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LP6 Plus, LP10, and LP20 Volume Ventilators Service Manual

1. 043 x3 212 o 015 x6 010 og X5 o 11 o7 November 2000 LP6 Plus LP10 and LP20 Service Manual Front Panel Meter Replacement Figure 4 21 Stud Red wire November 2000 Front Panel Disconnect meter wires from the Logic Board J2 on newer sur face mount board or J12 on older through hole board Remove the two 10 32 Kep nuts from the meter and remove the wires Remove and discard the old meter While holding the replacement meter vertically verify that the needle can be adjusted at least two divisions each side of 10 Since there are no markings to the left of 10 use your own judgment Set the needle exactly on 10 when done Install short piece of foam directly below meter window Install long piece of foam around the sides and top of meter window Check the meter window for scratches and debris Spray meter window with anti static spray and wipe clean Install meter into front panel Install one flat washer on each of the four threaded studs on the meter Install meter bracket over the round portion of the meter Install one flat washer one lock washer and one brass nut finger tight on each stud Mount meter to the front panel with three screws Verify meter is straight by looking through meter window of the top overlay Tighten the brass nuts with a nut driver Check meter wire assembly for proper crimps no exposed wire and no damaged insu
2. 4 27 Back Panel 4 29 AC Cord Replacement 4 29 Replacement of AC ON OFF Switch 4 31 Bearing Replacement 4 32 Ventilator Service Record 5 3 Ventilator Service Run In Log 5 5 6 Equipment Calibration Calibration of Model 6960 Calibrator 6 1 Calibration of Model 6951Right end Tester 6 2 7 Technical Bulletins 8 Miscellaneous Information Page ii November 2000 1 Introduction Chapters Introduction Maintenance Testing Repair Forms Equipment Calibration Technical Bulletins Miscellaneous Information November 2000 This manual is intended for use only by biomedical technicians who have successfully completed Nellcor Puritan Bennett Inc training on this product Nellcor Puritan Bennett believes the information herein is accurate but accepts no responsibility for errors omissions or misrepresentations NELLCOR PURITAN BENNETT INC FURTHER DECLINES ANY WARRAN TIES EXPRESSED OR IMPLIED FOR THE REPAIRED PRODUCT INCLUD ING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE It is the user s responsibility to assure that the product has been prop erly repaired and that it is in safe and proper operating condition before it is put into use This manual consists of the followin
3. Page 4 27 Back Panel Back Panel AC Cord Replacement RFI FILTER q LP6 Plus LP10 and LP20 Service Manual WASHER 8 INT STAR GREEN YELLOW a WIRE HARNESS WIRE GREEN YELLOW WIRE HARNESS WIRE B 32 X 3 4 SOCKET HEAD CAP SCREW 8 32 KEPS MV WA O 2X CABLE TIE O reat WIRE ASSY DETAIL A EARTH GROUND LABEL GROUND STUD BROWN WIRE ASSY GROUND STUD _ LOAD SEE DETAIL A BROWN WIRE FROM RFI FILTER BLUE WIRE FROM REEN POWER CORD WIRE RFI FILTER Oo Figure 4 28 Na f 4 STRAIN RELIEF BLUE WIRE ASSY BLACK POWER CORD WIRE Newer LP6 LP1 0 BROWN WIRE ASSY TERMINAL STRIP LABEL WHITE POWER CORD WIRE See Figure 4 28 and 4 29 1 Page 4 28 Note the position of the power cord connections On older LP6 LP10 and all LP20 models all three power cord wires attach to the terminal strip An additional green and yellow wire connects the terminal strip to the chassis ground stud On newer LP6 LP10 models the white and black wires from the power cord attach to the terminal strip while the longer green wire from the power cord attaches directly to the chassis ground stud Disconnect the power cord from all three points of attachment Remove the green and yell
4. 0 Setting MODE Standby LOW ALARM 2 CMH O hPa HIGH ALARM LIMIT 90 cmH20 hPa VOLUME 1 0 Liter BREATH RATE 10 BPM INSPIRATORY TIME 1 0 Second BREATHING EFFORT approximately 5 cmH O hPa Pressure Limit Control Fully Clockwise LP10 LP20 only 29 Leak Check q Turn the ventilators ON OFF switch to ON D Ensure the High Pressure Relief screw is tightened C With the calibrator still hooked up set MODE to Assist Con trol Allow the ventilator to retract and pause Attach a green test plug with adapter to the ventilator and block the small vent hole on the green test plug The motor must stall or move very slowly 30 High Pressure Relief HPR Calibration qA Press the PEAK button on the calibrator Allow reading to stabilize Reading must be greater than 120 cmH O hPa b Adjust the High Pressure Relief screw until the PEAK PROX PRESS is between 100 and 110 cmH yO hPa The PATIENT PRESSURE meter must peak greater than 100 31 Set MODE to Standby 32 Turn the unit OFF and disconnect the calibrator and green test plug with adaptor 33 Disconnect the unit from AC power 34 Passed units are ready for reassembly November 2000 Page 3 16 LP6 Plus LP10 and LP20 Service Manual Reassembly November 2000 1 2 Reassembly Verify the following q Harness wires and ribbon cable are not pinched b Unit serial number matches the paperwork C Motor Gearbox wiring is routed correctly and i
5. Press the CAL button on the calibrator D Enter the correct date and time using the number pad C Press the SET button Unplug the AC power cord of the ventilator Verify e Printout automatically generated Printout must say Alarms Power Switchover e POWER SWITCHOVER alarm sounds and corresponding alarm LED illuminates e Ventilator continues to run on internal battery e Internal battery LED flashes e No interrupted operation of flow occurs to patient ports Press ALARM SILENCE RESET button to reset the Power Switcho ver alarm condition Allow unit to run on internal battery Verify when next alarm sounds and that following conditions occur e Verify LOW POWER LED lights and the alarm sounds e Printout automatically generated e Verify that the ventilator ran at least 45 minutes on internal battery before switching to a low power condition Write the actual time on the Run In Log sheet If printout states 99 min verify actual time e Verify unit functioning properly November 2000 LP6 Plus LP10 and LP20 Service Manual 10 11 12 Run in You may silence the alarm with the calibrator if one is present Verify third printout generated automatically 15 minutes later Verify proper operation Connect ventilator to AC power or set back panel on off breaker to the On position and disconnect printer from venti lator Reset any alarms Note If at least one of the printed circuit boa
6. feeler gauge between the knob and the front panel Tighten the set screws in each knob Take five 5 8 regular knobs Obtain correct spacing with a 025 feeler gauge and orient indicator lines at the minimum furthest counter clockwise setting marks on the overlay Tighten knobs Note The indicators on the knobs must center precisely on the minimum setting marks on the overlay 4 Check that all knobs are in fact turned fully counter clock wise Check that there is some tension on the locking knobs during rotation November 2000 Front Panel LP6 Plus LP10 and LP20 Service Manual Overlay Replacement Top overlay Figure 4 25 Striker plate Remove the overlay to be replaced Scrape the adhesive residue completely from the front panel Residue left on the front panel where the overlay is adhered will cause a bubble or bump 2 Check overlays for flaws scratches discoloration bubbles illegible silk screening or holes before installing 3 Remove adhesive backing from top overlay window if present Spray both front and back of meter window area of the top overlay with anti static spray and wipe to prevent spotting 4 Check for continuous adhesive on the back of the overlay The following are suggestions for installing the overlays qQ Peel back a small portion of the overlay backing on one end Position the overlay accurately and then press down the exposed adhesive portion of the overlay Now peel the
7. Small Needle Nose Pliers Side Cutters Pliers 1 4 Ratchet with 5 64 Allen Bit November 2000 Page 1 4 Equipment Tools and Supplies LP6 Plus LP10 and LP20 Service Manual Heyco 29 Strain Relief Pliers Cable Tie Gun Putty Knife Scissors Ruler Mallet X Acto Knife with Pointed and Chisel Blades Single Edge Utility Blade I C Extraction Tool Supplies All purpose cleaner Acetone Isopropyl alcohol Cotton swabs Anti static spray Silicone RTV clear Silicone Spray Kel 110 Blue Loctite 242 Loctite 648 Primer N Loctite 7649 Prism 410 Loctite Blue Loctite 425 Lubricating oil November 2000 Page 1 5 Equipment Tools and Supplies LP6 Plus LP10 and LP20 Service Manual November 2000 Page 1 6 2 Preventive Maintenance and Recertification Preventive Maintenance November 2000 Forms Procedure This process describes the minimum steps necessary to perform a pre ventive maintenance to the LP6 Plus LP10 and LP20 Volume Ventila tors Reference to other repair processes may be necessary before performing calibration You must use a copy of the Service Record and Run In Log found at the end of this manual to document all repairs and testing and forward copies to Nellcor Puritan Bennett 1 Perform the Check In Process in Section 3 2 Replace the internal battery see Battery Replacement on page 4 1 and the Kapseal Quadring and Piston Guides see Kapseal Quadring and Piston Guide Repla
8. alarm within several seconds Set the INSPIRATORY TIME to 2 0 Verify the audible alarm silences within several seconds Momentarily press Alarm Silence Reset to reset the alarm LEDs Set MODE to Standby and disconnect red test plug from venti lator Set VOLUME to 1 on front panel Disconnect the red test plug if not already done Set the MODE to Assist Control Allow the ventilator to retract and pause then attach a green test plug with adapter to the ventilator Reset any alarms you might get Press the PEAK button on the calibrator Allow reading to sta bilize The PEAK PROX PRESS must not vary more than 4 cmH O hPa between three consecutive cycles Record the variance Set MODE to Standby Note The High Pressure LED must flash and alarm must sound during this section of the process 1 2 Page 3 32 Set VOLUME to 1 0 liter Set MODE to Assist Control Reset any alarms Allow the ventilator to cycle Press the Alarm Silence Reset Verify the PEAK PROX PRESS is between 100 AND 110 cmH O hPa for three consecutive cycles Record highest value Remove the green test plug and attach a red test plug Reset any alarms November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 Power Switchover Final Inspection High Alarm Limit l Final Inspection Attach the test battery to the EXTERNAL 12V DC receptacle Unplug the ventilator AC power cord The Power Switchover LED
9. and not bent in the base of the Motor Gearbox e There is no grease in the seam between the two halves of the Motor Gearbox Clean the gearbox of any residual grease including the output shaft e Key is in the output shaft and fully seated in slot and its end is flush with the end of the output shaft e There are no burrs on the key and crank 2 If the newer gearbox type is being used spray the inside of the shaft hole in the crank arm with a brief burst of Loctite Primer N7649 Allow to dry for at least a minute Apply one drop of Loctite 648 to each of the two flats on the gearbox output shafts November 2000 Page 4 9 Right End Figure 4 14 Page 4 10 Gearbox 10 11 12 LP6 Plus LP10 and LP20 Service Manual Slip the gearbox s output shaft into the crank To get the out put shaft to line up with the crank you may both rotate the crank into position and or rotate the rotor of the Motor Gear box to reposition the key in the output shaft Figure 4 14 Adjust the crankarm so it is flush with the end of the output shaft Position the gearbox on one side of the cylinder so the large hex head capscrew in the crank arm is facing up Apply a drop of Loctite 242 to the large cap head screw install into crank arm and tighten to 35 in lbs If the gearbox with keyed output shaft is used position the gearbox on the other side of the cylinder so that the small set screw of the crank arm is facing u
