`Cryomatic` Console Service Manual for
Contents
1.2. 20 Appendix 2 Pneumatic Module General Arrangement 23 KCU401 2 Keeler Cryomatic Service Manual Safety Considerations The system has been designed to comply with the following regulatory standards for Safety and Electromagnetic Compatibility gt EN60601 1 UL60601 1 amp CAN CSA C22 2 No 601 1 gt EN60601 1 2 Although compliant with applicable EMC directives this equipment may still be susceptible to excessive emissions and or may interfere with other more sensitive material For your own safety and the safety of the equipment always take the following precautions Keep the console away from sources of liquids and do not spray with water Switch off the electrical supply and disconnect from the mains supply before cleaning and inspection Do not use hypercarbonate or phenolic based cleaning solutions or disinfectants containing cationic surfactants e g Dettox to clean the console Ensure that the system is clean and dry prior to storage Observe the usual safety precautions associated with the use of medical gases at all times Copies of these guidelines will be available from the gas supplier Ensure the correct disposition of gas exhausted from the system so as to minimise the exposure to nitrous oxide This is the responsibility of the user Ensure that the system is inspected by properly trained personnel once per annum for performance and safety checks Vv Vv
3. replace if necessary 2 system appears to a contrast setting incorrect adjust contrast level to 5 power up but LCD correct setting screen is blank b LCD module faulty check that LCD flat ribbon is 5 connected properly replace if necessary 3 system appears to a_ firmware corrupted re install firmware 6 power up but b faulty controller PCB replace controller PCB 5 nothing happens 4 no gas supply a gas cylinder not connected connect cylinder and open indicated on LCD or valve not open valves screen b insufficient cylinder pressure replace cylinder c inlet filter clogged replace inlet filter 4 d 1 faulty pressure sensor replace pneumatic module 4 5 system will not a faulty memory IC in probe replace re program recognise probe coupling b possible damage to inspect contacts and clean electrical contacts of carefully if necessary console or probe dirty or oxidised probe contacts 6 probe does not a residual moisture in probe re purge probe freeze properly following sterilisation low or zero flow b probe blocked with replace repair probe particulate matter c gas supply insufficient check cylinder connection and valve replace cylinder if necessary d 1 faulty blocked control valve replace pneumatic module 4 e exhaust hose is blocked or check the exhaust hose for occluded blockages or occlusions replace if necessary f 1 faulty pressure sensor replace pneumatic module 4 g faulty controller PCB replace control
4. PITH OO MO On botz FASO58 MCU215 PU Tube 4mm 5 M O61 MCU214 1 8BSP 4mm Push In Stud Conn 1 MCU329 55 1 2X Feyie MCU061 FASO38 M3x10 Pozi Panhead Screw S S 2 2 FASO31 M3x6 Csk Pozi Screw S S 4 3rd Angle Projection Nu Perspectives Limited GE ees ve P ee SE BE M ANG 3405 deg Keeler Cryomatic Console LCD and retainer amended amp general simplification 15 02 11 F 2 PCB warning label added amp V3 orientation amended 14 07 10 Finish 31 03 08 carl This drawing and copies of it shall always remain the property of NU PERSPECTIVES LIMITED registered in England and Wales 65 KCU401 2 Keeler Cryomatic Service Manual R mus e GC 7506 The contents are confidential and shall only be used for the purpose for which the drawing was provided Page 21 of 24 E ER E GE 0988091 EG EE GE O ee D 1 PCB Connector MCU061 MCU059 Footswitch Loom MCU063 1 P2 Sensor Loom hMCU063 2 P3 Sensor Loom CN10 MCUQ Z SMPS Outputloom 0 Description meni gr FASOSS 4 10 Button Head Screw 3 5 MCU066 Probe Contact Loom CR 3rd Angle Projection Nu Perspectives Limited hu Material Tolerance Tel Fax 01962 761080 ui R www nu perspectives co uk persi Ka ANG 0 5 deg Keeler Cryomatic Console MH LCD and retainer amended amp general simplification 15 02 11 10024 1 2 PCB warning label added
