 Levels 30 31 and 32 are used to check that the compressor is at its maximum output and therefore the output pressure may not vary significantly between levels 30 and 32 At each level the compressor output stabilizes and then the value of the output pressure shown on the LCD display is compared with the value shown on the external pressure meter If the two values are within 5 mmHg of each other then the pressure transducer is calibrated and the pump is able to provide accurate therapy If not the pressure transducer must be re calibrated 7 1 Prepare the calibration test equipment Refer to Page 6 Section 6 Issue 2 Sep 2009 SER0009 Chap 4 Page 7 Testing Flowtron Universal Service Manual 7 2 Make sure that no calibration test equipment or other garments are connected to either pump hose set assembly 7 3 Initialise the pump Refer to Page 1 Section 1 7 4 Connect the right hose set assembly on the pump to the garment connector on the test equipment Refer to Figure 21 Note The calibration test equipment must only be connected to the right hose set assembly Do not connect anything to the left hose set assembly 7 5 Press the hidden Service button on the membrane panel Refer to Page 5 Section 4 to access the service screen on the LCD display Refer to Figure 22 Pump Info Set LCD Contrast Calibrate RFID Save Custom settings A w V Figure 2
73. lications you may be running Exit Setup Figure 65 Communicator Software Installation Close Other Applications 2 6 Make sure that any other applications running on the PC have been closed and then click OK 2 7 The Start Installation dialog box will be displayed refer to Figure 66 a Communicator Y2 4 Setup xj Begin the installation by clicking the button below Click this button to install Communicator 2 4 software to the specified destination directory C Program Files Communicator 2 41 Change Directory Exit Setup Figure 66 Communicator Software Installation Start Installation Directory 2 8 Click the 2 9 The Create Short Cuts dialog box will be displayed refer to Figure 67 f3 Create Short cuts 10l xj Select the Options you want button to start the installation process using the suggested default directory V Puta Shortcut on the Desktop Put a Shortcut in the Startup J Folder so it will start automatically every time you bootup Figure 67 Communicator Software Installation Create Short Cuts Issue 2 Chap 6 Sep 2009 SERO009 Page 3 Updating the software Flowtron Universal Service Manual 2 10 The default option is already ticked which will put a shortcut on the PC desktop Click OK and the Choose Program Group dialog box will be displayed refer to Figure 68 2 Communicator 2 4 Choose Program Group Setup will add items to the grou
74. lue will increase 8 9 2 To decrease the Output Pressure value scroll through the list of options to Decrease Zero Each time the W button is pushed the Output Pressure value will decrease 8 9 3 As these adjustments are being made to the Output Pressure value the Zero value on the Calibration Data will change Refer to Figure 26 Chap 4 Issue 2 Page 10 SERO009 Sep 2009 Flowtron Universal Service Manual Testing 8 10 To start the test scroll down the list of options to Run Compressor and select it using the d button The compressor will start running at output level 5 indicated by the 5 on the LCD display and the Output Pressure shown on the LCD display should rise and then stabilize Refer to Figure 27 Increase Zero 7 lt _ _ _ Output Pressure Decrease Zero typical value Increase Gain 35 30 typ Decrease Gai 5 lt Output Level A amp Y Figure 27 LCD Display Output Pressure 8 11 With the Run Compressor option still highlighted press the W button 5 more times The compressor output will increase to level 30 indicated by the 30 on the LCD display and the Output Pressure shown on the LCD display should rise and then stabilize 8 12 Compare the value of the Output Pressure on the LCD display with the value shown on the external pressure meter 8 12 1 Ifthe value of the Output Pressure on the LCD display is within 2 mmHg of the value shown on the pressure meter t
75. ly 1 30 509320 Air Inlet Filter Holder 1 Issue 2 Chap 5 Sep 2009 SERO009 Page 17 Pump Repair Flowtron Universal Service Manual Side View Stepper Motor Connector Transducer Outlet Rechargeable Battery if fitted Con 9 Stepper Motor LEDs Elbow Connector on Hose Set Assembly Transducer Figure 43 Replacing the Motor and Manifold Assembly Table 14 Motor and Manifold Assembly Parts List Part Number Description 507420 Motor and Manifold Assembly Spares Item REF Control PCB Assembly Spares Item 507421 Top Case Assy with Window amp Membrane Label Spares Item FAS223 Screw 3 dia x 10 Pan Head FAS223 Screw 3 dia x 10 Pan Head 507494 Transducer Tube Chap 5 Issue 2 Page 18 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 18 Removing the Motor and Manifold Assembly CAUTION Electrostatic discharge can seriously damage the control PCB assembly Note 18 1 18 2 18 3 Adequate earthing grounding precautions must be taken when handling it It is not necessary to remove the hose set assemblies from the pump in order to replace the motor and manifold assembly Separate the top case assembly from the front case Refer to Page 15 Section 14 Disconnect the stepper motor connector from the control PCB assembly Fig 43 PCB Con 9 Disconnect the small diameter transducer tube from the transducer on the m
76. mbly 29 Removing the Power Supply PCB Printed Circuit Board Assembly 31 Installing the Power Supply PCB Printed Circuit Board Assembly 31 Removing the LCD Sub Assembly o ce ee 33 Removing the Control PCB Assembly from the Top Case Assembly 33 Removing the LCD Sub Assembly from the Control PCB Assembly 33 Installing the LCD Sub Assembly o e o 34 Installing the LCD Sub Assembly onto the Control PCB Assembly 34 Installing the Control PCB Assembly into the Top Case Assembly 35 Issue 2 Page iv SERO009 Sep 2009 Flowtron Universal Service Manual Replacing the Membrane Label by removing the Control PCB Ass y from the Top Case Ass y 37 Replacing the Membrane Label without removing the Control PCB Assembly Removing the Run Button Installing the Run Button Replacing the Top Case Assembly Replacing the Battery on the Control PCB Assembly if fitted Removing the Compressor Assembly and Mounting Installing the Compressor Assembly and Mounting Bracket Removing the Compressor Assembly from the Mounting Bracket Installing the Compressor Assembly onto the Mounting Bracket Replacing the Rear Case Replacing the Front Case CHAPTER 6 Updating the software Introduction Installing the Communicator Software Connecting the Pump to a Laptop Desktop PC Launching the Communicator Software Exe