10. and routing of the meter wires 4 Set Up Note For units which already have the chassis assembled proceed to Step 7 qQ Fasten the Back Panel to the Right End with the three screws if not already done bD Remove and inspect the air tube o ring apply silicone spray Kel 110 to air tube with a cotton swab and reinstall the o ring Apply silicone to the o ring with a cotton swab Page 3 9 Calibration LP6 Plus LP10 and LP20 Service Manual C Remove the discharge plug from the Power Motor Board J6 on the newer surface mount board or J3 on the older through hole board and connect the 10 pin connector from the wire harness d For LP6 LP10 units connect the five pin connector from the remote alarm jack to the Logic Board J1 on the newer surface mount board or J11 on the older through hole board e Connect the tubing from the Patient Pressure port to P2 of the transducer f Connect the three pin connector from the solenoid to the Power Motor Board J1 on the newer surface mount board or J7 on the older through hole board Q Connect the 12 pin connector from the stator to the Power Motor Board J3 on the newer surface mount board or J6 on the older through hole board Note New motor gearbox assemblies feature a ferrite on the 12 pin con nector housing If this is used with the older through hole power motor board the ferrite needs to be rotated to miss the heat sink If not already done cut the cable tie aro
11. screw so that the top of the guide also just touches Then turn the bottom set screw again to take up any slack Using a cross pattern do this with all four piston angle brackets making sure that the tops of all four brackets are even with the top of the cylinder and that the piston remains centered within the cylinder Figure 4 12 Tops of four piston angle brackets even with top of cylinder edge November 2000 Right End LP6 Plus LP10 and LP20 Service Manual Set Piston Tension Work the piston back and forth in the cylinder a few times Push the piston down into the cylinder about 3 4 of the way 2 Place the right end plate assembly into the Right End Tester Model L 6951 Add the adapter plug to the manifold air tube Clamp in place with the two clamps Switch the tester on 3 Press and hold the SET PISTON button Look at the gauge on the left and see if the needle falls in the good range of 12 18 cmH O Hold the button until the tops of the piston angle brackets are again even with the top of the cylinder Note If anew cylinder is installed in a unit during a PM the Good range is 20 25 cmH30 4 If the tops of the piston angle brackets are equally distant from the top of the cylinder within 1 16 and the gauge needle was in the proper range while the piston was rising then the brack ets are adjusted correctly Go to step 7 5 If not correct Adjust the set screws as follows Note If the
12. top set screw is a little tighter than the bottom screw that angle bracket will be forced a little higher The reverse is true to cause an angle bracket to ride a little lower dQ For brackets that are too high loosen the top set screw slightly Verify bottom set screw is still snug but not overly tight b For brackets that are too low tighten the top set screw slightly Verify bottom set screw is still snug but not overly tight C After adjustments are made return to the beginning of this test to re test the piston tension d If the tension of the piston against the cylinder wall as measured by the gauge was outside the proper range adjust all set screws an equal amount in all of the brackets If above proper range adjust screws counter clockwise to lower pressure If below proper range adjust screws clock wise to raise pressure November 2000 Page 4 7 Right End System Leak Test Page 4 8 LP6 Plus LP10 and LP20 Service Manual e After adjustments are made return to the beginning of this test to re test the piston tension Repeat steps as necessary to obtain proper leveling and ten sion Check that the piston is centered in the cylinder Press and hold the LEAK TEST button The needle of the gauge on the right side must stay in the GOOD range when the leak test button is depressed Pressure may drop very slowly when LEAK TEST button is released Press and hold the VENT button to release t
13. 00 Page 4 26 Control Door LP6 Plus LP10 and LP20 Service Manual Control Door Magnetic strip a vapid pemueog jO MpD my uo an g ae oy ED SRA IER ay YEN PSY NOLNYO Y EE ORN O DUDO PUE OPERA jO BUNGEE IOUS SPALA PUNOR OI SRURLING MALER ji MINNA T UD OO UBL DUR pO BORO OLA Duuticnt Aq nirbhu ca uiis DAO SIU JOLE JssmoodOUR Y AERA FER i CFL TI UIEN E FAI JE eed cry UO JOEREN PA PEY a Addr saod srbepe 0 pouioo heppiuiip gt RPE yh ubi baL bag Kalb CAM B LD Ue iann dij uor apumi ep card Orne MINDEDE AADI DAP sec LAREO UUO BUNCA AADO LANIRE CA kO yy LAC pee AY HT ara u n ee GRO DUE A eeUCCUCIS A FURO BPA EHRE gt ag Door Figure 4 27 Front Panel Door Magnetic Strip Replacement 1 Remove the old strip and clean the adhesive residue from the door 2 Add magnetic strip to the door as shown making sure it does not overhang on either side Front Panel Door Overlay Replacement 1 Remove the old overlay and scrape the adhesive residue clean 2 Inspect the overlay for overall workmanship 3 Peel back the overlay backing 4 Center and apply Alarm Reference overlay in cutout on back side of door Overlay must be positioned accurately as follows qd Bottom of overlay oriented closest to magnetic strip b Position as shown in Figure 4 27 and then press down on the overlay C Smooth and check overlay to ensure centering November 2000
14. CONTROL Reset any alarms Record High Rate Run start date and time on Run In Log sheet Allow unit to run on above settings for minimum 2 hours Ver ify no alarms occur Turn MODE switch fully to STANDBY and remove GREEN run in plug Record High Rate Run end date and time on Run In Log sheet Set front panel to Max Volume Run parameters as follows e LOW ALARM Minimum e HIGH ALARM LIMIT Maximum e VOLUME Maximum 2 2 liter e BREATH RATE 7 BPM e INSPIRATORY TIME 2 5 seconds e BREATHING EFFORT 5 cmH O e MODE STANDBY Connect RED run in plug with silicone connector to the venti lator Turn MODE to ASSIST CONTROL Reset any alarms Record Max Volume Run start date and time on Run In Log sheet November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 30 31 32 33 34 35 36 Run in Allow unit to run on above settings for minimum 9 hours Run unit for a few breaths Disconnect unit from AC power momentarily Verify unit switched to internal battery and is operating normally Reset alarm and restore AC power to unit Run unit for a minimum of one minute Disconnect unit from AC power momentarily Verify unit switched to internal battery and is operating normally Reset alarm and restore AC power to unit Verify unit has run for minimum 20 hours Set MODE to STANDBY and the On Off switch to Off Disconnect the RED run in plug Unplug the unit from AC power
15. H ALARM LIMIT to 15 Within several breaths verify that the LED on the alarm tester turns off as the High Pressure LED lights and an audible alarm sounds Set the HIGH ALARM LIMIT to 90 Press Alarm Silence Reset Verify that the LED on the alarm tester lights Disconnect the Patient Pressure Tubing from the ventilator Within several breaths verify that the Low Pressure Apnea LED is lit and a dual pulsing alarm is generated along with a corresponding flashing of the alarm tester LED Reconnect the Patient Pressure Tubing Press Alarm Silence Reset Set the alarm tester to SUPPLY and disconnect it from the ven tilator Start the stopwatch while momentarily pressing Alarm Silence Reset Verify the Setting Error Presilence LED lights continu ously Set the INSPIRATORY TIME to 4 0 The Setting Error Presilence LED should start flashing with no audible alarm Disconnect the Patient Pressure Tubing from the ventilator Within several breaths verify the Low Pressure Apnea LED starts flashing along with the Setting Error Presilence LED with no audible alarm Stop the stopwatch upon hearing a dual pulse alarm Verify the stopwatch reads 60 0 2 0 seconds Page 3 31 Final Inspection 24 25 26 27 Volume Stability 1 5 Relief Valve LP6 Plus LP10 and LP20 Service Manual Reconnect the Patient Pressure Tubing to the ventilator Verify the audible dual pulse alarm changes to a steady on off puls ing
16. LP6 Plus LP10 and LP20 Volume Ventilators Service Manual NELLCOR PURITAN BENNETT L 005115 001 Rev B Copyright 2000 Nellcor Puritan Bennett Inc Minneapolis Minnesota U S A All rights reserved No portion of this manual may be copied reproduced or stored in any form without the express written permission of Nellcor Puritan Bennett Inc For more information For information on our full line of medical equipment and related services contact Nellcor Puritan Bennett directly General 800 497 4979 Customer Service 800 497 4968 Technical Service 800 497 3787 November 2000 page it LPG Plus LP10 and LP20 Service Manual Contents 1 Introduction COPIER eshse5 5 o eecer see eee ee se ee eee 1 1 Conventions 1 2 What s New in this Revision 1 3 Chapter 3 Testing 1 3 Chapter 4 Repair 1 3 Equipment Tools and Supplies 1 4 2 Preventive Maintenance and Recertification Preventive Maintenance 2 1 Recertification 2 2 3 Testing Check In 3 1 Calibration 3 8 Reassembly 3 17 Run in 3 21 Final Inspection 3 26 4 R
17. NOB 5 cm Turn the front panel s BREATHING EFFORT knob to 5 If OK appears on the display press the SET button to advance to the next step VOLUME KNOB 2 Turn the VOLUME knob fully counter clockwise then set to 2 If OK appears on the display press the SET button to advance to the next step VOLUME KNOB 1 0 Turn the VOLUME knob clockwise to 1 0 If OK appears on the display press the SET button to advance to the next step Page 3 11 Calibration LP6 Plus LP10 and LP20 Service Manual 16 VOLUME KNOB 2 0 Turn the VOLUME knob clockwise to 2 0 If OK appears on the display press the SET button to advance to the next step 17 METER 0 cm Nothing should be connected to the Patient Pressure port Use the calibrator s arrow keys to adjust the PATIENT PRESSURE meter needle to read exactly O It is important that you view the meter from directly in front and that the meter be in the nor mal orientation while setting the position of the meter needle If OK appears press the SET button Warning Immediately following Step 18 the motor will rotate the crank arm until it is approximately centered Keep hands clear during rotation 18 METER 90 cm Use the arrow keys to adjust the PATIENT PRESSURE meter needle to read exactly 90 If OK appears press the SET button 19 CRANKARM ALIGNED After the motor stops and the crankarm is approximately cen tered Slide the Crank Centering Tool o
