Service Guide - az897333.vo.msecnd.net · 8. Basic function test 9. Safety test 10. 12-hrs test 3.2 Replacing the Valve Unit of the Low Pressure Regulator LPR Replacing WARNING! Disconnect

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Service Guide

016/11 www.stryker.com P28713 B

Low Pressure Unit (LPU) and High Pressure Unit (HPU) for 40L Core Insufflator (F112)

Type: HPU LPU /10000015728 02/2016-11/Hahn

Stryker Endoscopy5900 Optical Court, San Jose CA 95138 (USA)(408) 754-2000 (800) 624-4422 www.stryker.com

This manual contains information that is subject to copyright. Allrights reserved. This manual should not be photocopied, dupli-cated on microfilm or otherwise copied or distributed, complete-ly or in part, without the approval of STRYKER ENDOSCOPY.

Some of the parts and equipment referred to in this manual bear registeredtrademarks but are not identified as such. It should therefore not be assumedthat the absence of the trademark indicates that any given designation is notsubject to trademark protection.

Users of this product should not hesitate to point out to us any errors or un-clarities in this manual.

Copyright © STRYKER ENDOSCOPY

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Table of contents

1 Safety Instructions .............................................................................................................................................................. 31.1 Liability ........................................................................................................................................................................................ 31.2 Certification/Seal ..................................................................................................................................................................... 31.3 Precautionary measures to avoid component failure ................................................................................................... 3

2 Tools and Equipment........................................................................................................................................................... 4

3 Replacing Components and Modules ................................................................................................................................. 53.1 Uninstalling/Installing PCU Board ...................................................................................................................................... 53.2 Replacing the Valve Unit of the Low Pressure Regulator LPR ...................................................................................... 73.3 Uninstalling/Installing Membrane of Low Pressure Safety Valve LSV ...................................................................... 93.4 Spare Parts Replacement of the High Pressure Unit HPU ............................................................................................ 103.4.1 Disassembling of the HPU ..................................................................................................................................................... 103.4.2 Replacement of the membrane ........................................................................................................................................... 123.4.3 Disassembling of the regulator unit................................................................................................................................... 133.4.4 Replacement of the sealing gasket of the needle valve................................................................................................ 133.4.5 Reassembling of the High Pressure Unit HPU.................................................................................................................. 143.4.6 Reassembling of the membrane.......................................................................................................................................... 153.4.7 Reassembling of the adjustment screw............................................................................................................................. 153.4.8 Final assembly of the HPU..................................................................................................................................................... 163.4.9 Installation of the HPU ........................................................................................................................................................... 16

4 Spare Parts List .................................................................................................................................................................... 17

5 Error and Warning Messages.............................................................................................................................................. 18

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Safety Instructions

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1 Safety Instructions

WARNING!Before opening the device, disconnect device from power supply by pulling thepower cable.

1.1 Liability

Device and accessories have been carefully inspected at the factory before ship-ping. However, the manufacturer is only liable for safety and reliability as well asfunctionality if all inspections and repairs have been performed by authorizedtechnicians and if the device and the accessories are used only as intended.

CAUTION!All maintenance and repair tasks as well as any modifications are to be per-formed only by personnel or technicians authorized by the manufacturer. Thepower supply has to be installed in compliance with DIN/IEC.

An authorized service technician has to inspect and service the device to ensurethe safety and functionality of the device every two years. If the service intervalis not maintained, the manufacturer does not assume any liability for the func-tional safety of the device. Authorized service technicians are trained and certi-fied only by the manufacturer. The manufacturer is not liable for direct orconsequential damages, and the warranty becomes null and void if:

• the device or the accessories are used improperly;• the instructions and rules in the manual are not adhered to;• the device or the accessories are improperly prepared or maintained;• unauthorized persons perform repairs, adjustments, or alterations on the de-

vice or accessories;• the prescribed inspection and maintenance schedules are not adhered to.

The service and maintenance of the device and its accessories has to be carriedout as per instructions to ensure the safe operation of the device. Check functionand completeness of the device after every service or maintenance activity to en-sure the safety of the patient and user/operator are not affected or diminishedin any way. Factory-new and repaired products must be prepared and tested ac-cording to the manual prior to use.

