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Flowtron Universal Service Manual

Pump Repair

Issue 2

Chap 5

Sep 2009

SER0009

Page 5

Note:

Item marked *CAB302 is a short male IEC to female IEC lead fitted to Chinese, Japanese,
Indian and South African 507UNI pumps only, along with the relevant country-specific mains
lead (CAB310 Japanese, CAB311 South African/Indian and CAB312 Chinese).

Table 9 - Main/Power Cordset version part numbers

Product

Model No.

(old Model No.)

Cable Part No./Description

5

0739

8

UK

ma

in

s

le

ad

I

E

C

5

0737

5

U

S

A

ma

in

s

le

ad

I

E

C

5

0739

9

Schu

ko

m

a

in

s

lead

IEC

5

0746

1

Au

st

rali

an

main

s

le

ad

IEC

CAB3

02*

Short male IEC to

fem

a

le

I

E

C

CAB3

12

Ch

in

a IEC stra

ig

ht

co

il

ed

cable

CAB3

10

Jap

an IEC

s

traigh

t

co

il

ed

cable

CAB

31

1

S.

Afri

ca

n/

In

di

an

IEC

strai

g

h

t/coi

led cab

le

507001
(AC600/UK)

507003
(AC600/US)

507004DE
(AC600/DE)

507004DK
(AC600/DK)

507004ES
(AC600/ES)

507004FR
(AC600/FR)

507004IT
(AC600/IT)

507004NL
(AC600/NL)

507009AU
(AC600/AU)

507009CN
(AC600/CN)

507009JP
(AC600/JP)

507009ZA
(AC600/ZA)

507EUR

507UNI
(2 part lead)

507UNI
(2 part lead)

507UNI
(2 part lead)

«
...
41
42
43
44
45
...
»

Summary of Contents for FLOWTRON UNIVERSAL

Page 1: ...Service Manual FLOWTRON UNIVERSAL ...

Page 2: ......

Page 3: ...ulletins Incorporated Bulletin Content Date incorporated SERB008 Cleaning Instructions Sep 2009 SERB022 Manifold Repair Sep 2009 SERB023 Software Upgrade to V3 00 Sep 2009 SERB028 Flowtron Universal LCD Replacement Sep 2009 SERB030 Software Upgrade to V3 01 Sep 2009 SERB034 PCB Changes Sep 2009 ...

Page 4: ...Flowtron Universal Service Manual Ammendment Record Issue 2 Page ii SER0009 Sep 2009 ...

Page 5: ...PTER 3 Maintenance 1 Service 1 Cleaning Instructions 2 Maintenance Checks 3 CHAPTER 4 Testing 1 Initialising the Pump 1 Garment Recognition Test 1 Checking the Basic Pump Operation 3 Location of the Soft Function Buttons on the Pump Membrane Label 5 Using the Buttons below the Service Screen on the LCD Display 5 Preparation of the Calibration Test Equipment 6 Checking the Calibration of the Pressu...

Page 6: ...the Mains Power Fuses on the Power Supply PCB Assembly 17 Replacing the Air Inlet Filter on the Compressor Assembly 17 Removing the Motor and Manifold Assembly 19 Repairing the Motor and Manifold Assembly 19 Installing the Motor and Manifold Assembly 25 Including a Longer Transducer Tube on the Motor and Manifold Assembly 25 PCB Part Numbers 27 Interchangeability of PCBs 27 Removing the Control Pr...

Page 7: ...or Assembly from the Mounting Bracket 45 Installing the Compressor Assembly onto the Mounting Bracket 45 Replacing the Rear Case 47 Replacing the Front Case 49 CHAPTER 6 Updating the software 1 Introduction 1 Installing the Communicator Software 2 Connecting the Pump to a Laptop Desktop PC 9 Launching the Communicator Software 11 Executing Commands on the Command Menu 12 Communication Error when E...

Page 8: ...Flowtron Universal Service Manual Issue 2 Page vi SER0009 Sep 2009 ...

Page 9: ...manual identify possible hazards in procedures or conditions which if not correctly followed could result in death injury or other serious adverse reactions CAUTIONS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in equipment failure or damage Notes given in this manual are used to explain or amplify a procedure or condition ...

Page 10: ...he battery pack slides onto the base of the pump and recharges itself when the pump is operating from the mains power supply The pump has the following controls Refer to Figure 1 A Run Standby push button This is used to start and stop the therapy applied to the patient An illuminated graphic LCD display This indicates The type of garment s connected The pressure delivered to each garment Alarm in...

Page 11: ...r calf garment Pressure Transducer Calibration The pump utilizes a precise and accurate pressure measurement and control system which is not expected to require re calibration until after several years of continuous use The measurement system automatically handles any adverse effects due to drift or temperature change and should not require any user intervention The pump is factory calibrated and ...

Page 12: ...Figure 3 LCD Display Standby 4 4 Connect the garments to the pump hose set assemblies and make sure the connectors click into place 4 5 Check that the connection and garment type are confirmed correctly on the display Figure 4 shows two single chamber calf garments connected to the pump Figure 4 LCD Display Garments Connected 4 6 Typical garment options and default therapy parameters are detailed ...

Page 13: ... 4 9 1 When the pump is in standby connect one garment to either hose set assembly 4 9 2 The LCD display will confirm that only one garment is connected Refer to Figure 6 Note If a garment is disconnected while the pump is running the system will alarm Lo If the single garment option is still required simply press the Run button to reset the system and press the Run button again to restart therapy...

Page 14: ...t the Language change option 4 11 3 Press the button to continue 4 11 4 Use the arrow buttons to scroll through the available languages 4 11 5 Highlight the desired language and press the button to select 4 11 6 Press the button again to confirm the selection 4 11 7 Use the arrow buttons to highlight Exit in the new language 4 11 8 Press the button to continue 4 11 9 The screen will now display th...