18. RATORY TIME to 3 0 seconds Close off the Pressure Limit Control fully clockwise Then open it six full revolutions counterclockwise Press the PEAK button on the calibrator Set the MODE switch to Assist Control and verify that the PEAK PROX stays stable 5 cmH O hPa for the first three cycles A popping noise should not be heard from the Pres sure Limit Control at any time during this process If a mechanical snapping sound is heard return the unit to Nellcor Puritan Bennett for repair November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 Check In k Set the INSPIRATORY TIME to 1 0 second remove the test lung and block the Patient Air port with your hand for two cycles Set the INSPIRATORY TIME to 3 0 seconds Reconnect the test lung and compare the PEAK PROX readings for three con secutive breaths to the PEAK PROX readings of the first three breaths in step 4J to verify whether or not the Pres sure Limit Control was sticking The averages of the two sets of readings must be within 3 5 cmH O hPa of each other Set the MODE to Standby Evaluate and try to verify the reason for return If the unit is returned for an internal battery problem perform a bat tery run down without charging the battery first Then allow the unit to charge for a minimum of three hours and perform a second battery run down Use the run down sec tion of the vent Run In process Set the front panel to the following s
19. Record Max Volume Run end date and time on run in log sheet Passed units are ready for Final Inspection Page 3 25 Final Inspection LP6 Plus LP10 and LP20 Service Manual Final Inspection The purpose of this process is to specify the test and parameters to inspect the ventilator Use the Service Record when completing this process Note If any calibration needs to be performed repeat Calibration Run In and Final Inspection Mark Pass Fail on the Service Record while performing the final inspection Visual Checks 1l Visually examine the ventilator for abnormalities 2 Verify all knobs are e turned fully counter clockwise Pressure Limit Control fully clockwise e tight e within a line s width of all panel markings Note The white pointer on the knob must be fully within the dashed lines as shown in Figures 3 5 3 6 and 3 7 i e the white pointer should cover some portion of the panel marking 3 Verify the PATIENT PRESSURE meter is within one division of 10 November 2000 Page 3 26 Final Inspection LP6 Plus LP10 and LP20 Service Manual Controls VOLUME BREATHING EFFORT LOW ALARM LITERS cmH 0 hPa 0 5e 5 10 e 10 SA Line width v 2 2 4 within a line s width V Line width SS 7 Line width within a line s width within a line s width Figure 3 5 Figure 3 6 Figure 3 7 Note Use Model L 6213 or L 6217 remote alarm for LP6 LP10 Use Model L 6217 remote alarm
20. UBING OUTER PIN 3 PIN CONNECTOR OUTER PIN Set cylinder on work surface with motor mounting holes down and closest to you Insert three align ment pins into every other hole in the top of the cylinder as shown in Figure 4 19 Inspect the manifold and cylinder gaskets for tears and cleanliness Install cylinder gasket over alignment pins and adjust to fit cylinder Place manifold assembly over cylinder gasket Note orientation Figure 4 19 Install the manifold gasket over the manifold and install two more alignment pins in manifold as shown in Figure 4 19 Place right end plate over manifold gasket Inspect cylinder gasket for proper alignment inside and outside of cylinder Page 4 13 Right End Page 4 14 11 12 13 14 LP6 Plus LP10 and LP20 Service Manual Start three 6 32 x 1 screws in the three cylinder holes not having alignment pins Turn screws down with a hex driver just enough to compress gaskets Remove the three alignment pins from the cylinder and start three more 6 32 x 1 screws Remove the remaining alignment pins and start 10 6 32 x 3 8 screws in the remaining right end plate holes Verify the following manifold gasket is visible around all edges of the manifold and cylinder gasket is visible around the entire interior and exterior of the cylinder Tighten screws evenly and in a crossing pattern starting with the cylinder screws as shown in Figure 4 20 Figure 4 20
21. cement on page 4 3 Perform the Calibration Process on page 3 8 Perform the Reassembly Process on page 3 17 Perform the Run In Process on page 3 21 gt a a Q Perform the Final Inspection Process on page 3 26 Page 2 1 Recertification LP6 Plus LP10 and LP20 Service Manual Recertification This process describes the minimum steps necessary to perform a recertification to the LP6 Plus LP10 and LP20 Volume Ventilators Ref erence other repair processes that may be necessary before performing calibration Forms You must use a copy of the Service Record and Run In Log found at the end of this manual to document all repairs and testing and forward copies to Nellcor Puritan Bennett Procedure Perform the Check In Process on page 3 1 Perform the Calibration Process on page 3 8 Perform the Reassembly Process on page 3 17 Perform the Run In Process on page 3 21 OV a amp N Perform the Final Inspection Process on page 3 26 November 2000 Page 2 2 3 Testing Check In November 2000 Exterior Visual Inspection a Verify that the ventilator s serial number agrees with the attached paperwork Verify any notes etc that may be attached to the unit b Verify that there is a J sticker on the serial number plate if the serial number is less than 101132 Note If the unit is within the range listed above and it does not have the appropriate sticker return the unit to Nellcor Pu
22. ch Date Check In Calibration Reassembly Calibration Reassembly Begin Run In End Run In Begin Run In End Run In Final Final FINAL INSPECTION P pass F fail FINAL INSPECTION P pass F fail Visual Visual Controls Controls Alarm check output test Alarm check output test Volume Stability lt 4 Volume Stability lt 4 Relief Valve Relief Valve Power Switch Power Switch High alarm lt 35 High alarm lt 35 Assembly Assembly Date Signature Hours out Ventilator Service Record LP6 Plus LP10 and LP20 Service Manual November 2000 Page 5 4 NELLCOR PURITAN BENNETT SERIAL NUMBER Ventilator Service Run In Log NORMAL RUN IN DATE TIME OCCURRENCE Begin Adult Run Begin Battery Run Down minutes to Low Power End Battery Run Down End Battery Run Down Adult Run Minimum 20 Hour RUN IN WHEN PRINTED CIRCUIT BOARDS HAVE BEEN REPLACED IN SERVICE DATE TIME OCCURRENCE Begin Adult Run Begin Battery Run Down minutes to Low Power End Battery Run Down Adult Run Begin High Rate Run End High Rate Run Begin Max Volume Run End Max Volume Run Minimum 20 Hour 6 Equipment Calibration Calibration of Model 6960 Calibrator Note Perform this procedure at least every three months Remove the left side cover from a functional LP6 Plus LP10 or LP20 ventilator that is ready for calibration Disconnect the inter nal battery from
23. d or U10 on the older through hole board is correct by match ing the notches on the ROM to the notch indicator on the board e EPROM leads are seated correctly and not bent e EPROM has a label Carefully mount the Power Motor Board by positioning it over the pins in the Logic Board Press the Power Motor Board evenly down onto the pins Figure 4 24 Check all the pins connecting the boards to make sure that no pins are bent and all pins are fully seated into the connectors Secure the Power Motor Board using five 6 32 x 3 16 button head hex screws at locations 7 9 11 12 and 13 in Figure 4 23 If a newer surface mount Power Motor board is used secure with a 4 40 x 3 16 button head hex screw at location 8 in Figure 4 23 Page 4 21 Front Panel Knob Installation Page 4 22 LP6 Plus LP10 and LP20 Service Manual If an older through hole Power Motor board is used install a 6 32 x 3 4 button head hex screw to secure the heat sink dampener to the front panel If a through hole Power Motor board has replaced a surface mount board a fan assembly from the L 1618 Fan Kit must also be installed Verify all shafts on the front panel are fully counter clockwise Place nylon washers and then O rings into locking knobs and install onto the two shafts with brass nuts VOLUME and BREATHING EFFORT Position the knobs with respect to the minimum overlay markings Obtain correct spacing with a 025
24. d remove the bottom cover Write the unit s serial number on the inside of the bottom cover if working on more than one vent at a time Verify proper fit of the top and side covers then remove the top cover both side rails and side covers Remove the filter cap filter screen filter filter screen and O ring Alternatively the unit may have the flatpak filter and retaining ring If so remove these and the O ring If present remove the communication port cover Remove the High Pressure Relief HPR Valve cover November 2000 Check In LP6 Plus LP10 and LP20 Service Manual 3 Internal Visual Inspection q Examine the circuit boards for damage by viewing them as well as possible D Check for liquid in the internal tubing C Check for any other visible damage 4 Ventilator Operations a Connect a calibrator ribbon cable to the communication port Verify that a printer is connected to the calibrator Verify the 110 220 V switch is set to 110 b Connect the ventilator s power cord to AC turn the ON OFF switch to ON and set the MODE switch to Assist Control e Verify proper LED and ALARM operation e Set the MODE switch to Standby e Verify the front panel AC Power Batt Charge LED is on Do not adjust any other settings Turn the printer on and press the Battery Test button on the ventilator to generate a status printout Note Any time the settings change or there is an alarm condition a print ou
25. dam aged D Verify the internal battery is disconnected from the harness and the red harness and red or white battery wires are both on the pointed side of the connectors C Verify the High Pressure Relief screw is tightened Right End Inspection qA Verify Motor Gearbox is secured to the cylinder with four screws b Verify that the six cylinder and ten manifold screws are properly seated November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 Calibration Verify the motor wiring assembly is not damaged or pinched between the gearbox and cylinder Verify three nylon washers and three retaining rings are present on the Connecting Rod Assembly Verify that Loctite is present on all piston feet set screws Verify Loctite is present on all Crank Arm set screws and they are properly seated 3 Front Panel Inspection Aq Verify the correct installation of the overlays D Verify all knobs are correctly aligned and are not loose C Verify the VOLUME and BREATHING EFFORT knobs do not turn without pushing the knobs in first d Verify the meter needle is within one division of 10 If nec essary readjust the needle to 10 MODE switch must be on Standby and the power switch Off Verify the Patient Air tube screen is not damaged f Verify all pins connecting the Power Motor and Logic Boards are seated correctly Q Verify Display Board ribbon cable is correctly connected Verify installation
26. e older through hole power motor board can be easily distinguished by its heat sink The newer sur face mount power motor board doesn t need a heat sink The LP20 has been using only through hole boards 5 Disassembly q Disconnect internal battery from wire harness D Remove the six screws attaching the left end plate For LP6 LP10 e Disconnect the fan and alarm wires e Remove left end plate e Verify the ventilator s serial number is on the left end plate For LP20 e Cut the cable tie securing the remote alarm and the alarm output cables to the external battery circuit breaker wires e Disconnect the remote alarm cable from the Logic Board e Disconnect the fan and alarm wires November 2000 Page 3 6 LP6 Plus LP10 and LP20 Service Manual November 2000 Check In e Remove the left end plate and disconnect J2 and J3 from the nurse call circuit assembly e Verify the ventilator s serial number is on the left end plate Remove the handle Remove the door door rod s Teflon washers and crescent springs Remove the three screws securing the front panel to the right end Remove the front panel and disconnect all connectors from the front panel Install a discharge plug on the 10 pin connector of the power motor board J6 on the newer surface mount board or J3 on the older through hole board Remove the three screws that secure the back panel to the right end Separat