1.2 Certification/Seal

The operator of the device has to receive a certificate from the service technicianstating the type and scope of the performed service or maintenance tasks. Thiscertificate must list the date of the service or maintenance task as well as thecompany and signature. Please use the maintenance and checklist enclosed inback of the service manual. After the repair work is concluded, a service seal willbe attached to the device by the authorized service technician.

1.3 Precautionary measures to avoid component failure

The following factors could contribute to a component damage:

• Use of non medical grade CO2 (e.g. technical or polluted gas)• Use without sinter filter in rear side gas connector• Use without patient filter in insufflation tubing• Use a gas bottle with riser pipe (damage due to liquid gas)• Use of gas bottles with fill pressure > 80 bar (1160 psi)

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Tools and Equipment

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2 Tools and Equipment

Make sure the measuring instruments are calibrated and in perfect working or-der before starting any repairs. In addition to the tools and measuring equipmentlisted in the service manual, you will need the following as well:

• Wrench SW 9, 32• Socket wrench SW 19, 22, 24• Open-end wrench SW 8, 17, 30• Nut driver SW 23• Torque driver SW 8, 17, 23, 32• Plastic cleaner• Super-O Lube (lubricant)

Tests, calibrations, and supplementary tools are described in detail and supple-mentary tools are described in detail in the service manual.

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Replacing Components and Modules

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3 Replacing Components and Modules

3.1 Uninstalling/Installing PCU Board

WARNING!

Disconnect device from power supply.

Uninstalling1. Uninstall the low pressure unit LPU as described in the service manual andplace the low pressure unit LPU onto a solid and stable surface.

2. Remove the ST6 plug (2) from the PCU board (3).3. Remove the ST4 plug (1) from the PCU board (3).4. Remove the ST8 plug (4) from the PCU board (3).

5. Remove the 3 screws (8) from the PCU board (7) and take the PCU board off-from the pneumatic unit PBU (6).

6. Follow these steps in reverse to install a (new) PCU board. Make sure you in-stall the correct PCU and check the silicone sealing block for leaks (10) (seeFig. 3-3 Silicone sealing block, page 5). The silicone sealing block is a compo-nent of the spare part kit of the PCU board (see chapter 4 Spare Parts List,

Fig. 3-1 Uninstalling the PCU Board

(1) ST4 plug/cable leading to valve unit VAU

(2) ST6 plug/cable leading to fluid sensor

(3) PCU board

(4) ST8 plug/cable leading to patient pressure valve PPV

(1) (4)(3)(2)

Fig. 3-2 Uninstalling the PCU Board

(5) Valve unit VAU

(6) Pneumatic unit PBU

(7) PCU board

(8) 3x fastening screws/toothed was-hers

(6)(5)

(8) (7)

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page 17).

7. Replacing the sintered metal filter is not required when replacing thePCUboard. This requires removing the valve unit VAU: Unscrew the 2 screws(13) at the valve unit VAU (14) (see Fig. 3-4 Uninstalling the valve unit VAU,page5).

8. Remove the valve unit VAU (14) from the pneumatic unit PBU (12) and re-place the sintered metal filter (17) with the new one (see Fig. 3-5 Installingthe valve unit VAU, page 6).

Installing Follow these steps to re-install the valve unit VAU (see Fig. 3-5 Installing the valveunit VAU, page 6). Make sure the surface of all O-rings is clean!

1. Lubricate the 3 O-rings 3x12x1.5 mm (15) with Super-O Lube.2. Insert the 3 O-rings (15) into the grooves of the side bore holes.

3. Insert the O-ring 1x14x2 mm into the bottom of the large side drill hole (16).4. Insert the sintered metal filter (17) centered into the large side drill hole (16).5. Insert the 3 slightly lubricated O-rings 25x2 mm, 14x2 mm, and 13x2 mm(18)

into the intermediate ring (19).

Fig. 3-3 Silicone sealing block

(9) PCU board

(10) Silicone sealing block

(11) 3x spacers

(10)(9)

(11)

Fig. 3-4 Uninstalling the valve unit VAU

(12) Pneumatic unit PBU

(13) 2x fastening screws/toothed was-hers

(14) Valve unit VAU

(12)

(14) (13)

Fig. 3-5 Installing the valve unit VAU

(15) 3x O-rings 3x12x1.5 mm

(16) Large side drill hole

(17) Sintered metal filter

(18) 3x O-rings: 25x2 mm, 14x2 mm, and 13x2 mm

(19) Intermediate ring

(20) Valve unit VAU

(15) (16) (17) (15)

(19)

(18)(20)

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6. Place the intermediate ring onto the sintered metal filter (17).7. Place the valve unit VAU (20) onto the pneumatic unit PBU, matching the

drill holes.8. Screw the valve unit VAU (20) firmly onto the pneumatic unit PBU using 2

screws/toothed washers.