Page 15: ...lectronics Alarm LED Alarm LED Run Standby Run Standby LED Buzzer Garment Sleeve Pressure Transducer Quick Connect Recognition Sense Coil Exhaust to Atmosphere Compressor Garment Sleeve Quick Connect Recognition Sense Coil Motor Optical Position Sensor Rotary Valve Hose Set Hose Set Electrical Connections Pneumatic Connections Mechanical Link LED Label ...

Page 16: ...c Series 6 Compressor Assembly Control PCB Assembly Motor and Manifold Assembly Hose Set Assemblies Membrane Label Connector LCD Display Connector Rechargeable Battery Mains Power Cordset Fuses Ribbon Cable Power Supply PCB Assembly Battery Pack Connector LCD Display Membrane Label Recognition Sense Coils if fitted ...

Page 17: ...sh and a message will appear on the LCD display until corrective action is completed The exception to this is a Pump Fault alarm which will alarm immediately Alarm Cancel After a fault has been corrected the alarm can be cancelled by either of the following two methods Press the Run button on the pump twice or until the green lights are lit and the pump is running With the exception of a Pump Faul...

Page 18: ... Page 7 Section 5 Chapter 5 Page 17 Section 17 Motor and manifold assembly failed Replace Chapter 5 Page 19 Section 18 Chapter 5 Page 25 Section 20 Compressor assembly failure or low output Replace Chapter 5 Page 45 Section 38 Chapter 5 Page 45 Section 39 HI High Pressure Alarm Garment Garment hose kinked Check garment hose for kinks or obstructions Pump Hose set assembly kinked Check hose set ass...

Page 19: ...c protection 1 Service The pump should be serviced every 12 months To service the pump do the following 1 1 Carry out the maintenance checks detailed below Refer to Chapter 3 Page 3 Section 3 1 2 Replace the inlet filter felt on the rear case Refer to Chapter 5 Page 7 Section 5 1 3 Carry out the following function tests on the pump 1 3 1 Garment recognition test in accordance with Chapter 4 Page 1...

Page 20: ...tions must be observed 2 1 Lay the pump down on its rear case so that the cleaning solution will not collect on the top cover assembly adjacent to the two hose set assemblies 2 2 Use a soft cloth to remove any unwanted cleaning solution from the top cover assembly Figure 10 Top Cover Assembly and Hose Set Assemblies Note Do not let any cleaning solution collect here Hose Set Assemblies Top Case Re...

Page 21: ... Check for damage and security Run button Check function Handle and hook assembly Check for damage and security Output hose set assemblies Check for damage and security of pump connection LCD display membrane label Check for damage and security to case Mains power cord Check for damage and security of plug Rubber feet 8 Off Check for security Labels Check all labels are present and legible Recharg...

Page 22: ...Maintenance Flowtron Universal Service Manual Chap 3 Issue 2 Page 4 SER0009 Sep 2009 ...

Page 23: ...emain until required for use Refer to Figure 12 Figure 12 LCD Display Standby 2 Garment Recognition Test 2 1 Initialise the pump Refer to Page 1 Section 1 2 2 Connect a garment to each pump hose set assembly Make sure the connectors click into place 2 3 Make sure the connection and garment types are confirmed correctly on the display as follows Note There is a separate graphic for each hose set as...

Page 24: ...ly and no garment connected to the other Figure 15 Only One Garment Connected 2 3 4 If the LCD display shows either an incorrect garment graphic or a no garment graphic when one is connected then carry out the procedure for recalibrating the pump for a new hose set assembly Refer to Page 12 Section 9 Table 3 Garment Options and Default Therapy Parameters Garment Type LCD Display Graphic Inflation ...

Page 25: ...essed air to the two connected garments which are inflated alternately During the test check the LCD display to make sure that 3 4 1 It shows the correct type of garments connected to the pump 3 4 2 The correct pressure is being applied to each garment Refer to Table 3 Note It is only necessary to check that the pressures are approximately correct 3 4 3 No fault messages appear 3 5 Check that the ...

Page 26: ...audible alarm sounds 3 6 4 2 The red alarm LEDs on the front of the pump flash 3 6 4 3 The message Lo Alarm Garment unplugged is shown on the LCD display Refer to Figure 17 Figure 18 LCD Display Lo Alarm Message 3 6 5 Check that if the garment is left disconnected the audible alarm will increase in pitch 3 6 6 Reconnect the garment to the hose set assembly and check that within three complete pump...

Page 27: ... is used during service and repair operations only 4 2 2 To access the service screen on the LCD display 4 2 2 1 Press and hold the Service button 4 2 2 2 The pump beeps when the service screen appears Note To prevent accidental operation of the Service button during normal pump operation the Service button must be depressed for approximately 30 seconds before the service screen appears 5 Using th...

Page 28: ...ation Test Equipment 6 1 Use a standard foot garment Fig 21 Item 10 as part of the test equipment 6 2 Find the approximate position of the middle of the foot garment tube and using a sharp knife cut the foot garment tube in two 6 3 Insert a T connector Fig 21 Item 30 into the two cut ends of the foot garment tube 6 4 Insert the remaining port on the T connector into the tube connected to the calib...

Page 29: ...essure shown on the LCD display is compared with the value shown on the external pressure meter If the two values are within 5 mmHg of each other then the pressure transducer is calibrated and the pump is able to provide accurate therapy If not the pressure transducer must be re calibrated 7 1 Prepare the calibration test equipment Refer to Page 6 Section 6 Table 4 Calibration Test Equipment for t...