27. e the gearbox and piston assemblies bD Remove all 16 screws from the right end plate C Separate the manifold cylinder and right end plate d Remove all gasket material from manifold cylinder and right end plate 2 Remove retainer ring filter screen and O ring if necessary 3 If expiration leaf is replaced reinstall O ring filter screen and retaining ring Note Replace this leaf if unit has low volume delivered at low flow rates Use Kit Model L 1724 Figure 4 16 Note Replace this leaf for internal leaf oN vibration Use Kit Model L 1724 Figure 4 17 4 Inspect manifold assembly for proper assembly and verify 10 brass inserts are present Replace internal tubing as needed Figure 4 18 5 If installing a new cylinder inspect cylinder and clean with iso propyl alcohol if necessary November 2000 Page 4 12 LP6 Plus LP10 and LP20 Service Manual SOLENOID PROXIMAL TUBE Figure 4 18 10 TUBINGy gt P EXHALATIO TUBE 3 5 TUBING Right end plate Figure 4 19 AS N 6 lt aN Manifold gasket Nye SSS RON Spee RG DR anifold gaske eS oS Manifold assembly 8 Alignment pin Cylinder gasket y 9 Cylinder Alignment pin 10 Motor housing holes on bottom November 2000 Right End LOCK WASHER INSTALLED ON SCREW BETWEEN MANIFOLD AND CABLE CLAMP CABLE CLAMP FLAT WASHER SCREW ADHESIVE SERIAL NUMBER VISIBLE CABLE TIE 5 5 T
28. e the two Separate the unit into the following sections e right end e back panel e front panel and left end plate with remaining covers and hardware If working on more than one vent at a time verify that the serial number is on the outside of the cylinder and the inside of the front panel Initial and date the service record sheet when finished Page 3 7 Calibration Calibration Using the Calibrator e Preliminary Checks and Set up Page 3 8 LP6 Plus LP10 and LP20 Service Manual By pressing the CAL button on the calibrator the first calibra tion step will appear on the calibrator s display A description of the calibration step being performed appears on the left and information concerning that step appears on the right of the calibrator s display If OK is displayed and the CAL ERROR LED is not on that cali bration step has been successful You must then press SET to record the data and advance to the next step If a number is displayed there has been a problem in that step of calibration reject the unit If a unit fails any test repeat the calibration If the unit still fails reject the unit and contact Nellcor Puritan Bennett Tech nical Service for assistance The SIL button may be used to silence the alarms Caution Use of an anti static workstation is necessary to perform the fol lowing process 1 Back Panel Inspection dQ Verify that the harness wires and ribbon cable are not
29. embly for workmanship Ensure the three nylon washers are in place Ensure the spacing on the pins is cor rect Ensure the bearings are properly seated 12 Apply silicone RTV adhesive to the two mounting holes in the piston and attach the crank assembly onto the piston with two 6 32 x 1 2 flat head hex screws November 2000 Page 4 34 5 Forms November 2000 On the following pages are blank copies of the forms used when servic ing the LP6 Plus LP10 and LP20 Volume Ventilators These forms are the e Ventilator Run In Log e Ventilator Service Record Photocopy these forms and use them to document maintenance and repair of your ventilator Use these forms for your internal documenta tion and to ensure accurate records are kept about necessary mainte nance and repairs You must complete a Service Record and Run In Log and return a copy to Nellcor Puritan Bennett each time you repair an LP6 Plus LP10 or LP20 Volume Ventilator Page 5 1 LP6 Plus LP10 and LP20 Service Manual November 2000 Page 5 2 NELLCOR PURITAN i BENNETT Ventilator Service Record Dealer Address Serial Number Model Start Date Reason for return Inspection results Technician Hours in LEDSs Alarms Pass Fail Software level Part Procedure Serial number Tech Date Work performed Te
30. epairs Battery Replacement 4 1 Right End 4 2 Motor and Piston Removal 4 2 Kapseal Quadring and Piston Guide Replacement 4 3 Piston Installation 4 6 Set Piston Tension 4 7 System Leak Test 4 8 Motor Gearbox Installation 4 9 Manifold Leaf and or Cylinder Replacement 4 12 Front PONGl s sss4escee a a ae ses 4 15 Meter Replacement 4 15 Power Motor Board Removal 4 16 Logic Board Removal 4 17 November 2000 5 Forms LPG Plus LP10 and LP20 Service Manual Disolay Board Removal 4 18 Display Board Installation 4 18 Logic Board Installation 4 19 Power Motor Board Installation 4 21 Knob Installation 4 22 Overlay Replacement 4 23 PLC Replacement LP10 LP20 only 4 24 Left End Plate 4 26 Fan Assembly Replacement 4 26 Control Door 4 27 Front Panel Door Magnetic Strip Replacement 4 27 Front Panel Door Overlay Replacement
31. er Page 6 2 Note Perform this procedure at least every six months 1 11 Disconnect the tubing from the two pressure gauges Carefully remove the face plates Connect a large syringe and a calibrated pressure meter to the gauge on the left Apply 12 0 2 cmH O of pressure as indicated by the calibrated pressure meter Using the zero screw adjust the needle of the left pressure gauge so it reads 12 Apply 18 0 2 cmH O pressure as indicated by the calibrated pressure meter The left pressure gauge should indicate 18 2 0 cmH O Repeat this step for pressure readings of 20 cmH O and 25 cmH O Connect the syringe and the calibrated pressure meter to the pressure gauge on the right Apply 100 0 2 cmH O pressure as indicated by the calibrated pressure meter Using the zero screw adjust the needle of the gauge so it reads 100 Remove the syringe and pressure meter Install the face plates and securely reattach the tubing to the gauges Check the system for leaks and signs of wear November 2000 7 Technical Bulletins Keep technical bulletins in this section November 2000 Page 7 1 LP6 Plus LP10 and LP20 Service Manual November 2000 Page 7 2 8 Miscellaneous Information Keep miscellaneous information in this section November 2000 Page 8 1 LP6 Plus LP10 and LP20 Service Manual November 2000 Page 8 2 NELLCOR PURITAN BENNETT Nellcor Puritan Bennett Inc Minneapo
32. ess and hold down the Alarm Silence Reset button for three seconds or longer Verify that e Setting Error Presilence LED lights continuously e All other LEDs light momentarily e The alarm sounds momentarily e Only the AC Pwr Batt Charge LED stays lit 3 Turn remote alarm on and set High Alarm Limit Switch of ven tilator to 15 cmH O hPa High Pressure LED on ventilator and Alarm LED on remote alarm must flash and alarm must sound on ventilator and remote alarm within two cycles 4 Set High Alarm Limit Switch to 90 cmH O hPa Press Alarm Silence Reset button on ventilator to reset the alarm November 2000 Page 3 29 Final Inspection Alarm Output Test LP20 only Page 3 30 LP6 Plus LP10 and LP20 Service Manual Disconnect the Patient Pressure tubing from the ventilator Low Pressure Apnea LED on ventilator and ALARM LED on remote alarm must flash and alarm must sound on ventilator and remote alarm within several cycles For LP20 verify audible alarm on ventilator and remote alarm is a dual pulse alarm Re connect the Patient Pressure tubing to the ventilator and press RESET button on remote alarm Set MODE to Standby The remote alarm must sound an audi ble alarm and ALARM LED must flash Turn remote alarm OFF and disconnect from ventilator Set On Off switch OFF then back to ON Connect the 1 4 phono plug on the Alarm Tester Model Y 6048 to the ALARM OUTPUT jack of the ventilator Connect a dig
33. ettings Oxo a ice Setting LOW ALARM 2 CMH5O hPa HIGH ALARM LIMIT 90 cmH20 hPa VOLUME 1 Liter BREATH RATE 10 BPM INSPIRATORY TIME 1 0 Second BREATHING EFFORT 5 CMH O hPa MODE Standby Pressure Limit Control Fully clockwise Set the MODE Switch to Assist Control Allow the unit to cycle at least three times Verify that the PEAK PROX does not vary by more than 4 0 cmH O hPa between three consecutive cycles Verify that the PATIENT PRESSURE meter reading is within 8 cmH O hPa of the PEAK PROX reading Page 3 5 Check In LP6 Plus LP10 and LP20 Service Manual Pp Allow the unit to cycle and check for any other unusual sounds or abnormal operation q Attempt to isolate any problems to the proper assembly If the problem is verified note it on the Service Record r Set the MODE switch to Standby and the ON OFF switch to OFF Disconnect the unit from AC power Set the MODE switch to Assist Control and verify proper start up operation on internal battery Set the MODE switch to Standby and disconnect the calibrator and test lung Note If unit is being recertified only proceed to Calibration Caution Use of anti static work station and wrist strap is necessary to avoid causing possible damage to the circuit boards Note There are two types of logic and power motor boards that have been used with the LP6 and LP10 an older through hole board and a newer surface mount board Th
34. f unit with two screws Install a top cover and retainer if needed Secure with two screws hand tightened Install the bottom cover and four bottom feet Passed units are ready for Run In FRONT PANEL A i Figure 3 2 POWER MOTOR BOARD LP6 LP10 with through hole Power Motor Board ALIAM WIRES November 2000 REMOTE ALARM CABLE ASSEMBLY LOW VOLTAGE WIRE HARNESS ASSEMBLY Page 3 19 Reassembly Figure 3 3 LP6 LP10 with surface mount Power Motor Board Page 3 20 10 and LP20 Service Manual ALARM WIRES ALARM LP6 Plus LP HANDLE FRONT PANEL 2 W _ pOWER MOTOR BOARD Ne REMOTE ALARM CABLE LOW VOLTAGE WIRE HARNESS ASSEMBLY ROUTE WIRES AS SHOWN BATTERY BRACKET Figure 3 4 LP20 y FRONT PANEL POWER MOTOR BOARD ALARM WIRES N NURSE CALL CABLE ASSEMBLY BATTERY BRACKET LOW VOLTAGE WIRE HARNESS ASSEMBLY November 2000 LP6 Plus LP10 and LP20 Service Manual Run in Before beginning the Run In process make a copy of Run In Log Sheet located in the back of this manual Note Reject the unit if one or more of the following conditions occur Run in 2 3 4 November 2000 Fai
35. fferent charge voltages Updated the LP20 Alarm Output Test for both normally open and normally closed modes The order of procedures has been rearranged to reflect the order of Preventive Maintenance A new gearbox is being used which has a different output shaft and a new crank arm with only one set screw The crank arm is now bonded to the output shaft with an adhesive A torque speci fication of 35 in lbs is now required for the crank arm set screw The AC power cord has been updated to a new grounding scheme for the LP6 and the LP10 New surface mount logic and power motor boards are installed differently Page 1 3 Equipment Tools and Supplies LP6 Plus LP10 and LP20 Service Manual Equipment Tools and Supplies Equipment Calibrator Model L 6960 Alarm Tester Model Y 6048 LP20 only Remote Alarm with Cable Model L 6213 or L 6217 for LP6 LP10 Model L 6217 for LP20 Right End Tester Model L 6951 Right End Tester Adapter Plug External Battery with Cable Printer Calibrated Digital Multimeter Anti Static Mat with Wrist Strap Arbor Press Stop Watch If calibrating own Model L 6960 and L 6951 Calibrated Pneumatic Indicator P101 or P102 Pressure Pump or equivalent Tools Allen Drivers 5 64 3 32 7 64 1 8 9 64 Allen Wrenches 050 1 16 Nut Drivers 3 16 1 4 3 8 1 2 9 16 Torque Wrench Torque Wrench 35 in lbs Large Slotted Screwdriver Small Slotted Screwdriver Large Needle Nose Pliers