5. 1 885 1 NYL 2 16 5084 O Ring NBR 70 Shore 10 82 x 1 78 e 24 O Ring NBR 70 Shore 3 5 x 1 5 3 Ca 181 FAS014 Bonded Seal 1 8 c Q 19 FASO40 Pozi Csk Screw S S L M3x10 20 MCU322_ Couping Inieriace Bezel 1 21 FASO98 Screw Pozi Csk St Stl M4 x 20 Ta 207 11 GC CR 0032 V2specification changed 5 25 04 11 CR 0029 valve iking separaled on BOM 4 14 07 10 GC CRI0022 orientation of V3 coillamended 3 0 07 09 CRI00I4 Recessed feature onMCU314 added pictorialy 2 12 03 08 GC ECNO30 General update for drawing Rev Name Description diminmm age 3rd Angle Projection Cryogenic Technology Limited Material Tolerance P Sht 1 na Pneumatic Module Assembly 2 ANG ali ien l F Fh Sate Sak Te clean Y als ee wm w r e This drawing and copies of it shail always remain the property of CRYOGENIC TECHNOLOGY LIMITED The contents are confidential and shall only be used for wt spose for which the drawing was provided L KCU401 2 Keeler Cryomatic Service Manual Page 23 of 24 croup C 0088 COMPANY Keeler Ltd Clewer Hill Road Windsor Berkshire SL4 4AA England Tel 44 0 1753 857177 Fax 44 0 1753 827170 www keeler co uk Keeler Instruments Inc 456 Parkway Lawrence Park Industrial Estate Broomall PA 19008 Phone 610 353 4350 800 523 5620 Toll Free www keelerusa com Keeler
6. 16 3 LCD and retainer amended amp general simplification 10024 12 View on rear of LCD Retaining Plate showing approximate position and orientation of Foam Pads Apply Foam Pads to LCD Retaining Plate prior to assembly into the moulding Nu Perspectives Limited Tel Fax 01962 761080 www nu perspectives co uk Keeler Cryomatic Console ESC This drawing and copies of it shall always remain the property of NU PERSPECTIVES LIMITED registered in England and Wales 6557506 The contents are confidential and shall only be used for the purpose for which the drawing was provided Mem PartNo Qiy MCU301 HnclosvreRer MCU302 16 MCUO54 0 PSU Sub assembly MCUO051 PneumoficModle 1 18 MCU3221 Coupling Bezel o MCUO51 19 51261 Switched Fused Inlet OOo Ol 1 MISO94 A Anfi surge Fuse KCU200 Serial Number Label KCU201 MCU325 MCU313 Exhaust Hosetail MCU059 Footswitch Loom 1 MC 0063 1 P2 Sensor Loom MCU063 2 P3 Sensor Loom MCU064 MCU213 Rubber Foot Blanking Plug MCU326 MCU350 06 ost 1 MCU066 Probe Contact Loom E CST264 sRefainingFlate 05 FASO40 M3x10 Csk Pozi Screw S S M UQ51 MCU323 ss Supportbracket FASO54 M3x8 Panhead Screw S S 8 MCUO33 M3 Washer S S 10 40 FA 032 M3 Plain Washer S S 4 FASO40 M3x10 Csk Pozi Screw S S 42 FASO42 Washer S S ie
7. VV V VV SAFETY WARNINGS Electrical equipment may be hazardous if misused The equipment covers should only be removed by authorised technical personnel Do not use the system in the presence of flammable gases such as anaesthetic agents KCU401 2 Keeler Cryomatic Service Manual 1 Introduction About this Manual This manual covers all aspects of servicing the Cryomatic System models from June 2011 onwards This manual is for use only by properly trained Keeler service engineers This manual assumes that the Cryomatic system has been correctly installed following the guidelines in the Cryomatic Instructions For Use Good Working Practices 7 is BE Potentially dangerous voltages are present inside the equipment care should be observed when operating the equipment with the front cover removed The Cryomatic contains several components sub assemblies which are sensitive to electrostatic discharge ESD and relevant precautions should be taken when handling such components KCU401 2 Keeler Cryomatic Service Manual 2 Scheduled Maintenance The Cryomatic system should ideally be inspected and serviced annually by Keeler trained personnel The following service points should be covered a b c d e g h i General inspection of console for any signs of damage Inspection of mains cord for signs of damage replace if necessary Inspection of high pressure gas hose for sig