Page 30: ...te PT and select it using the button below the LCD display A new list of options will appear Refer to Figure 23 Figure 23 LCD Display Run Compressor 7 7 To start the test scroll down the list of options to Run Compressor and select it using the button The compressor will start running at output level 5 indicated by the 5 on the LCD display and the Output Pressure shown on the LCD display should ri...

Page 31: ...f the Output Pressure on the LCD display is NOT within 5 mmHg of the value shown on the pressure meter then do the following 7 10 2 1 End this test by scrolling down the list of options to Exit and select it using the button 7 10 2 2 Carry out the procedure to re calibrate the pressure transducer Refer to Page 10 Section 8 7 10 2 3 Repeat this procedure to check the calibration of the pressure tra...

Page 32: ...play A new list of options will appear Refer to Figure 26 Figure 26 LCD Display Calibration Data 8 7 Before continuing with the re calibration procedure refer to the two Calibration Data values on the LCD display and make a note of the Zero and Gain values Refer to Figure 26 Note If the re calibration procedure goes wrong you can set the Zero and Gain values back to their original values and then ...

Page 33: ...on The compressor will stop 8 12 1 2 Go to Para 8 13 and continue the test 8 12 2 If the value of the Output Pressure on the LCD display is NOT within 2 mmHg of the value shown on the pressure meter then adjust the gain calibration factor of the pump as follows 8 12 2 1 To increase the Output Pressure value scroll through the list of options to Increase Gain Each time the button is pushed the Outp...

Page 34: ...ll down the list of options to Calibrate RFID and select it using the button Refer to Figure 28 Figure 28 LCD Display Calibrate RFID 9 5 A new list of options will appear Scroll down the list of options to Save as No Garment and select it using the button Refer to Figure 29 Figure 29 LCD Display Save as No Garment 9 6 Scroll down the list of options to Exit and select it using the button to end th...

Page 35: ... mains power cordset connector is pushed securely into the pump Mains Power Cordset Screw Case IEC Cover Note Insert the end of the test probe through the test hole in the rear case Rear Case of Pump Approximate dimensions of test probe Minimum length 100 mm Maximum diameter 2 mm Earth Ground Access Point Control PCB Assembly Compressor Assembly Earth Ground Test Pad IEC Connector Front Case of Pu...

Page 36: ...he earth ground test pad itself is approximately 90 mm below this access point on the corner of the control PCB assembly Therefore the test probe needs to have the following approximate dimensions Minimum Length 100 mm Maximum Diameter 2 mm This long test probe Table 5 Item 5 must be inserted carefully to make sure that it makes contact with the earth ground test pad and does not miss the control ...

Page 37: ...sing a much lower current 10 6 Remove the test probe from the earth ground access point on the pump 10 7 Install the case IEC cover to the rear case of the pump Chapter 5 Page 6 Section 4 Insulation Resistance Test This test checks the integrity of the pump s insulation This test is applied between the live and neutral wires connected together and earth ground Test Procedure 500 Vdc is applied to ...

Page 38: ...Testing Flowtron Universal Service Manual Chap 4 Issue 2 Page 16 SER0009 Sep 2009 ...

Page 39: ...te hose set assemblies will have to be replaced Note If the rear case of the pump is removed for any reason the mains power cordset will normally be removed first Refer to Page 7 Section 6 However the pump has a fail safe design which means that if the rear case is removed with the mains power cordset still connected to the pump the mains power cordset connector will be automatically removed with ...

Page 40: ... No No Hose Set Assembly Yes Yes Yes No No Rear Case Yes No No No No Front Case Yes No No No Yes Case Top Membrane Label Assembly Yes Yes Yes No Yes Handle and Hook Assembly Yes No No No No Motor and Manifold Assembly Yes No No No Yes Compressor Assembly Yes No No No Yes Compressor Inlet Filter Yes No No No No Power Supply PCB Assembly Yes No No No Yes Control PCB LCD Display Assembly Yes Yes Yes ...

Page 41: ... correct Refer to Figure 32 2 2 Put the product label Fig 32 Item 20 over the serial number label and stick it onto the rear case Make sure the orientation of the text on the product label is correct Refer to Figure 32 Figure 32 Pump Labels Table 7 Pump Label Parts List Item Part Number Description Qty 10 REF Pump Serial Number Label 1 20 LAB339 Pump Product Label 1 10 20 Fit the Serial Number Lab...

Page 42: ...s Power Cordset and Inlet Filter Felt Table 8 Mains Power Cordset and Inlet Filter Felt Parts List Item Part Number Description Qty 10 Refer to Table 9 Mains Power IEC Cordset 1 20 507374 Inlet Filter Felt 1 30 507315 Case IEC Cover 1 40 FAS045 Screw M3 x 10mm Pan Head 2 50 507413 Rubber Foot 10 30 20 40 10 50 50 ...

Page 43: ... No old Model No Cable Part No Description 507398 UK mains lead IEC 507375 USA mains lead IEC 507399 Schuko mains lead IEC 507461 Australian mains lead IEC CAB302 Short male IEC to female IEC CAB312 China IEC straight coiled cable CAB310 Japan IEC straight coiled cable CAB311 S African Indian IEC straight coiled cable 507001 AC600 UK 507003 AC600 US 507004DE AC600 DE 507004DK AC600 DK 507004ES AC6...

Page 44: ...cover is made easier if the two screws are removed completely from the cover and then the mains power cordset Fig 33 Item 10 is gently moved up and down while the cover is removed 4 Installing the Case IEC Cover 4 1 Make sure the mains power IEC cordset connector Fig 33 Item 10 is pushed fully into the IEC connector inside the pump Place the cordset cable into the groove in the rear case Note Make...