36. for LP20 1 Connect the following e LP6 Plus LP10 Calibrator ribbon cable to the communica tions port e remote alarm to remote alarm jack e ventilator power cord to AC 2 Set the On Off switch to ON Note Make sure that the printer is not connected at this point 3 Press the calibrator s BPM key Verify all positions of BREATH RATE switch on the calibrator display left number 4 Press the calibrator s INS key Verify all positions of INSPIRA TORY TIME switch 5 Press the calibrator s ALARM key then NEXT key twice Verify all positions of MODE switch Alarms should occur Return MODE to Standby 6 Press NEXT key Verify all positions of HIGH ALARM LIMIT switch November 2000 Page 3 27 Final Inspection LP6 Plus LP10 and LP20 Service Manual 7 Press NEXT key Verify all positions of LOW ALARM switch 8 Press VOL key 9 Set VOLUME knob clockwise to exactly 6 on front panel The left VOLUME value on the calibrator must be 600 0 050 10 Set VOLUME knob clockwise to exactly 1 6 on front panel The left VOLUME value on the calibrator must be 1 600 0 050 11 Verify PATIENT PRESSURE meter needle is within one division of 0 Note If meter needle is off do not adjust now Adjust meter only when unit is powered OFF 12 Turn BREATHING EFFORT knob towards zero until the green Breathing Effort LED just comes on The BREATHING EFFORT knob line must be within the green and blue front pane
37. four 6 32 x 1 2 hex head capscrews d Raise the motor being careful not to damage the two align ment pins Use both thumbs underneath 2 Remove the motor from the crank arm Set off to the side being careful with the wires Set with the circuit board facing up 3 Pull the piston out by the connecting rod and set aside November 2000 Page 4 2 Right End LP6 Plus LP10 and LP20 Service Manual Kapseal Quadring and Piston Guide Replacement Piston plate Figure 4 3 Quadring Kapseal See Figure 4 3 1 Use a single edge razor blade to carefully scrape out the resi due build up from inside the cylinder Wipe the cylinder clean The inside of the cylinder should be clean and free of scratches Wipe out with a paper towel and alcohol if neces sary 2 Remove and discard old Kapseal and Quadring from the piston using your nail or a delrin screwdriver 3 Remove and discard the eight 8 32 x 3 8 hex set screws from the piston angle brackets Remove Loctite residue from piston angle brackets using an x acto knofe November 2000 Page 4 3 Right End LP6 Plus LP10 and LP20 Service Manual 4 See Figure 4 4 Remove the old piston guides from the piston angle brackets Separate the plastic from the steel guides Dis card the plastic guides and clean the steel guides removing any silicone residue 5 Install two new 8 32 x 3 8 hex set screws into each of the pis ton angle brackets The ends of the
38. from AC Disconnect the calibrator Place a port cover fully over the COMMUNICATION PORT Remove the patient circuit from the unit Install a new intake filter Wrap AC cord Place completed certified sticker to the bottom of the front panel November 2000 4 Repairs Battery Replacement November 2000 Figure 4 1 Battery d S Transformer Blocks 2 Battery bracket Verify the two pin connector on the battery assembly is discon nected Loosen the four 3 hex screws in the bracket holding the battery assembly in place Remove the battery Check the new battery subassembly for the following e The black wire is negative and connected to the non pointed side of the connector e There are no cracks on the battery case Install new battery and tighten the four 3 hex screws in a criss cross pattern in the bracket holding the battery Tighten just enough that the battery doesn t move Be careful not to overtighten and crack the bracket Page 4 1 Right End LP6 Plus LP10 and LP20 Service Manual Right End Motor and Piston Removal Gearbox Figure 4 2 Crankarm Connecting rod First do the following see Figure 4 2 dQ Align the crank arm using the rotor until the piston is all the way into the cylinder b Remove and discard the small set screw on the crank arm if present and then remove and discard the large cap head screw on the crank arm C Remove the
39. g chapters Provides an overview of the manual Lists the procedures that comprise a Recertification and a Preventive Maintenance Provides procedures for verifying operation and calibrating the ventila tor Instructions to disassemble and replace parts as needed in the ventila tor Includes reproducible forms for run in log final inspection and service record Provides calibration procedures for the Calibrator and the Right End Tester Space for saving technical bulletins Space for saving miscellaneous information Page 1 1 Conventions LP6 Plus LP10 and LP20 Service Manual Conventions The following differentiation is made in this manual between Notes Cautions and Warnings Note Directions that make it easier to use or service the product Caution Directions that help avoid damaging the ventilator Warning Directions that warn of conditions or actions that put the patient the technician or other people at risk of injury November 2000 Page 1 2 LP6 Plus LP10 and LP20 Service Manual What s New in this Revision What s New in this Revision Chapter 3 Testing Chapter 4 Repair November 2000 Surface mount logic and power motor boards are being used in addition to through hole boards Procedures have been rewritten to include all board types The internal battery charge circuit has been updated to a charge voltage of 14 4V The calibration procedure has been changed to accommodate di
40. he pressure from inside the manifold Remove the assembly from the Right End Tester Remove the air tube adapter plug Apply a drop of Loctite 242 on each set screw and tilt the sub assembly such that the Loctite flows around the threads wipe off excess Push the piston about 1 2 way down into the cylin der Inspect the Manifold Assembly and verify that qA The solenoid is securely mounted b All three pieces of 1 4 internal tubing are present seated properly and no kinks are present C Patient Pressure and Exhalation Valve tubes appear straight secure and clean November 2000 Right End LP6 Plus LP10 and LP20 Service Manual Motor Gearbox Installation Note There are two types of gearboxes that have been used in LP ventila tors The only difference between the two is the shape of the output shaft The older type features a round output shaft with key The newer type features a round shaft with two flats cut into opposite sides See Figure 4 13 Note which type will be used because the pis ton crank arm is different for each 3 8 Key Q ja 93 8 O 1 Inspect the Motor Gearbox and verify that e Wires are not damaged 01 2 e Wires are correctly positioned on magnetic sensor terminals Figure 4 13 as follows Types of Output Shaft Wire Color Position yellow 0 red black e Terminals are properly seated e Two dowel pins are present
41. ital multimeter to the tester red wire to positive black wire to negative Set the multimeter to VDC Set the selection knob to BATTERY CHECK Verify that the dis played voltage is gt 8 VDC Set the selection knob to NURSE CALL Set the voltmeter to ohms e If the digital multimeter reads greater than 1 0 megohms go to step 5 e If the digital multimeter reads less than 1 0 ohm go to step 12 Disconnect the multimeter leads from the alarm tester Set the selection knob to ALARM TEST Set the MODE to Assist Control Set the HIGH ALARM LIMIT to 15 Within several breaths verify the LED on the alarm tester is lit continuously as the High Pres sure LED lights and an audible alarm sounds Set the HIGH ALARM LIMIT to 90 Press Alarm Silence Reset Disconnect the Patient Pressure Tubing from the ventilator November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Final Inspection Within several breaths verify the Low Pressure Apnea LED is lit and a dual pulsing alarm is generated along with a corre sponding flashing of the alarm tester LED Reconnect the Patient Pressure Tubing Press Alarm Silence Reset Proceed to step 19 Disconnect the multimeter leads from the alarm tester Set the selection knob to ALARM TEST Set the MODE to Assist Control Verify LED on alarm tester is lit Set the HIG
42. l it is properly seated 11 Verify proper installation by running a finger around the Kapseal feeling for bumps or gaps Look down the edge of the piston and ensure the Kapseal is flat and not at an angle as shown Figure 4 9 Correct Figure 4 6 Figure 4 7 Incorrect Incorrect Figure 4 8 Figure 4 9 November 2000 Page 4 5 Right End Piston Installation Motor mounting holes away from you Le Figure 4 10 Figure 4 11 Figure 4 12 Page 4 6 Equal space alll around piston Cross pattern LP6 Plus LP10 and LP20 Service Manual Inspect the Kapseal on the piston to ensure that it has not been damaged If it has a new Kapseal must be installed Check for three nylon washers and three ring retainers on the crank arm Place the cylinder with the motor mounting holes away from you Figure 4 10 Orient the piston so that the crankarm is also directly away from you Dip the front edge of the piston just down into the cylinder Figure 4 11 Press the piston against the cylinder wall so that the Kapseal at the rear of the piston will not catch on the top of the cylinder as you gently ease the rest of the pis ton into the cylinder Position the piston in the cylinder so that the tops of all four piston angle brackets are even with the top of the cylinder Turn the bottom set screw in one angle bracket until the plas tic piston guide just touches the cylinder wall Turn the top set
43. l markings 13 Set all knobs as follows Control Setting MODE Standby LOW ALARM 2 cmH20 hPa HIGH ALARM UMIT 90 cmH20 hPa VOLUME 1 0 Liter BREATH RATE 10 BPM INSPIRATORY TIME 1 0 Second BREATHING EFFORT approximately 5 cmH20 hPa Pressure Limit Control Fully Clockwise LP10 LP20 only 14 Connect the printer to AC and the calibrator and turn the printer ON November 2000 Page 3 28 Final Inspection LP6 Plus LP10 and LP20 Service Manual 15 Attach the red test plug to the ventilator and set MODE to Assist Control The printer will print a status printout 16 After the printer stops printing turn printer off and remove printout 17 On the printout verify serial number of the unit HOURS DATE and TIME are correct 18 Using a stop watch verify that the cycle time is 6 1 seconds Start the stop watch at the beginning of the the cycle then stop at the beginning of the next cycle Alarm Check 1l For LP6 LP10 ventilators performing the following Press the Alarm Silence Reset button Verify that all LEDs light and an alarm sounds then all LEDs turn off except the AC Pwr Batt Charge LED 2 For LP20 ventilators perform the following Note Two types of alarm sound patterns exist for the LP20 a steady on off pulsing alarm and a dual pulse alarm When verification of an audible alarm is necessary assume the steady on off type is required unless otherwise noted Pr
44. lation 7 Attach meter wire assembly with the red wire over the stud marked with a plus and the Meter black wire to the other stud as shown Figure f 4 21 To secure the wires place a 10 32 Kep nut on each stud and hand tighten with a 3 8 nut driver 10 32 Kep nut 2 8 Plug connector to the Logic Board J2 on the Black wire newer surface mount board or J12 on the older through hole board Tuck wires between circuit boards Page 4 15 Front Panel LP6 Plus LP10 and LP20 Service Manual Figure 4 22 Power motor board Logic board Front panel Caution Use of an anti static workstation is necessary to handle the front panel and circuit boards safely Power Motor Board Removal 1 Check for the presence of the resistor plug on the Power Motor board Install resistor plug for a minimum of one minute at J6 on the newer surface mount board or J3 on the older through hole board 2 Remove the five 6 32 x 3 16 button head hex screws and one 4 40 x 3 16 button head hex screw if present securing the Power Motor board to the stand offs Figure 4 22 3 Remove the 6 32 x 3 4 button head hex screw from the heat sink dampener if present 4 Raise the Power Motor board carefully from the front panel There are two sets of pin connectors November 2000 Page 4 16 LP6 Plus LP10 and LP20 Service Manual Logic Board Removal November 2000 Note Note Note Front Pa