Tests after reassemblyThe following tests/calibrations must be performed after installing a (new) PCUboard: The following tests/calibrations are described in detail in the service man-ual. Always comply with the indicated sequence of steps:

1. Software update via: GlobalServices.net www.womservice.com2. All offset calibration3. LOW pressure calibration4. HIGH pressure calibration5. Flow calibration6. Low pressure calibration controller (LPR calibration)7. Low pressure calibration safety valve (LSV calibration)8. Basic function test9. Safety test10. 12-hrs test

3.2 Replacing the Valve Unit of the Low Pressure Regulator LPR

Replacing

WARNING!


1. Uninstall the low pressure unit LPU as described in the service manual andplace the low pressure unit LPU onto a solid and stable surface.

2. Remove the 2 plug contacts (2) from the valve unit VAU.3. Turn the setscrew (3) counterclockwise to remove completely.

4. Remove the 6 screws (1) at the upper part of the low pressure regulator andtake off the upper part (4).

5. Remove the pressure plate (5), the spring (6), and the red membrane (7) to-gether with the membrane holder (8).

Fig. 3-6 Removing the upper part of the low pressure regulator

(1) 6x fastening screws

(2) 2x plug contacts/cable leading to valve unit VAU

(3) Setscrew

(4) Upper part of low pressure regula-tor

(1)

(1)

(3)

(4)

(2)

(1)

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6. Unscrew the valve unit (9) from the pneumatic unit PBU using a socketwrench SW22 and by turning counterclockwise.

7. Follow these steps in reverse to install the valve unit. Make sure that dirt orforeign particles do not penetrate the pneumatic chamber when replacing acomponent.

Tests after reassembly The following tests/calibrations must be performed after installing a (new)PCU board: The following tests/calibrations are described in detail in the servicemanual. Always comply with the indicated sequence of steps:

1. Software update via: GlobalServices.net www.womservice.com2. All offset calibration3. LOW pressure calibration4. Flow calibration5. Low pressure calibration controller (LPR calibration)6. Low pressure calibration safety valve (LSV calibration)7. Basic function test8. Safety test9. 12-hrs test

Fig. 3-7 Removing the pressure plate, spring, and red membrane

(5) Pressure plate

(6) Red membrane

(7) Spring

(8) Membrane holder

(8)

(7)

(5) (6)

Fig. 3-8 Unscrewing the valve unit

(9) Valve unit

(9)

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3.3 Uninstalling/Installing Membrane of Low Pressure Safety Valve LSV

WARNING!


Uninstalling1. Uninstall the low pressure unit LPU as described in the service manual andplace the low pressure unit LPU onto a solid and stable surface.

2. Remove the 2 plug contacts (4) from the valve unit VAU.3. Turn the setscrew (2) counterclockwise to remove completely.

4. Remove the 6 screws (1) at the upper part (3) of the low pressure safetyvalve and take off the upper part.

5. Remove the pressure plate (5), the spring (7), and the membrane (6) to-gether with the membrane holder (8).

6. Follow these steps in reverse for assembly. Use a plastic cleaner to wipe offthe black membrane before installing it. Make sure that dirt or foreign parti-cles do not penetrate the pneumatic chamber when replacing a component.

Test after reassemblyThe following tests/calibrations must be performed after installing the newblack membrane: The following tests/calibrations are described in detail in theservice manual. Always comply with the indicated sequence of steps:

1. LOW pressure calibration2. Low pressure calibration controller (LPR calibration)3. Low pressure calibration safety valve (LSV calibration)4. Basic function test5. Safety test6. 12-hrs test

Fig. 3-9 Removing the upper part


(2) Setscrew

(3) Upper part of the low pressure safety valve LSV

(4) 2x plug contacts/cable leading to valve unit VAU

(1)

(4)

(3)

(2)

Fig. 3-10 Removing the pressure plate, spring, and black membrane

(5) Pressure plate

(6) Black membrane

(7) Spring

(8) Membrane holder(8)

(7)

(6)

(5)

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3.4 Spare Parts Replacement of the High Pressure Unit HPU

NOTE!The replacement of components within the HPU is only possible for HPUs manu-factured after July 2013. Older HPUs are glued inside and therefore not repair-able.