Page 45: ...ection 3 6 2 Pull the mains power IEC cordset connector Fig 33 Item 10 out of the IEC connector inside the pump 7 Installing the Mains Power Cordset CAUTION Make sure the replacement mains power cordset Fig 33 Item 10 is the correct type and rating or the electrical safety of the pump may be impaired 7 1 Carefully push the mains power IEC cordset connector Fig 33 Item 10 fully into the IEC connect...

Page 46: ...ervice Manual Chap 5 Issue 2 Page 8 SER0009 Sep 2009 Figure 34 Replacing the Hose Sets Table 10 Hose Set Parts List Item Part Number Description Qty 10 507500 Hose Set Assembly Spares Item 2 20 FAS045 Screw M3 x 10mm Pan Head 2 10 20 ...

Page 47: ...ise the type of garment fitted to the connector e g foot garment or single chamber calf garment A cable passes through the middle of the tube and out of the side of the elbow retaining cover to connect the sense coil in the garment connector to a 6 way connector on the control board assembly in the pump To remove the hose set assembly from the top of the pump carry out the following procedure 8 1 ...

Page 48: ...Fig 34 Item 10 by the pump with the elbow retaining cover adjacent to the case cutout in the top of the pump 9 3 Plug the hose set cable connector into the 6 way connector on the control board in the pump Note Make sure the hose set cable connector is pushed fully into the control board connector 9 4 Carefully insert the excess hose set cable inside the pump case between the control board connecto...

Page 49: ...ining cover Refer to Figure 38 9 7 When the elbow retaining cover is in the correct position install the screw Fig 34 Item 20 and tighten it to secure the hose set assembly to the pump 9 8 Carefully press down the screw cover until it clicks into position Refer to Figure 35 Figure 38 Securing the Hose Set Connector Elbow Retaining Cover Lug Hose Set Cable Connector Control Board Connector Pneumati...

Page 50: ...Case and Handle Parts List Item Part Number Description Qty 10 507302 Rear Case 1 20 507396 Front Case Printed Flowtron Universal 1 30 507421 Top Case Assy with Window Membrane Label Spares Item 1 40 FAS223 Screw 3 dia x 10 Pan Head 4 50 507419 Handle and Hook Assembly Spares Item 1 40 10 50 20 30 Note the orientation of the Handle and Hook Assembly Item 50 Spigots ...

Page 51: ...e rear case locate in the corresponding holes in the top case assembly 11 3 Install the four screws Fig 39 Item 40 to secure the rear case to the front case 11 4 Install the mains power cordset to the pump Refer to Page 7 Section 7 12 Removing the Handle and Hook Assembly 12 1 Remove the rear case from the front case Refer to Page 13 Section 10 12 2 Lay the front case Fig 39 Item 20 and top case a...

Page 52: ... 12 Top Case and Front Case Parts List Item Part Number Description Qty 10 507396 Front Case Printed Flowtron Universal 1 20 507421 Top Case Assy with Window Membrane Label Spares Item 1 30 507306 Case Style Gasket 1 40 631073 Tube 100mm long Compressor Motor Manifold Assy 1 20 30 10 Ribbon cable from Control PCB onto Power Supply PCB connector Spigot 40 ...

Page 53: ...n the front case A large diameter tube Fig 40 Item 40 from the motor and manifold assembly in the top case assembly to the compressor assembly in the front case 14 1 Remove the hose set assemblies from the pump Refer to Page 9 Section 8 but ONLY if the top case assembly or the control PCB assembly is being replaced the motor and manifold assembly can be replaced without removing the hose set assem...

Page 54: ...er tube Fig 40 Item 40 onto either the motor and manifold assembly or the compressor assembly Note Make sure the tube is connected to the correct inlet tube on the motor and manifold assembly Refer to Figure 41 15 4 Install the top case assembly onto the front case Note Make sure the three spigots at the top of the front case locate in the corresponding holes on the underside of the top case assem...

Page 55: ...he second fuse Fig 42 Item 10 16 5 Install the rear case onto the pump Refer to Page 13 Section 11 17 Replacing the Air Inlet Filter on the Compressor Assembly 17 1 Remove the rear case from the pump Refer to Page 13 Section 10 17 2 Using a pair of tweezers remove the air inlet filter Fig 42 Item 20 from the air inlet filter holder Fig 42 Item 30 17 3 Push the new air inlet filter Fig 42 Item 20 f...

Page 56: ...and Manifold Assembly Spares Item 1 20 REF Control PCB Assembly Spares Item 1 30 507421 Top Case Assy with Window Membrane Label Spares Item 1 40 FAS223 Screw 3 dia x 10 Pan Head 4 50 FAS223 Screw 3 dia x 10 Pan Head 3 60 507494 Transducer Tube 1 10 40 50 20 Transducer Transducer Outlet Side View Stepper Motor Con 9 Stepper Motor 30 40 40 50 Connector LEDs Elbow Connector on Hose Set Assembly O Ri...

Page 57: ...0 and 30 Note If the hose set assemblies are still connected to the top case assembly the motor and manifold assembly will be a tight fit on the elbow connectors on the hose sets Note Do not loosen or remove the three screws Fig 43 Item 50 which secure the stepper motor to the manifold 19 Repairing the Motor and Manifold Assembly 19 1 Only carry out the actions in this section if BOTH of the follo...

Page 58: ...ew parts 19 7 1 507124 Pinned Rotor Assembly 19 7 2 507125 Module and Stator Subassembly Note All other parts in the motor and manifold assembly are re used 19 8 Re install the motor and manifold assembly into the pump 19 9 Replace the small diameter transducer tube between the motor and manifold assembly and the control PCB assembly with a new longer tube since the pressure outlet is in a differe...