45. liminate static before handling the circuit boards November 2000 LP6 Plus LP10 and LP20 Service Manual Logic Board Installation November 2000 Figure 4 23 Front Panel 1 Check the Logic Board for the following The proper orientation of the transducer mounting screws The locking nuts should be on the transducer side No component damage No trace or pad damage Nuts on switches and pots are tight Polarity of ROMs by matching the notches on ROMs to the notch indicators on the board All leads are seated correctly and not bent Presence of stick on labels on the two large EPROM chips U24 and U25 on the newer surface mount boards or U25 and U26 on older through hole boards 10 13 2 Mount the Logic board with five 6 32 x 11 16 stand offs at locations 7 9 11 12 and 13 in Figure 4 23 Hand tighten stand offs using a nut driver Install one 6 32 x 3 16 button head hex screw at location 10 in Figure 4 23 If a newer surface mount Power Motor board is being rein stalled install a 4 40 x 11 16 standoff at location 8 in Figure 4 23 If an older through hole Power Motor board is being reinstalled install a 4 40 x 3 16 button head hex screw at location 8 in Figure 4 23 Page 4 19 Front Panel Page 4 20 LP6 Plus LP10 and LP20 Service Manual 3 Connect the Display board ribbon cable to the Logic board J4 on the newer s
46. lis MN U S A General 800 497 4979 Customer Service 800 497 4968 technical Service 800 497 3787
47. ls to cycle or cycles erratically Exhibits any abnormal mechanical noise Produces unexpected alarms Generates incorrect printouts Does not pass battery run down The unit does not respond correctly to any condition explained in the Run In process Plug ventilator into AC power Turn power switch on Verify the pressure limit control is turned fully clockwise do not over tighten Set front panel to Adult Run parameters as follows LOW ALARM Minimum HIGH ALARM LIMIT Maximum VOLUME 1 0 liters BREATH RATE 16 BPM INSPIRATORY TIME 1 5 second BREATHING EFFORT 5 cmH 0 MODE STANDBY Connect RED run in plug with silicone connector to the venti lator Turn MODE switch to ASSIST CONTROL Reset any alarms Record serial number Adult Run start date and time on Run In Log sheet Allow unit to run for a minimum of 2 hours Ver ify no alarms Page 3 21 Run in Page 3 22 5 LP6 Plus LP10 and LP20 Service Manual Attach printer to the ventilator turn printer on and initiate a printout For the SET parameters on all printouts The Mode Breath Rate Inspiratory Time Low Alarm and High Alarm Limit must all be exact setting values e The volume must be 980 1 020 liters The breathing effort must be 4 5 to 5 5 cmH O hPa If the date or time on the printout is not correct connect a cal ibrator to the COMMUNICATION PORT and enter in the correct date and time using the following steps qA
48. m the outside going inward if not present already Remove the terminal strip from the back panel Connect the white and black wires of the power cord to the ter minal strip as shown Figure 4 28 and 4 29 Note the place ment of washers on the ground stud Connect the green wire of the power cord to the ground stud for the LP6 LP10 or the terminal strip for LP20 Apply Loctite 242 to terminal strip screws and reinstall onto the back panel Page 4 29 Back Panel 12 13 LP6 Plus LP10 and LP20 Service Manual For LP20 only connect the additional green and yellow wire to the terminal block and the ground stud Connect the green and yellow wire harness wire and any addi tional washers or nuts to the ground stud as shown in Figure 4 29 Secure the ground stud Replacement of AC ON OFF Switch See Figure 4 28 and 4 29 1 Page 4 30 Disconnect the four wires on the old ON OFF switch taking note of their location Depress the two locking tabs on each end of the ON OFF switch and remove the switch from the back panel Bend two lugs on the new ON OFF switch to match the bent lugs on the old ON OFF switch Install the new ON OFF switch in the back panel with the zero toward the bottom edge of the back panel Reconnect the four wires to their previous locations on the new ON OFF switch The wires from the terminal strip go to the lugs closest to the bottom edge of the back panel Figure 4 28 and 4 29 N
49. must flash and an alarm must sound The Internal Battery LED may flash momentarily Verify the External Battery LED is on Press the Alarm Silence Reset button to reset the Power Switchover LED and alarm Press and hold the Battery Test button The External Battery LED must flash and the PATIENT PRESSURE meter must indicate above 0 Release the Battery Test button Disconnect the test battery The Power Switchover and Internal Battery LED must flash and an alarm must sound Press the Alarm Silence Reset button to reset the Power Switchover LED and alarm Press and hold the Battery Test button The Internal Battery LED must flash and the PATIENT PRESSURE meter must indicate high Release the Battery Test button Reconnect unit to AC power Remove the red test plug and connect a patient circuit with a soft test lung Allow it to stabilize for a couple of cycles If nec essary adjust VOLUME until the PEAK PROX is 50 10 cmH O hPa Set the HIGH ALARM LIMIT to 25 cmH O hPa The High Pressure LED must flash and an alarm must sound within two cycles Press Alarm Silence Reset Wait 2 or 3 breaths until the PEAK PROX PRESS value on the calibrator stabilizes Verify PEAK PROX PRESS value is less than 35 cmH O hPa Record highest value Page 3 33 Final Inspection Page 3 34 Assembly 1 Oe N O ARA et LP6 Plus LP10 and LP20 Service Manual Set MODE to Standby Turn the unit OFF and disconnect
50. nal battery is disconnected from the har ness Connect the calibrator s external battery connector to the EXTERNAL 12VDC receptacle on the back panel of the ventilator Press and hold the CHARGE button on the calibrator Do not hold the CHARGE button for more than ten seconds If the OK appears on the display press the SET button on the calibrator and hold the CHARGE button down until the display has changed to the next step 22 EXT VOLTS qA With the calibrator s external battery connector still attached to the back panel connect a digital multimeter to the calibrator s internal battery connector D If necessary adjust the Trim Pot on the Power Motor board with a plastic screwdriver e For any through hole Power Motor board adjust the R60 until the voltage reads 13 80 05 VDC on the multi meter e For a surface mount Power Motor board with software Version C can be identified by pressing the TYPE button on the calibrator or P N Y 100116 00A can be identified by the label on the board adjust the R108 until the volt age reads 13 80 05 VDC on the multimeter Page 3 13 Calibration Page 3 14 LP6 Plus LP10 and LP20 Service Manual e For a surface mount Power Motor board with P N Y 100116 00B or higher can be identified by the label on the board adjust the R108 until the voltage reads 14 40 05 VDC on the multimeter Note The software version should not be used to determine if the charge voltage
51. nel Do not remove the pressure limit knob LP10 and LP20 only Previously when through hole logic boards were replaced the time amp date EEPROM U24 had to be transferred from the old board to the new board to retain device history i e hours since last preventive maintenance Now with the surface mount board the time amp date EEPROM now U26 has a different design The EEPROM from U24 on the through hole board will not fit in U26 on the surface mount board Therefore when a through hole logic board is replaced with a surface mount board a preventive maintenance must be performed Otherwise there would be no record of device hours since the last preventive maintenance When a surface mount logic board is replaced with another surface mount logic board the U26 time amp date EEPROM is to be trans ferred to the new board A preventive maintenance is not automati cally required Turn all seven knobs completely counter clockwise Loosen the set screws securing the knobs to the shafts Remove the knobs and the O rings behind BREATHING EFFORT and VOLUME 2 Remove the five 6 32 x 11 16 stand offs the one 6 32 x 3 16 button head hex screw and the one 4 40 x 3 16 button head hex screw or 4 40 x 11 16 stand off securing the Logic board to the front panel 3 Disconnect the meter wire assembly from the Logic board J2 on the newer surface mount board or J12 on the older through hole board 4 Disconnect the Displa
52. ng only light pressure Do not over tighten Install two hex head screws in the bottom of the bezel Hand tighten using only light pressure Do not over tighten Install a new bezel overlay over the two Phillips head screws Install the coil spring over the adjustment shaft to rest around the shaft busing November 2000 Front Panel LP6 Plus LP10 and LP20 Service Manual Install knob base grooved side connecting with the spring Align notches in knob base to the corners of the shaft busing Apply adhesive Loctite 425 to the top knob set screw threads Compress the spring with the knob base and hold down a amp ONS Install the top knob on the adjustment shaft with the set screw on the flat side of the shaft Tighten the set screw 7 Check the function of the locking knob November 2000 Page 4 25 Left End Plate LP6 Plus LP10 and LP20 Service Manual Left End Plate Figure 4 26 6 32x3 8 Nylok 2 y Left end plate GQ Fah ip 6 Flat washer 4 0 Nurse call board Fan Assembly Replacement See Figure 4 26 1 Remove the two 6 32 x 3 8 cap head screws 2 Remove and discard the old fan 3 Attach the fan at opposite corners to left end plate using two 6 flat washers per corner between fan and plate and two 6 32 x 3 8 cap head screws Hand tighten Ensure that the label is away from the plate and the wires come out of the fan towards the bottom front of the ventilator November 20
53. or board route the wires as shown in Figure 3 2 For LP6 LP10 with the newer surface mount power motor board route the wires as shown in Figure 3 3 For LP20 route the wire as shown in Figure 3 4 dA If the older through hole power motor board is used attach the fan assembly connector to J8 If the newer sur face mount power motor board is used a fan is not neces sary b If the newer surface mount power motor board is used attach the alarm connector to J7 on the board If the older through hole power motor board is used connect the alarm wires red wire to the terminal C For LP20 units connect the five pin connector from the nurse call circuit assembly P11 to the Logic Board Fasten the left end plate to the front and back panels with six screws Install e High Pressure Relief valve cover If standard inlet filter is used e O ring e Filter support screen e Filter e Filter support screen e Filter cap hand tightened If Flatpak inlet filter is used e O ring e Flatpak filter e Retainer ring hand tightened November 2000 LP6 Plus LP10 and LP20 Service Manual 13 14 15 16 17 18 Reassembly Secure the 1 4 tubing on the transducer with a cable tie Ver ify that the tubing is not kinked Position one side rail on the left side cover and fasten to the left side of unit with two screws Position one side rail on the right side cover and fasten to the right side o