To distinguish the older HPU from the new HPU please see the following picture:The new HPU (manufactured after July 2013) is screwed to the brass block, theolder one is not.

3.4.1 Disassembling of the HPU

WARNING!


1. Disconnect the pressure tube (2) from the HPU (1).2. Disconnect the sensor plug (3) from the PCU board (4).

3. Remove the 4 screws (5) on the backside of the device using a Phillips-tipscrewdriver.

Fig. 3-11 HPU Connection

(1) Connection bolt

(1)

Fig. 3-12 Disconnecting the pressure tube and sensor plug

(1) HPU

(2) Pressure tube

(3) Sensor plug

(4) PCU board

(2) (3) (4)(1)

Fig. 3-13 Removing the HPU


(5)

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4. Remove the connection bolt (6) using a open-end wrench SW 17.5. Remove the adjustment screw (7) using a open-end wrench SW 30.

6. Remove the spring (8) and bearing (9).7. Remove the regulator cap (10) using a wrench SW 32.

Fig. 3-14 Disassembling the HPU

(6) Connection bolt

(7) Adjustment screw

(6)

(7)

Fig. 3-15 Removing the regulator cap

(8) Bearing

(9) Spring

(10) Regulator cap

(10)(9)(8)

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3.4.2 Replacement of the membrane1. Put off the regulator cap (1).2. Remove the broken membrane (2).

3. Remove the nut (3) using a open-end wrench SW 8.4. Replace the membrane (4).5. Fix the nut using a 8, 1,5Nm-torque screwdriver.

Fig. 3-16 Removing the membrane

(1) Regulator cap

(2) Broken Membrane

(2)(1)

Fig. 3-17 Replacing the membrane

(3) Nut

(4) Membrane

(4)(3)

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3.4.3 Disassembling of the regulator unit1. Remove the regulator unit (1) using a nut driver SW 23.

2. Remove the regulator screw (3).

3.4.4 Replacement of the sealing gasket of the needle valve1. Remove the nut (1) of the needle valve using a wrench SW 9.2. Replace the sealing gasket (2).3. Fix the nut of the needle valve hand-tight using a wrench SW 9.

Fig. 3-18 Removing the regulator unit

(1) Regulator unit

(2) Copper washer

(2)(1)

Fig. 3-19 Disassembling the regulator unit

(3) Regulator screw

(4) Needle valve

(3)

(4)

Fig. 3-20 Disassembling the needle valve

(1) Nut

(2) Sealing gasket

(2)(1)

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3.4.5 Reassembling of the High Pressure Unit HPU1. Reassemble all parts of the regulator unit.2. Fix the regulator screw (2) hand-tight.

3. Use always a new Copper washer (3).4. Fix the regulator unit (4) using a torque driver SW 23, 60 Nm.

Fig. 3-21 Reassembling the regulator unit

(1) Needle valve

(2) Regulator screw

(1) (2)

Fig. 3-22 Reassembling the regulator unit

(3) Copper washer

(4) Regulator unit

(3) (4)

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3.4.6 Reassembling of the membrane1. Use a new membrane (1).2. Fix the regulator cap (2) using a torque driver SW 32, 10 Nm.

3.4.7 Reassembling of the adjustment screw1. Put the spring (1) and bearing (3) into the regulator cap (2).2. Fix the adjustment screw (4) using a wrench SW 32.

Fig. 3-23 Reassembling the membrane

(1) Membrane

(2) Regulator cap

(2)(1)

Fig. 3-24 Reassembling the adjustment screw

(1) Spring

(2) Bearing

(3) Regulator cap

(4) Adjustment screw

(4)(2)(1) (3)

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3.4.8 Final assembly of the HPU1. Replace the plastic washers (1) if necessary.2. Fix the connection bolt (2) using a torque driver SW 17, 30 Nm.

3.4.9 Installation of the HPU

Calibration Please calibrate the device after the installation of the HPU according to the ser-vice manual.

