SERVICE MANUAL - Progressive Dynamics, Inc.
Contents
1. 5 JILJIIJUJ ISOH ASSY asoH ASSY YOUMS 159 1501 dd VAJA LAO TALL ATTITONULNOD HA ST 0001C4 1 0001 STAGOW Weisel YO 0001 NIV 34I1 15 Setup Plug Unit into 120VAC Select 80 Degree Setting Attach Hose to Blower Outlet NOTES For PD2580 PD1000 S with Single Sensor If the Blower Operates for more than 4 min without a Hose Attached to the Blower and Blanket orthe Test Port the Breaker will Trip Is ON Illuminated Nt To AC Tests Replace Front n Is 80 Panel Control and Faceplate Illuminated Y Check AC Volts on 5 Blower N Orange and Red Wires From Control Board Operating Select 110 Replace Front Degree Setting eplace Fron Is Voltage gt 105 2 Panel Control and Faceplate Watch Replace Blower Measure DC Volts on the Black and White Wires from the Thermal Sensor While the Unit is Warming Does the Display Slowly Rise Does the Voltage Rise While the Unit is arming 2 Is the Alarm Sounding To Heating Tests Replace Heater and Plenum Assembly To Control Board Tests 16 Is the Unit N Plug Unit In Is the Breaker Tripped Y Turn Unit Reset Off Breaker Measure AC Volts fram the Outlet Allow the N Breaker to ee Coolfor 1 Min Did the Breaker Attach Ho2. d Press the Self test button located on the bottom of the unit inside the test port Turn unit on The TEST lamp will start flashin g Connect the hose to the self test port The temperature display will slowly climb into the overtemp area After the display reaches the red area the CAUTION lamp will start to flash and the alarm will start to sound After a few seconds the display will start to drop back to the normal operating range When this happens the flashing lamps and the alarm should shut off There 2 types of Time out circuitry used in the LIFE AIR 1000 each requires different testing procedures The procedure to be used can be determined by looking into the air outlet on the top of the unit If there is 1 thermal sensor in the Plenum use procedure 1 if there are 2 sensors use procedure 2 4 Time out test Procedure 1 a Set the Main Power Switch to the OFF Position b Plug the LIFE AIR 1000 into a properly grounded electrical outlet c Remove the hose from the top of the unit d Set the Heater Control Switch to the 110 setting e Turn the unit on f After about 4 minutes the circuit breaker should trip g Turn the unit off and reset it by depressing the circuit breaker located on the bottom front of the unit Safety Inspection Procedure 5 Time out test procedure 2 a b Set Heater Control Switch to the 100 setting d Disconnect the from th
3. 1000 1 01000 15 Vv seasors when viewer Larought the hose pert on the vp of tae unit TT W CRATURE CONTROLER amp ASS 2215727 KENK JA ON IHE B ake 4 IKGTA 7 Hx HOT h ALL UNITS DRCA CR Way DI IJE ZAME MIRC THC ay 35 dd SHOWN ON T Z PC 232 TA 3RZAKZR HLAIL PL_NUM ASSY ave CUAL CONTROL GEEN EROUKD A Sv WATE DLAZ4 mnes 11 LIFE AIR 10007 WIRING DIAGRAM MODEL PD1000 1 PD1000 18 Rev B Two sensors wher Ihreugt hose part on top Ie 1 DONIEC TERA ASSY 3 425 STOR DEERD Nh THF Al KETA LET HIS PESISTO M Y RT INTR HAYBE 3aM 4 THF 3 4F X2 AT SIAH ON T IZ FE td it TABREAKER HEATERIPLENUM A3SY DUAL CONTROL ORFFH RAAMI H Inc 12 DILA PAULI LATS ASILE J3 5E TI ASE AMT AVILA BED SMAS TNT T pog aL 3p 1 Ii Assy 9528 SUOT TARI RUGAN UON 1 ASF ASSH 260 SNZLURH YF LAG PIL p100 ARSY ABJA AANT amadu ASSY V VL 1318944 NII SSV Mog MOE O M 9 14U0 SS y Sapnysuy 19 011U07 3IBJIIJUT ISOH ASSV 350 ASSY YAMS 159
4. LIFE AIR 1000 HYPOTHERMIC THERAPY SYSTEM SERVICE MANUAL MODELS PD2580 PD1000 PD1000 S PD1000 1 amp PD1000 1S 507 Industrial Rd Marshall Mi 49068 616 781 4241 fax 616 781 7802 www progressivedynamicsmedical com IMPORTANT NOTICE Caution The repair calibration and servicing of the LIFE AIR 1000 requires the skill of a qualified Medical Equipment Service person familiar with good practice for Medical Device Repair Service to be done only by Authorized Service Personnel Improper repair can result in patient injury IMPORTANT NOTES READ BEFORE SERVICING EQUIPMENT This equipment contains static sensitive components Proper static handling procedures and equipment must be used when servicing this equipment Perform a safety inspection after making repairs to the LIFE AIR 1000 and before returning the unit to service A safety inspection procedure is included in this manual 700880R102 Safety Inspection Procedure 1 Fully assemble unit 2 Perform a leakage and hi pot test according to UL 544 CSA std 22 2 125 M1984 or IEC 601 1 reguirements for non patient contact medical eguipment as determined by your biomedical department Refer to the above standard for the maximum allowable leakage 3 Perform a Self test of the unit as follows a rh Connect the air hose to the outlet located on the top of the unit b Plug unit into a proper power source as noted on the units rating label