77. mp Refer to Page 13 Section 12 40 3 Lay the new rear case Fig 62 Item 10 down with the inside surface pointing upwards 40 4 Stick the two compressor support rubbers Fig 62 Item 20 onto the front case 40 5 Install the handle and hook assembly and the rear case onto the pump Refer to Page 13 Section 13 40 6 Install the mains power cordset onto the pump Refer to Page 7 Section 7 40 7 Stick the serial number and product labels onto the rear case Refer to Page 3 Section 2 Figure 62 Replacing the Rear Case Table 27 Rear Case Parts List Part Number Description 507302 Rear Case BP027 Compressor Support Rubber Issue 2 Chap 5 Sep 2009 SERO009 Page 47 Pump Repair Flowtron Universal Service Manual Battery Pack Connector Slot Figure 63 Replacing the Front Case Table 28 Front Case Parts List Part Number Description 507396 Front Case Printed Flowtron Universal BP027 Compressor Support Rubber BP042 Ferrite Magnet 507386 Magnet Mounting Pad 507410 Connector Sealing Strip Chap 5 Issue 2 Page 48 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 41 Replacing the Front Case 41 1 Separate the top case assembly from
78. mp Refer to Page 27 Section 22 Remove the button return spring Fig 48 Item 60 and the Run button Fig 48 Item 50 from the top case assembly Fig 48 Item 20 Installing the Run Button Install the Run button Fig 48 Item 50 into the cutout in the top case assembly Fig 48 Item 20 Install the button return spring Fig 48 Item 60 onto the Run button Install the control PCB assembly into the top case assembly and then re assemble the pump Refer to Page 29 Section 25 Replacing the Top Case Assembly The top case assembly Fig 48 Item 20 comprises the top case moulding and the membrane label Remove the control PCB assembly from the top case assembly Refer to Page 27 Section 22 Remove the Run button Refer to Page 40 Section 32 Install the Run button into the new top case assembly Refer to Page 40 Section 33 Install the control PCB assembly into the top case assembly and then re assemble the pump Refer to Page 29 Section 25 Issue 2 0 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 35 Note Note 35 1 35 2 35 3 35 4 35 5 35 6 Replacing the Battery on the Control PCB Assembly if fitted The battery on the control PCB assembly provides power for the real time clock If the battery is disconnected for more than 20 seconds the real time clock will lose its time and date settings If the time and date settings are lost they have to be reloaded from a PC based se
79. o States a ii agen Mee A A AA a A 1 Cleaning Instructions ee 2 Maintenance Checks ee 3 CHAPTER 4 WOSUNG oia a ds a A LA A AAA 1 Initialising the PUMP a h Be a a ar a a a A E 1 Garment Recognition Tost a xa cga Soe dans ae eG a Re Ea ee aed 1 Checking the Basic Pump Operation oaoa aaa ee 3 Location of the Soft Function Buttons on the Pump Membrane Label 5 Using the Buttons below the Service Screen on the LCD Display 5 Preparation of the Calibration Test Equipment oaao eaa 050002 6 Checking the Calibration of the Pressure Transducer oa aoao a a 000008 7 Re calibrating the Pressure TransQucer 000 eee eee ee eee 10 Recalibrating the Pump Hose Set Assemblies 2 a a a a 000 ee eee eee 12 Electrical Safety Testing o a aa ee 14 Electrical Safety CheCks s T oss bbe eet ee ek a ea ea ea hw a a 14 Earth Ground Continuity Test 2 o 14 Issue 2 Sep 2009 SERO009 Page iii Flowtron Universal Service Manual Insulation Resistance Test 2 e 15 Dielectric Strength Test Flash Test 2 2 aa ee 15 Leakage Earth Ground Current Test USA 2 020000002 oe 15 CHAPTER 5 P mp R pair soe ane EA a a A ee 1 Generaler ca eta te Ante A go land ete seen tel a ch Bee 1 Pump Labels 25 053 fae a SA ev dee LE ee Sea Bo E hee 3 Removing the Case IEC Cover 2 2 6 Installing the Case IEC Cover 2 2 ee 6
80. oader tab will reappear with FlowtronUniversal_V3 01 H00 in the Bank 0 File Name box 10 6 4 Repeat the procedure in Para 10 6 3 to select the FlowtronUniversal_V3 01 H01 software file for Bank 1 10 6 5 Repeat the procedure in Para 10 6 3 to select the FlowtronUniversal_V3 01 H02 software file for Bank 2 10 7 On the dialog box under Download Option click the box to the right of Auto Run to enable it There will be a tick f in the box Y Serial Communicator Flowtron Universal Connection Option Help File Names BankO Fon Select Bank1 FlowtronUniversal V3 00 H01 Select Bank2 Select Sera Download Option Auto Run Vv L ith moni Cancel Loader o a i vin Fian Londe Mliol Status Loading Bank 0 Progress MENA Flowtron Universal 30 05 2006 11 53 Figure 86 Communicator Software Downloading the Software Chap 6 Issue 2 Page 18 SERO009 Sep 2009 Flowtron Universal Service Manual Updating the software Flash Loader Fail Fail to communicate with the Flash Loader Check the pump is in standby Figure 87 Communicator Software Flash Loader Fail 10 8 On the dialog box under Download Option click Load with Flash Loader to start the software download of the V3 01 Flowtron Universal software to the pump 10 8 1 Ifthe Flash Loader Fail dialog box refer to Figure 87 is displayed when you click Load with Flash Loader click OK 10 8 1 1 The software download should
81. ocking plate is in the fully open position fully extended The LCD cable is now released Note The total travel of the locking plate is less than 2mm 28 7 2 Remove the LCD cable from the ZIF connector and remove the LCD sub assembly Installing the LCD Sub Assembly Installing the LCD Sub Assembly onto the Control PCB Assembly 29 1 Position the new LCD sub assembly Fig 52 Item 20 by the side of the control PCB assembly as follows 29 1 1 Put both assemblies on a flat surface refer to Figure 52 29 1 2 The ZIF socket should be on the top side of the control PCB assembly 29 1 3 The four locating lugs should be on the top side of the LCD sub assembly Note Make sure the outer face on the underside of the LCD sub assembly is protected from damage 29 1 4 Ensure the orientation of both assemblies is as shown in Figure 52 The LCD cable should be adjacent and pointing towards the ZIF socket Chap 5 Issue 2 Page 34 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 29 2 29 3 29 4 29 5 29 1 5 Raise the LCD sub assembly by 15 20mm so that it is at a similar height to the control PCB assembly and support it in this position This will make it easier to connect the short LCD cable to the ZIF socket on the control PCB assembly To connect the LCD cable on the new LCD sub assembly to the ZIF socket on the control PCB assembly do the following refer to Figures 52 and 53 29 2 1 Make sure