8. be accessed by removing the inlet adapter refer to GA in Appendix 2 Once the adapter has been removed the filter can be unscrewed using a flat bladed screwdriver Re fitting is the reverse of removal A new Dowty seal should be fitted when the inlet adapter is replaced Should the need arise solenoid valves can be replaced without removing the pneumatic module from the enclosure Remove the electrical connector noting orientation by undoing the central retaining screw Remove the solenoid valve coil noting orientation Remove the 2 countersunk fixing screws The solenoid valve can now be removed Care must taken to note the orientation of the valve as they have an arrow on the body denoting the direction of flow Re fitting is the reverse of removal taking care to install the valve in the correct orientation refer to GA in Appendix 2 KCU401 2 Keeler Cryomatic Service Manual 5 Electronic System Footswitch The footswitch is connected to the Cryomatic at the rear of the console The footswitch is not a serviceable item and if it is faulty then it should be returned to the manufacturer for replacement Controller PCB Assembly Observe proper precautions for the prevention of damage n to static sensitive devices The Controller PCB Assembly can be removed in the following manner a Unlatch the connection for the LCD panel in position CN1 Carefully withdraw the flexible cable assembly b Unplug the front pa
9. 401 2 Keeler Cryomatic Service Manual Part Number KCU050 MCU051 MCU054 MCU065 CST261 MCU068 MCU301 MCU302 MCU204 MCU205 MCU206 MCU217 MIS094 MCU213 FAS014 MCU219 FAS055 FAS044 FAS031 FAS054 FAS033 FAS032 various CST267 MIS 104 PKGO15 PKG004 S KCU400 KCU401 9 Warranty The Cryomatic and its components are covered by warranty that they meet their performance standards and are free from any defects in materials or workmanship Within 12 months from delivery by Keeler the manufacturer shall at no charge to the customer upon written notice from the customer repair or replace any components which are defective in material or workmanship The customer agrees that it shall have no remedy in the event of any breach of the foregoing warranty other than as provided above This warranty is exclusive and in lieu of all other warranties expressed or implied and all implied warranties of merchantability or fitness for a particular purpose are expressly disclaimed The obligations of the manufacturer as set forth in this warranty are expressly conditioned on the following i No alterations or repairs of any malfunction of the system shall be made to the system except by the manufacturer or his authorized representative without the prior written approval of the manufacturer or his authorized representative and in no case will the manufacturer assume responsibility for repairs or alterations made by those other th
10. Keeler Cryomatic Cryomatic Console Service Manual for 2509 P 1000 JPN 2509 P 1000 September 2011 onwards Contents Introduction isietieicsicennidieviidcainesid dois aaue adaa ENEE KEEN e aad da eh ey 4 About this Manual EEN 4 Good Working Practices EE 4 Scheduled Maintenance uge eNeNRSNNNEENENENENEN EES ERNEEEENEeSKEEueNeEEN 5 Enclosure amp Fittigs 6 Programming Port COVE a ya pa aaa aa daa 6 ne EE EE 6 Rubber EE 6 El ctrical System Zeie ee EE EA 7 Replacing Mains Fuses 5 ci stne ie aad A lab bas l 7 Mains CGOrd EE 7 Mains Met eaae E EAE EAE ANENE GEA EEE EEE ye 8 Power Supply Sub assembly AAA 9 Pneumatic System 10 Pneumatic Module Sub assembbly 10 Replacing the Inlet IT 11 Solenoid 11 EEN RENE 12 Peer ebe eebe Ae 12 Controller PCB Assembly EE 12 KLOD anla E s a 13 Firmware Upgrades web EeEeNENkSE aa dada aya AR y aaa EENS Raya NENNEN 14 Programming EELER Pad ee eecht eet ech eegent aqa 14 Re elle Ce RE ut 14 ISP ere 15 Spare Parts and Accessories 16 Faultfinding Chart EE 17 aaa deg evades 18 Dispos l RE 18 Technical Data e cc eicicniaecsce a cats NEE NENNEN nt ae NEE NN eae eae 19 Appendix 1 Console General Arrangement
11. Select the Device drop down menu and select Erase On the Erase dialogue box select Full Chip Erase and press Erase Wait until this action has been completed On the File drop down menu select Load Hex Use the browser to select the appropriate file and select Open to load the program into the buffer Wait until this action has been completed Select the Device drop down menu and select Program When this has completed remove the ribbon cable connector from the ISP header port on the target system m If accessible press the reset button on the target system to start the application alternatively turn the machine off at the main switch and then back on again Occasionally as with any RS232 communication system the data transfer fails A time out message usually results If any operation fails simply try again until proper communication is established Consult the FLIP User Manual if problems persist KCU401 2 Keeler Cryomatic Service Manual 7 Faultfinding Chart Problem Fault Possible Cause Corrective Action Section 1 system does not a mains fuse in plug blown replace with correct rating power up and type b inlet fuse s replace with correct rating 3 and type c mains inlet module faulty check for mains voltage on 3 output terminals replace if necessary d power supply faulty Check for correct voltages 3 on output connector