Page 59: ... Lift them off the module and stator sub assembly 19 14 2 Turn them over and place them on a flat surface so that the pinned rotor assembly is on top Note It will be easier to disassemble and re assemble the components if the pinned rotor assembly is on top Table 15 Motor and Manifold Sub Assemblies Item Part Number Description Qty 10 507124 Pinned Rotor Assembly Spares 1 20 507125 Module and Stat...

Page 60: ...embly Table 15 Item 20 Note Make sure the hole in the centre of the pinned rotor assembly is located over the bush in the centre of the stator 19 20 3 With the orientation of the module and stator sub assembly as shown in Figure 46 turn the spring mount and pinned rotor assembly round so that the slot in the drive dog is in the approximate East West position shown Note This alignment is necessary ...

Page 61: ...tem 30 use the following procedure refer to Figure 47 19 25 1 Push one end of the transducer tube fully onto the transducer outlet on the motor and manifold assembly Note The transducer outlet on the new module and stator sub assembly is in a different position 19 25 2 Push the other end of the transducer tube onto the top outlet of the transducer on the control PCB assembly CAUTION Do not handle ...

Page 62: ...009 Figure 47 Installing the New Longer Transducer Tube Table 16 Long Transducer Tube Parts List Item Part Number Description Qty 10 507494 Silicone Tube 1 5 mm ID 3 5 mm OD 160 mm Long 1 Control PCB Assembly Transducer Motor and Manifold Assembly Transducer Tube Transducer Outlet 10 ...

Page 63: ... assembly onto the front case Refer to Page 16 Section 15 20 9 If the hose set assemblies were removed from the pump then inspect and install new or the original hose set assemblies Refer to Page 10 Section 9 21 Including a Longer Transducer Tube on the Motor and Manifold Assembly 21 1 Originally the transducer tube was part of the control PCB assembly The pressure outlet is in a different positio...

Page 64: ...n Parts List Item Part Number Description Qty 10 REF Control PCB Assembly Spares Item 1 20 507421 Top Case Assy with Window Membrane Label Spares Item 1 30 FAS223 Screw 3 dia x 10 Pan Head 4 40 REF Screw 2 5mm x 8 Pan Head 4 50 507305 Run Button 1 60 507411 Button Return Spring 1 40 50 60 30 20 10 30 40 Membrane Cable Con 10 Membrane Cable 30 40 Battery may not be fitted ...

Page 65: ...NEW Power Supply PCB Assembly The NEW PCB assemblies MUST NOT be mixed with the OLD assemblies 23 1 2 When the 507061 Control PCB is no longer available it can be replaced with 507131 but the Power Supply MUST also be changed to a 507137 23 2 Software Versions 23 2 1 OLD Control PCB assemblies 507061 are only compatible with software versions up to and including V3 001 NEW Control Boards 507131 ar...

Page 66: ...epair Flowtron Universal Service Manual Chap 5 Issue 2 Page 28 SER0009 Sep 2009 Figure 49 Installing the Control PCB Assembly Run Button Button Return Spring Run Switch Control PCB Assembly Top Case Assembly ...

Page 67: ...ase assembly Fig 48 Item 20 on a horizontal surface with the inside surface pointing upwards and position the control PCB assembly Fig 48 Item 10 just above it 25 2 Carefully push the membrane cable into the membrane connector on the control PCB assembly Fig 48 PCB Con 10 25 3 Make sure the Run button Fig 48 Item 50 is installed into the cutout in the top case assembly and the button return spring...

Page 68: ... Supply PCB Assembly Parts List Item Part Number Description Qty 10 REF Power Supply PCB Assembly Spares Item 1 20 FAS223 Screw 3 dia x 10 Pan Head 6 30 507410 Connector Sealing Strip 2 40 BP027 Compressor Support Rubber 2 10 20 40 Battery Pack 20 30 30 Connector Rear view of Battery Pack Connector showing position of Connector Support Strip Item 30 ...

Page 69: ... WARNING DO NOT CONNECT THE MAINS POWER CORDSET TO THE POWER SUPPLY PCB ASSEMBLY AND SWITCH ON THE MAINS POWER SUPPLY WHEN THE REAR CASE IS REMOVED FROM THE PUMP VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC ARE PRESENT ON THE POWER SUPPLY PCB ASSEMBLY AND CAN IN CERTAIN CIRCUMSTANCES BE LETHAL 27 1 Put the power supply PCB assembly Fig 50 Item 10 onto the front case and install the four screw...

Page 70: ...ntrol PCB Assembly Table 20 LCD Sub Assembly Parts List Item Part Number Description Qty 10 FAS240 Screw 2 5mm x 8mm PT 4 20 507126 LCD Sub Assembly Spares includes LCD Graphic Module Holder Diffuser and Spacer 10 May not be fitted LCD Sub Assembly on underside of Control PCB Assembly Control PCB Assembly 20 Locating lug Switch Control PCB Assembly LCD Cable Locating Hole ZIF Zero Insertion Force ...

Page 71: ...D Sub Assembly from the Control PCB Assembly 28 2 If the membrane label on the top case assembly is to be replaced carry out the procedure detailed in Chapter 5 Page 36 Section 28 3 Put the complete control PCB assembly on a flat surface so that the LCD Fig 52 Item 20 sub assembly is on the underside refer to Figure 51 Note If the LCD sub assembly is to be re used make sure the outer face of the L...

Page 72: ...et gently push the outer edges of the locking plate away from the connector body on the ZIF socket until the locking plate is in the fully open position fully extended The LCD cable is now released Note The total travel of the locking plate is less than 2mm 28 7 2 Remove the LCD cable from the ZIF connector and remove the LCD sub assembly 29 Installing the LCD Sub Assembly Installing the LCD Sub A...