82. om list This will start the Communicator software running using the Serial Communications Pack to connect the pump to the PC Note Do NOT click the IrDA Communicator MCM Calibrator or Battery Pack Logger buttons as these functions are not used 4 3 The No command list loaded dialog box will be displayed refer to Figure 77 4 3 1 Make sure the title at the top of the dialog box is Serial Communicator and the top right of the dialog box shows the Serial Communicator icon J B If these are incorrect then the Communicator software is not using the Serial Communications Pack to connect the pump to the PC 4 3 2 Make sure that the top right of the dialog box shows File Version SERS001 XX where XX is the version number and must be 03 or higher If this is incorrect then the Communicator software has not been installed correctly 4 4 Click Connection then click Flowtron Universal refer to Figure 82 45 The menu of Flowtron Universal Commands is then displayed refer to Figure 79 4 6 Before starting any test procedure using the Communicator software always click the middle button at the top right of the dialog box to maximise the screen refer to Figure 79 Note The Tx Rx box will display all commands sent to the pump all parameters sent with each command and all responses received from the pump Issue 2 Chap 6 Sep 2009 SERO009 Page 11 Updating the software Flowtron Universal Service Manual 5 Executing
83. om the control PCB assembly Refer to Page 19 Section 18 Carefully pull the membrane cable out of the membrane connector on the control PCB assembly Fig 48 PCB Con 10 Remove the four screws Fig 48 Item 30 and lift the control PCB assembly Fig 48 Item 10 out of the top case assembly Fig 48 Item 20 Note Do not remove the four smaller screws Fig 48 Item 40 which secure the LCD display to the control PCB assembly Installing the Control Printed Circuit Board PCB Assembly Put the top case assembly Fig 48 Item 20 on a horizontal surface with the inside surface pointing upwards and position the control PCB assembly Fig 48 Item 10 just above it Carefully push the membrane cable into the membrane connector on the control PCB assembly Fig 48 PCB Con 10 Make sure the Run button Fig 48 Item 50 is installed into the cutout in the top case assembly and the button return spring Fig 48 Item 60 is installed on the Run button Lower the control PCB assembly onto the four pillars in the top case assembly Note Make sure the membrane cable is positioned in the cutout in the control PCB assembly Note As the control PCB assembly is lowered onto the top case assembly make sure the Run switch on the control PCB assembly stays in the centre of the button return spring on the top case assembly Refer to Figure 49 Install the four screws Fig 48 Item 30 to secure the control PCB assembly Install the motor an
84. omplete hose set assemblies will have to be replaced Note If the rear case of the pump is removed for any reason the mains power cordset will normally be removed first Refer to Page 7 Section 6 However the pump has a fail safe design which means that if the rear case is removed with the mains power cordset still connected to the pump the mains power cordset connector will be automatically removed with the rear case and so the mains power will be immediately disconnected from the pump 1 1 Page 2 Table 6 defines the testing which must be carried out following each repair 1 1 1 To check the Basic Pump Operation refer to Chapter 4 Page 3 Section 3 1 1 2 To carry out the Garment Recognition Test refer to Chapter 4 Page 1 Section 2 1 1 3 To Recalibrate the Hose Sets refer to Chapter 4 Page 12 Section 9 1 1 4 To Reset the Service Log refer to Chapter 3 Page 3 Section 3 2 1 1 5 Tocarry out the Electrical Safety Tests refer to Chapter 4 Page 14 Section 10 Issue 2 Chap 5 Sep 2009 SERO009 Page 1 Pump Repair Components Assemblies Flowtron Universal Service Manual Table 6 Repair to Testing Requirements Basic Pump Operation Garment Recognition Test Recalibrate Hose Sets Reset Service Log Electrical Safety Tests Mains Power Cordset Yes No No No Yes Case Inlet Filter Felt Yes No No No No Hose Set Assembly Yes No No Rear Case Yes
85. on any pump within the serial number range specified but only at the following times At the next scheduled service After any repair carried out on the pump e Ifthe pump is exhibiting excessive kinked tube alarms Serial Number range Any pump up to and including serial number 507032000 a All pumps from serial number 507032001 onwards already have version 3 01 or later software installed at the factory Before upgrading the pump to the new V3 01 software check the current software version by initialising the pump refer to Chapter 6 Page 15 Section 8 If the software is already at V3 01 or higher do not attempt the upgrade To perform the check and the upgrade a Personal Computer is required equipped with a serial port and running Microsoft Windows This Laptop or PC must have the ArjoHuntleigh Serial Communications Pack software installed in order to communicate with the pump To install the Serial Communications Pack refer to Chapter 6 Page 9 Section 3 Issue 2 Chap 6 Sep 2009 SER0009 Page 1 Updating the software Flowtron Universal Service Manual 2 Installing the Communicator Software The Communicator software Table 29 Item 10 can any be instalon on a Laptop PC or a Desktop PC which is fitted with a serial port and is running Microsoft Windows The Communicator software is installed and run on the PC which sets up a Windows Graphical User Interface GUI on the computer The different menus provide
86. on the Power Supply PCB Assembly WARNING MAKE SURE THE REPLACEMENT FUSES ARE THE CORRECT TYPE AND RATING OR THE ELECTRICAL SAFETY OF THE PUMP MAY BE IMPAIRED Note Always replace both fuses even if only one has blown 16 1 Remove the rear case from the pump Refer to Page 13 Section 10 16 2 Un clip the plastic cover on one of the fuseholders and remove the fuse Fig 42 Item 10 16 3 Install the new fuse Fig 42 Item 10 into the fuseholder and clip the plastic cover onto the fuseholder 16 4 Repeat for the second fuse Fig 42 Item 10 16 5 Install the rear case onto the pump Refer to Page 13 Section 11 17 Replacing the Air Inlet Filter on the Compressor Assembly 17 1 Remove the rear case from the pump Refer to Page 13 Section 10 17 2 Using a pair of tweezers remove the air inlet filter Fig 42 Item 20 from the air inlet filter holder Fig 42 Item 30 17 3 Push the new air inlet filter Fig 42 Item 20 fully into the air inlet filter holder 17 4 Install the rear case onto the pump Refer to Page 13 Section 11 Figure 42 Replacing the Mains Power Fuses and Compressor Air Inlet Filter Table 13 Mains Power Fuse and Compressor Air Inlet Filter Parts List Part Number Description 10 507422 Fuse 3 15A 20mm Type T Spares Item 2 20 509317 Air Inlet Filter Compressor Assemb