54. ovember 2000 Back Panel LP6 Plus LP10 and LP20 Service Manual Bearing Replacement 1 Remove the two 6 32 x 1 2 flat head hex screws holding the connecting rod mount to the piston plate Remove the three retaining rings from the crank assembly Press the crank pin and the connecting rod pin out of the assembly Connecting Figure 4 30 Crank pin Crank arm Nylon Connecting washer Connecting fod mount rod pin Note The crank pin must remain in the crank arm The connecting rod pin should be pressed out with the locating mark up Figure 4 32 2 Press the two bearings out of the connecting rod Using Ace tone clean the adhesive residue from inside the bearing holes on the connecting rod Lay the connecting rod on a paper towel so the counterbores for the bearing flanges are facing up 3 Spray the inside of the holes for the bearings in the connecting rod with a brief burst of Loctite Primer N7649 Wipe the primer from the outer surface of the connecting rod Allow the primer to dry for three minutes minimum 4 Carefully clean the outside race on the two replacement bear ings Rotate the races of the bearings and feel for any rough ness 5 Apply a thin layer of Loctite 648 adhesive on the outside sur face of the bearing Note Application of the adhesive should be followed by the installation of the component within one minute November 2000 Page 4 31 Back Panel Page 4 32 LP6 Plus LP10 and LP20 Se
55. ow wire from between the terminal strip and chassis ground stud if present Squeeze the strain relief with pliers to pull the power cord from the rear panel November 2000 LP6 Plus LP10 and LP20 Service Manual RFI FILTER GRN YEL WIRE HARNESS WIRE q Back Panel Figure 4 29 Older LP6 LP10 All LP20 8 32 X 5 16 SOCKET Z HEAD CAP SCREW 8 INT stan WASHER 3 RED A PIN 3 DETAIL A PROFILE VIEW BLACK amp BLUE TO D 2X CABLE TIE GROUND STUD SEE DETAIL A BROWN WIRE FROM RFI FILTER BLUE WIRE ASSY SEE DETAIL B BROWN WIRE ASSY GRN YEL WIRE ASSY BLUE WIRE FROM mito LAS GREEN POWER CORD WIRE PIN 1 DETAIL B BLUE WIRE ASSY BROWN WIRE ASSY TERMINAL STRIP LABEL 11 November 2000 _ aie o Ld LINE BLACK POWER z CORD WIRE STRAIN RELIEF WHITE POWER CORD WIRE Inspect new power cord for properly stripped wires approxi mately 5 16 and no insulation damage Install strain relief on power cord approximately one inch from the end of the large insulation Orient the strain tab down and the green wire up Install power cord and strain relief into the back panel For LP6 LP10 only insert the 8 32 x 3 4 socket head cap screw into the ground stud threaded hole fro
56. p Apply a drop of Loctite 242 to the small set screw then install into crank arm and tighten Rotate the rotor until the magnetic sensor and the crank arm are aligned Loosen the two 4 40 x 3 4 cap head hex screws and place the Magnetic Sensor Spacer between the magnetic sensor and the crankarm Press the sensor firmly against the spacer tighten in place Remove the spacer Check the spacing between the crank and the sensor using the Magnetic Sensor Gauge Only the first and second levels of the sensor gauge should fit between the sensor and the crank arm The third level should not fit Reset if not acceptable Figure 4 15 Route motor wiring assembly toward the manifold air tube and ensure that they will not be pinched between the cylinder and the gearbox Push the piston into the cylinder or rotate the rotor so that the gearbox will align with the motor mounting holes in the cylin der Insert the dowel pins on the base of the gearbox into the cylinder holes Secure the gearbox to the cylinder with four 6 32 x 1 2 cap head hex screws using crisscross pattern Re check motor wire routing to ensure wires have not been pinched November 2000 Right End LP6 Plus LP10 and LP20 Service Manual Yellow Figure 4 15 Magnetic proximity sensor November 2000 Page 4 11 Right End LP6 Plus LP10 and LP20 Service Manual Manifold Leaf and or Cylinder Replacement 1 Manifold and Cylinder Removal qd Remov
57. rds has been replaced during servicing go to step 18 13 14 15 16 17 Allow the ventilator to run until the total hours of the Run In is a minimum of 20 hours Verify the unit has run for a total of 20 hours minimum Set the MODE to Standby and the On Off switch to Off Discon nect the RED run in plug Unplug the unit from AC power Record Adult Rate Run end date and time on Run In Log sheet Passed units are ready for Initial Inspection Note The following steps are only for ventilators where at least one of the printed circuit boards has been replaced during servicing 18 19 20 November 2000 Run ventilator for approximately 5 minutes and disconnect unit from AC power momentarily Verify unit switched to inter nal battery and is operating normally Reset alarm and restore AC power to ventilator Turn MODE switch to STANDBY and disconnect RED run in plug with silicone connector Record Adult Rate Run end date and time on Run In Log sheet Page 3 23 Run in Page 3 24 21 22 23 24 25 26 27 28 29 LP6 Plus LP10 and LP20 Service Manual Set front panel to High Rate Run as follows e LOW ALARM Minimum HIGH ALARM LIMIT Maximum e VOLUME Minimum e BREATH RATE 38 BPM e INSPIRATORY TIME 0 5 seconds e BREATHING EFFORT 5 cmH20 e MODE STANDBY Connect GREEN run in plug with silicone connector to the ventilator Turn MODE switch to ASSIST
58. reads 13 80 05 VDC on the multimeter e For a surface mount Power Motor board with P N Y 100116 00B or higher can be identified by the label on the board adjust the R108 until the voltage reads 14 40 05 VDC on the multimeter Note The software version should not be used to determine if the charge voltage should be 14 4V because a 13 8V Power Motor board can possibly have a logic board with the version D software C If OK appears on the display press the SET button on the calibrator d If an error code appears reject the unit Disconnect the calibrator from the internal battery har ness Reconnect the ventilator s internal battery into the harness f Disconnect the multimeter from the calibrator s external battery connector 25 SET SERIAL NUMBER XXXXXX Verify serial number on the calibrator s display matches serial number of the unit If correct press SET If not correct verify that it is the correct front panel for the ventilator and enter the unit s serial number and press SET 26 RESET MACHINE HOURS HOURS NOW XXXXX Note If hours have already been reset or a Preventive Maintenance has not been performed proceed to Step 27 If a Preventive Maintenance has been performed and hours have not been reset press SET 27 Turn the ventilator OFF November 2000 Page 3 15 Calibration LP6 Plus LP10 and LP20 Service Manual 28 Set the front panel as follows Oxo a
59. remainder of the backing while pressing down the overlay as the backing is removed to avoid air bubbles from being trapped D Peel back the entire overlay carefully holding the edges Lay overlay on panel lightly and press up the center of the overlay Smooth overlay from center to outside edges 5 Check all overlays to ensure edges are even with panel edges Smooth the overlays as needed November 2000 Page 4 23 Front Panel LP6 Plus LP10 and LP20 Service Manual PLC Replacement LP10 LP20 only PLC Removal PLC Installation PLC Knob Installation Page 4 24 1 Remove the PLC knob and knob spring using a 1 16 hex driver Remove the bezel overlay with Patient Pressure and Exhala tion Valve printed on it Remove the two Phillips head screws from the bezel Remove the two hex head screws from the bezel using a 7 64 hex driver Remove the bezel Remove the gasket from around the patient pressure port Remove the four hex head screws from the PLC manifold using a 5 64 hex driver Remove the PLC Manifold Fasten the PLC manifold to the ventilator s front panel with the four hex head screws and tighten using a crisscross pattern Rotate the PLC knob shaft clockwise until the two set screws are pointing to the right of the assembly Install the patient pressure port gasket Set the bezel onto the PLC manifold Install two Phillips head screws in the top of the bezel Hand tighten usi
60. ritan Bennett for ser vice Call to verify before returning C d Examine the ventilator for physical abnormalities Examine the AC power cord for damage There should not be any cuts through the outer insulation Pull on the cord mak ing sure strain relief holds the cord Only Nellcor Puritan Ben nett authorized power cords and plugs should be on the units Clean the AC cord Wrap the AC cord with a large cable tie Check the unit for loose or missing hardware e g cord wrap feet Examine the breaker ON OFF switch for damage Verify that is clicks into position Verify that the serial number plate and all silk screens and labels are legible All Warning and Caution labels must be legi ble and visible If not readily visible relocate the labels Examine the patient airtube screen for damage Use a flash light if necessary Examine the overlays for damage Page 3 1 Check In LP6 Plus LP10 and LP20 Service Manual Verify that the PATIENT PRESSURE meter needle is within one division see Fig 3 1 of 10 cmH O hPa If it is not then remove the meter adjustment hole plug if provided and using a screwdriver verify that the meter needle can be adjusted above and below 10 Set the meter needle at 10 Figure 3 1 2 Cover Removal Note Put on anti static wrist strap at this point a Page 3 2 Verify proper fit of the bottom cover Remove the four feet from the bottom of the ventilator an
61. rvice Manual Figure 4 31 Bearing 2 O Recesses for bearing flanges face up 6 Press the bearing into the connecting rod using a bearing press bearing press tool and bearing press plate Figure 4 31 Caution Press only on the outer race of the bearings 7 Remove any excess adhesive November 2000 LP6 Plus LP10 and LP20 Service Manual November 2000 Back Panel Figure 4 32 Locating mark Connecting rod Connecting rod pin 8 Hold the connecting rod mount with the locating mark side up Start the connecting rod mount pin through the hole from below Place a nylon washer the connecting rod bearing flanges up and another nylon washer onto the pin Figure 4 32 Slip the pin up through these parts Install the assembly in a mounting bracket press plate Press the pin through the mount until the two grooves are equally spaced on either side of the mount Figure 4 33 Figure 4 33 Press Connecting rod pin Note Turn over assembly and press as shown Page 4 33 Back Panel LP6 Plus LP10 and LP20 Service Manual Figure 4 34 Connecting rod pin Figure 4 35 9 Apply a light coat of lubricant onto the crank pin Slip a nylon washer onto the pin Press the crank pin into the bearing until Cranicena Brees the groove just passes the bearing inner race Figure 4 35 Ni 10 Push three retaining rings into the grooves on the pins Figure Nylon washer 4 34 S24 11 Inspect the ass
62. s not pinched d Meter wires are routed correctly Solenoid wires are routed correctly f All connectors and internal tubing are properly connected Locate the correct assembly parts for the unit being assembled Note For units which already have the chassis assembled proceed to step 12 3 4 Set the ventilator on its right side Install on the right end of the door rod a Teflon washer and a crescent spring pointed ends of the crescent spring towards the Teflon washer Insert the right end of door rod into the front panel bezel and close door onto the front panel striker plate Install on the left end of the door rod a Teflon washer and a crescent spring pointed ends of the crescent spring towards the Teflon washer Orient handle with flat side away from front panel and mold mark down Insert handle into right end plate assembly Position left end plate to front and back panels If necessary reposition harness wires to keep wires from being pinched or damaged For LP20 connect J2 to P2 and J3 to P3 on the nurse call cir cuit assembly and using a cable tie bundle the two cables con Page 3 17 Reassembly Page 3 18 Note 10 11 12 LP6 Plus LP10 and LP20 Service Manual nected to P2 and P3 on the nurse call circuit assembly to the blue wire from the DC breaker and the brown wire from the wire harness Connect the following For LP6 LP10 with the older through hole power mot