Page 73: ...tion on the control PCB assembly and turn the complete control PCB assembly over so that the LCD sub assembly is on the underside refer to Figure 51 Note Make sure the outer face on the underside of the LCD sub assembly is protected from damage 29 5 Install the four screws Fig 51 Item 10 to secure the LCD sub assembly to the control PCB assembly CAUTION Do NOT over tighten the screws or you may da...

Page 74: ... Figure 54 Replacing the Membrane Label when the Control PCB Assembly has been removed from the Top Case Assembly Table 22 Top Case Membrane Label Parts List Item Part Number Description Qty 10 507397 Top Case Membrane Label 1 10 Membrane Cable Slot for Membrane Cable Top Case Assembly ...

Page 75: ...val process 30 5 Inspect the surface of the top case from where the membrane label was removed Carefully remove any adhesive residue 30 6 Remove the backing paper from the new self adhesive membrane label Fig 54 Item 10 30 7 Make sure the orientation of the membrane label is correct and pass the end of the membrane cable through the slot in the top case assembly refer to Figure 54 Note Do not bend...

Page 76: ...or on the Control PCB Assembly Figure 56 Replacing the Membrane Label without removing the Control PCB Assembly from the Top Case Assembly Membrane Connector Top Case Assembly Control PCB Assembly Cutout in Control PCB Assembly Membrane Cable May not be fitted 10 Membrane Cable Slot for Membrane Cable Top Case Assembly Rear Egde of Top Case Assembly ...

Page 77: ...as removed Carefully remove any adhesive residue 31 3 Remove the backing paper from the new self adhesive membrane label Fig 56 Item 10 31 4 Make sure the orientation of the membrane label is correct and then do the following 31 4 1 Pass the end of the membrane cable through the slot in the top case assembly and then towards the rear edge of the top case assembly refer to Figure 56 31 4 2 Carefull...

Page 78: ...e button return spring Fig 48 Item 60 onto the Run button 33 3 Install the control PCB assembly into the top case assembly and then re assemble the pump Refer to Page 29 Section 25 34 Replacing the Top Case Assembly The top case assembly Fig 48 Item 20 comprises the top case moulding and the membrane label 34 1 Remove the control PCB assembly from the top case assembly Refer to Page 27 Section 22 ...

Page 79: ...ures the battery Fig 57 Item 10 to the control PCB assembly Fig 57 Item 30 and move the battery a small distance away 35 3 Put the new battery Fig 57 Item 10 onto the control PCB assembly adjacent to the old battery 35 4 Secure the new battery to the control PCB assembly with a new cable tie Fig 57 Item 20 35 5 Disconnect the old battery and connect the new battery in less than 20 seconds as follo...

Page 80: ...r Parts List Item Part Number Description Qty 10 509051 Compressor Assembly Series 6 5 5V 50 60Hz 1 20 507316 Compressor Mounting Bracket 1 30 FAS218 Screw 4mm dia x 12 Pan Head 2 40 REF Power Supply PCB Assembly Spares Item 1 50 631073 Tube 100mm long Compressor Motor Manifold Assy 1 30 10 40 Con 6 Compressor Con 7 Compressor 30 Location Spigot A Location Spigot B Unused Hole 20 50 Air Inlet Filt...

Page 81: ... 1 2 The eight push on cable connectors from the power supply PCB assembly Fig 58 PCB Con 6 and 7 37 2 Put the compressor assembly and mounting bracket into the front case Note Make sure the two locating holes at the outer ends of the mounting bracket are installed over the corresponding location spigots A and B in the front case Refer to Figure 58 Note Make sure the wires from the power supply PC...

Page 82: ...ble 26 Compressor Assembly and Mounting Bracket Parts List Item Part Number Description Qty 10 509051 Compressor Assembly Series 6 5 5V 50 60Hz 1 20 507316 Compressor Mounting Bracket 1 30 507380 Compressor Bracket Grommet 2 40 507317 Compressor Bump Stop 2 50 FAS223 Screw 3 dia x 10 Pan Head 2 60 509307 Anti vibration AV Mount Series 6 4 30 50 40 20 60 10 ...

Page 83: ... in towards the centre of the compressor assembly 38 4 3 At the same time carefully push the AV mount in the opposite direction and out of the slot in the mounting bracket 38 4 4 Repeat for the other three corners of the compressor assembly 39 Installing the Compressor Assembly onto the Mounting Bracket 39 1 Lay the compressor assembly Fig 59 Item 10 down with the AV mounts Fig 59 Item 60 on top a...

Page 84: ...39 6 Install the two screws Fig 59 Item 50 to secure the compressor bump stops 39 7 Check that the two wire assemblies long and short are correctly connected to the compressor assembly Refer to Figure 61 for the correct wire colours and compressor terminal connections Note The two wire assemblies are part of the compressor assembly 39 8 Install the compressor assembly and mounting bracket into the...

Page 85: ... inside surface pointing upwards 40 4 Stick the two compressor support rubbers Fig 62 Item 20 onto the front case 40 5 Install the handle and hook assembly and the rear case onto the pump Refer to Page 13 Section 13 40 6 Install the mains power cordset onto the pump Refer to Page 7 Section 7 40 7 Stick the serial number and product labels onto the rear case Refer to Page 3 Section 2 Figure 62 Repl...

Page 86: ...ng the Front Case Table 28 Front Case Parts List Item Part Number Description Qty 10 507396 Front Case Printed Flowtron Universal 1 20 BP027 Compressor Support Rubber 2 30 BP042 Ferrite Magnet 1 40 507386 Magnet Mounting Pad 1 50 507410 Connector Sealing Strip 1 40 10 50 30 20 Battery Pack Connector Slot ...