12. amp V3 orientation amended 14 07 10 10022 T Fstsse 3T0308 18 125 52 This drawing and copies of it shall always remain the property of NU PERSPECTIVES LIMITED registered in England and Wales 6557506 contents are confidential and shall only be used for the purpose for which the drawing was provided 5 Wiring Connections Between Front amp Rear Assemblies KCU401 2 Keeler Cryomatic Service Manual Page 22 of 24 Appendix 2 Pneumatic Module General Arrangement ES CS Set Se See Nee ee 6 6 T 1 Ensure that items 1 amp 2 are clean and free from contamination before commencing assembly MEM PART NO DESCRIPTION doya i a q 1 A 4 Items 5 9 and 10 should be tightened to a torque of 27 Ham oupling Interface T 2 nems 319 2 20 fu for relsens b hey re fed o later assembly ES 7 thread sealants should be used during the assembly process ae mate ees Sever tog 6 MCU205 Solenoid Valve N C 0 8mm 24VDC 10VV 1 k l amp KCU204 Solenoid Valve N O 1 0mm 24 14 2 i MCU220 Pressure Transducer 100 1 k tan E O rings HR Pressure Transducer 16 11 should be supplied as 111 5 56 Shakeproof Washer ST SH 4450000 03 part of ins sorenow valve 0 BARLAR GH MCU214 Push in Stud Connector 1 8 BSPPx 4mm 7 IRA 15 MCU219 Bintered Filter
13. an the manufacturer or his authorized representative And ii The customer shall give notice to the manufacturer or their authorized representative of any malfunction of the system and shall not use the system in any surgical operation after they are aware of any malfunction iii The customer complies with manufacturer s recommended Preventative Maintenance see Section 8 and can provide proof of such action 10 Disposal Ensure that this equipment is disposed of in accordance with local regulations Please contact the supplier if in doubt KCU401 2 Keeler Cryomatic Service Manual 11 Technical Data Cryogenic System Gas Specification Operating Pressure Range Maximum Pressure Freeze Control Electrical Ratings Input Voltage Range Power Rating Fuses Dimensions Width Depth Height Weight Medical Grade Nitrous Oxide N20 or Carbon Dioxide CO2 in non syphon cylinders 3100 5860 kPa 450 850 PSI 8275 kPa 1200 PSI Footswitch press to freeze release to defrost 110 240Vac 50 60Hz 100VA T2AH 250V 305mm 12 200mm 8 190mm 7 5 2 5kg 6lbs Classification 8 Safety Standards Complies vvith Equipment Classification Mode of operation Protection against ingress EN60601 1 UL60601 1 amp CAN CSA C22 2 No 601 1 Class 1 Type BF Applied Part Continuous Console IPx0 Footsvvitch TP68 Environmental Conditions Temperature Range Relative Humidit
14. e cover Download Utility FLIP The FLIP programming application from Atmel is available as shareware This is available as a free download from the Atmel website or alternatively a copy can be obtained from the manufacturer This application software is required to control the communication between the PC laptop and the Cryomatic The software can be downloaded by the using the following link http www atmel com dyn products tools_card asp tool_id m2707 KCU401 2 Keeler Cryomatic Service Manual ISP Procedure The exact procedure may vary slightly depending on the version of FLIP that is being used The following procedure should be followed when performing a firmware upgrade in the field a b c d e g h i k The Cryomatic should be povvered up Launch the FLIP application Press F2 for Device Selection Select T89C51AC2 from the list then select OK Connect the ribbon cable connector into the ISP programming port on the Cryomatic Press F3 for Communication Settings If using the computers serial port select COM1 and 19200 baud from the drop down lists Check the manual sync box OR if using the USB adapter select COM3 and 19200 baud from the drop down lists Check the manual sync box Press Connect then press the reset button on the ISP adapter Press the Sync button the system will respond by automatically filling in the device information