87. otor and manifold assembly Fig 43 Item 10 CAUTION Do not disconnect the transducer tube from the transducer on the control 18 4 19 19 1 19 2 19 3 Issue Sep 2 PCB assembly The transducer is a sensitive device and is easily damaged Remove the four screws Fig 43 Item 40 and carefully lift the motor and manifold assembly from the control PCB and top case assemblies Fig 43 Items 20 and 30 Note If the hose set assemblies are still connected to the top case assembly the motor and manifold assembly will be a tight fit on the elbow connectors on the hose sets Note Do not loosen or remove the three screws Fig 43 Item 50 which secure the stepper motor to the manifold Repairing the Motor and Manifold Assembly Only carry out the actions in this section if BOTH of the following criteria are true e The serial number of the pump is LESS than that detailed in Para 19 3 below e The pump exhibits any of the problems detailed in Refer to Page 20 Section 19 4 Flowtron Universal Pump Part Numbers affected 507001 Flowtron Universal Pump UK Saudi Arabia 507003 Flowtron Universal Pump USA Canada 507004DE Flowtron Universal Pump Germany 507004FR Flowtron Universal Pump France 507004IT Flowtron Universal Pump Italy 507004NL Flowtron Universal Pump Netherlands Belgium 507009AU Flowtron Universal Pump Australia New Zealand 507009ZA Flowtron Universal Pump South
88. p With the orientation of the stepper motor mounting bracket as shown in Figure 46 turn the stepper motor drive shaft round so that the pin in the end of the drive shaft is in the approximate East West position shown Assemble the stepper motor and mounting bracket onto the spring mount and the module and stator sub assembly as follows refer to Figures 44 and 46 19 24 1 Turn the stepper motor and mounting bracket back over so that the drive shaft is on the underside and put it onto the top of the spring mount module and stator sub assembly Chap 5 Issue 2 Page 22 SER0009 Sep 2009 Flowtron Universal Service Manual Pump Repair 19 24 2 Press the two parts firmly together so that the pin on the drive shaft engages in the slot in the drive dog The stepper motor mounting bracket should then rest on top of the three support pillars on the module and stator sub assembly Note lf necessary turn the spring mount and pinned rotor assembly forward and back a small amount to make sure the pin engages in the slot 19 24 3 Using a Torx T8 screwdriver install the three screws to secure the stepper motor mounting bracket to the module and stator sub assembly refer to Figure 44 19 25 Install the motor and manifold assembly into the pump Refer to Page 20 Section 19 8 To install the new longer transducer tube Table 15 Item 30 use the following procedure refer to Figure 47 19 25 1 Push one end of the transducer tube fully on
89. p shown in the Program Group box You can enter a new group name or select one from the Existing Groups list Program Group Figure 68 Communicator Software Installation Choose Program Group 2 11 Click Continue to use the suggested default program group 2 12 The installation process will start and the progress will be indicated by a moving bar refer to Figure 69 2 Communicator 2 4 Setup i x Destination File C Program Files Communicator 2 4 RICHED32 DLL Baas 43 Figure 69 Communicator Software Installation Progress Chap 6 Issue 2 Page 4 SERO009 Sep 2009 Flowtron Universal Service Manual Updating the software 2 13 Atthe end of the installation the Installation Complete dialog box will then be displayed to indicate that the Communicator software has been successfully installed refer to Figure 70 Communicator 2 4 Setup E xj Communicator 2 4 Setup was completed successfully Figure 70 Communicator Software Installation Complete Click OK and the Setup Message is then displayed refer to Figure 71 Setup Message xj 37 The program needs to copy files from the CD Do you want to start the program now Figure 71 Communicator Software Installation Setup Message 2 14 In order to complete the installation you need to copy files from the Communicator software CD ROM and then start the Communicator program running Note It is preferable to do this now while the CD RO
90. rations only Red and green LED indicators on the front of the pump to show alarm and run status Automatic detection of the connected garment type Run Standby Button LCD Display Membrane Label Power Alarm LED Indicators Hose Set Assemblies to Garments Figure 1 Flowtron Universal Pump Chap 1 Issue 2 Page 2 SERO009 Sep 2009 Flowtron Universal Service Manual Introduction 3 Technical Description The pump consists of an electronically controlled air compressor with associated air routing and alarm facilities The operation of all the pump features is driven by microcontroller software The key parts of the pump are as follows e Compressor This provides a flow of air to the pneumatic system thus allowing inflation of the garments The output of the compressor is fed to the motor and manifold assembly e Motor and Manifold Assembly This includes a rotary valve which routes the air pressure to the garments The rotary valve also makes sure that as one garment is being inflated the other garment is vented to the atmosphere e Pressure Transducer This provides the monitoring system with the means of accurately measuring the pressure fed to each garment e Control Printed Circuit Board PCB This PCB controls the compressor the motor and manifold assembly and the illuminated graphic LCD display panel It also performs a continuous check of the operation and performance of the pneumatic cir
91. red alarm LEDs flash and a description of the fault condition is indicated on the LCD display If the fault condition is unaltered the audible alarm will increase in pitch until the fault is corrected and or the system is reset Note If a Pump Fault is detected the pump will alarm immediately Battery on the Control PCB Assembly if fitted The battery on the control PCB assembly provides power for the real time clock The battery should not require replacement until after several years of continuous use If the battery has to be replaced then it must be replaced in less than 20 seconds or else the real time clock will lose its time and date settings If the time and date settings are lost they have to be reloaded from a PC based service tool so the procedure should only be carried out in a ArjoHuntleigh service environment Schematics Refer to Figure 8 for the Pneumatic Control Schematic of the pump Refer to Figure 9 for the Electrical Schematic of the pump Issue 2 Chap 1 Sep 2009 SERO009 Page 3 Introduction Flowtron Universal Service Manual 4 System Operation 4 1 Plug the pump into an electrical outlet and switch on 4 2 The pump will first go through a self test routine Refer to Figure 2 PLEASE WAIT running diagnostic Figure 2 LCD Display Running Diagnostic 4 3 Atthe end of the self test routine the pump will beep and go into Standby mode where it will remain until required for use Refer to Fig