63. screws should be flush with the inside of the bracket Figure 4 4 Plastic piston guide 4 Figure 4 5 Plastic piston guide Piston angle bracket 4 Steel Silicone piston guide adhesive flat side here toward angle 6 Insert a steel guide into each piston angle bracket flat side bracket first Apply two beads of silicone RTV adhesive into plastic pis ton guides Figure 4 5 Caution Use only small amounts of silicone so silicone does not seep out into the assembly later 7 Insert plastic guides into angle brackets silicone side inward Check that no silicone is exposed wipe clean if necessary A rubber band may be looped around all 4 piston guide angle brackets to hold the guides in place 8 Inspect the Quadring and install into piston groove verify it is not twisted November 2000 Page 4 4 Right End LP6 Plus LP10 and LP20 Service Manual 9 Inspect the Kapseal assuring that it has no creases or nicks Install the Kapseal over the Quadring as shown in Figure 4 6 Caution Be very careful not to stretch the Kapseal 10 With a fingernail or plastic screwdriver work the Kapseal over the entire Quadring Ensure the flanges at the edges of the Kapseal are seated between the Quadring and flange on both sides of the piston as shown Figure 4 7 Caution It is common for the Kapseal to rest on the piston or Quadring as shown Figure 4 8 Keep working the Kapseal around the perim eter of the piston unti
64. should be 14 4V because a 13 8V Power Motor board can possibly have a logic board with the version D software C If OK appears on the display press the SET button on the calibrator If an error code appears reject the unit Disconnect the external battery connector from the back of the ventilator Disconnect the multimeter from the calibrator s internal battery connector 23 INT CURRENT Connect the calibrator s two pin internal battery connector to the plug for the battery in the harness Press and hold the CHARGE button Caution Do not hold the CHARGE button for more than ten seconds 24 If OK appears on the display press the SET button on the cali brator and hold the CHARGE button down until the display has changed to the next step INT VOLTS a With the calibrators internal battery connector still attached to the harness connect the multimeter to the cal ibrator s external battery connector If necessary adjust the Trim Pot on the Power Motor board with a plastic screwdriver e For any through hole Power Motor board adjust the R60 until the voltage reads 13 80 05 VDC on the multi meter e For a surface mount Power Motor board with software November 2000 Calibration LP6 Plus LP10 and LP20 Service Manual Version C can be identified by pressing the TYPE button on the calibrator or P N Y 100116 00A can be identified by the label on the board adjust the R108 until the volt age
65. t is automatically generated every 4 hours C Turn the printer off and remove the printout from the printer Compare settings on the printout to the knob set tings on the front panel d Record hours on the Service Record top right corner Note Units are required to undergo a Preventive Maintenance at 6 000 hours and a recertification annually November 2000 Page 3 3 Check In Note Note Note Pressure Limit Control PLC Test Note Page 3 4 e LP6 Plus LP10 and LP20 Service Manual Press the TYPE button on the calibrator and record the soft ware level on the Service Record Level A reads LP8 LP10 on the calibrator or printout and when the keys are pressed on the calibrator an audible chirp is heard Level B reads LP6 10 on the calibrator or printout Level C or higher reads LP6 10 Y2K on the calibrator or printout f Connect a test lung to the unit The large tube to the Patient Air port small striped tube to the Patient Pressure port and the other small tube to the Exhalation Valve port on the ventilator If you are working on an LP6 proceed to step M The PLC test takes one reading occluding the airway to maximize the back pressure on the pressure arm in the vent PLC The test then takes another reading to see if it caused pressure to vary g Set e LOW ALARM to 2 cmH O hPa e HIGH ALARM LIMIT to 90 cmH0 hPa e VOLUME to 1 0 liter e BREATH RATE to 10 BPM INSPI
66. the harness 2 Connect the Calibrator to the Internal Battery harness and the COMMUNICATION PORT of the ventilator 3 Plug the ventilator into AC power and set the MODE switch to Standby Set the back panel ON OFF switch to ON 4 Monitor the DC voltage across the red and black wires of the two pin connector on the Calibrator 5 Remove the bottom cover of the ventilator Using a non conductive screwdriver adjust R60 on the Power Motor board such that the monitored voltage is 13 80 0 01 VDC 6 Adjust the CHARGE VOLTAGE pot on the bottom of the Calibrator until the VOLTAGE LED lights solidly Note Do not press the CHARGE button for longer than 10 seconds at a time If readjustment is necessary wait three minutes and then repeat the step 7 Press and hold the CHARGE button adjust the CHARGE CUR RENT pot on the Calibrator until the voltmeter shows 10 50 0 01 VDC 8 Pull the syringe on the Calibrator to the end of its stroke and attach a calibrated pressure meter to the open brass port 9 Apply pressure with the syringe until the pressure meter indicates 50 0 1cmH30 10 Adjust the PRESSURE pot on the Calibrator until the PRESSURE 50 CM LED lights solidly 11 The contrast of the display can be set as desired by adjusting the display contrast pot on the Calibrator November 2000 Page 6 1 Calibration of Model 6951Right end Tester LP6 Plus LP10 and LP20 Service Manual Calibration of Model 6951Right end Test
67. und the ferrite not the cable tie around the ferrite and connector housing and swing the ferrite in the opposite direction 5 Fasten the Front Panel to the Right End with three screws 6 Set LOW ALARM to 2 cmH O hPa and HIGH ALARM LIMIT to 90 cmH 0 hPa 7 Connect the ribbon cable from the Back Panel to the Logic Board J3 on the newer surface mount board or J10 on the older through hole board 8 Connect a Model L 6960 calibrator to the COMMUNICATION PORT 9 Connect the unit to AC power and turn the ventilator s On Off switch to ON All LED s should light momentarily except for the AC Pwr Batt Charge LED it should remain on Note Allow all changes to stabilize for three seconds before pressing SET November 2000 Page 3 10 LP6 Plus LP10 and LP20 Service Manual 10 11 12 Calibration Press the CAL button on the calibrator to start the first calibra tion step Set Date Time Use the number pad to enter the date and time of day as shown in the example below Each bold number is entered proceeding from left to right SET DATE TIME 04 22 97 10 22 00 Press the SET key when date and time are correct EFFORT KNOB 0 cm Note When calibrating BREATHING EFFORT and VOLUME view knobs from straight on 13 14 15 November 2000 Carefully turn the front panel s BREATHING EFFORT knob to 0 If OK appears on the display press the SET button to advance to the next step EFFORT K
68. urface mount board or J9 on the older through hole board 4 Connect the meter wiring assembly to the Logic board J2 on the newer surface mount board or J12 on the older through hole board 5 If a new Logic board has been installed transfer the time and date EEPROM from the old board if possible to retain device history qQ Through hole board replacing a through hole board Transfer EEPROM U24 using an I C extraction tool Note polarity b Surface mount board replacing a surface mount board Transfer EEPROM U26 using an I C extraction tool Note polarity C Surface mount board replacing a through hole board EEPROMs have incompatible sockets and cannot be trans ferred Keep the existing U26 in the new board A PM must be performed on this unit d Through hole board replacing a surface mount board EEPROMs have incompatible sockets and cannot be trans ferred Keep the existing U24 in the new board A PM must be performed on this unit November 2000 LP6 Plus LP10 and LP20 Service Manual Power Motor Board Installation November 2000 Front Panel Figure 4 24 Power motor board Logic board io Front panel Check the Power Motor Board to ensure that e No component damage exists e The resistor plug is inserted into the 10 pin connector J6 on the newer surface mount board or J3 on the older through hole board e Polarity of EPROM U17 on the newer surface mount boar
69. ver the crankarm and rotate the rotor by hand until the notch is lined up with the rib on the gearbox Any play should be taken up by gently push ing the tool towards the rear of the unit If OK appears press the SET button and remove the crank cen tering tool 20 CONNECT 50 cm PRESSURE Pull back handle of the calibrator s syringe to the outer mark Then connect the 1 4 clear tubing from the calibrator to the Patient Pressure port Using the syringe apply pressure slowly until the calibrator s green PRESSURE LED remains lit November 2000 Page 3 12 LP6 Plus LP10 and LP20 Service Manual November 2000 Note Caution Calibration If OK appears press the SET button Make sure that the green PRESSURE LED remains lit until the calibrator display changes to the next step Remove the tubing from the Patient Pressure port Units with the newest surface mount Power Motor boards P N Y 100116 00B as combared to the original P N Y 100116 00A sur face mount Power Motor board have a different external and inter nal charge voltage of 14 4 VDC A newer version of software Level D is included with these units which does not light the current LED or the voltage LED when within the acceptable range during calibra tion Instead only an OK on the display will be used to set the charge current and a multimeter will be used to set the charge volt age during calibration 21 EXT CURRENT Verify that the inter
70. y board ribbon cable from the Logic board J4 on the newer surface mount board or J9 on the older through hole board 5 Raise the Logic board from the front panel Page 4 17 Front Panel Display Board Removal Display Board Installation LP6 Plus LP10 and LP20 Service Manual Remove the 6 32 x 3 16 button head hex screws from the top of the Display board three screws if removing a newer surface mount board or two screws if removing an older through hole board Remove the three flat head screws from the bottom of the Dis play board Remove the Display board Check the Display board for damaged components and traces Check the ribbon cable on the replacement Display board ensuring that the e Connectors are fully pressed together e Wires are not broken e Colored line on the cable is connected to the 1 pin in the gray connector This is the pin indicated by a polarizing mark on the connector Mount the Display board by installing the 6 32 x 3 16 button head hex screws on the top of the Display board Use three screws if a newer surface mount Power Motor board will be reinstalled or two screws leave middle open if the older through hole Power Motor board will be reinstalled Install the three flat head screws on the bottom of the Display board using Loctite 242 Note The Logic board and the Power Motor board are sensitive to static Page 4 18 electricity Take precautions to e

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