15. he following dc voltages can be measured with respect to the black connection pin 4 red pin 1 5 V yellow pin 2 24 V white pin 3 12 V The entire power supply sub assembly can be removed as follows a Remove the inlet connection from the power supply b Remove the 3 pan head screws which secure the component plate Note that these fixings also provide secure protective earth points c Carefully remove the sub assembly from the enclosure d Re fitting is the reverse of removal ensuring that earth connections are re instated correctly KCU401 2 Keeler Cryomatic Service Manual 4 Pneumatic System Pneumatic Module Sub assembly The complete pneumatic module sub assembly can be removed as follows a Loosen and remove the bezel from the probe connector b Push back the collar and remove the flexible exhaust connection from the module c Remove the pneumatic module support bracket d Carefully remove the cap head screws that secure the module to the rear enclosure e Withdraw the pneumatic module from the enclosure f Re fitting is the reverse of removal KCU401 2 Keeler Cryomatic Service Manual Replacing the Inlet Filter Solenoid Valves The inlet filter is included to prevent any minute particulate debris from entering the pneumatic system This component should be inspected and replaced as part of the routine maintenance schedule The inlet filter is situated within the manifold block It can
16. l adhesive should be removed using an alcohol based cleaner before the new foot is firmly pressed into the square locating recess on the base of the enclosure KCU401 2 Keeler Cryomatic Service Manual 3 Electrical System Replacing Mains Fuses Mains Cord The Cryomatic must be disconnected from the mains before attempting to replace the mains fuses The mains fuses are housed in the small drawer below the rocker switch on the side of the unit A screwdriver or similar should be used to unlatch the drawer to gain access to the fuse compartment Fuses should only be replaced vvith the same type and rating The mains cord should be replaced if there are any signs of damage upon inspection The mains cord is of medical grade and replacements should be obtained from the manufacturer KCU401 2 Keeler Cryomatic Service Manual Mains Inlet The mains inlet unit can be removed in the following manner a Remove the crimped electrical connections from the rear of the unit make a note of the correct orientation b Remove the 2 countersunk screws which are accessed from the outside of the unit c Carefully withdraw the mains inlet unit from the enclosure d Re fitting is the reverse of removal KCU401 2 Keeler Cryomatic Service Manual Power Supply Sub assembly Disconnect the power connection from CN3 on the Controller PCB Use a digital multi meter to check the output of the power supply Verify that t
17. ler PCB 5 7 probe defrosts a probe fault possible replace probe slowly internal leak b faulty leaking control valve replace valve or pneumatic 4 module c leak internal to console check for internal gas leaks 4 repair leak s or replace pneumatic module 8 excessive flow rate a faulty leaking control valve replace valve or pneumatic 4 from exhaust module 9 gas leaks from a 1 faulty o rings in QR replace pneumatic module 4 coupling when connectors probe is disconnected 10 mute control does a faulty membrane label replace enclosure front 2 not function KCU401 2 Keeler Cryomatic Service Manual 8 Spare Parts Listing The following spare parts are available from the distributor Description Controller PCB Assembly Pneumatic Module Assembly Power Supply Assembly High Pressure Hose Assembly Mains Inlet Case Front Assembly Case Rear Cover Plate LCD Panel Solenoid Valve N C 0 8mm Orifice 24V 10W Solenoid Valve N O 0 5mm Orifice 24V 14 5W Footswitch Assembly 2A Anti surge Fuse Rubber Foot 1 8 Dowty Seal Inlet Filter M4 x 10 Tamperproof Pan head Screw M3 x 16 Pozi Countersunk Screvv M3 x 6 Pozi Pan head Screvv M3 x 8 Pozi Pan head Screvv M3 Shake proof VVasher M3 Plain VVasher Mains Cord Exhaust Hose 5m Exhaust Silencer Cryomatic Console Carton Cryomatic Probe Carton Cryomatic Instructions For Use Cryomatic Service Manual Programming Adapter KCU