92. ring the Hose Set Connector Issue 2 Chap 5 Sep 2009 SER0009 Page 11 Pump Repair Flowtron Universal Service Manual Spigots Note the orientation of the Handle and Hook Assembly Item 50 Figure 39 Replacing the Rear Case and Handle Table 11 Rear Case Front Case Top Case and Handle Parts List Part Number Description 507302 Rear Case 507396 Front Case Printed Flowtron Universal 507421 Top Case Assy with Window amp Membrane Label Spares Item FAS223 Screw 3 dia x 10 Pan Head 507419 Handle and Hook Assembly Spares Item Chap 5 Issue 2 Page 12 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 10 Removing the Rear Case from the Pump Note It is not necessary to remove the hose set assemblies from the pump in order to remove the rear case from the pump 10 1 Remove the mains power cordset from the pump Refer to Page 7 Section 6 10 2 Lay the pump face down on a flat surface 10 3 Remove the four screws Fig 39 Item 40 and lift the rear case Fig 39 Item 10 away from the front case Fig 39 Item 20 and top case assembly Fig 39 Item 30 11 Installing the Rear Case onto the Pump 11 1 Lay the front case Fig 39 Item 20 and top case assembly Fig 39 Item 30 down with the inside surface pointing upwards 11 2 Install the rear case Fig 39 Item 10 onto the front case and top case assembly Note Make sure the five spigots on the underside of the rear c
93. ront Case Printed Flowtron Universal 507421 Top Case Assy with Window 8 Membrane Label Spares ltem 507306 Case Style Gasket 631073 Tube 100mm long Compressor Motor amp Manifold Assy Chap 5 Issue 2 Page 14 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 14 Separating the Top Case Assembly from the Front Case CAUTION Do NOT remove the hose set assemblies from the pump Refer to Page 9 Section 8 unless the top case assembly or the control PCB assembly is being replaced the motor and manifold assembly can be replaced without removing the hose set assemblies The elbow retaining covers on the hose set assemblies are not designed to be removed from the pump more than a couple of times If the hose set assemblies are removed unnecessarily the screw cover hinges on them may split and then the complete hose set assemblies will have to be replaced When the rear case has been removed from the pump the top case assembly Fig 40 Item 20 is held in position on the front case Fig 40 Item 10 by three spigots on the front case which locate in the corresponding holes in the top case assembly There are also two connections between the top case assembly and the front case A ribbon cable connection from the control PCB assembly in the top case assembly to the power supply PCB assembly in the front case A large diameter tube Fig 40 Item 40 from the motor and manifold assembl
94. rvice Manual Con 6 Con 7 40 Compressor Compressor _ Air Inlet Filter Location Unused Spigot A Hole Figure 58 Replacing the Compressor Assembly and Compressor Filter Table 25 Compressor Assembly and Compressor Filter Parts List Part Number Description 509051 Compressor Assembly Series 6 5 5V 50 60Hz 507316 Compressor Mounting Bracket FAS218 Screw 4mm dia x 12 Pan Head REF Power Supply PCB Assembly Spares Item 631073 Tube 100mm long Compressor Motor amp Manifold Assy Chap 5 Issue 2 Page 42 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 36 Removing the Compressor Assembly and Mounting Bracket 36 1 Remove the rear case from the pump Refer to Page 13 Section 10 36 2 Lay the front case down with the inside surface pointing upwards 36 3 Disconnect the large diameter tube Fig 58 Item 50 from the compressor assembly 36 4 Disconnect the two compressor cable connectors Fig 58 PCB Con 6 and 7 from the power supply PCB assembly Fig 58 Item 40 36 5 Remove the two screws Fig 58 Item 30 and lift the compressor assembly and mounting bracket Fig
95. rvice tool so this procedure should only be carried out in a ArjoHuntleigh service environment In the following procedure do not disconnect the 2 pin battery cable connector from the control PCB assembly until instructed to do so Remove the control PCB assembly from the pump Refer to Page 27 Section 22 Cut and remove the cable tie Fig 57 Item 20 which secures the battery Fig 57 Item 10 to the control PCB assembly Fig 57 Item 30 and move the battery a small distance away Put the new battery Fig 57 Item 10 onto the control PCB assembly adjacent to the old battery Secure the new battery to the control PCB assembly with a new cable tie Fig 57 Item 20 Disconnect the old battery and connect the new battery n less than 20 seconas as follows 35 5 1 Disconnect the 2 pin battery cable connector from the battery connector on the control PCB assembly Fig 57 PCB Con 5 and remove the battery 35 5 2 Connect the 2 pin battery cable connector onto the control PCB assembly Install the control PCB assembly into the top case assembly and then re assemble the pump Refer to Page 29 Section 25 Con 5 Battery Figure 57 Replacing the Rechargeable Battery Table 24 Rechargeable Battery Parts List Part Number Description 151457 Rechargeable Battery Spares Item Cable Tie Control PCB Assembly Spares Item Issue 2 Chap 5 Sep 2009 SERO009 Page 41 Pump Repair Flowtron Universal Se
96. s 15 20 25 30 31 and 32 After the final check of the compressor output at level 32 continue the test at Para 7 12 Note Levels 30 31 and 32 are used to check that the compressor is at its maximum output and therefore the output pressure may not vary significantly between levels 30 and 32 7 12 The calibration check of the pressure transducer is now complete and the pump is able to provide accurate therapy To end the test do either of the following 7 12 1 With the Run Compressor option still highlighted press the W button to stop the compressor 7 12 2 Scroll down the list of options to Exit and select it using the W button Issue 2 Sep 2009 Chap 4 SERO009 Page 9 Testing Flowtron Universal Service Manual 8 Re calibrating the Pressure Transducer Note This procedure is carried out without opening the pump case 8 1 Prepare the calibration test equipment Refer to Page 6 Section 6 8 2 Make sure that no calibration test equipment or other garments are connected to either pump hose set assembly 8 3 Initialise the pump Refer to Page 1 Section 1 8 4 Connect the right hose set assembly on the pump to the garment connector on the test equipment Refer to Figure 21 Note The calibration test equipment must only be connected to the right hose set assembly Do not connect anything to the left hose set assembly 8 5 Press the hidden Service b