1. Tighten the 4 fastening screws (1) on the backside of the device using a Phil-lips-tip screwdriver.

2. Connect the pressure tube (3) with the HPU (2).3. Connect the sensor plug (4) with the PCU board (5).

Fig. 3-25 Final assembly of the HPU

(1) 2x Plastic washer

(2) Connection bolt

(2)

(1)

Fig. 3-26 Installing the HPU

(1) 4x fastening screws (1)

Fig. 3-27 Connecting the pressure tube and sensor plug

(2) HPU

(3) Pressure tube

(4) Sensor plug

(5) PCU board

(3) (4) (5)(2)

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Spare Parts List

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4 Spare Parts List

Article Order number

Valve unit LPR (low pressure regulator) P28714

PCU board with sintered metal filter P28715

LSV membrane (low pressure safety valve) P28716

Membrane (regulator unit) P28717

Sealing gasket (needle valve) P28718

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Error and Warning Messages

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5 Error and Warning Messages

Error message Error cause Troubleshooting

0 General error Replace LPU

1 Timeout Replace LPU

2 General software error Replace LPU

3 EEPROM write error Replace LPU

4 General gas supply error Check gas supply

10 General offset calibration error Replace PCU

11 Offset I low pressure sensor too low Replace PCU

12 Offset II low pressure sensor too low Replace PCU

13 Offset safety pressure sensor too low Replace PCU

14 Offset differential pressure sensor too low Replace PCU

16 Offset temperature sensor too low Replace PCU

19 Offset I low pressure sensor too high Replace PCU

20 Offset II low pressure sensor too high Replace PCU

21 Offset safety pressure sensor too high Replace PCU

22 Offset differential pressure sensor too high Replace PCU

24 Offset temperature sensor too high Replace PCU

26 Offset current monitor of high pressure gas heating too high Replace LPU

50 General calibration error, low pressure Check calibration

51 Low pressure – large leak Check manometer connection, replace PCU

52 Low pressure – small leak Check manometer connection, replace PCU

53 Low pressure input value too low Check gas supply, HPU, LPR calibra-tion

54 Low pressure input value too high Check Gas Supply, LPR calibration

55 Low pressure sensor amplification I too low Replace PCU

56 Low pressure sensor amplification I too high Replace PCU

57 Low pressure sensor amplification II too low Replace PCU

58 Low pressure sensor amplification II too high Replace PCU

59 Safety pressure sensor amplification too low Replace PCU

60 Low pressure safety pressure sensor amplification too high Replace PCU

90 General calibration error, low pressure regulator Replace PCU

91 Adjustment, low pressure regulator not within range Repeat calibration

110 General calibration error, low pressure safety valve Replace LPU, replace LSV membrane

111 Adjustment, low pressure safety valve not within range Repeat calibration

130 General error, flow Check flowmeter, replace LPU

131 Flow resistance too high Check flowmeter, replace LPU

133 Flow input value too low Incorrect operation: Repeat calibra-tion

134 Flow input value too high Incorrect operation: Repeat calibra-tion

135 Modified flow sensor value Replace LPU

136 Flow sensor amplification too low Check flowmeter, replace LPU

137 Flow sensor amplification too high Check flowmeter, replace LPU

138 Offset proportional valve too low Replace LPU

139 Offset proportional valve too high Replace LPU

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Error and Warning Messages

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140 Hysteresis proportional valve too low Replace LPU

141 Hysteresis proportional valve too high Replace LPU

142 Proportional valve amplification too low Replace LPU

143 Sticky proportional valve Replace LPU

Display E20 Sensor error Replace PCU

Display E21 Contamination Replace LPU (the enire unit must be replaced! Do not make a repair!)

Display E22 Valve malfunction Replace LPU

Display E59 - flas-hing

Calibration error Re-calibrate device. Replace pressure sensor/switch if high pressure cali-bration fails

Error: Permanently venting of High pressure relief valve (HSV)

Defective membrane or defective sealing gasket of needle valve Replacement of membrane or seal-ing gasket of the High Pressure Unit (see chapter 3.4)

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Service Guide - az897333.vo.msecnd.net · 8. Basic function test 9. Safety test 10. 12-hrs test 3.2 Replacing the Valve Unit of the Low Pressure Regulator LPR Replacing WARNING! Disconnect

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