Page 87: ...he front case 41 4 1 The two compressor support rubbers Fig 63 Item 20 41 4 2 The connector sealing strip Fig 63 Item 50 adjacent to the battery pack connector slot 41 4 3 The magnet mounting pad Fig 63 Item 40 onto the front case in the appropriate slot 41 4 4 The ferrite magnet Fig 63 Item 30 onto the ferrite mounting pad Note Make sure the ferrite magnet and magnet mounting pad are aligned with...

Page 88: ...Pump Repair Flowtron Universal Service Manual Chap 5 Issue 2 Page 50 SER0009 Sep 2009 ...

Page 89: ...e alarms Serial Number range Before upgrading the pump to the new V3 01 software check the current software version by initialising the pump refer to Chapter 6 Page 15 Section 8 If the software is already at V3 01 or higher do not attempt the upgrade To perform the check and the upgrade a Personal Computer is required equipped with a serial port and running Microsoft Windows This Laptop or PC must...

Page 90: ...T department 2 1 Make sure that any other programs running on the PC have been closed 2 2 Load the Communicator software CD ROM Table 30 Item 10 into the PC The Communicator software should start to auto install 2 3 After a few seconds the Initialisation dialog box should be displayed refer to Figure 64 Figure 64 Communicator Software Installation Initialisation 2 4 If there is a Log On as Adminis...

Page 91: ... Other Applications 2 6 Make sure that any other applications running on the PC have been closed and then click OK 2 7 The Start Installation dialog box will be displayed refer to Figure 66 Figure 66 Communicator Software Installation Start Installation 2 8 Click the button to start the installation process using the suggested default directory 2 9 The Create Short Cuts dialog box will be displaye...

Page 92: ...p Click OK and the Choose Program Group dialog box will be displayed refer to Figure 68 Figure 68 Communicator Software Installation Choose Program Group 2 11 Click Continue to use the suggested default program group 2 12 The installation process will start and the progress will be indicated by a moving bar refer to Figure 69 Figure 69 Communicator Software Installation Progress ...

Page 93: ... is then displayed refer to Figure 71 Figure 71 Communicator Software Installation Setup Message 2 14 In order to complete the installation you need to copy files from the Communicator software CD ROM and then start the Communicator program running Note It is preferable to do this now while the CD ROM is still loaded in the PC 2 15 Click Yes to start copying the additional files and then the Commu...

Page 94: ...nicator Software Installation Locating Communicator Files on the CD ROM 2 17 Click on the down arrow on the right side of the Look in box at the top of the dialog box and browse for SERS001 03 the Communicator software CD ROM and select it 2 18 Click on Communicator Files and click Open refer to Figure 74 Figure 74 Communicator Software Installation Locating the Installation cfg File ...

Page 95: ...Note While the files are copied a Communicator Command Configuration Files dialog box is displayed refer to Figure 75 Figure 75 Communicator Software Installation Command and Configuration Files 2 20 When the files have been copied the Communicator software will then start to run refer to Chapter 3 Using the Communicator Software 2 21 The installation is now complete and you can now safely remove ...

Page 96: ...software Flowtron Universal Service Manual Chap 6 Issue 2 Page 8 SER0009 Sep 2009 Figure 76 Communicator Software Application Startup Screen Figure 77 Communicator Software No Command List Loaded Serial Communicator ...

Page 97: ...s on the base of the pump and click into place 3 2 3 Connect one end of the Data Cable to the 9 way connector on the Serial Communications Pack and the other end to the serial port on the PC 3 3 To remove the Serial Communications Pack from the pump refer to Figure 78 3 3 1 Remove the Data Cable from the Serial Communications Pack and the PC 3 3 2 Depress the Reset Status Latch at the rear of the ...

Page 98: ...oftware Flowtron Universal Service Manual Chap 6 Issue 2 Page 10 SER0009 Sep 2009 Figure 79 Communicator Software Flowtron Universal Commands with Screen Maximised Figure 80 Communicator Software Communication Error ...

Page 99: ... This will start the Communicator software running using the Serial Communications Pack to connect the pump to the PC Note Do NOT click the IrDA Communicator MCM Calibrator or Battery Pack Logger buttons as these functions are not used 4 3 The No command list loaded dialog box will be displayed refer to Figure 77 4 3 1 Make sure the title at the top of the dialog box is Serial Communicator and the...

Page 100: ...ot a pump command but a comment or instruction to the service engineer e g SERVICE 5 3 To send a command to the pump 5 3 1 Click on the appropriate command on the left side of the dialog box e g 201 Read_Service_Hours 5 3 2 If instructed by the test procedure add or change any parameters on the right side of the dialog box above the Send button 5 3 3 Click Send to send the command to the pump 5 3 ...

Page 101: ...t the other COM port on the PC as follows 6 1 6 1 Click Connection then click Exit on the drop down menu 6 1 6 2 The application startup dialog box is then displayed refer to Figure 76 6 1 6 3 Select another COM port on the PC refer to Page 9 Section 3 6 1 6 4 Click the Serial Communicator button to restart the program Re send the command to the pump 7 Closing the Communicator Software 7 1 To clos...

Page 102: ... Chap 6 Issue 2 Page 14 SER0009 Sep 2009 Table 31 Power Up Self Test Sequence Step Elapsed Time approx Duration approx Sounder LCD Screen 1 Start 0 sec 23 sec Silent 2 Software Version 23 sec 7 sec Double beep 3 End 30 sec Waiting to start treatment Silent ...