97. sal Service Manual Pump Repair 5 1 5 2 5 3 5 4 6 1 6 2 7 Replacing the Inlet Filter Felt Remove the case IEC cover Refer to Page 6 Section 3 Remove the inlet filter felt Fig 33 Item 20 from the back of the case IEC cover Fig 33 Item 30 and discard Push the new inlet filter felt into the back of the case IEC cover Install the case IEC cover Refer to Page 6 Section 4 Removing the Mains Power Cordset Remove the case IEC cover Refer to Page 6 Section 3 Pull the mains power IEC cordset connector Fig 33 Item 10 out of the IEC connector inside the pump Installing the Mains Power Cordset CAUTION Make sure the replacement mains power cordset Fig 33 Item 10 is the 7 1 7 2 Issue 2 correct type and rating or the electrical safety of the pump may be impaired Carefully push the mains power IEC cordset connector Fig 33 Item 10 fully into the IEC connector inside the pump Place the cordset cable into the groove in the rear case Note Make sure the cordset cable is not pulled tight when it is installed into the rear case There should be some slack in the cordset cable under the case IEC cover Install the case IEC cover Refer to Page 6 Section 4 Chap 5 Sep 2009 SER0009 Page 7 Pump Repair Part Number Flowtron Universal Service Manual Figure 34 Replacing the Hose Sets Table 10 Hose Set Parts List Description 507500 FAS04
98. splay Therapy Started The pump provides intermittent cycles of compressed air to the two connected garments which are inflated alternately During the test check the LCD display to make sure that 3 4 1 It shows the correct type of garments connected to the pump 3 42 The correct pressure is being applied to each garment Refer to Table 3 Note It is only necessary to check that the pressures are approximately correct 3 43 No fault messages appear Check that the inflation hold time and cycle time are correct Refer to Table 3 Note It is only necessary to check that the times are approximately correct Check the Lo alarm on the pump as follows 3 6 1 Disconnect a garment from its hose set assembly while the pump is running and check that within one complete inflation cycle which will be between 30 and 72 seconds depending on the garment types connected to the pump the pump will detect the fault and flash Lo Alarm Garment unplugged on the LCD display Refer to Figure 17 Note Ifthe garment is disconnected while it is actually being inflated the LCD display may initially flash Lo Alarm Garment leak instead followed by Lo Alarm Garment unplugged Lo Alarm Garment unplugged Figure 17 LCD Display Lo Alarm Fault Message Issue 2 Chap 4 Sep 2009 SERO009 Page 3 Testing 3 6 2 3 6 3 3 6 4 3 6 5 3 6 6 Flowtron Universal Service Manual Reconnect the garment to the hose set assembly and check that wi
99. ssembly and then towards the rear edge of the top case assembly refer to Figure 56 31 4 2 Carefully guide the end of the membrane cable so that it passes through the cutout in the control PCB assembly refer to Figure 55 Note Do not bend or crease the membrane cable 31 5 Align the membrane label with the recess in the top case and lower the membrane label onto the top case Press down firmly on the membrane label to secure it to the top case Note Make sure the alignment is correct before you stick the membrane label to the top case If you have to remove the membrane label to re align it then the membrane label will have to be discarded because of the loss of adhesive and possible damage to it 31 6 Turn the top case assembly over so that the control PCB assembly is on top 31 7 Carefully push the end of the membrane cable into the membrane connector on the control PCB assembly Note Less than 2mm of the membrane cable can be inserted into the connector 31 8 Install the top case assembly onto the front case assembly refer to SER0009 Chapter 5 Pump Repair Page 14 Section 15 Table 23 Top Case Membrane Label Parts List 507397 Top Case Membrane Label Issue 2 Chap 5 Sep 2009 SERO009 Page 39 Pump Repair Flowtron Universal Service Manual 32 32 1 32 2 33 33 1 33 2 33 3 34 34 1 34 2 34 3 34 4 Chap 5 Page 4 Removing the Run Button Remove the control PCB assembly from the pu
100. steps to rectify the problem Where possible reference is made to the relevant repair chapter Issue 2 Chap 2 Sep 2009 SERO009 Page 1 Troubleshooting Fault Flowtron Universal Service Manual Table 2 Troubleshooting Table Possible Cause Remedy LO Low Pressure Alarm Garment Hose disconnected at garment Loose fitting garment Garment leak Check the hose connections at the garment end Rewrap snugly Check garment and replace if necessary Kinked tube to the transducer on the control PCB Damaged disconnected internal tube Damaged hose set assembly Blocked air filters Motor and manifold assembly failed Compressor assembly failure or low output Check tube for kinks or obstructions Check internal tubes and replace if necessary Check hose set assemblies and replace if necessary Chapter 5 Page 9 Section 8 Chapter 5 Page 10 Section 9 Replace inlet filters on the rear case and compressor assembly Chapter 5 Page 7 Section 5 Chapter 5 Page 17 Section 17 Replace Chapter 5 Page 19 Section 18 Chapter 5 Page 25 Section 20 Replace Chapter 5 Page 45 Section 38 Chapter 5 Page 45 Section 39 HI High Pressure Alarm Garment Garment hose kinked Hose set assembly kinked Check garment hose for kinks or obstructions Check hose set assemblies for kinks or obstructions Pump Fault Control
101. ter title refer to text within the same chapter Warnings Cautions and Notes WARNINGS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in death injury or other serious adverse reactions CAUTIONS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in equipment failure or damage Notes given in this manual are used to explain or amplify a procedure or condition WARNING BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY DECONTAMINATED WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET WARNING VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN IN CERTAIN CIRCUMSTANCES BE LETHAL WHEN WORKING ON EQUIPMENT REQUIRING EXPOSURE TO LIVE HOT UNPROTECTED CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT EXTREME CARE MUST BE EXERCISED 2 General Description The Flowtron Universal system is a non invasive external intermittent pneumatic compression system for reducing the incidence of deep vein thrombosis DVT The application of external intermittent pneumatic compression has two effects Augments venous blood flow velocity thereby reducing stasis Enhances fibrinolytic activity to reduce the risk of early clot formation Issue 2 Chap 1 Sep 2009 SER