5. NLET 7 LIFE AIR 1000 WIRING DIAGRAM MODLL PD2580 PD 1000 Rev A Using 4 Minute Time Single sensor when wewed throught the hose pert nn the top ef the unit 1 JKE CON IRGI HR amp PAGHE ASSY Dul Kets Ive Ou Ab Fo Bins avin VALS Yims be Md a Eer A WE SHITE OM TABREA ER HEATERIPLENUM ASS CONTRI GRUND BLOWER ASS W RI AC LIFE AIR 10007 WIRING DIAGRAM MODEL 1000 PDIOOQ S Rev B Using Temperature Controlled Time Out Tan seniors vs hin viewed Huron Hie bose pier art Hie lan af ihe TENPEF ATURE CONTRO_LE 8 FACEFLAX ASSY lime Out ssy ba Howe SIR Seren Zo oz kor arac WES NATOS ASSY 455 DUAL CONTROL FUNC d SLOWER ASSY AC POWER CORD TEST SWITCH LIFE AIR 10007 WIRING DIAGRAM MODEL FD1000 PD1000 5 Rev Using Temperature Controlled Time Out Two sensors when viewed zhreugat tae hose port on the toa o7 the vuit T MPFRATUR CONTROL FR amp FACFPI NF ASSY 1 44 E 42k _____ BED 5 SWITCH 1 ASSY NITE ME M T TA BREAKER JEATER PLENLII 4357 DU CONTROL INT GPZUND BLOWER AS Sv LIFE AIR 1000 WIRING DIAGRAM MODEL
6. PD1000 S Rev 7 PD1000 PD1000 S Rev amp 8 PD1000 1 1000 15 9 PD1000 1 PD1000 1S Rev 10 Block Diagrams PD2580 PD1000 1000 11 PD1000 PD1000 S Rev 12 PD1000 1 PD1000 15 tu 13 Trouble Shooting Flow Chart deserit RSS 14
7. S0 ICId S 0001CId 0001CId 085204 42014 0001 HIV AAIT 13 8221A3 P LISUSS 21056 SIUIL ARYL WYSE 2246 5 11 7 y ampa VUL ONEN 1215875 SUIJIOPFUON 19158 ASS 29294 ASSAI SSOLLIEH 3 dA 182 y ASSP KIRJ Aa mandari ASSY ASST SSV 1940 Imola Assy umuo d ISOH ASSV 25 10184 13158 Assy 2509 V yeg NIIT Assy Assy 4 8 mosu WOK SSV UIHMS 1591 O IOO 3INLI WA 000144 S 0001 dd STACOW 3014 0001 HIV AAIT 14 2081 SAUS y 55241 s 12152 INBRED LY SMAI 1521 2501 ASSV osteg TASA 123567 BUOJ UON ENSE ASH SEE ASSP SSATILTT 27 TOMAS 3527 ASS 9214 YF a ASSI 130d 2 SuysrT Ajquiassy VL 1942229 UNI mas Assy H ISAO TEET AS SV dua Assy 2
8. e Hose Storage Port and press the Test Switch The Connect the hose to the Warm Air Port to the Hose Storage Port Turn the unit on and allow to stabilize at the 100 setting test light will flash Block the free end of the hose by placing it on a hard flat surface As the unit heats into the red zone the Caution light will flash and the buzzer will sound As the unit continues to heat the Test light will stop flashing The unit should trip the circuit breaker between 1 minute to 1 minute 30 seconds from the time the Test Lamp quits flashing Reset circuit breaker INSTRUCTIONS FOR REMOVAL OF ASSEMBLIES CAUTION THE PLENUM AND FRONT PANEL ASSEMBLY CONTAIN STATIC SENSITIVE DEVICES PROPER HANDLING PRECAUTIONS MUST BE USED PD2580 PD1000 PD1000 S Unplug unit from 120 VAC line Remove the Rear Filter Cover Remove the filter element Using a 1 8 inch drill bit drill out the 4 rivets holding the wire filter basket in place Remove the wire basket KON PD1000 1 PD1000 1S Unplug unit from any power source Remove the Rear Filter Cover Remove the filter element Using a 2 Phillips screwdriver remove the screw and lock washer from the center top of the filter guard 5 Remove the wire basket AUC N REVOVE SCREW BLOWER AND PLENUM ASSEMBLY Support the Blower and Plenum Assembly while removing the 4 screws from top hose interface Unplug
9. or Installation of the following Assemblies Temperature Controller amp Faceplate When replacing this assembly it is required that a bead of clear Silicone Sealant be placed around the perimeter of the faceplate to provide a seal This Assembly is STATIC SENSITIVE Proper precautions must be used when removing or installing this Assembly Test Switch Assembly When replacing this assembly it is necessary to seal the switch with a piece of heat shrink and hot melt glue to provide a seal as done from the factory MELT GLUE Circuit Breaker When replacing this part it must be sealed at the mounting surface and at the adjustment holes on the top of breaker Hot melt glue or silicone sealant may be used for this KNURI NUT BEVELED SIDE TORD BREAKER BODY REF CABINET 18 APPROX INSTALL amp TIGHTEN HEX NUT FURNISHED Y BRCKCR TO 10 IN LBS GRCAKCR ASSCMBY DETAIL AC Power Cord When replacing the power cord the Heyco strain relief must be sealed at the mounting surface as received from the factory If the unit is PD1000 1 or PD1000 1S the power cord is attached with a strain relief and plugged into an IEC connector on the bottom of the unit CASLZ CLAMP POWER GABLE CLAMP R E CABLE CLAHF X 1 IN 16 35m 1 NYLON 16 32 x 23 IN PAN HEAD PILL PS SCREW N BLOWER UNIT ROTTOM VIEW PHILLIPS OR VER AFPLIANCE