Page 103: ...ence is complete and before upgrading the pump software make sure that the PC can communicate correctly with the pump as follows refer to Chapter 6 Updating the software Page 12 Executing Commands on the Command Menu 8 5 1 The pump must be left in Standby 8 5 2 Scroll through the menu of Flowtron Universal Commands on the Communicator software on the PC to the section heading VERSIONS 8 5 3 Send t...

Page 104: ...are Initialising the Bank Loader Figure 85 Pump LCD Screen Standby Software file selected for Bank 0 Click here to browse for software file Click here to enable Bank 0 Click here to maximise the screen to view the TxRx box Click here to enable Auto Run Click here to start the software download with the Flash Loader TxRx Box ...

Page 105: ...1 The software for the Flowtron Universal pump is contained in the following three files which must be downloaded to the pump using the Communicator software FlowtronUniversal_V3 01 H00 FlowtronUniversal_V3 01 H01 FlowtronUniversal_V3 01 H02 10 1 2 These three software files will normally be supplied on either of the following media CD ROM File attachments on an email 10 1 3 If the three software ...

Page 106: ...hree pump software files on the CD ROM or the PC refer to Para 10 1 10 6 3 3 Select FlowtronUniversal_V3 01 H00 and click Open 10 6 3 4 The Bank Loader tab will reappear with FlowtronUniversal_V3 01 H00 in the Bank 0 File Name box 10 6 4 Repeat the procedure in Para 10 6 3 to select the FlowtronUniversal_V3 01 H01 software file for Bank 1 10 6 5 Repeat the procedure in Para 10 6 3 to select the Fl...

Page 107: ...ware Page 13 Communication Error when Executing Commands 10 9 As the software is downloaded the progress is shown in the dialog box as follows refer to Figure 86 The Status part of the dialog box shows Loading Bank 0 followed by Loading Bank 1 and then Loading Bank 2 and a moving Progress status bar The Tx Rx box counts up from B0 S0 OK to B0 S128 OK followed by B1 S0 OK to B1 S128 OK and then B2 ...

Page 108: ...Updating the software Flowtron Universal Service Manual Chap 6 Issue 2 Page 20 SER0009 Sep 2009 ...

Page 109: ...ch Belgium Australia NZ China Japan South Africa India Europe Universal Pressure Range 40 5 mmHg Calf 130 5 mmHg Foot Supply Voltage 100 230 VAC Supply Frequency 50 60Hz Power Input 120 VA Size 254 x 267 x 152 mm 10 0 x 10 5 x 6 0 Weight 3 9 kg 8 5 lb Case Material ABS Plastic Plug Fuse Rating 5A to BS1362 UK ONLY Fuse 2 x T3 15AL 250 V Degree of protection against electric shock Mains Connected C...

Page 110: ...e and mechanical hazards only in accordance with UL60601 1 and CAN CSA C22 2 No 601 1 MEDICAL EQUIPENT Fuse ENVIRONMENTAL INFORMATION Condition Temperature Range Relative Humidity Atmospheric Pressure Operating Pump Battery Pack 10 C to 40 C 30 to 75 700hPa to 1060 hPa Storage and Transport Pump 40 C to 70 C 10 to 95 non condensing 500 hPa to 1060 hPa Storage and Transport Battery Pack 10 C to 30 ...

Page 111: ...al Assembly 1 507001 previously AC600 UK Flowtron Universal Pump UK KSA 507003 previously AC600 US Flowtron Universal Pump USA Canada 507004DE previously AC600 DE Flowtron Universal Pump Germany 507004DK previously AC600 DK Flowtron Universal Pump Denmark Sweden 507004ES previously AC600 ES Flowtron Universal Pump Spain 507004FR previously AC600 FR Flowtron Universal Pump France 507004IT previousl...

Page 112: ...d Assy 40 40 58 50 1 FAS223 Screw 3 dia x 10 Pan Head 43 40 48 30 8 507305 Run Button 48 50 1 507411 Button Return Spring 48 60 1 507306 Case Style Gasket 40 30 1 Front Case Assembly 507396 Front Case Printed Flowtron Universal 39 20 40 10 63 10 1 507058 Power Supply PCB Assembly Spares Item 58 40 50 10 1 507137 Power Supply PCB Assembly New item 58 40 50 10 1 507422 Fuse 3 15A 20mm Type T Spares ...

Page 113: ... 1 Rear Case Assembly 507302 Rear Case 39 10 62 10 1 507419 Handle and Hook Assembly Spares Item 39 50 1 Mains Power IEC Cordset 33 10 1 507374 Inlet Filter Felt 33 20 1 507315 Case IEC Cover 33 30 1 BP027 Compressor Support Rubber 62 20 2 507413 Rubber Foot 33 50 10 FAS223 Screw 3 dia x 10 Pan Head 39 40 4 FAS045 Screw M3 x 10mm Pan Head 33 40 2 Hose Set Assemblies 507500 Hose Set Assembly Standa...

Page 114: ...Parts List Flowtron Universal Service Manual Chap 8 Issue 2 Page 4 SER0009 Sep 2009 ...

Page 115: ... TIEL Postbus 6116 4000 HC Tiel Tel 31 0 344 64 08 00 Fax 31 0 344 64 08 85 SWITZERLAND ArjoHuntleigh AG Florenzstrasse 1D CH BASEL 4023 T 41 0 61 337 97 77 F 41 0 61 311 97 42 DENMARK Huntleigh Healthcare A S Vassingerødvej 52 DK 3540 LYNGE T 45 4 913 8486 F 45 4 913 8487 NEW ZEALAND Huntleigh Healthcare Ltd Unit 6 38 Eaglehurst Road Ellerslie Auckland New Zealand T 64 9 525 2488 F 64 9 525 2433 ...

Page 116: ...SER0009_02 September 2009 ...

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