18. nel membrane connector in position CN13 c Remove the 6 pozi pan head screws that secure the PCB to the enclosure being careful to retain all washers d Withdraw the PCB from the enclosure e Re fitting is the reverse of removal Care should be taken when re connecting the LCD flexible cable assembly as this is easily damaged Ensure that the latch is closed properly KCU401 2 Keeler Cryomatic Service Manual LCD Panel Observe proper precautions for the prevention of damage to static sensitive devices Ax It is unlikely that the LCD panel will fail but should the need arise the LCD panel can be removed in the following manner a Remove the Controller PCB Assembly see previous section b Remove 4 pan head screws which secure the LCD retaining bracket Ensure that the 4 spacers are retained c Carefully remove the LCD Panel d Re fitting is the reverse of removal ensure that the panel is centred correctly before finally tightening the retaining bracket KCU401 2 Keeler Cryomatic Service Manual 6 Firmware Upgrades Firmware upgrades can easily be performed using the In System Programming ISP facility which is incorporated in the Cryomatic Programming Adaptor A special programming adaptor is required to connect a PC or laptop to the Cryomatic This can be obtained from the manufacturer The programming port is accessed at the rear of the equipment and is located behind a small removabl
19. ns of damage replace if necessary Inspection of footswitch for signs of damage replace if necessary Inspection of exhaust hose assembly for signs of damage replace if necessary Replace gas inlet filter Check probe couplings for signs of wear or damage Check probe coupling electrical contacts clean if necessary Performance check using test probe KCU401 2 Keeler Cryomatic Service Manual 2 Enclosure amp Fittings Programming Port Cover The programming port cover may need to be removed in the event of a firmware upgrade see Section 6 This is secured at the rear of the unit by 2 small screws Removal of Front Cover Almost all of the servicing and or rectification will require the removal of the front cover This can be carried out as follows a b c d e f g h Remove the cryoprobe if fitted Switch off and disconnect gas supply Disconnect Cryomatic from the mains electrical supply Disconnect footswitch Remove 4 tamper proof fixings at the rear of the enclosure using the appropriate tooling Withdraw the front cover and carefully disconnect all connections to the Controller PCB Assembly Completely withdraw the front cover Re fitting is the reverse of removal Rubber Feet The rubber feet are secured to the base of the enclosure by an adhesive layer They are very robust If they should become detached due to rough handling they should be replaced Any residua
20. y Atmospheric Pressure Storage Operating 20 C to 50 C 10 C to 40 C 10 to 80 30 to 70 500hPa to 1060hPa 700hPa to 1060hPa Symbols used on the equipment All symbols used are in accordance with BS EN60417 2 1999 Graphical Symbols for use on Equipment BF Applied Part Refer to the User Manual ZN 7 Dangerous voltages present inside the equipment AC voltage input Fuse rating gt gt Exhaust connection Gas inlet connection Footswitch connection KCU401 2 Keeler Cryomatic Service Manual Appendix 1 Console General Arrangement Membrane connection through slot in moulding _7 and over top of PCB __LCD tail connection thru slot in PCB Port Number Description Ofy 0 2 Enclosure Front Silver 8 4 MCU204 QVGA LCD Module O l MCU331 MCU32 7__ LCD Retaining Plote RP99 99253 Foam Pad 19 3 FASO33 5 Shokeproof Washer s s 10 FASO53 M3 x 8 Pozi Panhead Screw S S 58 KCU203 Cryomatic Membrane Label 9 052 2 _ Controler PCB Assembly 18 FASO54 M3 x 6 Pozi Panhead Screw S S 6 11 EP39 49888 60345 W g Lab l MCU213 Z ehs f PS WEE GE KE Il PCB warning label added amp V3 coil orientation amended 14 07 10 31 03 08 3rd Angle Projection Material Tolerance XX 0 2 01 A4 ANG 1 5 deg Finish ining i nish Machining te sl 1 KCUU51 clean
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