10. se to Test Part No Power 10 Outlet Is the Voltage gt 105 Select 110 K Replace Degree Setting Measure AC volts on the Black and White Wires atthe Control Turn Unit Board On Check Int Is the Voltage NN f Remove Brown Wiring for Isthe Breaker N Wire from the gt 1 5 Open Circuit Tripped Front Panel Replace Front Run su Panel Control and Least 5 Min Faceplate Check Internal Wiring for Short Circuit ls the Breaker Tripped Isthe Breaker Tripped Restart Test Replace Front Panel Control and Faceplate Replace Front Panel Control and Faceplate 17 Control Board Tests Attach to Test Port After 2 Min is Temperature in the Proper Range Is Proper Display Illuminated Run Unit in Each Temperature Range Perform Self Test as Described in the Operators Manual Replace Front Panel Control and F ac eplate Isthe Test Lamp Flashing Replace Front Did the Unit Pass Panel Control and Self Test Faceplate Unit Functions Properly Attach a Voltmeter to the Blue and Yellow Wires from the Control Board Press Self Test Isthe Voltage gt 105VAC Y Replace Heater and Plenum Assy Replace Front Panel Control and Faceplate Remove the 2 Pin Harness from the Control Board Mea
11. sure the Resistance of the Test Switch While Button is Depressed Isthe Resistance 5 Ohms Test Switch 8 Harness Assembly Replace Front Panel Control and Faceplate 18 Heating Tests Is the Caution Lamp Flashing Is the Temperature Display in the Overtemp Range Is the Thermal Sensor Plugged into the Board Replace Front Panel Control and Faceplate Plug In Sensor Turn Unit Off and Allow Connect a DC Voltmeter to Cool for 15 Min Turn to the Black and White Unit On Wires on the 3 Pin Harness from the Plenum Slowly Apply an External Does the Unit Heat Source to the Continue to Sensor such as a Hair Overtemp Dryer Turn Unit Off and Doesthe Remove Filter Allow Unit Voltage Rise with to Cool for 15 Min Turn Heat Unit On N Replace Heater and Plenum Assy Does the Unit Replace Front Continue to Panel Control and Overtemp Faceplate Replace N Filter 19 CONTENTS Safety Inspection Procedures t aal a ea teens 1 Time out Test 1 Time out Test 2 aa 2 Assembly Removal Filter and Wire Cage 3 Blower and Plenum ASSy 4 Front Panel ASSY cae tu 4 Special 5 Wire Diagrams PID LOO oie E maa 6 PD1000
12. the 3 pin harness from the temperature sensor to the Front Panel Control Some units may have two 3 pin harnesses to be removed If this is the case the sensors must be marked so that they can be reconnected to the same location when reassembled Keep the heat shrink with the plugs This must be reinstalled to keep harnesses from vibrating free Unplug the 4 pin harness connecting the Front Panel Control and the Blower and Plenum Assembly Remove the Green wire from the Blower housing Remove the assembly from the back of the unit To remove the Blower from the Plenum assembly remove the 3 or 4 nuts holding the blower to the Plenum 4 SCRONS FRONT PANEL CONTROL AND FACE PLATE Remove the Blower and Plenum assembly as shown above Remove the 6 4 nuts from the studs holding the front panel to the chassis using a 1 4 inch nut driver Disconnect the brown wire from the Time out control board Some units may have connecters in line with the brown wire Ifthis is the case disconnect the wire at the connecters Disconnect the White and Black wire harness using the in line connectors Disconnect the 2 pin Self test switch harness from the control board With a SHARP razor knife carefully cut the silicone sealant between the front panel and the chassis Lift the Front Panel from the chassis REMOVE 6 NUTS HOLDING HE FACEPLATE 6 FROM THF INSIIF THF Special Instructions f
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