102. the front case Refer to Page 15 Section 14 41 2 Remove the power supply PCB assembly compressor assembly and mounting bracket from the pump Refer to Page 31 Section 26 41 3 Lay the new front case Fig 63 Item 10 down with the inside surface pointing upwards 41 4 Stick the following parts to the front case 41 4 1 41 4 2 41 4 3 41 4 4 The two compressor support rubbers Fig 63 Item 20 The connector sealing strip Fig 63 Item 50 adjacent to the battery pack connector slot The magnet mounting pad Fig 63 Item 40 onto the front case in the appropriate slot The ferrite magnet Fig 63 Item 30 onto the ferrite mounting pad Note Make sure the ferrite magnet and magnet mounting pad are aligned with the sides of the slot in the front case 41 5 Install the power supply PCB assembly compressor assembly and mounting bracket onto the pump Refer to Page 31 Section 27 41 6 Install the top case assembly onto the front case Refer to Page 16 Section 15 Issue 2 Sep 2009 Chap 5 SERO009 Page 49 Pump Repair Flowtron Universal Service Manual Chap 5 Issue 2 Page 50 SERO009 Sep 2009 Flowtron Universal Service Manual Updating the software CHAPTER 6 UPDATING THE SOFTWARE 1 Introduction This section describes the procedure to upgrade the pump software to Version 3 01 The upgrade is required to improve the reliability of the kinked tube alarm for supine patients The upgrade should be carried out
103. the locking plate on the ZIF socket is still in the fully open position fully extended 29 2 2 Insert the end of the LCD cable fully into the ZIF socket Note Less than 2mm of the LCD cable can be inserted into the ZIF socket Note Make sure the LCD sub assembly and control PCB assembly do not move so that the LCD cable remains in the ZIF socket 29 23 Using your thumbnails or a small tool which will not damage the ZIF socket gently push the outer edges of the locking plate into the connector body on the ZIF socket until the locking plate is in the closed position fully retracted 29 2 4 The LCD cable is now secured in the ZIF connector Carefully rotate the LCD sub assembly onto the control PCB assembly and put the four locating lugs in the LCD sub assembly into the corresponding holes in the control PCB assembly refer to Figure 52 Hold the LCD sub assembly in position on the control PCB assembly and turn the complete control PCB assembly over so that the LCD sub assembly is on the underside refer to Figure 51 Note Make sure the outer face on the underside of the LCD sub assembly is protected from damage Install the four screws Fig 51 Item 10 to secure the LCD sub assembly to the control PCB assembly CAUTION Do NOT over tighten the screws or you may damage the LCD sub assembly 29 6 29 7 Turn the control PCB assembly over and remove the protective plastic film from the front of the LCD sub assembly
104. the pump case Refer to Figure 37 Issue 2 Page 10 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair Elbow Retaining Cover Control Board Connector Insert excess hose set cable this side of control Elbow Connector Hose Set Cable Connector board connector to prevent damage by the lugs on elbow retaining cover Lug Pump Case C Case Cutout for Elbow Retaining Cover Pneumatic Outlet Figure 37 Installing the Hose Set Connectors 9 6 When the elbow retaining cover is installed into the pump case cutout turn the elbow retaining cover approximately 20 degrees clockwise to the secured position Refer to Figure 38 Note To turn the elbow retaining cover more easily use the tube and elbow connector to provide extra leverage Turn the tube and elbow connector counterclockwise until the elbow connector touches the screw cover and then continue turning them to turn the elbow retaining cover Refer to Figure 38 9 7 When the elbow retaining cover is in the correct position install the screw Fig 34 Item 20 and tighten it to secure the hose set assembly to the pump 9 8 Carefully press down the screw cover until it clicks into position Refer to Figure 35 Screw Cover gt 20 degrees de Elbow Retaining Cover Elbow Connector in Secured Position Elbow Retaining Cover in Free Position Tube Turn Tube and Elbow Elbow Connector Retaining clockwise Cover Figure 38 Secu
105. thin two complete pump cycles the pump automatically senses the garment and resumes normal operation Disconnect the garment again as detailed in Para 3 6 1 and leave disconnected Check that after 10 successive inflation cycles which will be between 5 and 12 minutes depending on the garment types connected to the pump the pump will alarm as follows 3 6 4 1 The audible alarm sounds 3 6 4 2 The red alarm LEDs on the front of the pump flash 3 6 4 3 The message Lo Alarm Garment unplugged is shown on the LCD display Refer to Figure 17 Lo Alarm Garment unplugged Figure 18 LCD Display Lo Alarm Message Check that if the garment is left disconnected the audible alarm will increase in pitch Reconnect the garment to the hose set assembly and check that within three complete pump cycles the pump automatically senses the garment and resumes normal operation 3 7 To stop the therapy press the green Run button Y and keep it depressed until the pump beeps The green LEDs on the front of the pump will extinguish and the compressor will stop Note The green LEDs do not illuminate when operating from the battery Chap 4 Page 4 Issue 2 SERO009 Sep 2009 Flowtron Universal Service Manual Testing LCD Display Hidden Service Button Run Button a Normal User Buttons Membrane Label Figure 19 Soft Function Buttons on the Membrane Label 4 Location of the Soft
106. through the test hole in the rear case Approximate dimensions of test probe Minimum length 100 mm Maximum diameter 2 mm Figure 30 Inserting the Test Probe through the Rear Case a Control PCB Assembly Front Case of Pump IEC Connector Earth Ground Test Pad inside dotted line Compressor Assembly Figure 31 Earth Ground Test Area on Control PCB Assembly Issue 2 Chap 4 Sep 2009 SERO009 Page 13 Testing Flowtron Universal Service Manual 10 Electrical Safety Testing To test and calibrate the pump unit correctly the test equipment in Table 5 is required Table 5 Electrical Test Equipment Test Equipment Insulation Resistance Tester Megger 500 Vdc Portable Appliance Tester Multimeter Continuity Tester 4 Test Probe Minimum Length 100 mm Maximum Diameter 2 mm approximate dims Electrical Safety Checks There are several electrical safety checks that must be carried out after breakdown repairs and servicing Where alternatives are given the test will depend upon the available test equipment The tests are as follows e Earth Ground Continuity Test e Insulation Resistance Test Megger Test or e Earth Ground Leakage Current Test USA Earth Ground Continuity Test This test checks the earth ground wire continuity between the e
107. to the transducer outlet on the motor and manifold assembly Note The transducer outlet on the new module and stator sub assembly is in a different position 19 25 2 Push the other end of the transducer tube onto the top outlet of the transducer on the control PCB assembly CAUTION Do not handle the transducer on the control PCB assembly unnecessarily The transducer is a sensitive device To avoid damage put your finger at the back of the transducer while you carefully push the tube onto the top outlet at the front of the transducer Note Make sure the transducer tube is not kinked Stepper Motor Spring Mount and l l Mounting Bracket Pin in Drive Shaft Pinned Rotor Assembly Slot in Drive Dog View of Underside of Stepper View of Top of Module Motor and Mounting Bracket and Stator Sub Assembly Figure 46 Aligning the Stepper Motor Drive Shaft and Pinned Rotor Assembly Issue 2 Chap 5 Sep 2009 SER0009 Page 23 Pump Repair Flowtron Universal Service Manual Transducer Tube Motor and Manifold Assembly Transducer Outlet Transducer Control PCB Assembly Figure 47 Installing the New Longer Transducer Tube Table 16 Long Transducer Tube Parts List Part Number Description 507494 Silicone Tube 1 5 mm ID 3 5 mm OD 160 mm Long Chap 5 Issue 2 Page 24 SERO009 Sep 2009 Flowtron Universal Service Manual Pump Repair 20 20 1 20 2 20 3
108. ure 3 Standby Attach Garments Figure 3 LCD Display Standby 4 4 Connect the garments to the pump hose set assemblies and make sure the connectors click into place 4 5 Check that the connection and garment type are confirmed correctly on the display Figure 4 shows two single chamber calf garments connected to the pump Press 5 to Run Ortions T Figure 4 LCD Display Garments Connected 4 6 Typical garment options and default therapy parameters are detailed in Table 1 Table 1 Garment Options and Default Therapy Parameters Garment Type and Inflation Pressure Inflation Hold Cycle LCD Display Graphic mmHg seconds seconds t Foot 130 3 30 Single chamber 40 f 60 Pas Calf and Thigh Calf Chap 1 Issue 2 Page 4 SERO009 Sep 2009 Flowtron Universal Service Manual Introduction 4 7 To start the therapy press the green Run button on the top of the pump and keep it depressed until the pump beeps The green LEDs on the front of the pump will illuminate and therapy will begin Figure 5 shows the pump running and the left calf garment inflated to 40 mmHg Note The green LEDs do not illuminate when running from the battery pack Figure 5 LCD Display Therapy Started 4 8 To stop the therapy press the green Run button Y a second time and keep it depressed until the pump beeps The green LEDs on the front of the pump will extinguish and therapy will stop 4
109. utton on the membrane panel Refer to Page 5 Section 4 to access the service screen on the LCD display Refer to Figure 25 Pump Info Set LCD Contrast Calibrate RFID Save Custom settings A amp J Figure 25 LCD Display Calibrate PT 8 6 Using the Down and Up buttons below the LCD display Refer to Page 5 Section 4 scroll down the list of options to Calibrate PT and select it using the V button below the LCD display A new list of options will appear Refer to Figure 26 0 lt _ Output Pressure Decrease Zero Increase Gain 35 30 Calibration Data D Gai o Zero Gain typical values 4 amp J Figure 26 LCD Display Calibration Data 8 7 Before continuing with the re calibration procedure refer to the two Calibration Data values on the LCD display and make a note of the Zero and Gain values Refer to Figure 26 Note Ifthe re calibration procedure goes wrong you can set the Zero and Gain values back to their original values and then start the re calibration procedure again 8 8 Make sure the external pressure meter shows zero pressure 8 9 Check the value of the Output Pressure shown on the LCD display Refer to Figure 26 lt should show zero pressure If it does not show zero pressure then adjust the zero calibration factor of the pump as follows 8 9 1 To increase the Output Pressure value scroll through the list of options to Increase Zero Each time the W button is pushed the Output Pressure va
110. vice Manual Testing 7 8 2 1 7 8 2 2 7 8 2 3 End this test by scrolling down the list of options to Exit and select it using the W button Carry out the procedure to re calibrate the pressure transducer Refer to Page 10 Section 8 Repeat this procedure to check the calibration of the pressure transducer Refer to Page 7 Section 7 7 9 With the Run Compressor option still highlighted press the W button again The compressor output will increase to level 10 indicated by the 10 on the LCD display and the Output Pressure shown on the LCD display should rise and then stabilize 7 10 Compare the value of the Output Pressure on the LCD display with the value shown on the external pressure meter 7 10 1 7 10 2 If the value of the Output Pressure on the LCD display is within 5 mmHg of the value shown on the pressure meter then continue with the test Go to Para 7 11 If the value of the Output Pressure on the LCD display is NOT within 5 mmHg of the value shown on the pressure meter then do the following 7 10 2 1 7 10 2 2 7 10 2 3 End this test by scrolling down the list of options to Exit and select it using the W button Carry out the procedure to re calibrate the pressure transducer Refer to Page 10 Section 8 Repeat this procedure to check the calibration of the pressure transducer Refer to Page 7 Section 7 7 11 Repeat Para 7 9 and Para 7 10 six more times for compressor output level
111. y in the top case assembly to the compressor assembly in the front case 14 1 14 2 14 3 14 4 14 5 Remove the hose set assemblies from the pump Refer to Page 9 Section 8 but ONLY if the top case assembly or the control PCB assembly is being replaced the motor and manifold assembly can be replaced without removing the hose set assemblies Otherwise the top case assembly can be separated from the front case with the hose set assemblies installed on the pump Remove the handle and hook assembly and the rear case from the pump Refer to Page 13 Section 12 Carefully lift the top case assembly Fig 40 Item 20 off the three spigots on the front case Fig 40 Item 10 Note Removal of the ribbon cable and tube between the top case assembly and the front case is made easier if the top case assembly is separated from the front case first Disconnect the following from between the top case assembly and the front case Refer to Figure 40 The ribbon cable connector from the top of the power supply PCB assembly The large diameter tube Fig 40 Item 40 from either the motor and manifold assembly or the compressor assembly Remove the top case assembly from the front case and the case style gasket Fig 40 Item 30 from the top case assembly Issue 2 Chap 5 Sep 2009 SERO009 Page 15 Pump Repair Flowtron Universal Service Manual 15 15 1 15 2 15 3 Pneumatic Inlet Chap 5 Page 1 Installing the

FLOWTRON® UNIVERSAL - Frank`s Hospital Workshop

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FLOWTRON® UNIVERSAL - Frank`s Hospital Workshop